DCS Worldwide Profiles 09

Distributed Control Systems Worldwide Outlook • Supplier Profiles
Chapter 5
Supplier Profiles
The following pages provide profiles of the leading DCS suppliers world-
wide. These profiles analyze the total business of each company as well as
the DCS-related portion. Information is provided regarding current model
numbers, associated components, communication protocols, and system-
level offerings. We‟ve also provided information on served markets and
alliances where appropriate. ARC derived this information from company
annual reports and in-depth discussions with senior company officials.
Copyright 2009 © ARC Advisory Group • ARCweb.com • For Internal Use Only • 5-1
ABB
http://www.abb.com
DCS Offerings
System 800xA, Freelance 800F are current offerings. Prior generation sys-
tems include Symphony (Harmony and Melody); INFI 90; Contronic;
Master; MOD 300; Freelance 2000; SattLine; DCI System Six.
Regions
North America; Europe, Middle East & Africa; Asia; China; Latin America;
India
Description
Central to ABB‟s automation offerings is IndustrialIT. In ABB‟s view, the
primary market drivers behind the implementation of automation today
are increased productivity and flexibility, reduced lifecycle costs, safe-
guarding investments, energy efficiency and environmental and safety
management. These are also the primary drivers behind the IndustrialIT
philosophy.
Industrial IT is ABB‟s architecture for collaborative process automation. At

the core of all Industrial IT solutions is the System 800xA Extended Auto-
mation control system. Extending the core of System 800xA hardware and
applications are ABB and third party products that have been tested and
certified (Industrial IT Enabled) to verify proper operation with an 800xA
system.
A powerful object-oriented technology, called Aspect Objects, underlies all

of the Industrial IT offerings and resides at the core of System 800xA. Put
simply, Aspect Objects allows users to view any aspect of the automation
scheme, from a pump or a valve to a process unit or pressure transmitter, as
a software object. Each object in the system has a number of attached as-
pects that can range from integration to computerized maintenance
management systems (CMMS) and enterprise asset management (EAM)
systems to schematic drawings and trending information. Aspect Objects
provides the key real-time linkage between equipment and applications.
System 800xA provides these functions with a single window environment

for context-sensitive information access and navigation, and builds on a
5-2 • Copyright 2009 © ARC Advisory Group• ARCweb.com • For Internal Use Only
common environment for engineering, operations, information manage-

ment, and asset optimization. System 800xA also provides a common
operator environment for ABB‟s entire portfolio of safety and process con-
trol systems, providing access to information across the enterprise as well
as context-sensitive decision and action tools that allow the right users
access to the right information at the right time from any point within the
system.
A key strength of System 800xA is its ability to extend its reach beyond the
traditional functions of the DCS to include functions such as collaborative
production management, safety and critical control, advanced control, in-
formation management, smart instrumentation, smart drives and motor
control centers, asset management, enterprise connectivity and documenta-
tion management capabilities. System 800xA was built from the ground up
as an integration platform and its architecture, together with the Aspect
Object technology, provides the foundation for integrating ABB and third-
party hardware and software.
In early 2009, ABB released the latest version of its Industrial IT Extended
Automation System 800xA with SIL3 integrated safety. This latest release
completes ABB‟s portfolio of SIL-certified safety systems and provides a
diverse architecture that supports both dual and quad configurations.
In addition to SIL3, ABB also released its IEC61850 communication module

supporting the IEC61850 standard for communications with medium and
high voltage switchgear and protection equipment. This enables ABB to
deliver a seamlessly integrated automation and electrical solutions provid-
ing interoperability between IEDs (intelligent electrical devices) and thus
reducing operational and engineering costs. Today, ABB can integrate the
process control, process electrification, and power distribution and man-
agement portions of a plant with System 800xA, so information is available
to all areas. The IEC61850 standard is a key component of their strategy.
This strategy is particularly interesting to industries that are heavy electric-
al users such as oil & gas, utilities, pulp & paper, and metals that view
electricity as a raw material.
ABB has also released a more powerful AC800M controller, which provides
significant CPU performance and software execution improvements. This
will enable System 800xA to deliver improved productivity with less cost
and in a smaller footprint. Process Graphics II was also released in 2008
and provides a significant boost in engineering efficiency through the addi-
tion of standard Microsoft WPF features and increased run-time
performance.
New AC800M function code libraries for the Harmony and MOD300 sys-
tems enables ABB to provide an evolution path to System 800xA controllers
as well as operator graphics. With the release of the new control libraries,
any Harmony of MOD300 system can be expanded using AC800M control-
lers while preserving familiar control configuration, faceplates and alarms.
All of these features are designed to increase flexibility and efficiency while
reducing the risk of unnecessary downtime and providing cost efficiencies.
This is consistent with ABB's approach of equating Industrial IT and 800xA
to key end user business value propositions, specifically reduction of total
cost of ownership, increasing productivity, and reducing risk/enhancing
security. The ability to evolve the installed based to the most current Sys-
tem 800xA offering enables ABB to support their customers throughout the
product lifecycle while making new features and applications available to
users of any ABB system. This is a key factor in helping reduce risk and
increase productivity in today‟s plants.
Industrial IT Enabled Applications

In addition to ABB‟s new System 800xA features, several integrated appli-
cations have been Industrial IT Enabled over the past few years. These
applications include ABB‟s cpmPlus Enterprise Connectivity, Matrikon‟s

AlarmInsight for System 800xA, Intergraph‟s Smart Plant Instrumentation,
and ABB‟s 800xA Evolution for Honeywell System Migration (HSM).
The cpmPlus Enterprise Connectivity solution (ECS) provides a stream-

lined, single point interface for vertical integration that is suitable for
enterprises of all levels of complexity. ECS provides a unified framework
for dealing with transactional and event-driven systems in a common envi-
ronment. It provides a single, highly flexible and configurable interface,
which results in a higher degree of reliable information flowing between
manufacturing and business systems and lower engineering and interface
maintenance costs.
Matrikon‟s AlarmInsight for System 800xA provides a configurable inter-

face between Matrikon‟s ProcessGuard and ABB‟s System 800xA. This
integration allows 800xA users to view any ProcessGuard report or Alarm
MOCCA report, so users can access Alarm history, Alarm performance
KPIs and operator assistance documentation through their existing 800xA
displays. AlarmInsight provides context-sensitive access to any available
alarm information; turning data into actionable information.
The Intergraph Smart Plant Instrumentation (SPI) integration with System

800xA provides automatic configuration of the control system; updates to
the control system during design changes; documentation of control system
configuration; consistent as-built documentation during plant handover;
and improved decision-making during critical maintenance and operations
events. The bi-directional synchronization between SPI and 800xA enables
efficient engineering and maintenance through the entire lifecycle of the
control system.
The 800xA Evolution for HSM connectivity package enables supervision

and operation of objects from a Honeywell TDC3000 from System 800xA. It
provides integrated alarm and events, standard 800xA graphical elements
and browsable OPC items. The single-window environment of 800xA pro-
vides visibility for all control data (from 800xA and TDC3000) to the
operator to ensure that the right information is provided in the right con-
text to support accurate decisions and actions.
800xA Controllers Receive Cyber Security Certification

In September of 2007, ABB announced that its System 800xA Extended Au-
tomation AC 800M controller achieved Mu Security‟s Industrial Control
(MUSIC) Foundation-level Certification. MUSIC certification means that

AC 800M meets industry-defined best practices for safety, reliability, and
security. During the evaluation process, the AC 800M met or exceeded the
requirements of MUSIC‟s multi-faceted security and stress tests.
MUSIC Foundation and Advanced certifications both ensure critical infra-

structure and process control-focused organizations verify a diverse range
of network equipment and application protocols to meet industry-defined
best practices for safety, reliability, and security testing. For the chemical
industry, this means that MUSIC Certification and product safety ben-
chmarking, using the Mu-4000 appliance, minimizes process control
product safety issues and minimizes costly downtime due to implementa-
tion flaws. The MUSIC program also provides a migration path to open
industrial control systems security specifications currently under develop-
ment by government and industry groups,
including ISA Security Compliance Institute
(ISCI) and ISA SP99.
Earlier in 2007, ABB announced that the Sys-

tem 800xA Extended Automation AC 800M
controller achieved Achilles Controller Level 1
cyber security certification. Wurldtech Securi-
ty Technologies, a leading provider of security
products and services for the industrial auto-
mation industry, introduced its Achilles
Controller Certification Program several years ago.
The Achilles testing process is rigorous. According to Wurldtech, the ma-

jority of controllers submitted failed Level 1 Certification testing, and a
substantial number have still not passed on retest. AC800M passed each of
the over 30 million individual tests required to achieve Achilles Level 1
Certification.
Wurldtech and its partners developed the Achilles Certification Program to

provide a benchmark for certifying secure industrial controllers. The certi-
fication process presents device manufacturers with an independently
verified result from which to communicate their product security to cus-
tomers, while providing operators of control systems the most complete,
accurate, and trustworthy information currently possible on the security of
their deployed products. Achilles Level 1 Certification verifies the security,
reliability, and robustness of a device's implementation of OSI layers 2 – 4,

including Ethernet, ARP, IP, ICMP, TCP, and UDP.
System 800xA AC 800M controller is one of the first controllers in the in-
dustry to have achieved both Foundation-level MUSIC and Achilles Level 1
security certification.
Automation Sentinel
In March of 2007, ABB announced the release of its Automation Sentinel
program for ABB control system software management. Designed to help
customers actively manage their lifecycle costs, Automation Sentinel ex-
tends support for, and the value of, existing ABB control software
investments. Automation Sentinel combines comprehensive technical and
online support with a planned evolution path to latest-generation functio-
nality for earlier control system software versions. When evolving to
System 800xA, program subscribers do not incur additional license fees for
upgrades to functional equivalent System 800xA software. Automation
Sentinel program subscribers automatically receive all available updates
and enhancements to their current System 800xA software. In addition,
they have the option to stay on that version for an extended period up to
seven years. The Automation Sentinel program provides not only software
updates, but also extended version support, comprehensive evolution
planning, on-line access to patches and downloads, and access to technical
specialists for software installation and troubleshooting support.
Load-Evaluate-Go as a Path to High Availability Control

The Load-Evaluate-Go feature sprang from ABB‟s relationship with Dow
and is a key requirement for Dow applications. Load-
Evaluate-Go enables users to modify, download, and eva-
luate a “revised” application without interfering with the
running or “current” application. The “revised” applica-
tion can then be put on line, further modified, or
discarded. Load-Evaluate-Go provides many end user
benefits in the area of reducing risk. Aside from reducing
the overall risk of unplanned downtime, Load-Evaluate-
Go reduces the risk of applying erroneous application
changes to the process during application changes in run-
ning processes.
System 800xA supports on-line version upgrades. With

Load-Evaluate-Go Workflow System 800xA AC800M controllers in a redundant configu-
ration, online upgrades of the controller‟s firmware is accomplished by

loading the new firmware into the backup controller, evaluating various
parameters, and then switching it to be the primary controller. The second,
now the backup controller, will then have its firmware upgraded and re-
dundancy will be re-established. This is particularly important in the
chemical industry, where process plants often have many process streams
plus a “common” for process services that never shuts down to facilitate
such upgrades.
System 800xA supports Load, Evaluate, Go for application modifications in

System 800xA. Load Evaluate Go allows you to “load” a modified control
application to System 800xA‟s AC800M controller without replacing the on-
line, running control application. Both application versions will then be
executed in parallel using the same controller inputs. However, only one
application's outputs will be used to control the process. With both appli-
cations running in parallel, you can compare the two versions and
“evaluate” the new application using actual process inputs without inter-
fering with the on-line application. The evaluation is done by looking at
the “evaluation environment,” which shows key operating parameters,
alarms and events, and even graphics. After the evaluation is complete, the
user may choose to accept the new application as the online version, by se-
lecting the “Go” command, or reject the new application, which removes it
from the controller. For added security, “Administrate” permission is re-
quired to enable and use Load Evaluate Go sessions in addition to the re-
authentication features mentioned previously.
Freelance 800F System

ABB has also fully reintroduced the smaller Freelance control system to the
marketplace for North America and the rest of the world. Hartmann &
Braun originally developed Freelance to address the requirements of the
small- to medium-size applications in the hybrid industries, including fine
chemicals. It provides a good counterpart to the more highly scalable and
fully functional 800xA system. Freelance features a new HMI and a new
compact controller in the form of the 700 series. This latest version of Freel-
ance goes a long way toward addressing a very important segment of the
market for ABB.
Partnerships and Acquisitions

ABB recently made news in the oil & gas world when it signed an agree-
ment to acquire the business of Ber-Mac Electrical and Instrumentation Ltd.
of Calgary, Canada. Ber-Mac specializes in industrial automation, electric-

al, instrumentation design, process optimization, panel fabrication, and
field services. It is particularly strong in the oil & gas industry. Established
in 1980, the company has enjoyed steady growth in recent years and earned
revenues of ca. $100 million in 2007.
Key Industries
Cement & Glass; Chemical; Chemical Fine; Chemical & Petrochemicals;
CPG; Electrical; Food & Beverage; Life Sciences; Metals; Mining; Oil & Gas;
Oil & Gas Pipelines; Oil & Gas Production; Oil & Gas Refining; Plastic &
Rubber; Pharmaceutical; Power; Power Generation; Power T & D; Printing
& Publishing; Pulp & Paper; Textiles; Water & Wastewater.
Strengths and Challenges

ABB‟s positioning of Industrial IT around the three primary domains of
reduced cost of ownership, increased productivity, and reduced risk is a
good fit with this increased focus on business value. ABB also has the ad-
vanced capabilities in products, services, and vertical industries to help end
users realize the business value and increased performance potential of au-
tomation. In terms of offering a high degree of functionality and a wide
array of advanced applications, ABB is very strong and has a lot to offer.
The future success of ABB depends largely on its ability to successfully
provide its customers with sustained and measurable benefits from auto-
mation that provide a path to continuous improvement for business
performance and profitability.
In the realm of reduced cost of ownership, ABB has made great steps for-
ward evolving its installed base to the latest version of System 800xA,
providing performance improvements through its solutions for enhanced
OEE, and implementing an ISA 95-based approach to production manage-
ment and enterprise integration. No other supplier had been able to
rationalize such as large installed base of diverse process automation sys-
tems under a common framework as ABB. Preserving installed base will
remain perhaps the biggest ongoing challenge for ABB moving forward.
ABB‟s comprehensive lifecycle support policy is designed to protect cus-

tomer‟s intellectual investment beyond the lifecycle of the underlying
hardware and software platform products. The Automation Sentinel soft-
ware subscription service provides not only software updates, but extended
version support, comprehensive evolution planning, on-line access to
patches and downloads, and access to technical support specialists for

software installation and troubleshooting support.
ABB‟s solutions for improving productivity are also formidable. As far as

providing information in context and enabling a knowledge workforce, the
800xA system is extremely powerful and strongly corresponds to the ARC
collaborative process automation system framework. The company also
provides an integrated approach to maintenance and plant asset manage-
ment that can provide true bottom line results by reducing maintenance
costs and eliminating unnecessary maintenance.
One of ABB‟s primary challenges, however, lies in making these solutions

easier to implement and to use for their customers. The high degree of
functionality offered by 800xA and Industrial IT and the wide range of asset
management services offered by the company also require a significant
component of implementation services, training, and vertical industry ex-
pertise, which ABB provides. A consultative selling approach is also
required where, ideally, ABB is involved from the front-end engineering
and design through project execution and the operational phase, which
ABB also provides and must continue to strengthen and sustain. ABB‟s has
leveraged their global project execution capability into a strong Main Au-
tomation Contractor (MAC) offering. This approach can deliver significant
savings during engineering and in overall project cost.
Integrated safety and high availability control are both key concerns for end
users today, and ABB is a leader in this regard with its 800xA High Integri-
ty platform. ABB also takes a leading approach to security with its Load-
Evaluate-Go functionality, audit trail, and other features. As with the com-
pany‟s other offerings, however, a sophisticated approach to security, high
availability control, and risk mitigation requires a sophisticated approach to
the end user in the form of a consultative sale and an ability to effectively
articulate the benefits. Industrial IT can help end users achieve a sustained
economic benefit from automation. ABB must continue to build on its ser-
vices and solutions expertise and increasingly focus on ease of use to help
end users realize that vision.
Emerson Process Management
http://www.emersonprocess.com
DCS Offerings
DeltaV and Ovation are current offerings. Previous offerings include RS3;
PROVOX; WDPF II, RMV9000
Regions
India
Description
Emerson‟s Process Management business is organized around the four
main areas of Systems and Solutions, Asset Optimization, Measurement
and Analytical, and Final Control Elements. Emerson‟s Process Systems
and Solutions division includes their control systems platforms and global
product support services, project planning and execution and optimization
services. The Asset Optimization division includes the AMS Suite software
and comprehensive asset optimi-
zation services. The Measurement
and Analytical division includes
Rosemount, Micro Motion, Rose-
mount Analytical, Daniel, Mobrey,
and Saab Rosemount. Final Con-
trol Elements includes the Fisher
Valves business, Fisher Regulators,
and Valve Automation.
Emerson utilizes industry stan-

DeltaV Architecture dards like HART and Foundation
Fieldbus to integrate their intelli-
gent field devices, control platforms, and asset software into a digital plant
architecture, called PlantWeb. Emerson offers two primary digital automa-
tion platforms: Ovation, targeted to the power and water market; and
DeltaV, targeted to the industrial process control market, including batch
applications.
DeltaV
Emerson originally introduced the DeltaV digital automation system for
small and hybrid market opportunities. More recently, however, the sys-
tem has fulfilled the promise of being fully scalable for large applications.
DeltaV system hardware consists of Intel processor-based PC workstations
running Windows Vista and/or XP and Windows Server software. The
controller features a 500-channel control module running on a Motorola
microprocessor, Foundation Fieldbus and HART protocol interfaces for
smart field devices, and modular plug-in I/O in a compact, field-mountable
package.
Version 7.4 of DeltaV was released at the beginning of 2005. This release
added a new engineering productivity tool with integration of the INtools
instrument design software from Intergraph. The DeltaV system and IN-
tools now share common data structures and seamlessly exchange data
using XML and Microsoft .NET technology. This enables the reuse of in-
strumentation information during instrumentation design, reducing
engineering effort and speeding up project execution. INtools has also been
enhanced to be "DeltaV-aware" and is embedded directly into the DeltaV
system. Intergraph has also been included as a partner in the Emerson
Process Management Alliance Program -- a global, business-to-business
network connecting third party suppliers and their products directly to the
Emerson sales and project execution channel for use with DeltaV projects.
DeltaV Version 7.4 also offers many fieldbus enhancements. The number of
Virtual Communications Relationships among Foundation Fieldbus devices
has been increased to 50, significantly increasing communications power
for customers who gain the ability to address more complex devices and
expand possibilities for more intricate control relationships. Enhancements
to DeltaV operations software also permit faster access to Foundation
Fieldbus parameters, enabling AMS Device Manager diagnostic screens to
populate data much faster. This reduces the time required for customers to
commission or troubleshoot fieldbus devices.
The DeltaV Continuous Historian stores the wealth of information available

in the intelligent field devices. The status of a parameter configured for his-
tory collection is automatically stored along with its value. Status and
value are visible through a new Excel based analysis and reporting tool.
The new release also includes an OPC Historical Data Access (OPC HDA)
server for use with the DeltaV Continuous Historian, enabling integration
of a variety of third party analysis tools.
DeltaV Version 8.3, introduced in August 2005, marked the initial release of
DeltaV SIS, part of Emerson‟s smart SIS solution built upon PlantWeb tech-
nologies. These technologies provide continuous diagnostics and testing
across the complete safety instrumented function, including sensors and
final control elements. The DeltaV SIS system earned formal TÜV certifica-
tion in July 2005. The version 8.3 release also included remote I/O. System
security and maintenance throughout the lifecycle are enhanced by a confi-
gurable Guardian Portal dashboard website that provides automated, up-
to- date access to Knowledgebase Articles, Technical Support calls, and sys-
tem lifecycle details and customized semi-annual system analysis reports
outlining specific recommendations for system maintenance.
Emerson Process Management released version 8.4 of DeltaV system soft-

ware in 2006. Version 8.4 includes enhancements to help users prevent
abnormal situations. DeltaV digital automation systems are a core compo-
nent of Emerson‟s open, standards-based PlantWeb digital plant
architecture.
With the new software release, standard HART device status information
can now be used by predictive diagnostics that generate PlantWeb Alerts.
The unique alerts are categorized and targeted to specific departments (Op-
erations, Maintenance, etc.) and provide specific guidance help users take
corrective actions that can head off abnormal situations in the plant. In an
additional enhancement, conditional alarming has been extended to
FOUNDATION fieldbus devices, enabling the devices to deliver critical
predictive alarms for immediate attention by operations staff to avoid un-
planned downtime.
Key Enhancements to Version 10.3

Version 10.3 of the DeltaV system includes some key functional enhance-
ments, such as incorporation of the Microsoft Vista operating system and
larger DeltaV MX Controllers. Emerson also limits major revision releases
to every 18 months, and end users can count on there being only three revi-
sions to every major version release (which is why 10.3 will be the last
major revision of version 10 of DeltaV). Another strategy the company em-
ploys is to keep service pack releases limited to hot fixes and updates.
Version 10.3 began shipments in late 2008. In addition to the Vista compa-
tibility, the larger DeltaV MX Controllers deliver 2.5 times the performance
and twice the memory of previous controllers. The new MX controllers are
primarily targeted at large continuous and batch applications and as a re-
placement for PROVOX controllers with the same form factor as current
DeltaV controllers. The DeltaV workstation count also increases from 60 to
65.
Version 10.3 also includes a redundant Profibus DP card, which is a drop-in

replacement for the existing Profibus card and includes features such as
autosense of redundant pairs, requires no added configuration, and fea-
tures a Profibus DP V1 pass-through. Version 10.3 also includes increased
secure communications bandwidth for DeltaV Safety Instrumented Systems
(SIS). New controller function blocks such as the DeltaV SIS, analog voter,
discrete voter, cause and effect matrix, state transition, and step sequencer
are also available in the 10.3 release.
DeltaV Smart Switch Provides Built In Security Features

The DeltaV Smart Switch is a major aspect of the 10.3 release and embodies
Emerson‟s strategy of driving increased ease-of-use into its products. Cy-
ber security is not normally something that would be equated with ease of
use, but the new switch, made in partnership with Hirschmann, has many
features that make security easier. This includes an “Auto Lockdown” port
security function that requires no configuration. This allows a user to au-
tomatically lock and unlock the port access of all the switches in the
network. This lockdown will disable all unused network connections
(ports) on the switch. One of the biggest security vulnerabilities in a control
system is that network devices, such as Ethernet-based network switches,
are located in unsecure locations out in the process and thus easily accessi-
ble to everyone. Locking down switch ports will prevent accidental
connection, and virtually prevent the deliberate connection of an unautho-
rized device to the switch.
Integrated Wireless Functionality

No discussion of Version 10.3 would be complete without a discussion of
the integrated wireless functionality in the DeltaV system. In the new re-
lease, the 1420 gateway functions as a node on the DeltaV control network
and can be auto-sensed and auto-configured in the DeltaV Explorer. Wire-
less I/O from the 1420 WirelessHART device appears as native I/O in the
DeltaV system. HART alerts from WirelessHART devices can also be
passed directly through to the AMS Suite Intelligent Device Manager, eli-
minating the need for an additional Ethernet network.
Making FOUNDATION Fieldbus Easier to Use

ARC has been saying that suppliers need to do more to make fieldbus easi-
er to use for some time now. Emerson is taking steps to make that happen
with easier FF device commissioning and replacement. The new automated
process eliminates the human-software interaction and essentially enables
“commissioning with a wrench,” eliminating the need to decommission
devices, put them in standby states, and so on. Emerson will also be offer-
ing FF segment downloading, where multiple segments can be downloaded
simultaneously, reducing the time needed for FF segment startup and
shutdown.
Fieldbus devices mounted on OEM skids can greatly reduce plant startup
times. Emerson is striving for faster commissioning of OEM skids with FF
devices by providing users with the option to retain the commissioning
state of FF devices upon import of configuration. New fieldbus multip-
lexed function blocks will also be introduced, specifically to deal with
multiport devices. In DeltaV 10.3, Emerson has improved the overall confi-
guration experience for FF devices so only the applicable engineering units
and channel selection are shown.
Ovation
Emerson offers its Ovation expert control system primarily for power gen-
eration and water/wastewater applications. There are currently over 3,000
Ovation systems in operation around the world. In the US, Ovation sys-
tems are installed in hundreds of power generation facilities, with a
combined generation capacity of over 300,000 Megawatts, or approximately
40 percent of average US peak demand. In nuclear power, Emerson has a
long-standing agreement with Westinghouse Electric to supply Ovation
controls for Westinghouse plant modernization projects as well as its new
AP-1000 advanced nuclear plant. In water and wastewater applications,
Ovation is utilized for process control and monitoring at major metropoli-
tan systems including New York City, Chicago, Los Angeles, Washington,
San Diego, Seattle, Detroit, Philadelphia, and Pittsburgh.
Ovation is designed to provide a flexible and easy-to-upgrade platform for

mission-critical control and is based on widely adopted computer industry
standards. It features fully redundant PC-based controllers, an unaltered
Fast Ethernet network, and wide range of standard and specialized I/O
modules. Since its introduction in 1997, Ovation has continuously evolved
to incorporate new technologies and capabilities designed to match the
unique operational needs of the power generation and water/wastewater

industries.
Ovation incorporates an array of embedded software capabilities required

in power generation control applications, including fully coordinated boi-
ler/turbine control, emissions monitoring and optimization, economic
dispatch and fleet management. It also includes native HART, Foundation
fieldbus, Profibus, and DeviceNet connectivity as well as seamless interfac-
ing to wireless field devices. Ovation offers connectivity to a wide range of
third-party I/O, PLCs, and other control devices as well as providing high-
speed interfaces to General Electric, Mitsubishi, and Toshiba turbine con-
trollers. It also includes wide area SCADA capabilities necessary for the
water, wastewater, district heating, and renewable energy applications such
as wind farms, solar fields, and hydroelectric stations.
Recent Ovation Upgrades and Enhancements

Recent upgrades to the Ovation system include the Scenario Virtual Engi-
neer, which combines simulation, virtual technology, and Ovation within a
single desktop computer. Scenario Virtual Engineer provides users with
the necessary tools to easily build, test, verify, and download process
graphics, control logic, and process point databases without affecting plant
operation. The Virtual Engineer consists of a single PC workstation loaded
with complete Ovation engineering, operator, and database server software
as well as the Ovation Developer Studio configuration and simulation tools.
Because this workstation supports virtual controller technology, up to 20
Ovation controllers can be virtually duplicated within this one Windows-
based workstation.
Emerson has also integrated the Bristol ControlWave remote terminal unit
(RTU) technology into the Ovation SCADA platform. Traditionally, SCA-
DA systems poll RTUs for information either at specified time intervals or
on demand. With the tight integration of the ControlWave RTU to the Ova-
tion SCADA platform, users now have a configurable polling mechanism.
This allows operators the option of having the RTUs send data directly to
the SCADA server or central Ovation control system only when values
change. This “report by exception” messaging scheme not only optimizes
bandwidth but also provides real-time alarming of remote sites.
The Ovation Security Center consists of a suite of security packages and

services that have the ability to enhance and manage the cyber security of
Ovation systems without disrupting the controlled process. These security
products allow operators to detect vulnerabilities in operating systems, con-

figurations, patches, and other system software. It addresses all network
devices, including servers, workstations, laptops, switches, and routers
while helping users comply with the North American Electric Reliability
Corporation (NERC) Critical Infrastructure Protection (CIP) standards.
The Ovation Alarm Analysis tool performs statistical analysis by leveraging

the information stored in the Ovation historian. The alarm analysis tool can
run on any laptop or desktop computer and data can be imported manual-
ly. An excessive volume of alarms can make it difficult for operators to
distinguish between critical events that require intervention, and nuisance
alarms or non-critical alarms. Emerson‟s Alarm Analysis tool examines
alarm data collected by the Ovation historian, providing the information
necessary to minimize unnecessary alarms and allow plant operators to
more effectively address real, high-priority issues and focus on actionable
items.
Ovation System Transitions for Legacy ABB and Siemens Systems

Emerson provides system transition programs for a number of legacy DCS
systems. These allow users to move to a full-function Ovation system with
little plant disruption while retaining significant elements of their current
infrastructure investment. Ovation transitions are available for ABB-Bailey
Symphony/Harmony, INFI 90 and Network 90 systems, as well as Siemens
Teleperm XP systems.
Emerson/Mitsubishi Alliance for Turbine Retrofit Projects

Emerson Process Management and Mitsubishi Power Systems Americas,
Inc. have formed an alliance that combines Emerson's turbine control exper-
tise and Ovation technology with Mitsubishi's experience in gas and steam
turbine design, manufacture, and service. The alliance applies to North and
South American turbine retrofit projects for Siemens-Westinghouse W251,
W501D5, W501D5A, and W501F gas turbines as well as all vintages of Sie-
mens-Westinghouse steam turbines.
Emerson Power & Water Extends Contract with Westinghouse Nuclear

In 2007, Westinghouse Electric and Emerson Process Management an-
nounced a 10-year extension to an existing agreement in which Emerson
will provide key technology for automation of nuclear power plants that
utilize the important Westinghouse AP1000 design. The AP1000™ is the
only Generation III+ design for nuclear power plants to have received de-
sign certification from the Nuclear Regulatory Commission. Westinghouse
will use Emerson‟s Ovation system to control power generation processes,

provide operations and maintenance interface, and collect and distribute
plant-wide information for process and power generation management.
Emerson Develops Comprehensive Migration Program

Emerson has a three-tiered approach to delivering migration solutions that
starts with its domain expertise and high level consulting capabilities. The
company has considerable domain expertise migrating its installed base of
RS3 and PROVOX systems, and Emerson has made significant investments
in building deep domain expertise in competitor systems. The company
has hired several high-level migration consultants, most with 20-30 years
experience in Bailey Infi 90, Honeywell TDC 2000 and TDC 3000, and other
competitor systems. These high-level consultants work closely with the
customers to develop migration strategies based on unique requirements.
Once the requirements are determined, the transition or migration products

and services come into play. These include a range of solutions designed to
migrate the user‟s system one component level at a time, from the wiring
and I/O to controllers, HMI, and other applications that can be applied in a
flexible fashion and work seamlessly with the legacy system. Emerson ser-
vice people and Emerson Local Business Partners (LBPs) then execute the
project. In many cases, the LBPs act more like systems integrators or engi-
neering firms, bringing a lot of expertise to the table. Emerson augments
this execution capability with long-term system plans, field audits, and a
broad scope of after-sales services.
All of this is done with an eye toward

maximizing the end user‟s existing in-
vestment, reducing overall transition
costs as much as possible, eliminating
downtime during transition, and leverag-
ing the technology available in the
DeltaV system and PlantWeb architec-
ture. This includes Emerson‟s
considerable capabilities in plant asset
management (PAM), fieldbus, advanced
control capabilities, and expertise in
batch control.
PlantWeb Migration Options Target Every Major Emerson has five primary methods of
Facet of the Process Automation System
transition from their own legacy systems
as well as competitor legacy systems that allow for a flexible migration

path. Each method targets a layer of the system, from the field wiring and
I/O through the controller layer, and finally the workstation, data historian,
and advanced application domains. This allows end users a phased ap-
proach that will preserve the assets that are still functional.
DeltaV Connect resides at the application workstation layer, and allows end
users to add DeltaV workstations to existing control networks of competi-
tors‟ systems. Likewise, DeltaV Operate allows users of Emerson systems
to add DeltaV workstations. These solutions preserve the end user‟s in-
vestment in legacy controllers, I/O, and wiring.
FlexConnect is a method of connecting multi-conductor cables to the exist-

ing termination panels and auto-marshalling the signals to DeltaV I/O.
The existing I/O signals can be controlled and monitored by the DeltaV
system through a pre-engineered marshalling solution. FlexConnect is
available for a wide range of systems, including Emerson‟s own RS3 and
PROVOX systems, as well as systems from ABB, Honeywell, Invensys,
Siemens, and Yokogawa. FlexConnect can reduce downtime by up to 75
percent versus rewiring. Documentation costs are also reduced because the
end user does not have to change loop sheets.
Emerson also offers I/O Bus Interfaces that allow end users to connect di-
rectly to legacy I/O subsystems. These are available for several competitor
systems as well as Emerson PROVOX and RS3 systems. The DeltaV Serial,
Virtual Interface Module, Profibus DP, or DeviceNet Interfaces provide the
connection between the DeltaV system and I/O devices. Using these inter-
faces, plant operators have access to the legacy control system data via
DeltaV operator consoles.
Emerson‟s migration program also includes expert platform-specific and

industry-specific consulting services, aimed at helping customers identify
areas where new technologies, such as advanced control and asset man-
agement, can improve operational performance. The purpose of a
consulting engagement is to ensure the objectives of a modernization
project match the customer‟s business drivers and that the project is finan-
cially justifiable. The consulting engagement includes the early stages of
project planning, providing various migration and conversion options with
associated cost estimates.
To round off this impressive portfolio, Emerson has enhanced its project
services capability by developing sophisticated conversion utilities for sev-
eral competitors‟ systems as well as continuing to improve utilities for
PROVOX and RS3 systems. Control database, displays, DeltaV Operate,
and DeltaV Connect conversions are made easier, more efficient and accu-
rate. Services based on tools minimize the risk of translation errors and
give customers a high level of confidence that Emerson experts will deliver
a fully functional system modernization project while minimizing project
time, project cost, and disruptions to operations.

In January of 2008, Emerson acquired The Automation Group (TAG). TAG
provides process automation/control system engineering, instrument, and
electrical design, project management services to the refining, petrochemi-
cal, chemical and coal power industries. The company is headquartered in
Houston, Texas, and has branches in Corpus Christi, Texas; Bloomington,
Minnesota; Concord, California; and Baton Rouge, Louisiana. TAG sup-
ports all of the leading process automation systems and will continue to do
so. TAG's expertise covers a wide range of process automation technolo-
gies. These include distributed control systems (DCSs), safety shutdown
systems, programmable logic controllers (PLCs), human machine interfaces
(HMIs), supervisory control and data acquisition (SCADA), process analyz-
ers, control networks, control room design and system documentation.
Key Industries
Food & Beverage; Lifesciences; Metals; Mining; Oil & Gas; Oil & Gas Pipe-
lines; Oil & Gas Production; Oil & Gas Refining; Pharmaceutical; Power;
Power Generation; Power T & D; Printing & Publishing; Pulp & Paper; Tex-
tiles; Water & Wastewater.

Emerson‟s key strength has always been its leading position in the field de-
vice and control valve market. With the DeltaV systems, it is able to
integrate its strong field offerings with its AMS software and the DeltaV
control system through Foundation Fieldbus to significantly reduce main-
tenance costs and process variability. Emerson has also considerably
strengthened its position in the APC market through the acquisition of
MDC.
Emerson must continue to penetrate new markets successfully with DeltaV

to maintain its high level of growth. Emerson has also made great strides in
providing a migration path away from legacy systems, such as PROVOX
and RS3, to PlantWeb and DeltaV. In ARC‟s view, Emerson has developed
a strong migration and transition path for both its own systems and many
of its competitors. Emerson‟s focus on migration project services is a key
strength. By tailoring specific service offerings to meet the demands of hot
cutovers, maintenance turnarounds, and particularly the consulting and
FEED stages of projects, Emerson demonstrates capabilities far beyond the
standard products and applications offerings. Engaging in early stages of
projects creates more business opportunities for Emerson and, more impor-
tantly, creates more opportunities for the end user to take advantage of the
business value provided by Emerson‟s offerings.
GE Fanuc Intelligent Platforms
http://www.gefanuc.com/
DCS Offerings
GE Fanuc Process Solutions
Regions
India
Description
GE Fanuc has combined its long-time expertise in real-time control applica-
tions with its production management and HMI capabilities to produce a
process automation system, which the company has dubbed Proficy
Process Systems. Proficy Process Systems play well against many of GE
Fanuc‟s strengths to produce a cost-effective, standards-based, collaborative
production environment that addresses the requirements of hybrid manu-
facturers. Proficy Process Systems are more than just GE Fanuc‟s answer to
a collaborative production system. GE Fanuc‟s capabilities in areas such as
condition monitoring, advanced process control, environmental monitor-
ing, and even wireless technology all provide promising synergies that the
company is developing to become a true global player in process automa-
tion.
The company‟s name change to GE Fanuc Intelligent Platforms in late 2007,

reflects its expanding reach into process and hybrid automation. Tying to-
gether the company‟s business of GE Fanuc Automation, CNC, and
Embedded Systems, the name change is intended to accurately represent to
their customers and the marketplace who they are and what they do.
GE Fanuc Intelligent Platforms launched the Proficy Process System to pro-

vide a fully integrated system that provides customers with improved
quality and reliability; increased throughput, performance, and efficiency;
and reduced total cost of ownership. GE Fanuc‟s Proficy software technol-
ogies empower users with visibility, analytics, and connectivity throughout
their enterprise. The HMI/SCADA and Historian technologies, coupled
with Batch and a complete Production Management suite, allows customers
to finally close the gap between automation and information. All of this
exists within an open communications framework based on industry stan-
dards to facilitate the sharing of data throughout a manufacturing organiza-

tion.
PACSystems Provide a Single Platform for Process, Discrete, and Motion

Applications
The foundation for Proficy Process Systems is the single, open control plat-
form in the form of PACSystems controllers. These are multi-disciplined
controllers that allow end users to run process, discrete, and motion appli-
cations in the same controller simultaneously. Whether the end user has a
process control application that requires function block programming, or
high speed packaging application that requires ladder logic, both applica-
tions can be run in the controller at the same time.
Being able to use the same controller across an entire plant or facility can
lower the end user‟s total cost of ownership by reducing training time,
maintenance, spare parts, and increasing uptime and availability. PACSys-
tems controllers are VME64-based, and support all standard VME-based
modules, yet operate at four times the bandwidth of standard VME.
PACSystems controllers are available in two configurations – the RX7i and

RX3i. The PACSystems RX3i is an integrated programmable automation
controller (PAC) solution that can address applications in the discrete and
hybrid domains. The PACSystems RX7 offers more power, memory, and
bandwidth to han-
Engineering Workstations Operator
Historian, dle mid- to high-end
Application
Change Management Consoles

applications.
Another key feature
that makes PACSys-
Ethernet tems different is a
Controller
common engine
PACSystems Controller used in both the
RX7i and RX3i,
Fieldbus & I/O
providing consistent
Fieldbus & I/O
Open Fieldbus
– Foundation Fieldbus deterministic con-
– Profibus
– Hart trol. Both
– AS-I Interface
– Ethernet controllers are ca-
I/O Devices and
– Genius Instrumentation pable of running
– PACSystems I/O
– VersaMax I/O process, discrete,
Proficy Process Systems Architectural View and motion applica-
tions. Programs
created in one can easily be moved to another. The end user can start with
an RX3i and, as the system grows and expands, switch to an RX7i without
having to reprogram the system.
Support of Third-Party I/O and Controllers

Proficy Process Systems supports a range of I/O offered by GE Fanuc, in-
cluding PACSystems I/O, VersaMax I/O, and Genius I/O. Because of the
system‟s strong roots in the HMI marketplace, Proficy Process Systems can
easily interface to most suppliers‟ I/O and controllers. GE Fanuc has also
been a strong advocate of OPC and has one of the strongest OPC offerings
in the process automation market today.
HMI Environment
The Proficy Process Systems‟ Operator Console provides a user-friendly
environment for process operations and information access. In addition to
state-of-the-art graphical components for process monitoring and control,
the Operator Console also includes alarm monitoring and management
tools for process and system diagnostics and troubleshooting.
Proficy Process Systems offers a choice of visualization technology for host-

ing the Operator Console technology in the form of iFIX or CIMPLICITY.
In 2007, GE Fanuc announced the availability of Proficy HMI iFIX 4.5, pro-
viding monitoring, control and data management for companies
worldwide. This new version of the visualization product addresses a wide
range of customer-identified needs, including advanced reliability to im-
proved ease of use, while adding more power and flexibility.
iFIX 4.5 supports operation on the Microsoft Windows Vista operating sys-
tem. The software automatically adopts the latest operating system look
and feel throughout all of its applications and dialogs. In addition to inte-
gration with its award-winning Proficy Change Management and Microsoft
Windows Vista support, other major enhancements in iFIX 4.5 include dy-
namo versioning, multiple display instances, support for up to 200 clients
connected to one HMI node, and improved OPC functionality and certifica-
tion.
CIMPLICITY is based on open, distributed client/server architecture and

provides plant wide data collection, distribution, and visualization to users
across extended enterprises. The product is scalable and supports both
symmetric multiprocessing architectures and multi-user systems. CIM-
PLICITY clients are Internet-enabled and provide platform independent
visualization to wireless Windows CE-based operator interface devices.
CIMPLICITY connects to enterprise-level systems to distribute production

requirements to the shop floor and feed back production results.
Global Namespace Allows Points to be Referenced throughout System

One intriguing thing about Proficy Process Systems is the ability to do plant
wide control in a single namespace environment. Process control and PID
functionality is available in the same programming and configuration envi-
ronment as discrete and motion control functionality. GE Fanuc‟s approach
of a global namespace, combined with a system that is designed to provide
scalability from very small systems to larger systems in an environment
that is totally network-neutral and offered at a value price point, is a com-
petitive advantage for the company.
Global Namespace provides

real-time data broadcasted from
the controllers and received by
each console, including process
data and process alarms. Proficy
Global Process Systems alarms, for ex-
Namespace ample, are generated directly in
Historian
the controller and sent to the
consoles through the Global
Namespace. Because each con-
sole receives the data and alarm
information independently,
there is inherent redundancy in
Global Namespace Provides Real-Time Data Broadcasted
from the Controllers & Received by Each Console, Including the architecture. When used to
Process Data & Process Alarms create control logic, the Logic
Developer also generates a
global namespace. Once the point is created in the logic, it becomes part of
the Global Namespace and is available throughout the system, including in
graphics or by the Historian.
Ethernet Global Data Provides Standard Control Network

The Global Namespace, along with Ethernet Global Data (EGD) and Ether-
net, provides for common data communications for the system. Ethernet
Global Data is a technology that was developed by GE Energy and GE Fa-
nuc to enable high speed, reliable communications between computer
systems and controllers. Information is broadcasted on the Ethernet and
received by all interested recipients. EGD server can be local to the Engi-
neering Workstation, or it can be in a remote machine. This “configure
once” aspect of the Proficy Process System greatly simplifies creating, main-
taining, and operating the system and GE Fanuc claims it can cut
development times by as much as 40 percent over traditional systems.
Continuous Control Programming via Function Block Diagramming

Within the Engineering Workstation, the Process System Logic Developer is
used to configure control strategies. It provides a flexible choice of lan-
guages for programming the controllers. In addition to Function Block
Diagrams, the Logic Developer also supports IEC languages such as struc-
tured text (ST) and standard ladder logic for high-speed discrete
applications like packaging. End users can create and define their own
function blocks using structured text, ladder logic, or function blocks. This
allows users to take specific knowledge and embed it as a reusable compo-
nent in the system. This feature is particularly valuable to integrators and
OEMs because it allows them to lock their intellectual property in function
blocks that their customers can easily use. Proficy Process Systems also
provides an Advanced PID block, which consists of both feedback control
and feedforward control. It supports adaptive tuning in which users can
change the setpoint into the PID.
Historian
Proficy Process Systems offers a scalable historian that grows with the sys-
tem. The historian is designed specifically for handling process data and
provides high performance storage and retrieval with sub-second collection
and millisecond time stamp-
ing through the Global
Namespace. The historian
has the ability to handle
20,000 events per second for
both read and write. An
EGD OPC Server feeds data
into the historian through the
Historian OPC Collector.
Control Memory Exchange Allows Data in One Controller to
be Exchanged & Shared with Another Controller at High The historian offers functions
Speeds such as trending and a Mi-
crosoft Excel add-in that
allows users to easily extract historical data to an Excel spreadsheet for de-
tailed analysis.
Control Memory Exchange

Proficy Process Systems features Control Memory Exchange, a technology
that GE Fanuc incorporated from its Embedded Systems business. Through
high-speed fiber optics, Control Memory Exchange allows data in one con-
troller to be exchanged and shared with another controller at a rate of over
two gigabaud. Essentially, it provides “Shared Memory on a Wire” for tru-
ly distributed control. This allows end users to synchronize controllers for
distributed control, or reflect the memory state of one controller to another
for redundant operations.
This provides the end user with several key benefits. It allows the end user
to move large amounts of data in one command, in real time, and to coor-
dinate control between processors. It also provides users with the freedom
to design distributed control systems that are easier to build and maintain.
No message protocol is required, allowing the user to simply write or read
data between controllers. Control Memory Exchange is also a good solu-
tion for applications that require redundant controllers. Users can reflect
the entire data state from one controller to another, also known as Reflec-
tive Memory Exchange. Should a problem arise in the primary controller,
the secondary controller can instantly take over with the full and current
state of the process.
Target Industries
GE Fanuc Intelligent Platforms is specifically targeting a range of industries
for Proficy Process Systems. Aside from the pharmaceutical, food & beve-
rage, and consumer products industries, GE Fanuc is also targeting sectors
such as ethanol, power, water & wastewater, and oil & gas. In ARC‟s view,
these sectors play best against GE Fanuc‟s strengths in batch and hybrid
control. GE Fanuc also has considerable expertise in specific applications,
including blending, fermentation, and LNG regasification.
GE Fanuc Intelligent Platforms took advantage of many of GE‟s recent ac-

quisitions to develop Proficy Process Systems. This includes an optional
advanced multivariable control capability from GE Energy (via the Conti-
nental Controls advanced process control software acquisition). GE Fanuc
jointly developed the Global Namespace, which is core to the Proficy
Process System, with the Turbine Control group. Some of the key visuali-
zation (iFIX) and batch (Proficy Batch ) technology derives from the
Intellution acquisition, while elements of the Production Manage-
ment/MES (Historian, Plant Applications) technology come from the
Mountain Systems acquisition.
Proficy Process Systems is available now, and GE Fanuc is going to contin-

ue to drive functionality into regular new releases of the platform. The
company is currently working on the 1.5 version release of the Proficy
Process Systems product, which is due in Q2. This will add the capabilities
for dynamic modifications to the EGD Global Namespace, update the sys-
tem for iFIX 4.5, and provide Batch 5.1 on the installation DVD.

GE Fanuc Intelligent Platforms recently acquired the assets of the MTL
Open Systems Technology (MOST) product lines, including the MTL8000
general purpose I/O, intrinsically safe I/O, SafetyNet system, and process
control technologies. With the addition of a line of redundant-capable,
SIL2-certified controllers and intrinsically safe I/O to its Process Solutions,
GE Fanuc is now able to fully address the safety system needs of key
process industries including oil & gas, chemical & petrochemical, water &
wastewater, natural gas, and pulp & paper. Allowing the I/O to be
mounted directly in Division 2/Zone 2 or Division 2/Zone 1 hazardous
areas provides a cost-effective intrinsic safety solution.
The MTL8000 I/O and its proven technologies are deployed around the
world by process system OEMs, system integrators, and end users to solve
their most demanding process control applications. It is built to withstand
the extremes of temperature and vibration, as well as the hazardous and
corrosive gases, that rule out the use of conventional I/O in unfriendly en-
vironments. Included in this product line is a comprehensive solution for
safety-related applications, including: process shut down (PSD), emergency
shut down (ESD) systems, and burner management systems (BMS). It is a
SIL2 safety system in compliance with IEC 61508, and is built on the same
platform that is already widely used in process control applications.
This is an excellent fit for GE Fanuc, which will now have a full line of SIL
2- compliant and intrinsically safe open control platform products. MOST
offers a totally open control environment that can address SIL 2 and intrin-
sically safe requirements. They have a good installed base in the same
process industry segments that GE Fanuc is targeting with its Proficy
Process Systems offering. These include the oil & gas and water & waste-
water industries.
MOST has had a lot of success in applications where a pure PLC platform
provides too little functionality and a full-blown DCS too much (a space
that GE Fanuc fully addresses with its PAC Systems). The MOST offering
essentially provides a blank slate to which GE Fanuc can apply its own ap-
plication expertise and further develop GE Fanuc‟s adherence to ARC‟s
Collaborative Production Systems (CPS) model.
Key Industries
CPG; Food & Beverage; Life Sciences; Metals; Mining; Oil & Gas Pipelines,
Production, and Refining; Pharmaceutical; Power; Power Generation; Pulp
& Paper; Water & Wastewater

In ARC‟s view, GE Fanuc is in a good position to take advantage of the
many opportunities that the process automation marketplace now offers.
Of course, the company has a long road ahead in a market that is already
saturated with players both big and small, but GE Fanuc‟s‟ capability for
plant wide control, combined with a value price point and network-neutral
stance, should appeal to many process manufacturers.
GE Fanuc may be a new entrant into the marketplace for process automa-
tion systems, but it already has a strong presence in several markets that
serve the process industries that will give it an advantage when it comes to
getting new business and expanding its footprint at existing customer in-
stallations. Intellution has a huge installed base among the process and
hybrid industries, as do the company‟s batch solutions and PLCs. GE Fa-
nuc also has the advantage of being free to pursue these opportunities
without having to migrate an existing base of process automation system
customers.
ARC has said for some time that the hybrid industries in particular are ripe
for innovation and change. A key enabler for this is the adoption of a Col-
laborative Production System framework where all types of control from
continuous process to batch, discrete, and motion control can exist in and
be configured through a single, open environment. More importantly,
these domains of control must also exist in an environment that has stan-
dards-based and transparent access to data from the operations
management domain. Building an open control platform is one thing, but
placing it in context with an open and collaborative environment for opera-
tions management is where the real power is. It provides a totally open
window into the entire manufacturing enterprise that lays the groundwork
for real optimization of manufacturing processes.
What‟s interesting about GE Fanuc‟s approach, however, is the company‟s

acceptance of the fact that we live in an open world. Through their back-
ground in providing solutions that often coexist with other suppliers‟
hardware and applications, GE Fanuc has a lot of expertise that it can leve-
rage to provide an open and neutral environment.
GE Fanuc‟s level of openness also plays well with its OEM and system inte-
grator partners. Most automation suppliers today are focused on building
their own service capabilities, but GE Fanuc has a lot of strength it can draw
from through its existing network of partners. The company will have to be
careful to take the right approach developing its own internal service capa-
bilities while cultivating relationships with partners.
Despite these advantages, the company realizes that it has a long road
ahead and its work is just beginning. There is already a lot of competition
in the process automation marketplace and GE Fanuc is not the only new
entrant into this market. The company will really have to play to its
strengths and not try to cast itself in the mold of the traditional large DCS
suppliers. The key industries that GE Fanuc is targeting are those that are
typically underserved by adopting a combination of PLC and HMI technol-
ogies, but for whom the functionality of a full-scale DCS that would
normally be used in the refining or petrochemical industries might be over-
kill. Offering these industries the specific functionality they require, along
with a CPS-based approach to batch and operations management, should
serve the company very well.
GE Fanuc must also continue to drive synergies with the other businesses
in GE Infrastructure and Industrial to expand functionality of Proficy
Process Systems. Many possibilities exist with the Bently Nevada, Conti-
nental Controls, and other GE businesses that have a hand in automation
and production management
Honeywell Process Solutions

http://hpsweb.honeywell.com
DCS Offerings
Experion Process Knowledge System (PKS); TPS; PlantScape; TDC3000
Regions
India
Description
Honeywell has the largest contiguous installed base of any single process
automation system, with the TDC2000, TDC3000, TPS, and Experion PKS
systems. The system is contiguous because Honeywell has taken an evolu-
tionary approach since the inception of the DCS in 1974, with incremental
changes over time that have kept the system up to date with current tech-
nology trends.
Honeywell‟s latest evolution in its system platform is Experion PKS, first

introduced in 2002. The goal of Experion is to provide Honeywell custom-
ers with single, scalable open system architecture while preserving their
investment in their
installed base of
TDC, TPS, Alcont,
PlantScape, and
other Honeywell
control systems.
PKS is a significant
evolutionary step
for several reasons.
From an application
perspective, Expe-
rion leverages
Honeywell‟s
strengths in numer-
ous areas such as
collaborative pro-
duction
management
Experion PKS Architecture (CPM), advanced
control and optimization, and vertical industry solutions capabilities. This

evolution extends into integrated solutions for capturing and automating
the knowledge from a transitioning workforce, delivering on their com-
mitment to improving plant safety and efficiency.
Experion PKS was the first system from Honeywell to embed domain ex-
pertise and related functionality from its advanced control and
optimization business in a significant way. It also was the first platform
from Honeywell to rely on an industrial Ethernet-based network with Fault
Tolerant Ethernet (FTE), and was the first to incorporate a unified approach
to fieldbus and bundled plant asset management (PAM) applications with
the inclusion of Asset Manager. The system also took a unified approach to
safety with the Safety Manager platform, which Honeywell claims is the
first safety instrumented system (SIS) to earn certification from TUV Rhi-
neland for Safety Integrity Level (SIL) 3 applications (IEC 61508 and 61511
standards). Honeywell provides integrated MES solutions with POMSnet
production management functionality for the pharmaceutical industries,
Business FLEX® production management applications for the process in-
dustries, and OptiVision for the pulp & paper industry.
With the new Series C I/O and controller, Experion release R300 took con-
trol hardware one step further into the future, while also protecting
customers‟ current installed investments. For some time, ARC has been
saying that it is becoming increasingly difficult for suppliers to add value to
their control hardware. The influx of commercial off the shelf (COTS) com-
ponents has drastically reduced the price of proprietary control hardware,
which at the base level, is usually little more than standard commercial
components packaged in a configuration that is acceptable for hazardous
industrial environments.
Honeywell, however, has taken a unique approach to the philosophy of

control hardware with a new design that rethinks the role of hardware and
its future in the plant. Series C incorporates a vertically designed cabinet
architecture. Instead of racks of controllers and I/O mounted horizontally
one immediately next to the other, each Series C module sits on its own
modular and removable terminal, with modules mounted vertically on top
of one another in an angled fashion, allowing for convection air currents
between modules. The new design actually allows for a smaller footprint,
and better thermal management. This eliminates the need for a common
backplane, thus also eliminating the corresponding single point of failure.
Honeywell extends the capacity of the control system to improve plant effi-
ciency with its second-generation wireless solution, OneWireless. The
OneWireless network is a universal and multi-functional mesh network
that supports multiple wireless-enabled applications simultaneously to op-
timize plant efficiency, improve safety and reliability, and help ensure
regulatory compliance. The breakthrough value of the solution lies in the
ability to integrate valuable data into existing control systems and ad-
vanced applications, while also sharing that data with other networked
applications.
Experion PKS Release 310

The newest version of Experion PKS is version R310. Key enhancements
include integration of Honeywell‟s Safety Manager safety system platform,
a new option that allows users to “shelve” non critical alarms (a develop-
ment related to Honeywell‟s involvement in the Abnormal Situation
Management Consortium), a set of power and turbine control function
blocks, and the new Batch Manager that drives batch control directly into
the controller.
The new Peer Control Data Interface (PCDI) provides a direct interface to
Modbus TCP control devices, such as RTUs, which are accessed through
the Tofino firewall. Honeywell has an agreement with MTL to sell the To-
fino in addition to its own Experion PKS Control Firewall. Other new
features include Series C Digital Input Sequence of Events (DISOE) and in-
tegration with Rockwell Automation PowerFlex drives. To expand on its
integrated safety capabilities with Experion PKS and Safety Manager, Ho-
neywell is also offering integrated fire and gas detection capabilities. By
2010, Honeywell expects to have incorporated Windows Vista and Win-
dows 2008 Server capabilities. Class-based recipes for Batch Manager.
Series C Profibus will also be supported.
There is also a lot more activity around Honeywell‟s migration solutions.

Honeywell has always provided its end users with a consistent migration
path for its own control systems. Honeywell has no end-of-life date for ei-
ther the TDC platform or the C200 controllers, and is even enhancing the
C200 offering. Honeywell has now turned its attention to many of its com-
petitors, offering a growing set of migration solutions, from panel-boards
that can interface directly from competitor‟s I/O to Honeywell controllers,
to things like automated graphics conversion tools and a full set of services.
Honeywell is taking a risk-mitigation approach to migration that empha-
sizes reduced downtime and, when possible, hot cutover with zero down-
time.
Honeywell Controllers Achieve MUSIC Certification

Honeywell announced that its Experion Process Knowledge System (PKS)
C300 Process Controller has achieved the new Mu Security Industrial Con-
trol Certification (MUSIC). The MUSIC certification is designed specifically
for IP-based controllers and is closely aligned with the emerging ISA-SP99
security standards. It enables organizations that rely on critical infrastruc-
ture or process control to ensure their network equipment and applications
meet industry-defined benchmarks for safety, robustness, resiliency, and
conformance. Mu Security utilized its Mu-4000 security analyzer to test the
C300 controllers with about 60,000 communication variations in an attempt
to crash the system.
Honeywell Expands Batch Capabilities

Honeywell‟s Experion batch control solution has three major components:
Experion Batch Manager, Procedure Analyst, and POMSnet. Batch Manag-
er resides in a controller to provide more security and speed of execution
than a conventional batch control package, where it may reside in a
workstation or server. Batch Manager includes a Recipe Control Module
(RCM), a Unit Control Module (UCM), and a Phase Function Block. The
RCM stores formula variables in phases and retrieves batch record values
during phase execution. The UCM represents plant equipment. It executes
phases and can manage simple queues in RCMs. The Phase Function Block
initiates Phase (Sequential Control Module (SCM)) execution and sends and
receives recipe and report values to and from the Phase. Batch applications
that require high availability or have short cycle times are ideal candidates
for Batch Manager.
Procedure Analyst provides integrated batch information, including batch

and continuous control history, alarm and event history, query, trends, and
reports. It can interface directly with Batch Manager in a controller display-
ing information on running or completed batches. POMSnet provides the
higher level production management and MES functionality, such as recipe,
procedures, and electronic batch record documents control; and integration
of HMIs, unit graphics, and instructions.
Honeywell calls this combination of integrated batch control application

working in the Experion environment their Manufacturing Control System
(MCS). It integrates MES and process control that leverages ISA-88 stan-
dards to provide a single environment for manufacturing operations and

automation with seamless transactions between systems and personnel.

Honeywell acquired Tridium in 2005. Tridium‟s Niagara Framework is an
open software platform that integrates diverse systems and devices from
different manufacturers, regardless of communication protocol. It is easily
managed and controlled in real time using a standard web browser inter-
face. Current applications include energy management, building
automation, telecommunications, security, lighting control, maintenance,
and total facilities management. Tridium‟s Niagara Framework is the basis
of Honeywell„s ComfortPoint control system, and Honeywell‟s acquisition
of Tridium will facilitate further integration of its advanced technology into
Honeywell‟s BAS products and services. While Tridium will be part of the
Honeywell BAS business, the acquisition is interesting for the process au-
tomation community because the company is implementing around the
1499 standard.
Also in 2005, Honeywell acquired InterCorr International, Inc., a worldwide

leader in solving corrosion and materials problems. InterCorr‟s proprietary
SmartCET* technology gives plant operators access to current, actionable
process variable information, such as the corrosion rate and pitting (loca-
lized corrosion) detection. Other parameters available through SmartCET
can be used for online corrosion diagnostics and for improved accuracy of
corrosion rate data previously unavailable through process control systems.
Integrated with Experion, SmartCET allows operators to transform raw cor-
rosion-monitoring data into high-value process knowledge. Operators can
use this information to make critical business decisions quickly and take
proactive actions to optimize plant performance and reliability. Benefits
include reduced maintenance costs and increased unit productivity through
minimizing failures, avoiding unplanned downtime, and increased run
time.
Recently, there has been much discussion about the IEC61499 standard.
This standard defines the structure and interoperation of function block-
based resources in a truly distributed system. It is the next logical evolu-
tion from IEC61131 based systems. Both utilize function blocks and the
IEC61131 languages, but where '1131 relies on common services such as a
single master clock, '1499 has the ability to reconcile different services, such
as different time bases, into a single execution environment. This is ex-
tremely well-suited to a geographically distributed, resource-disparate

SCADA system. ARC predicts that, in the future, a IEC61499 Reference
Model will provide the foundation for SCADA systems.
In 2007, Honeywell announced it had signed a definitive agreement valued

at approximately $260 million to acquire Enraf Holding B.V., a division of
privately held Delft Instruments, based in Delft, Netherlands. Enraf is now
part of Honeywell Process Solutions (HPS), expanding Honeywell‟s global
portfolio in high-growth, high-service industries, including oil & gas. In
2006, Enraf had sales of approximately $130 million.
Key Industries
CPG; Electrical; Food & Beverage; Lifesciences; Metals; Mining; Oil & Gas;
Oil & Gas Pipelines; Oil & Gas Production; Oil & Gas Refining; Pharma-
ceutical; Power; Power Generation; Printing & Publishing; Pulp & Paper;
Water & Wastewater.

Honeywell has taken some unique steps with the Experion PKS R300 and
subsequent releases. With the influx of commercial off the shelf technology
in control hardware, it is increasingly difficult for process automation sys-
tem suppliers to add value at the hardware layer of the system, particularly
at the controller and I/O level. Honeywell's new vertical design is unique
in the industry and provides the reduced footprint that has increasingly
become a concern for users.
Honeywell, however, has also had to bear the cost of developing and de-
signing this new hardware platform, as well as bringing it forward in the
future. In Honeywell‟s view, this was a necessary step to keep its technolo-
gy offerings as current as possible and provide the most value to the user.
Cyber security breaches and virus attacks continue to plague business and
industry with no signs of slowing down. Honeywell's steps to address the
issue of cyber security with embedded control firewalls and a more secure
network architecture also addresses key user concerns regarding the vulne-
rability of automation systems. Honeywell must continue to build more
security into Experion PKS to address the ever-growing list of threats, not
only in the realm of IT, but also in the realm of physical plant security. Ho-
neywell can take advantage of its security systems business to drive this
functionality. With the release of the Modbus Firewall in Experion R310
coincident with C300-based Modbus TCP redundant Ethernet communica-

tions, Honeywell continues to demonstrate a serious focus on cyber-
security.
Perhaps the most interesting aspect of this release from a functional pers-
pective, however, is the enhanced procedural operations. ARC definitely
sees a continued reduction in workforce knowledge that can only be accu-
mulated with experience. Capturing this knowledge will be essential for
the future success of any process manufacturer. More importantly, the Pro-
cedural Operations function conforms to a key aspect of ARC‟s CPAS
vision, which is the automation of state transitions in the plant.
Invensys Operations Management (IOM)

http://www.ips.invensys.com
DCS Offerings
I/A Series, Foxboro A2
Regions
India
Description
In June 2009, Invensys announced the newly organized Invensys Opera-
tions Management division, which incorporates the industrial automation
business‟ of Invensys Process Systems (Foxboro, Triconex, SimSci-Esscor,
and Avantis), Wonderware, and Eurotherm into a single Invensys division.
The Invensys DCS business included in the scope of this report includes the
core Foxboro systems, I/A Series and Foxboro A2, as well as the DCS busi-
ness of Eurotherm.
I/A Series system

The I/A Series system is Invensys‟ flagship DCS. I/A Series is unique in
that it has remained a consistent platform since its inception in the late „80s,
and has evolved to keep pace with current technology trends. The I/A Se-
ries was the first system to embrace Ethernet as its control network and the
first to embrace a fully functional object-oriented architecture with the Ob-
ject Manager (OM). Both the Ethernet-based control network and OM
remain key components of the I/A Series today.
In recent years, Foxboro has refreshed virtually every component of the I/A
Series system. The latest iteration of I/A Series features one-gigabit Ether-
net Mesh Networking technology, FCP270 field-mounted control
processors, and Field Device System Integrator (FDSI) modules. Remaining
true to its “continuously current” philosophy, the I/A Series system allows
seamless integration of the new process controllers, Fieldbus Module (FBM)
I/O, and Operator Stations that are available in both Windows and UNIX
configurations.
The introduction of the 200 Series of Fieldbus I/O modules brought Ether-
net communications in the product down to the I/O device level. These
modules communicate via a redundant 100MB Ethernet to Control Proces-
sors. Peer-to-peer communications between controllers and all controller-

to-host communications are also via Ethernet. The product employs a top-
to-bottom fault-tolerant architecture. Foxboro provides standard TCP/IP
Ethernet communications for all servers in the system (both Windows and
UNIX). Both Ethernet and serial devices can be integrated into the PAS
network. Dedicated, device-level I/O is supported for Foundation Fieldbus
H1 and HART, as well as Profibus DP. Ethernet-based integrator devices
are provided for various PLCs and other control systems. MODBUS,
ABDH, and proprietary serial devices are integrated via a family of soft-
ware-defined device integrator modules.
Version 8.0 of the I/A Series system also offers optionally redundant Foun-
dation Fieldbus H1 interface modules and enhanced Foundation Fieldbus
configuration tools. I/A Series is also the first system using FOUNDA-
TION Fieldbus that integrates both FDT and DD technologies. Invensys is
a key member of the FDT Group and a leader in the adoption and devel-
opment of FDT technology. FDT complements other open standard
technologies for advanced maintenance and diagnostics.
In 2004, Invensys announced a new suite of Alarm Management Services

that can be applied to both I/A Series and competitor systems. Using
alarm diagnostic software, Invensys' process control specialists provide ex-

pert alarm rationalization, re-engineering, and ongoing support services.
In 2005, Invensys announced that all new I/A Series Workstations for Win-
dows will come with McAfee VirusScan Enterprise software pre-installed at
the factory. This provides I/A Series systems with a very high degree of
protection from plant disruptions caused by software virus outbreaks be-
ginning right from the point of manufacture through system setup, confi-
guration, acceptance testing, commissioning, and day-to-day process
control operations.
Recent I/A Series Enhancements

Invensys has introduced important incremental enhancements to the I/A
Series automation system controller family. These I/A Series Version 8.3
hardware and software enhancements provide a straightforward, cost-
effective path for users of older I/A Series systems to upgrade their systems
to the latest I/A Series Version 8.X technology (including the high-
performance/high-availability Mesh Control Network) without having to
replace or rewire their existing I/O modules. This allows users of these
older I/A Series systems to take advantage of the latest control capabilities
of the high-capacity, rack-room-mounted I/A Series ZCP270 controller to
help further improve plant performance, and/or remove previous limita-
tions on the number of I/O modules that can be supported by the field-
mounted, I/A Series FCP270 controller.
Foxboro A² and SCADA Systems

Early in 2003, Invensys introduced the Foxboro A² automation system, a
new economical, easy-to-use, and expandable DCS. Foxboro A² integrates
technology, expertise, and services from across Invensys to provide process
plants with an automation solution that fits their applications better than
PLCs and costs less than traditional DCSs. Based on Invensys‟ well-proven
Eurotherm technology, the system I/O combines flexibility, high capability,
and ruggedness at a low price point. A wide variety of different analog and
digital process inputs and outputs come in high-density configurations that
minimize space requirements. Several different controller options are
available. Controllers can be mixed and matched as needed to meet specific
control requirements at the lowest possible cost. Full PID and advanced
regulatory control functions are supported. Excellent support is also pro-
vided for IEC 1131 sequential control and phase logic, plus ISA S88 batch
control.
The Foxboro A² automation system provides DCS level functionality at

prices comparable to PLCs and can be used to configure batch control strat-
egies within the standard configuration capabilities, or it can be used as the
control platform for Wonderware‟s FactorySuite and InBatch software.
Foxboro A² is Microsoft Windows-based and supports graphic, IEC-61131
configuration tools (including function block, sequential function charts,
and structured text), and PID and advanced regulatory control. A library of
pre-constructed function blocks is also available to speed application de-
velopment.
Invensys presents the company‟s FoxSCADA system presented as an open

SCADA architecture with the capacity to integrate legacy SCADA, IT, and
voice/vision systems to provide a unified operator environment. The sys-
tem uses an ODBC-compliant, object-oriented database that supports
distributed data and distributed processes. High availability is achieved by
multi-level redundancy with hot failover. Redundancy is managed at the
object level and objects can include all system components including
workstations, software processes, customer calculations communication
channels and point objects.
InFusion
Released in 2006, Invensys‟ InFusion Enterprise Control System (ECS) ful-
fills the vision of an enterprise-level control system and conforms to ARC‟s
vision for a Collaborative Operations Management platform.
What is InFusion and what makes it unique? This discussion is probably

best prefaced by describing what InFusion is not. InFusion is not a “new
DCS” from Invensys and is not designed to replace the I/A Series system,
Foxboro A2 system, or any other DCS offering supported by Invensys. In-
stead, InFusion is designed to operate at a level above where the traditional
DCS operates, providing a single information space throughout the enter-
prise and across multiple process control domains. InFusion can retrieve
and incorporate data and information from any element of the control sys-
tem at any time. In fact, InFusion is designed to aggregate the data and
information provided by DCSs, safety systems, production management
applications, and enterprise level systems into a unified environment.
By using a common actionable context, every person in the company can be

empowered to access the information they need at the right time. InFusion
also has the ability to capture the knowledge of workers so that knowledge
can be reused and distributed throughout the enterprise. All of this is done
in an environment that incorporates the same determinism and high avail-

ability that is found in the process automation system.
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InFusion Historian
IEE & Galaxy Server

InFusion View
Asset Set Engineering Base Asset Management

Optimization Environment
Fault-Tolerant 1 GB Mesh Control Network
I/A Series DIN Installed DCS

Rail Mounted
Distributd Control
Mobile Operation
Station
Safety System
InFusion Logical View
InFusion combines a framework that binds everything together

and executes necessary tasks, with a set of applications and tools. Invensys‟
ArchestrA technology is the glue that integrates of all these systems and
applications. ArchestrA, which Invensys describes as an industrial services
oriented architecture (SOA), is already Installed in over a thousand plants
around the world. InFusion also relies heavily on Microsoft technology and
offers close integration with SAP and other ERP systems. InFusion will be a
constantly and consistently evolving offering that will eventually incorpo-
rate all of the automation expertise of Invensys.
Two of the most important basic components of InFusion include the Ap-
plication Environment and the Historian. The InFusion Application
Environment is a plant information and automation software environment
that brings together all aspects of the plant in real time. Application objects
are the core component of the InFusion Application Environment and
represent various functional elements that can contain data, execute pro-
grams, or transact information in real time.
Inside the Application Environment, users and developers can engineer

application objects that can represent anything in the plant, not just control
elements. For example, an application object can be created that modifies
alarm states in controllers, or an object that monitors runtime of a pump.
Application objects can be widely varied in function and are fully available
to the users, allowing Invensys, end users, or other engineers to create ap-
plication objects that are instantiated and then mass deployed throughout
the system. This is a powerful capability, providing a foundation to distri-
bute best practices. Any template that is created in the system can be
modified and the redeployed throughout the system. This ability to build
object templates can greatly reduce engineering time. Objects can have a
number of facets and metadata associated with them, such as alarming, vi-
sualization, and so on.
InFusion Access offers a library of communication interfaces that allow us-

ers to connect to practically all legacy control systems and other common
third-party subsystems that have the ability to communicate digitally.
These interfaces, called Data Access Servers (DAServers), standardize how
information is presented to other InFusion components, such as visualiza-
tion or historian applications. The driver library supports more than 300
third-party device protocols. InFusion Access enables various specialized
systems to speak a common language. It also provides a level of common
data aggregation, promoting security and effective data management.

Acquisition of CIMNET
In 2007, Invensys announced an agreement to merge CIMNET into the for-
mer Invensys Process Systems (IPS) division in an all-cash transaction.
With headquarters in Wyomissing, Pennsylvania, CIMNET is a leading de-
veloper of manufacturing execution systems (MES) and manufacturing
intelligence (MI) software. The Factelligence Industrial Portal and DNC
Professional products are used by Fortune 100 companies for managing
and controlling manufacturing operations. CIMNET's MES software, DNC
software, and DNC hardware have provided the backbone for over 1,000
customers worldwide.
Divestiture of APV
In 2007, Invensys agreed sell APV to SPX Corporation for a cash considera-
tion of £250 million. In ARC‟s view, this sale is consistent with Invensys'
overall strategy, which seems to be increasingly focused on the services
business and automation. While APV (which originally stood for The
Aluminum Plant and Vessel Company) does have a services and automa-
tion component to its business, its real strength is in process equipment.
Invensys had developed some synergies between APV and the former IPS
business, and we would expect that relationship to continue in some form
even after the sale.
Key Industries
CPG; Food & Beverage; Lifesciences; Metals; Mining; Oil & Gas; Oil & Gas
Pipelines; Oil & Gas Production; Oil & Gas Refining; Plastic & Rubber;
Pharmaceutical; Power; Power Generation; Power T & D; Pulp & Paper;
Water & Wastewater.

The continuous evolution of the single I/A Series PAS platform is a key
strength for Invensys. Being the third largest PAS/DCS supplier, the com-
pany also has an impressive installed base of systems.
As did IPS, Invensys‟ newly formed Invensys Operations Management

(IOM) division also has considerable services and solutions capabilities,
and will continue to experience significant revenue growth in its services
business. Another key strength for Invensys, is its advanced approach to
real-time performance management through its Dynamic Performance
Management (DPM) business.
IOM‟s key challenges ahead include the continuing evolution of the I/A
Series system. While the role of the ArchestrA common architecture is al-
ready mapped out in many Wonderware offerings, as well as in the
Foxboro A² system, the future of ArchestrA in the context of the I/A Series
system is still in the formative stages. IOM must continue to evolve the I/A
Series platform while maintaining and supporting its considerable installed
base. On the other hand, according to company reports, Invensys already
has had much success leveraging InFusion as the platform for many of its
customers advanced SCADA applications and other challenging applica-
tions requiring multi-platform integration, including digital oilfield appli-

cations in the upstream oil & gas industry.
Metso
http://www.metsoautomation.com
DCS Offerings
metsoDNA; maxDNA
Regions
India
Description
Metso‟s Automation business line specializes in automation and informa-
tion management application networks and systems, field control
technology, and life cycle
performance services. Au-
tomation business line is a
part of Metso Corporation‟s
Energy and Environmental
Technology Segment. Met-
so's other business
segments are Paper and
Fiber Technology and Min-
ing and Construction
Technology. Metso em-
ploys over 29,000 people
worldwide, of which over
3,800 work for Metso‟s Au-
tomation business line.
Metso shares are traded on
the Helsinki Stock Ex-
change.
Metso‟s Automation busi-

ness comprises two
operating divisions to serve
Metso DNA Architecture
distinct customer segments
worldwide. Main customers are the energy, power, and oil and gas indus-
tries as well as the pulp and paper industry. Today, Automation business
line‟s primary businesses are in automation and information management
application networks and systems, field control technology, and lifecycle

performance services.
Metso Automation‟s original system platform was Damatic, the last incar-
nation of which was Damatic XDi. In the late „90s, the company released
the new metsoDNA platform, which embraced the Windows operating sys-
tem and provided enhanced functionality in terms of production and asset
management, as well as fieldbus connectivity through Profibus DP and Pro-
fibus PA. The latest platform release is metsoDNA CR - released Autumn
2006. metsoDNA CR is sold to all process areas. Metso Automation offers
a comprehensive application compatibility and upgrade path for the in-
stalled base.
Metso acquired the MAX Control system business in the United States in
2000, and has since migrated MAX to its own maxDNA platform. maxD-
NA is primarily sold to the electric power industry.
Metso Automation‟s business line generates the majority of its automation

system revenues from the sale of control systems to the pulp, paper, and
energy industries for continuous applications. Metso also gained a large
installed base of systems in the power industry when it acquired the MAX
control systems division of Leeds & Northrup.
metsoDNA CR
Introduced in Autumn 2006, metsoDNA CR is a single platform for all con-
trol, information management, and communication purposes. It offers tools
for transforming a production organization into a results-providing com-
munity. metsoDNA CR combines the machine, process, quality, and drive
controls, as well as information management applications. metsoDNA CR
is scalable from a few I/Os, to a large system having tens of thousands
I/Os. The name-based communication allows an easy way to expand the
system without additional links. Innovative solutions for process control
and optimization with a wide range of interfaces to field and third-party
systems are available with metsoACN controllers and metsoACN I/O.
metsoDNA CR also introduced a new I/O family, a new controller, new
integrated engineering and maintenance for control applications, fieldbus-
es, and devices as well as a new user environment for operation and
reporting.
metsoDNA CR consists of three activities. User Interaction activity gathers

together intuitive tools for users and communities and gives everyone from
the control room to corporate management access to the same facts and in-
formation. Automated Process activity offers efficient solutions for all
process targets with high availability and a high safety level is achieved by
integrated Safety Instrumented Systems. Secured Life Cycle activity pro-
vides tools to engineer and maintain the entire metsoDNA CR platform.
The network architecture is either turbo ring or star topology fast-switched
Ethernet, with layered security, firewall, antivirus, and DMZ solutions.
The User Interaction Activity‟s main component is DNAuse. The role-

based configurations of DNAuse support production, maintenance, and
other tasks. Any process picture can be switched to the history mode; a vir-
tual time machine to track and analyze what happened in the past –
without any additional configuration. The adaptation to tasks and roles is
quick, with relevant pictures and information easily selected. With the abil-
ity to freely arrange, resize, zoom, and pan windows on the desktop, the
user can store picture selections and desktop layouts. Integrated web-
based reporting tools help building the overall awareness of process and
production situation in the organization. DNAtracer integrates process da-
ta and alarm functions, enabling quick alarm analyses directly from a trend
– with one click. DNAreport integrates events, operations, log book entries,
and process data into a single trend or report. The wireless hand-held re-
mote user interface can be deployed anywhere in the organization.
The Automated Processes Activity offers efficient control solutions in the

new generation metsoDNA CR platform. It seamlessly combines controls
for the most demanding process (DCS), machine (MCS), quality (QCS), and
drive applications with a wide range of fieldbuses and interfaces to third-
party systems. Automated Processes Activity enables a scalable approach,
from a limited number I/O mini system to a large-scale mill network, pro-
viding an open platform of automation and information applications. The
new ACN I/O combines features of centralized and distributed I/O in one
compact design. Offering higher density packaging, better measurement
accuracy, and HART support, ACN IO is fully compatible with earlier ACN
controllers. The latest ACN SR1, designed specifically for use with the
ACN IO, is a compact, rail-mounted controller for small, embedded, and
distributed field solutions. With ACN controllers and ACN IO, all field-
buses are supported using the same technology, tools, and diagnostics, thus
eliminating the need to learn and support several systems. Fast execution
cycles (down to 20 ms with 1ms sequence of events), ensure powerful per-
formance for the most demanding applications.
In the Secured Lifecycle Activity, the core of engineering and maintenance

is DNAexplorer. It provides one easy-to-use configuration and mainten-
ance tool for all control applications, fieldbuses, and field devices, as well as
network document management. The integrated DNAfieldAssessor, a con-
figuration and condition monitoring tool, brings field devices closer to
process operators and engineers, helping them find the right solutions
quickly in disturbance situations. Condition monitoring and advanced de-
vice diagnostics enable proactive field asset management, reducing
unplanned shutdowns and optimizing maintenance costs.
Metso Automation introduced the latest addition to enhanced tools for im-
proved productivity with the new metsoDNA CR LoopBrowser. Integrated
within the metsoDNA CR automation system, LoopBrowser provides au-
tomatic monitoring of control performance. Web-based reporting alerts the
user of poorly operating control loops that can cause increased quality vari-
ation, affect the lifetime of field equipment, or waste raw material and
chemicals. DNAautoTune is a fully integrated, intelligent tool to assist con-
trol loop tuning.

In 2008, Metso acquired a paper quality control business from Finnish Fast-
pap Oy that comprises the manufacturing and final assembly of the
measuring scanners used in Metso‟s Quality Control Systems (QCS) as well
as after-sales services.
Key Industries
Oil & Gas; Oil Power Generation; Pulp & Paper.

Metso's key strengths are its large installed base and application knowledge
in the pulp and paper industry. Metso is particularly strong in integrating
paper machine controls and machinery. The acquisition of MAX control
systems has broadened Metso's existing knowledge of power applications.
Metso has also acquired Aker Kvaerner Pulping power and recovery boiler
business (now part of Metso Power), which provides more in-house power
knowledge. The primary challenge of the Metso‟s Automation business
line is to diversify its installed base so it is not subject to the cyclical nature
of the paper industry, which accounts for a roughly half of its revenues.
Metso Automation is expanding its portion into other industries such as
power and oil & gas to address this issue.
Rockwell Automation
http://www.rockwellautomation.com/solutions/process/
DCS Offerings
PlantPAx Process Automation System
Regions
India
Description
The culmination of the functional enhancements and new developments for
process automation is the PlantPAx Process Automation System. Unlike
ProcessLogix, PlantPAx is a system built from the ground up by Rockwell
Automation that incorporates a unified HMI, control platform, and engi-
neering tools.
Introduction of PlantPAx
In 2008, Rockwell Automation announced the new umbrella name for the
company‟s process automation portfolio – PlantPAx Process Automation
System, which covers all the systems and solutions investments the compa-
ny has made in process automation. A PlantPAx Process Automation
System has a defined & characterized core of Integrated Architecture (logix
+ Factory Talk) but also the ability to add integrated extensions, such as
PlantPAx
AOC from Pavilion or SIL 3 safety from ICS Triplex, as the customer needs
dictate. The company has laid out plans for continued expansion of the
PlantPAx Process Automation Aystem based on a combination of the two
core Rockwell Automation PlantPAx technologies, Logix and FactoryTalk,
and those leveraged from co-investments with partners such as En-
dress+Hauser, OSIsoft, and acquired companies such as ICS Triplex ,
Pavilion Technologies, ProsCon and others.
In ARC‟s view, PlantPAx is a much better name than “Logix Integrated Ar-
chitecture for Process Automation”. The new name also allows for
inclusiveness of what is now a multi-faceted process automation offering
that includes process safety & critical control, process optimization, and
integrated production and operations management functions
The two primary layers of the PlantPAx Process automation are the Logix
control platform and the FactoryTalk suite of applications. The Logix plat-
form provides a unified and common infrastructure that can address
continuous applications as well as traditional batch and discrete applica-
tions. FactoryTalk encapsulates the production management environment
and includes other applications such as batch control, batch management,
asset management, and integration with enterprise resource planning (ERP)
systems. PlantPAx incorporates standards such as IEC 61131-3 program-
ming, EDDL, FDT/DTM, Foundation Fieldbus, HART, EtherNet/IP,
DeviceNet, and ControlNet. ISA-88 hierarchies are now implemented in
the system, as are structural and transactional elements of the
ISA-95 standard. Security is addressed in conformance with the
ISA-99 standard.
Rockwell Automation is focusing on its core strengths that al-

ready exist in process, hybrid, and discrete industries. The goal is to supply
users with a process automation system that suits their needs in terms of
scalability, ease of use, and a plantwide view of control. Current customers
tend to use small to medium size systems, according to ARC‟s definition.
PlantPAx is capable of meeting those requirements as well as the require-
ments for large systems.
PlantPAx Provides a Unified Engineering & Configuration

Environment
A unified engineering environment is a core CPAS requirement. Design
and configuration for PlantPAx in process applications is done through an
integrated environment for creating, modeling, and programming produc-
tion processes. PlantPAx provides automation control programming, al-

lows users to set up and propagate reusable equipment, order and define
products, and allows for process development, simulation, and deploy-
ment. PlantPAx provides a consistent look and feel for all control strategy
development tasks as well as a consistent environment for developing and
testing control applications.
PlantPAx configuration environment covers process control, motion, safety,

discrete control, and drives applications, enabling information to be pro-
vided in context to the users or other applications in the environment.
Rockwell Automation‟s configuration supports the IEC 61131-3 languages,
and they are integrated with each other, enabling function blocks to call
ladder routines, sequential function charts (SFCs), structured text, and so
on. In ARC‟s view, this is a unique ability for Rockwell Automation.
PlantPAx Provides Single HMI Environment

A common HMI environment where users have a consistent interface to
data, when and where they need it, from any point in the system is another
key CPAS requirement. PlantPAx has a common HMI environment, which
is integrated with the Logix control layer.
PlantPAx Provides Single Open Hardware Environment for

Controllers & I/O
The CPAS model specifies a common environment for control hardware
due to its ability to reduce integration costs and provide better scalability
both up and down. PlantPAx can scale from a single unit controller, asso-
ciated I/O, and workstation up to a system with tens of thousands of I/O
points, multiple servers, and multiple controllers. One of Rockwell Auto-
mation‟s advantages is that it has been making control hardware for use in
harsh industrial environments for years. Logix I/O and controllers are
highly durable and can be mounted in harsh environments outside the con-
trol room. Another key advantage is that many Rockwell Automation
systems are already installed today; making it easy to find personnel
trained to program and maintain Rockwell Automation systems.
The recent creation and adoption of new performance based safety stan-
dards such as IEC 61508 and IEC 61511 has led to the need for solutions to
meet these new non-prescriptive requirements. Adoption of the standards
has required quantifying the “risk” and reducing it to an acceptable level.
The risk requirement is quantified as one of four Safety Integrity Levels
(SILs). Process safety standards such as IEC 61511 and its predecessor AN-
SI/ISA-84 identify layers of protection to mitigate the risk.
One way to mitigate risk is through use of an independent Safety Instru-

mented System (SIS). To meet these new requirements, Rockwell
Automation had TÜV certify ControlLogix for use in up to SIL 2 applica-
tions. Rockwell Automation has developed a SIL 3-rated 1oo2 offering
called GuardLogix. The company provides a redundant version of Con-
trolLogix for implementing high availability, which can be used in fault
tolerant applications of the SIL 2 ControlLogix and I/O. These same High
Availability and SIL rated offerings are available for the ControlLogix when
it is used as a basic process control system (BPCS).
The controllers support full redundancy, avoiding a single point of failure.

No extra programming is required for redundancy, which minimizes engi-
neering effort. Automatic program synchronization eliminates the need to
maintain separate programs for the primary and secondary controllers.
PlantPAx controllers and I/O also offer high availability, supporting run-
time edits for tags and logic. One unique feature that benefits users of
highly available systems is the ability to upgrade the controller firmware
and control strategies while a system is running.
EtherNet/IP Provides Common Control Network

At the heart of CPAS is a unified communications framework that provides
a common fault-tolerant backbone and delivers synchronized information
among CPAS applications in a plug-and-play environment and manufac-
turing management applications.
EtherNet/IP is the industrial Ethernet solution from the Open Device Ven-
dors Association (ODVA), an industrial consortium also known for its CIP
networks DeviceNet, ControlNet (through a joint technology agreement
with ControlNet International), and now the new CompoNet. The common
thread of all four networks is the “Common Industrial Protocol” (CIP). CIP
is a command set for industrial information exchange that grew out of a
proprietary protocol used in the past by Allen-Bradley (now Rockwell Au-
tomation) controllers. The advantage of the CIP model is that the same
command set is common to all CIP networks, enabling applications to cross
networks without the need to translate protocols.
Since the first EtherNet/IP-enabled nodes shipped in 2000, ODVA has been
busy adding capabilities and extensions to the network through the devel-
opment efforts of its Joint Special Interest Groups – working groups that
focus on a particular technology or application need. These efforts include
CIP Sync, which provides support for IEEE 1588 for synchronization of
clocks and timestamps within a control environment. IEEE 1588 is the fun-
damental synchronization method used by CIP Sync.
New Developments in System Engineering and Control Include

Object Library & Advanced Regulatory Control
Many of the new developments around PlantPAx focus on integrating the
functionality of the company‟s acquisitions and partnerships into the over-
all process automation system architecture, but there are also many new
developments around the core architecture of the PlantPAx process auto-
mation system. One example is in the engineering software. Rockwell
Automation recently announced
the creation of a new engineering
environment that includes a li-
brary of reusable control objects
with tools to simplify its deploy-
ment.
The latest engineering develop-

ment software also provides three
advanced regulatory control
(ARC) instructions that are useful
for applications with multiple inte-
FactoryTalk VantagePoint Dashboard racting inputs/outputs, lengthy
dead times and other applications
that are difficult to control with traditional PID instructions. New ARC in-
structions include internal model control (IMC), which controls a single
process variable by manipulating a single controller output. Coordinated
control (CC) manages a single process variable by manipulating as many as
three different outputs; and modular multivariable control (MMC), which
runs two interacting process variables using up to three outputs. All three
instructions are native to the control platform with built-in auto-tuners.
These are elements of a comprehensive process optimization suite that in-
cludes model predictive control (MPC) from Pavilion Technologies.
Future releases will include the ability to populate the PlantPAx system
with modules from multiple plant design and engineering tools. There was
discussion of incorporating two-way integration with InTools from Inter-

graph.
Smart Binding for Batch Applications

Rockwell Automation has always been strong in batch applications, and its
future philosophy is to apply batch capabilities to solve common problems
that all process industry end users face. The new Smart Binding technology
for PlantPAx gives end users the ability to define characteristics of their sys-
tem, after which they can use these characteristics to make run time
decisions about things like what equipment to use during a production run.
Equipment or unit binding requirements are built into procedures, and de-
cisions can be based on preference or requirement. Smart binding can also
directly address cost concerns, such as being able to pinpoint not just the
right equipment but also the most suitable equipment, such as the warmest
reactor, clean in place, etc. The company is also offering integrated batch
reporting and web based batch reporting as part of its standard batch solu-
tion.
New Control and Visualization Offerings Include Web-Based

Dashboards Based on Incuity, Silverlight
FactoryTalk VantagePoint is a new addition to the FactoryTalk Suite that
allows end users to self-configure Web-based dashboards, trends and re-
ports quickly. VantagePoint software leverages the FactoryTalk service-
oriented architecture and technology acquired through the company‟s pur-
chase of Incuity Software to deliver automatic access to production
information from Rockwell Automation and third-party systems. Through
Internet Explorer, Microsoft Office user interfaces and pre-defined connec-
tors to third-party systems, VantagePoint users can install and configure
their systems in as little as a few hours with minimal technical support.
Manufacturers can also remotely monitor the plant-floor operations status

using FactoryTalk ViewPoint software from Rockwell Automation. Facto-
ryTalk ViewPoint software is one of the first commercially available, thin-
client applications for manufacturing built using the new Microsoft Silver-
light technology. The initial release extends visualization and real-time
decision capabilities beyond FactoryTalk View clients to browser-based re-
mote users.
Integration of ICS Triplex Safety Functions

ICS Triplex safety systems have been integrated with the PlantPAx system
to allow critical information sharing between the systems and provide
plant-wide safety point data, diagnostics, alarms, and operator displays to
any operator station in a plant. These simplify operator effectiveness across
both safety and process control systems. The ICS Triplex system can com-
municate with PlantPAx over EtherNet/IP for control actions. These could
include simple actions such as exchanging interlocks between the systems
as well as opening/closing actuators and initiating shutdown procedures.
The level of integration alleviates the need for any custom integration by
the user and presents operational value for both control & visibility across
systems. The approach allows the systems to be "integrated" while main-
taining "separation", both are important to safety and process control
customers.
Rounding out the Competitive Migration Portfolio

Competitive control system migration continues to be a strategic focus for
Rockwell Automation. The company has been developing solutions for
competitive migration for many of its major DCS competitors for some
time, and has an approach for systems from ABB, Honeywell, and Emer-
son. Rockwell Automation recently announced a wiring conversion
solution designed to migrate legacy PLC users from platforms such as
Modicon to PlantPAx systems. Users can now quickly replace Modicon 800
Series I/O racks with the ControlLogix I/O system without disturbing ex-
isting field wiring. The swing-arm conversion system takes the existing
Modicon 800 I/O swing arm and converts the field terminations to match a
compatible ControlLogix I/O module. The I/O wiring conversion system
for Modicon 800 Series I/O racks is targeted for distribution within Decem-
ber 2008. Conversion systems for other competitive PLC offerings are also
on the way.
Other Relevant PlantPAx Enhancements

Some of the key development activities that have happened in the past two
years for Rockwell Automation‟s process offerings (V16 of RS Logix 5000)
include enhanced Foundation Fieldbus, Profibus PA, and HART integra-
tion, the introduction of FactoryTalk AssetCentre (a joint development
between Rockwell Automation and Endress+Hauser), redundant I/O, user
defined add-on instructions, integrated drives configuration capabilities,
and incorporation of alarms and events. Other key advancements for 2007
include the release of FactoryTalk Historian Site Edition, which was re-
leased in October of 2007 and is the product of the alliance with OSISoft.
ProsCon Acquisition
Rockwell Automation announced it has acquired ProsCon Holdings, a pri-
vately held engineering firm offering proven and technically unique design
solutions to the process industries. Areas of expertise include process tech-
nology, control systems and information technology. ProsCon also
provides modular solutions as an innovative and cost-effective approach
delivering faster implementation of new facilities as well as retrofits for ex-
isting plants. This modular approach helps customers speed up their time
to market for new products.
Headquartered in Cork, Ireland, with an office in Dublin, ProsCon primari-

ly serves major customers in the pharmaceutical and biotechnology
markets. It has a strong reputation for helping companies comply with
regulatory standards and manage their business risk. ProsCon's manage-
ment team and its employees will join the Rockwell Automation global
solutions team and continue to serve their customers locally and around the
world.
This is consistent with Rockwell Automation's strategy for expansion in

their process automation and, more importantly, their services business.
Rockwell Automation needs to continue to expand its services and solu-
tions capabilities for process automation to continue its momentum.
Building industry-specific engineering expertise at a regional level like this
is key to the long-term success of any large process automation supplier.
ICS Triplex Acquisition

In May of 2007, Rockwell Automation announced the acquisition of safety
and critical control system supplier ICS Triplex. Rockwell Automation, Inc.
announced that it has reached an agreement by which it will acquire Indus-
trial Control Services Group Limited (ICS) for £110 million (British pounds)
in cash. ICS trades and does business as ICS Triplex, a leading global sup-
plier of critical control and safety solutions to process industries. With 40
years of experience, ICS Triplex develops, delivers and maintains advanced
products and solutions for high availability, fault-tolerant applications in
process industry segments worldwide.
ICS Triplex annual revenues were projected to be approximately £70 mil-

lion (British pounds) for their current fiscal year, which ends May 31, 2007.
Headquartered in Maldon, United Kingdom, ICS Triplex has more than 500
employees and operations across Europe, the Middle East, Asia and North
America. ICS Triplex provides engineering services, products, and solu-
tions for industries that demand high-integrity critical control. These
industries primarily include Oil & Gas Exploration, Production, Transpor-
tation, and Refining as well as Chemicals and Power Generation.
Pavilion Acquisition
In October of 2007, Rockwell Automation announced that it would acquire
Pavilion Technologies, a privately held company that is a recognized leader
in advanced process control, production optimization and environmental
compliance solutions for process and hybrid industries. Terms of the trans-
action were not disclosed. Headquartered in Austin, Texas, with offices in
Europe and the Asia-Pacific region, Pavilion Technologies serves major cus-
tomers in consumer products, Oil & Gas, Chemicals, and other process
industries. The Pavilion Technologies management team and employees
will become part of Rockwell Automation‟s Architecture & Software seg-
ment. Pavilion Technologies software products will be integrated into the
Rockwell Automation FactoryTalk integrated production and performance
suite, as well as the Logix Control Platform.
The acquisition of Pavilion Technologies bolsters Rockwell Automation‟s

FactoryTalk portfolio by adding strong predictive model-based solutions
that work more closely with other production management functions and
applications. The acquisition clearly puts Rockwell Automation and Pavi-
lion Technologies in a favorable position in the markets they serve.
However, the real winners of the deal are the customers of each company,
who now have access to a more powerful, integrated, scalable, and func-
tionally rich operations management solution.
Incuity Software Acquisition

In April of 2008, Rockwell Automation announced that it has reached a de-
finitive agreement to acquire Incuity Software, Inc., a privately held
company that is a leading supplier of Enterprise Manufacturing Intelligence
(EMI) software. Incuity‟s software provides real-time intelligence for busi-
ness decision support to improve operations and reduce production waste
by providing valuable management insight into a company‟s operations.
Terms of the transaction were not disclosed.
Headquartered in Mission Viejo, Calif., with regional offices in the U.S.,

Canada and South Africa, Incuity Software currently has more than 45,000
seats of its products installed in more than 40 countries in 13 languages.
The Incuity Software management team and their employees will become
part of Rockwell Automation‟s Architecture & Software operating segment.
EMI real-time visibility and performance management software is part of

the fastest-growing segment of production management software. By col-
lecting real-time data at the plant floor, establishing operational context,
and revealing manufacturing information to the rest of the enterprise, it
enables a higher level of performance at the plant level and throughout the
distributed manufacturing enterprise and supply network. Incuity Soft-
ware is a pioneer in this market space. Their team understands the value
and flexibility of enterprise visibility built on the foundation of a strong da-
ta model - which is a key differentiator from many other providers. This
acquisition gives Rockwell Software an excellent way to meet their custom-
ers‟ business need to leverage real-time manufacturing information.
Acquisition of Rutter Hinz Expands Oil and Gas Services

Capabilities
In early 2009, Rockwell Automation, announced its acquisition of Rutter
Hinz Inc., a leading engineering company with expertise in the Canadian
oil and gas industry. Rutter Hinz is a wholly owned subsidiary of Rutter
Inc., a publicly held Canadian company. Headquartered in Saskatoon,
Canada, Rutter Hinz has eight offices in Canada and two in the US, and its
annual sales are approximately $35 million (US). Rutter Hinz has engineer-
ing expertise in industrial automation, process control and power
distribution, specifically for the oil and gas industry, in addition to the
pipeline, utility, mining, forestry and food and beverage sectors. The com-
pany‟s management team and approximately 220 employees have jointed
Rockwell Automation‟s Systems & Solutions business unit.
Rockwell Automation Acquires Xi'An Hengsheng Science &

Technology Company
In November 2008, Rockwell Automation announced its acquisition of
Xi'An Hengsheng Science & Technology Company Limited, a privately
held Chinese engineering firm. Xi'An Hengsheng Science & Technology
delivers automation solutions to the electrical power and other heavy
process industries in China. Located in Xi‟an, China, Xi'An Hengsheng
Science & Technology Company Limited serves customers in the power,
petrochemical, coal mining, chemical and oil markets. The company con-
ducts much of its business in the fast-growing regions of middle and
western China with an installed base of approximately 300 customers. The
company has 85 employees.
Key Industries
Cement & Glass; Chemical; Chemical Fine; CPG; Food & Beverage; Lifes-
ciences; Metals; Mining; Oil & Gas; Oil & Gas Pipelines; Oil & Gas
Production; Plastic & Rubber; Pharmaceutical; Power; Power Generation;
Pulp & Paper; Water & Wastewater.

Rockwell Automation is well positioned to take advantage of the growth
opportunities provided by the global process automation market. The
company has developed a fully functional process automation system that
conforms to ARC‟s CPAS model in key areas, from engineering and confi-
guration to a common hardware platform to presenting information in
context to the right people at the right time from any point within the sys-
tem. The major process automation system players should consider
Rockwell Automation as a formidable competitor in the years ahead, in
North America and globally.
Rockwell Automation‟s background in the discrete industries and its large

presence in the markets for drives, PLCs, discrete sensors, and motion con-
trol provide the company with some unique advantages when it comes to
addressing the process automation space, particularly for its core target in-
dustries such as life sciences, food & beverage, consumer products, fine
chemicals, and oil and gas. These industries typically involve a significant
amount of discrete and motion control processes that are not typically inte-
grated into a single automation system framework. It is this unified
framework across multiple domains of automation that is enabled by The
PlantPAx Process Automation System.
Rockwell Automation does have its work cut out for it. In the process au-
tomation system marketplace, the top tier of suppliers controls well over
two thirds of the market. The company must provide a superior business
value proposition and continue to live up to its release schedule and invest
heavily in research and development. Rockwell Automation is not initially
trying to take share away from the big process automation suppliers in
their core markets such as refining, petrochemicals, and central station
power generation, and this gives the company an edge. The industries that
most underutilize automation to their advantage, such as food & beverage,
consumer products, pulp & paper, and water & wastewater, are the same
industries that Rockwell Automation is targeting with PlantPAx Process
Automation System. . Rockwell Automation must also continue to build
up its capabilities in the area of services and solutions, and it must do this
while maintaining its already strong relationship with preferred system
integrator partners. Much of the value that suppliers can provide their cus-
tomers in process automation comes from services and the ability to
increase plant performance.
Siemens
http://pcs.khe.siemens.com/index_simatic_pcs_7-1075.htm
DCS Offerings
SIMATIC PCS 7, APACS, Teleperm
Regions
India
Description
Siemens AG, headquartered in Munich, Germany, is a major global auto-
mation supplier with activities focused on the areas of industrial and
infrastructure, energy, and healthcare. In fiscal year 2008 (ended Septem-
ber 30), the company had over 400,000 employees in 190 countries and
revenue from continuing operations of €77.3 billion, a 7 percent increase
over the previous year. Siemens underwent a major reorganization in 2008.
Siemens‟ businesses are now grouped into three operating Sectors: Indus-
try, Energy, and Healthcare. The Industry Sector and its products and
solutions address industry customers in the fields of production, transpor-
tation, and building systems. The sector comprises six divisions: Industry
Automation, Drive Technologies, Building Technologies, Industry Solu-
tions, Mobility, and the Energy Sector.
The range of offerings at the Industry Automation and Drive Technology

divisions extends from standard products to system solutions for the ener-
gy and automation technologies used in the manufacturing and processing
industries. These divisions are responsible for the design and production of
a wide range of industrial automation products, including PLCs, CNC,
DCS, industrial PC, industrial drives, as well as the usual array of support-
ing software and peripheral products, including low voltage products,
communications products, configuration and programming software, and
HMI up to MES systems. Drive Technologies offers solutions for electronic
manufacturing as well as complete systems, including standard and large
drives applications for the entire drive train.
The Building Technologies Division bundles Siemens‟ offerings for building

security, automation, and operation – both as a service provider and a
manufacturer of products and systems. Osram‟s product portfolio includes
lamps and optoelectronic semiconductor light sources such as light-

emitting diodes, the related electronic control systems, and light manage-
ment systems. The Industry Solutions Division is a systems and solutions
integrator for the industrial plant market, covering everything from plan-
ning to construction and operation. The Mobility Division networks a wide
array of transportation systems in order to move people and goods effi-
ciently.
The Energy Sector primarily addresses energy providers, but also industrial
companies particularly in the oil & gas industry. The Sector is solidly posi-
tioned in its market, with all six of its divisions holding leading market
positions. The Fossil Power Generation Division offers highly efficient
products and solutions for power generation based on fossil fuels. Offer-
ings range from individual gas and steam turbines and generators, to
power plant construction on a turnkey basis. The Renewable Energy Divi-
sion bundles Siemens‟ activities in the wind energy market. The Oil & Gas
Division offers customers products and solutions for the extraction, trans-
port and conversion of oil and gas.
The Service Rotating Equipment Division provides comprehensive services

for complete power plants and for rotating machines such as gas and steam
turbines, generators and compressors. The Power Transmission Division is
a leading supplier of products and solutions in the high-voltage field. The
specialties of the Power Distribution Division range from solutions for the
automation of power grids to products like medium-voltage switchgear
and components.
Siemens' "Totally Integrated Automation”

Siemens' all-encompassing automation concept is known as Totally Inte-
grated Automation (TIA). This concept leverages one class of automation
products across all applications. While some standard components are
used to achieve the Totally Integrated Automation vision, the emphasis re-
mains largely on integration of Siemens‟ products.
TIA is characterized by a three-fold uniformity in software (configuration

and programming), data management, and communication. This is accom-
plished using common engineering tools and common hardware, software,
and networking interfaces. In the marketplace, this strategy translates into
common components applied to a variety of applications formerly served
by application-specific products.
Siemens' industrial automation solutions use the networking technologies

from Profibus International (PI) and Industrial Ethernet. Industrial Ether-
net is used as the system bus connecting controllers, HMI servers, and
batch servers, and for inter-controller communication. At the I/O level,
PROFIBUS DP serves as the high-speed network, while PROFIBUS PA
segments extend the fieldbus to networked field instruments. Finally,
PROFInet is Profibus' emerging industrial Ethernet standard that will aug-
ment the Profibus architecture as Ethernet gains acceptance at the device
level. Profibus also offers application-specific profiles to address a wide
variety of specific networking requirements. For HART users, PCS 7 offers
integration of HART-compatible field devices.
SIMATIC PCS 7
SIMATIC PCS 7 is Siemens‟ PAS offering that serves as the fulcrum for all
of Siemens‟ process industry strategy. SIMATIC PCS 7 currently has over
seven thousand reported installations worldwide. Fulfilling the TIA vision
of common hardware infrastructure across application domains, SIMATIC
PCS 7 includes hardware based on the common SIMATIC platform. SI-
MATIC PCS 7 utilizes common ET200 Series I/O, common PROFIBUS and
Ethernet communications, common configuration, engineering, operator
interface, and a single unified automation database.
The SIMATIC PCS 7 Engineering Station (ES) provides tight integration

and automated data transition between engineering, configuration, opera-
tions, and HMI. The IEC 61131-compliant programming tools offer easy
engineering of the configuration logic using a single database, pre-
configured library blocks or custom blocks, statement list, ladder diagram
and function blocks. The ES is based on Siemens‟ Step 7 programming
software, thus contains all its strengths in addition to Structured Control
Language (SCL), Process Object view, Continuous Function Chart (CFC),
Sequential Function Chart (SFC), Safety Matrix, and ISA-88 compliant plant
hierarchy views.
The Component View in the ES allows for configuration of control hard-

ware and is typically the view for maintenance personnel or technicians.
Configuration can be done in standard function blocks or in SFC. Users can
also create customized function blocks. The Plant View within ES is the
logical view that provides hierarchical structuring of the plant by process
area, unit, or component.
The Process Object view in ES is the primary engineering view of ES and

offers a single point of entry. It provides a modular and object-based
graphical view of the engineering process and provides a device-oriented
perspective for configuration. Process Objects represent devices such as
pumps, motors, and field devices by providing access to context-specific
information such as I/O assignment, control hardware, HMI representa-
tion, archives, function block parameters, alarm priorities, and alarm
messages.
ES reduces design costs and startup times by automatically reusing data

from the control strategy configuration during the creation of the HMI en-
vironment. The ability for the operator to view and interact with SFCs is
generated automatically for both continuous and batch applications.
Graphical representations of faceplates can also be derived automatically
from control strategies. Users can automatically generate process graphics
from the controller configuration. Displays are populated automatically
with symbols, which are pre-linked. Configuration management tools
within ES include a central change management tool for SFC modifications
and an audit trail for configuration changes. Security in ES can be linked to
the Windows security scheme to control logon access.
ES also offers concurrent engineering, enabling a whole team of engineers

to work on the same control strategies from multiple, geographically distri-
buted locations simultaneously. This allows for global distribution of
engineering tasks and engineering of multiple projects simultaneously.
More important, however, is the collaborative sharing of engineering best
practices in a dynamic way across multiple plants.
The system automatically guarantees data consistency. Linking CAD/CAE

tools to Simatic PCS 7 improves data transfer from the P&ID (Piping and
Instrumentation Diagram). The output data of the CAx tools can be trans-
ferred direct to the engineering system of Simatic PCS 7, which simplifies
data exchange, reduces potential error sources, avoids duplicated entry of
data, and cuts the configuration time.
OS Provides Common HMI

The common HMI environment for SIMATIC PCS 7 is the Operator Station
(OS), which is based on the standard Siemens SIMATIC WinCC HMI, with
additional features to make it suitable for process applications and distin-
guish it from the standalone WinCC HMI offering. OS offers customized,
contextual operator views and features a SQL Server-based historian.
The Data Storage compression within OS allows for online modifications

and upgrades, which is consistent with ARC‟s CPAS vision. OS is also de-
signed to reduce operator response times to abnormal situations. Alarm
status is shown at all times, and alarms and messages are automatically se-
gregated by process area. OS also offers alarm filtering and prioritization
through alarm classes and priorities.
Common Hardware and Control Platform

The common control hardware platform for SIMATIC PCS 7 is the 400 Se-
ries of controllers, including the 412, 414, 416, and 417 Automation Stations
(AS). These Automation Stations are based on standard SIMATIC Control-
lers. Used as DCSs, the controllers offer variable scan rates down to 10
milliseconds. Larger controllers can execute over 1,000 PID loops in 0.5
seconds and support online expansion of programming memory. There are
two controller versions for Simatic PCS 7 Box; a rugged PCI slot version,
and a soft controller that runs on the integral PC processor. The slot ver-
sion is equipped with its own operating system and power supply and
offers higher availability.
ET200M is the primary I/O offering and can be placed in hazardous areas,
including Class 1 Division 2. Failsafe versions are TÜV-approved and can
be used for SIL 3 applications with the integrated safety system controllers.
SIMATIC IT
Production Management/MES
ISA-95 Definitions
Simatic PCS 7
Batch
Continuous Safety
Logic
ISA-88 Structures
Common Industrial Ethernet Network
Common HMI and Engineering
Common Profibus DP/PROFIsafe/Industrial Ethernet Control Network
Common Controllers and I/O
Common Profibus PA Field Network
Simatic PCS 7 Functional View
The ET 200S Series I/O is designed for motor control, starter control, and
pneumatic valve control applications. The I/O is designed to support dis-
tributed architectures natively, allowing the user full flexibility in choosing
the location for the I/O (Remote I/O). The HART I/O module provides
redundancy capability for the ET 200M distributed I/O station. This has a
high channel density for analog inputs and outputs, supports the connec-
tion of HART field devices and is integrated into the asset management
system of Simatic PCS 7. The IM 153-2 HF interface module for the ET
200M distributed I/O station offers high-accuracy time stamping for re-
cording the SOE (sequence of events) and supports the operation of up to
12 I/O modules in one I/O device.
Common Information Infrastructure

The common information infrastructure provides a single communications
framework for the CPAS model. At the field level, the infrastructure hosts
sensors, actuators, and logical devices in their primary functions and pro-
vides a standards-based distributed computing environment for field
devices. At the control level, the common information infrastructure pro-
vides a common fault-tolerant backbone that synchronizes information in
both process control and production management applications. This re-
sults in a single, robust, secure, and data-rich environment that extends
from field devices through the business system interface.
The common communications infrastructure for SIMATIC PCS 7 is based

on the standard PROFIBUS protocol and Siemens‟ Industrial Ethernet
backbone. PROFIBUS DP connects remote I/O (including HART), drives,
and provides an interface to other device networks, such as AS-i, Modbus
and FF. PROFIBUS PA operates at the process field device level and pro-
vides connectivity for fieldbus-compatible process field instrumentation
and intelligent control valve positioners. PROFIsafe is also integrated into
the system architecture through Siemens‟ safety system offering. The In-
dustrial Ethernet control network provides for the specific needs of a real-
time controller on a standard Ethernet backbone.
SIMATIC PCS 7 Supports Multiple Application Domains

A typical process plant requires up to three different types of control appli-
cations, from regulatory control, to sequential control, discrete control, and
safety applications. CPAS incorporates these functions as well as asset
management, advanced control, and production management.
SIMATIC PCS 7 addresses the needs of process, hybrid, and discrete appli-
cations within a single framework. The common hardware platform and
common network infrastructure, as well as the unified 61131 and SFC-
based configuration environment, allow for seamless incorporation of dis-
crete control capabilities, batch, and safety system applications along with
process. Batch applications are supported with Siemens‟ SIMATIC BATCH
application, which serves the purpose of a high-performance basic batch
engine and is fully integrated into PCS 7. An Advanced Batch Reporting
package enables drafting of customized reports using MS SQL or Crystal
Reports. Reports can be converted to .pdf file format for forwarding or sto-
rage.
Process Safety can be fully integrated in standard PCS 7 Automation Sta-

tions. The integration of the safety engineering in the standard automation
means less demand for space, less hardware and wiring and less work for
assembly, installation, and engineering. Additional applications, such as
those needed for separate safety controllers due to the substantial
integration work in the DCS, are avoided with the homogeneous
integration of PCS 7. Together with SIMATIC PCS 7, powerful, flexible
solutions can be realized for integrated automation and safety applications
in an integrated automation network.
With the safety matrix, fail-safe functions can be created without

programming skills based on the rules of a cause and effect matrix. Flexible
Modular Redundancy™ provides scalable, cost effective solutions that
allow users to implement multiple levels of fault-tolerance exactly where it
is needed for their application. The new Simatic S7-412FH controller can be
used both as a fault-tolerant standard controller and as an SIS (Safety In-
strumented System). It is suitable for smaller applications with up to 50 F
(failsafe) I/O.
Advanced control options in SIMATIC PCS 7 include Model-based multi-

variable control systems, Operating point-dependent regulating parameter
control, and Control quality monitoring.
PCS 7 simulation and operator training are accomplished through the SI-
MIT process training simulation package. The system‟s configuration tool
automatically creates the simulation environment directly from the control
strategy. For production management applications, SIMATIC PCS 7 inter-
faces directly to the SIMATIC IT Production Suite.
For plant asset management applications, Siemens offers PDM (Process De-
vice Manager). Using PDM from a central engineering station, users can
parameterize and troubleshoot intelligent field devices remotely. PDM
serves as the communications basis for the asset management system and is
available either integrated with SIMATIC PCS 7 or in standalone configura-
tions. PDM reduces factory acceptance testing (FAT), commissioning, and
startup times. FAT is also facilitated and optimized by using SIMBA which
can simulate the complete behavior of I/O devices (PROFIBUS DP and PA)
on the fieldbus and makes it possible to test automation functions, like
measurement and control loops, and safety-relevant functions, like emer-
gency shutdowns, before doing it on a live plant.
Latest Version Release of Simatic PCS 7

Siemens Industry Automation Division introduced version 7.1 of its Simatic
PCS 7 process control system in March of 2009 with numerous new func-
tions. The primary focus of the latest release is to help shorten engineering,
installation, and commissioning times, while reducing operating and main-
tenance costs. Automation of key engineering tasks with version 7.1
streamlines engineering workflow. Use of centralized visualization sche-
mas for color palettes, styles, or optical effects enables automatic
propagation of graphical changes to all process pictures. The design is con-
figurable in "classical" or "modern" look. Drag and drop connection of
process values between controllers provides seamless communication se-
tup. Versioning for CFCs and SFCs, as well as for SFC type enhance change
documentation.
Engineering Checklists provide step-by-step verification of engineering

steps, described in the new Engineering Compendium thus reducing FAT
and commissioning time. Forcing of all CFC parameters allows engineers
to test system functionality quickly. The newly designed operator interface
with v7.1 increases operational efficiency. An optimized color schema and
improved alarm control raises awareness of critical conditions. The alarm
control allows for user-specific adaption of filters, selections, and sorting
during runtime.
New trending capabilities provide a high level of data transparency to ena-

ble operators to respond quickly to process changes. The trend control is
individually configurable for tables and graphic displays and features a
combination of several trend windows. Representation of process values is
done either in relation to time or to other process values in tabular, curve,
and function windows. Scaling of the value axis is either linear, logarith-
mic, percentage, or even freely configurable.
It‟s also been made easier to retrieve and analyze both historical and live
process data. An enhanced Trend Control provides access and visualiza-
tion at the Operator Stations. The new Data Monitor tool provides a direct
link to process data from Excel, allowing users to leverage the power and
familiarity of Excel for efficient analysis and reporting.
New hardware allows more flexible configuration. High channel density

with ET 200M can be achieved with the 64-channel digital modules. ET
200iSP features new EEx e digital output for switching magnetic valves, DC
contactors or pilot lamps and new four-channel analog input module for
resistance measurement.
The release of v7.1 marks the introduction of a new library in addition to

the Standard Library that was created from the ground up to provide more
comprehensive functionality out-of-the box. The library supports addition-
al modes of operation such as “local” and “out of operation,” making it
easy to adapt the configuration to the plant hardware and operational phi-
losophy. Technological function blocks can be extended with additional
analog values and alarm modules. I/O signal data quality information is
passed through the configuration and up to the HMI, ensuring that opera-
tors know when a signal is bad, is being simulated, or is being forced for
troubleshooting purposes.
Ergonomic symbols and task-oriented faceplates created for the new Ad-
vanced Process Library provide a consistent look and feel to the operator
and a uniform representation of state information. Faceplate operation can
be easily adjusted to be consistent with the plant‟s operational philosophy,
for example, the use of confirmation steps when energizing a motor. New
interlock faceplates allow operators to quickly identify the status of inter-
lock conditions and to navigate to the source of the interlock. Advanced
Process Library blocks support simulation of process values directly in the
faceplate, resulting in faster commissioning.
Siemens Strengthens Migration Capabilities

Siemens has developed a well-thought-out approach to control system mi-
gration for both its own legacy systems and those of its competitors. The
company offers a stepwise, phased migration plan that includes a full suite
of services, applications, and a strong set of automated conversion tools
that ease the migration process for end users, while allowing them to retain
the functions and the look and feel of their legacy systems. Siemens‟ in-
vestment in conversion tools, for example, has been considerable. The
company has spent significant resources on making it easy for users to con-
vert legacy graphics and faceplates to the company‟s SIMATIC PCS 7
process automation system.
Siemens‟ official name for its migration program is Performance Upgrade.

In this phased approach, ten layers address each major layer of the control
system architecture. These ten layers include HMI Connectivity, HMI Con-
version, Enhanced Batch Management, Engineering Library Conversion,
Application Conversion, Control Network Gateways, I/O Gateways (PFM),
SIMATIC IT I/O Replacement, I/O
Legacy – System SIMATIC PCS 7 Interfaces (DPIO), and
Cl. Cl.
Field Termination As-
HMI HMI
semblies (FTA).
Runtime Batch
Engineering & & OS Manager
Automated Eng.
Conversion Eng. These ten layers are
Tools/DBA/ Server Server
Engineering grouped into three
Libraries
primary phases of mi-
Controller S7 400
Controller
gration that address
Gateway
Network
Controller
Gateways
Conversion PROFIBUS PA the three typical phas-
DP / IO
es of a migration
PROFIBUS DP
Motor project. Phase I deals

I/O
I/O Interface with the HMI and
batch layer, and in-
ET200M
Field I/O cludes HMI
Marshalling Termination
Adapters connectivity, HMI
Conversion, an En-
Complete Scope of Migration Services
hanced Batch
Siemens’ Stepwise Migration Path Management. Phase
II includes the crea-
tion and conversion of engineering libraries, application conversion, and
control network gateways. Phase III includes I/O Gateways, I/O Replace-
ment, I/O Interfaces, and Field Termination Assemblies.
As part of Siemens‟ strategic focus on migration, the company has devel-

oped multiple centers of excellence (COE) for migration that provide
technology, support, and educational resources for end users considering a
migration project. The primary COE for migration is located in the compa-
ny‟s Spring House, Pennsylvania location and is designed to provide global
support for migration, but has particular expertise in migrating the compa-
ny‟s installed base of Moore APACS systems and 505 systems, the latter
which were the product of the Siemens TI acquisition in the early 1990s.
Siemens also has a COE for migration in Cologne, Germany for legacy Con-
tronic systems from ABB/Hartmann & Braun. Another COE for Siemens
Teleperm and other competitor systems is located in Karlsruhe, Germany.
While Siemens‟ migration centers of excellence provide technology and
services, the most important thing they provide for end users is assisting
them in developing a real business case for migration and providing the
training and education services that are necessary to realize the vision of
the migration project.
Siemens has a dedicated Project Engineering Team comprised of experts

that already have a record of accomplishment in delivering successful mi-
gration projects. This team also conducts front-end engineering and design
(FEED) studies and provides consulting services to help customers deter-
mine the breadth and scope of their migration project. Siemens has also
developed strong relationships with local third-party systems integrators,
all of which are picked, trained, and certified by Siemens specifically for
migration projects, particularly in the North American market. Finally, the
global migration Center of Excellence in Spring House is responsible for
testing and developing all migration products. This is consistent with Sie-
mens‟ overall approach to the DCS market.

In 2008, Siemens acquired innotec GmbH. The company was assigned to
the Industry Automation Division and changed its name to Comos Indus-
try Solutions GmbH. Comos is a leading supplier of lifecycle management
systems, especially for plant in the process industry. The acquisition will
allow the Industry Automation Division to expand its portfolio for custom-
ers in the process industry. Comos enables Siemens to offer an integrated
software solution, all the way from the planning stage of a production
plant, through operation, right up to modernization and planning of de-
commissioning work. This will help Siemens to extend its global reach in
the market for industrial software.
Key Industries
Cement & Glass; Chemical & Petrochemicals; Food & Beverage; Lifes-
ciences; Oil & Gas Pipelines, Production, and Refining; Power Generation;
Power T&D; Pulp & Paper; Retail; Water & Wastewater

For some time now, ARC has reported on the trend of the declining hard-
ware business for automation in both the process and discrete domains.
There are few companies left who can view the mass production of control-
related hardware as a profitable business, but Siemens‟ capability in hard-
ware with its large PLC and I/O business is an exception. Siemens large
volume of hardware sales does not mean that its hardware business for
DCSs needs to be a cost center. In fact, the company can leverage many of
its best manufacturing practices that it has rigorously developed over the
past decades to offer its customers a wide range of highly reliable hardware
options from I/O, to controllers, and industrial PCs.
For process automation systems, Siemens primary challenge is growing its

installed base outside of its traditional European market in North America,
Asia, and Latin America. Siemens must also successfully migrate its exist-
ing installed base of APACS and Teleperm users to Simatic PCS 7.
azbil (Yamatake)
http://www.yamatake.co.jp/
DCS Offerings
Harmonas-DEO
Regions
Japan, Asia
Description
With the celebration of the company‟s 100th anniversary in 2006, Yamatake
announced a new Group philosophy, “to realize safety, comfort and ful-
fillment in people ‟s lives and contribute to the global environment through
„human-centered automation.‟” This philosophy indicates the new direc-
tion the company will use to develop its businesses for the next generation.
In addition, the company also created a new name, azbil (Automation Zone
Builder), to represent this new philosophy. azbil provides solutions for
process, building, and factory automation. With manufacturing facilities
worldwide supported by R&D centers, azbil is a pioneer in developing new
technologies in the field measurement and control market.
azbil‟s flagship process automation system is called Harmonas-DEO, which

is comprised of human-machine interface (HMI) nodes to be used for sys-
tem monitoring and control operations, highly reliable process controller
nodes that can be arranged in a redundant configuration, and redundant
control LAN (Ethernet) systems to connect all the nodes. Windows is used
for all HMIs as the basic operating system to provide users with a comfort-
able monitoring and control operation environment, as well as to provide
an open data processing environment.
To establish a control system that is well-suited for the application, various

types of application modules are available. These include field operation
modules, remote monitoring modules, history analysis modules, batch
process control modules, communication gateway modules, transient oper-
ation support modules, and alarm analysis modules.
DEO Supervisory Station (DOSS, DOSS_H)

DOSS provides system construction (engineering) functions as well as HMI
functions for process control and monitoring operations. DOSS_H is im-
plemented with the process history database (MS-SQL server) functions in

addition to the basic HMI functions of DOSS. Either a general-purpose
desktop CPU type or a console type (single-stage or dual-stage) configura-
tion is selectable for these nodes.
DEO Open History Station (DOHS)

A DOHS node is implemented with a process history data server (MS-SQL
server) and is dedicated to history data collection functions.
DEO Process Controller (DOPC II, DOPC)

DOPC II and DOPC are multi-functional process controllers that can be
used for implementing process input/output control, loop control, logic
control, and sequence control functions. High density and redundantly
configurable process I/O modules are connected to DOPC and DOPC II.
DOPC II is a controller with redundant control CPUs and communication
modules. DOPC is a small-capacity controller; its non-redundant configu-
ration is also available.
DEO Open PLC Linker (DOPL II)

DOPL II is a multi-functional and redundant-configurable controller used
for integrating and controlling Mitsubishi MELSEC devices through MEL-
SECNET/10 (or MELSECNET/ H) networks. By using DOPL II, all link
devices of MELSECNET are handled as I/O devices for enabling loop con-
trol, logic control, and sequence control functions, as well as the operations
with DOPC II. The control database of DOPL II is constructed in common
with DOPC II.
Thin-client Supervisory Server (TSS)

TSS server nodes provide client PCs installed in remote fields and offices
with a DCS operations environment. DOSS-like control operations can be
made from client PCs. Display applications of TSS are constructed in com-
mon with DOSS.
DEO Open Gateway (DOGS)

A DOGS general-purpose communications gateway connects the Harmo-
nas-DEO system to information networks for enabling data communication
with host computers. DOGS uses OPC as the communications protocol.

None Reported
Key Industries
Chemical; Chemical & Petrochemicals; CPG; Food & Beverage; Lifesciences;
Oil & Gas Refining; Pharmaceutical

azbil has expertise in systems integration and applications for a variety of
industrial processes. It has the capability to conduct total turnkey solution
with a broad range of industrial automation products. azbil‟s major chal-
lenge is to achieve growth outside of the Japanese market and become a
single source vendor for its customers.
Yokogawa
http://www.yokogawa.com
DCS Offerings
Centum, Stardom NCS
Regions
India
Description
Yokogawa‟s CENTUM system has always been at the core of the company‟s
DCS business. The latest version of Centum is Centum CS 3000 R3, which
is the sixth generation since the introduction of the first CENTUM system
in 1975. The company currently supports six versions of Centum. Many
Centum V systems, for example, are still up and running and supported by
Yokogawa, who guarantees support of all its control systems for up to 10
years after sales of new systems are discontinued.
Centum CS 3000 R3 is a major upgrade over the R2 version, and integrates

advances in information technology with the rapidly evolving needs of the
modern manufacturing environment. Key features of Centum CS 3000 in-
clude Windows 2000
HMI, Fieldnetwork I/O,
native Foundation
Fieldbus (FF) functio-
nality, and a series of
advanced functions
such as embedded ad-
vanced control and
Plant Resource Manager
(PRM). The R3 version
is also backward-
compatible with older
CENTUM versions and
is easily upgraded in
phases or replaced with
Centum CS 3000 R3
minimal investment.
Yokogawa‟s new Centum CS 3000 R3 field network I/O, developed in con-

junction with Fuji Electric. The new I/O incorporates an Extended Serial
Backboard (ESB) Bus with a speed of 128 MBPS. Centum CS 3000 R3 also
incorporates a high-speed Ethernet-based control network. At the fieldbus
level, CS 3000 R3 incorporates a Foundation Fieldbus H1 I/O card.
The advanced functions of CS 3000 R3, however, provide the true value
add. The first of these is integrated Foundation Fieldbus engineering with
Yokogawa‟s Plant Resource Manager (PRM) software. PRM is Yokogawa‟s
plant asset management (PAM) solution. In ARC‟s view, providing inte-
grated PAM functionality is a key part of any effective Foundation Fieldbus
Solution.
CS 3000 R3 also includes a new control platform, called Advanced Process

Control Station (APCS). Through Yokogawa‟s alliance with Shell Global
Solutions, Shell‟s SMOC advanced process control software has been em-
bedded in the CS 3000 control architecture.
Yokogawa‟s answer to incorporating open networking technology in its

systems comes with the release of the Vnet/IP control network, which is
available in the latest major version release of the CENTUM CS 3000 control
system. The first widely available DCS control network based on Gigabit
Ethernet, Vnet/IP offers redundant communications and communications
band partitioning over standard Ethernet, while providing the high reliabil-
ity and deterministic response required for process automation. Vnet/IP
offers ten times the throughput of Vnet, and routers are available that can
switch between Vnet and Vnet/IP.
The openness of Vnet/IP makes it easier for users to connect non-CENTUM

components to the control network through Vnet/IP‟s TCP/IP communica-
tions capabilities and enables their network configuration with
commercially available network equipment. Data from third-party devices
can be integrated with CENTUM CS 3000 through the GSGW process data
server on Vnet/IP.
Since Vnet/IP is Ethernet-based, users have the ability to choose from a

wide range of hardware, and Yokogawa does not specify which hardware
vendors are to be used. Yokogawa has, however, certified and tested Cisco
and Dell hardware for Vnet/IP, which is consistent with the Ethernet-based
offerings of many other DCS suppliers.
Yokogawa Stardom Network Control System

Yokogawa‟s Stardom Network Control System (NCS) addresses the needs
of applications where the combination of a PLC and HMI package are often
used, but found to be inadequate. With the release of Stardom, Yokogawa
is addressing the needs of markets that traditional DCSs have not yet met.
Many of these, if automated at all, have used a variety of technologies rang-
ing from PLCs to PCs that have required significant effort for system
component connections. By leveraging the Internet and internet technolo-
gies, these types of applications can be addressed more effectively with fit-
for-purpose configurations. Stardom NCS is the system that will fully real-
ize Yokogawa‟s e-RM vision for collaborative manufacturing.
Yokogawa Releases Enhanced Version of STARDOM Network-based

Control System
In April of 2008, Yokogawa released an enhanced version of the STARDOM
Network-based Control System that complies with US gas industry stan-
dards and provides a new data-logging function for the FCN/FCJ
autonomous controllers. These enhancements reduce costs by improving
the efficiency of both operation and maintenance. Yokogawa will use the
release of this enhanced
version to strengthen its
sales targeting the oil and
gas upstream processes.
The enhanced STAR-

DOM version supports
the American Gas Asso-
ciation's AGA3, AGA7,
and AGA8 standards
used in North America,
Stardom NCS South America, and Asia.
This ensures correct flow
measurement as gas is transported between drilling companies and distri-
bution companies. STARDOM provides both gas metering and control
functions.
The FCN/FCJ autonomous controllers have been enhanced with the intro-
duction of a new data logging function. The controllers can now store
control data and data from field instruments and facilities for access from
distant locations via the Web, enabling efficient remote monitoring.
The STARDOM engineering tool has been enhanced with network tem-
plates that improve the reusability of applications. Yokogawa provides
samples of these network templates. The engineering tools for STAR-
DOM's FCN/FCJ autonomous controllers will also support Windows Vista.
Vigilance Campaign
Yokogawa has come a long way in making its message clear to the world of
process automation. Several years ago, the company embarked on a full-
scale global marketing campaign to make customers aware of Yokogawa‟s
focus on system reliability, security, dependability, and robustness.
Dubbed “Vigilance,” the campaign created a unified message for the com-
pany and greatly helped expand awareness of the Yokogawa brand and
corporate philosophy. Vigilance is successfully increasing brand awareness
and communicating Yokogawa‟s message of reliability and quality to the
worldwide market, particularly outside of Japan.
While the Vigilance campaign successfully expresses the company‟s philos-

ophy, articulating the value proposition of the company‟s product,
application, and services offering remains a key challenge for the company.
Yokogawa, for example, has long been known for its control systems, field
instrumentation, and fieldbus capabilities. Many customers, however, re-
main unaware of Yokogawa‟s capabilities in production management,
safety systems, alarm management, plant asset management (PAM), and
many other areas. Yokogawa‟s ongoing Vigilant-Plant campaign is de-
signed to raise customer awareness of Yokogawa‟s solution set and where it
fits in the Vigilance scheme.
The VigilantPlant philosophy eliminates unplanned downtime and allows

businesses to adapt and change quickly and with agility, to shifting market
conditions and customer demands. This is consistent with ARC‟s view that
giving personnel access to the right information at the right time combined
with the ability to take action is crucial for achieving OpX, and is the foun-
dation of real-time performance management (RPM).
CENTUM Release 3.08

Yokogawa announced CENTUM CS 3000 R3 Release 3.08 in October of
2007. Key features of the new version included enhanced gateway func-
tions that provide enhanced connectivity with competitors' DCSs and PLCs
and a Consolidated Alarm Management Software (CAMS) offering, which
Yokogawa claims is the first true CAMS-based approach available in the

industry.
Yokogawa's gateway functionality is embodied in the System Integration

OPC Station (SIOS). Enhancements to the gateway mean that operators
will be able to control and monitor both DCS and PLC systems from Yoko-
gawa competitors with the same look and feel as CENTUM CS 3000. Data
linkage to Yokogawa's STARDOM system has also been enhanced.
The CAMS alarm management package for the CENTUM CS 3000 Human
Interface Station can integrate and control alarms from CENTUM CS 3000,
the ProSafe-RS Safety Instrumented System, Plant Resource Manager
(PRM), and STARDOM systems. CAMS for HIS collects alarms and events
from each system, identifies expressions, and eclipses duplicate alarms.
This package also provides value-added alarm information such as priority
level, sorting identifier, root cause, and action to be taken. It helps reduce
alarm flooding that may cause critical plant problems and relieves opera-
tors from cumbersome alarm acknowledgement tasks to let them
concentrate on controlling and monitoring the process.
Yokogawa Unveils Centum VP

CENTUM VP is the eighth generation of the CENTUM series, and succeeds
the CENTUM CS 1000/CENTUM CS 3000. While securing clear backward
compatibility and consistency with previous CENTUM systems, CENTUM
VP redefines the role of a production control system, commonly known as a
DCS. Going beyond the traditional DCS function of controlling and moni-
toring a plant, CENTUM VP integrates plant information management,
asset management, and operation support functions, achieving a unified
operating environment. CENTUM VP provides a foundation for opera-
tional excellence by delivering information in context and allowing easy
role-based access to all key information.
The first major component of the system, released in May of 2008, was the
Centum VP HMI, which is one of the first HMI applications for automation
to be available in Windows Vista and Windows XP. The new HMI incorpo-
rates a universal color scheme, greatly reducing the chance of an operator
misinterpreting information due to color blindness, and increasing the
overall visibility of the most important information to the end user. Yoko-
gawa did a lot of research into this HMI to drive increased productivity and
decrease the chance of operator error. Yokogawa claims that the new HMI
"more than doubles the speed of operational decision making." The HMI
also offers integrated alarm management capabilities, faceplates, trends,

and history windows.

None Reported
Key Industries
CPG; Food & Beverage; Life Sciences; Metals; Mining; Oil & Gas Pipelines,
Production; and Refining; Pharmaceutical; Power; Power Generation; Pulp
& Paper; Water & Wastewater

It is not easy for a supplier to place its products and solutions into a frame-
work for OpX. Many companies have tried to do so without much success.
Today‟s manufacturing end users are finding it increasingly difficult to jus-
tify automation investments without a case for business value and are
looking more than ever at the bottom line economic impact of automation.
VigilantPlant has so far been successful in placing Yokogawa‟s offerings in
the context of a pathway to OpX for its customers. Yokogawa has truly
“discovered” marketing, and must not lose this focus of proactively and
intelligently marketing its products, applications, and services.
Yokogawa is unique among automation suppliers in that it is willing to

share detailed roadmaps for its asset, production, and safety excellence of-
ferings. The drive to reach the goals laid out in these roadmaps will be
challenging, requiring significant investment in research and development
and a significant overall commitment to maintaining a consistent vision
throughout the next several years. The company will need to be make con-
tinuous enhancements to remain competitive.
At the same time, however, Yokogawa must continue to release new prod-
ucts, and this balance between core products and new products requires
careful handling. The company must also continue to build on its adhe-
rence to standards, such as the IEC fieldbus standard, ISA 95, and the many
other standards incorporated into the company‟s products.
It will also be a challenge for Yokogawa to reach its other stated goal of be-
coming the number one supplier for the process automation marketplace
worldwide by 2010. Sustained growth of 10 percent or more through the
next several years is possible, but only if the company stays on track and
continues to build on the successes it has made for itself in the past couple
of years.
Balancing the requirements of a considerable installed base while cultivat-

ing new business will be a challenge. Yokogawa‟s existing customers will
be just as important a source of business for the company as new clients,
since many of the products and services the company is selling through Vi-
gilantPlant are designed to provide OpX just as much during the
operational phase of the plant as they are during installation, commission-
ing, and startup.

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Distributed Control Systems Worldwide Outlook • Supplier Profiles

Industrial IT is ABB‟s architecture for collaborative process automation. At

A powerful object-oriented technology, called Aspect Objects, underlies all

System 800xA provides these functions with a single window environment

common environment for engineering, operations, information manage-

In addition to SIL3, ABB also released its IEC61850 communication module

Industrial IT Enabled Applications

applications include ABB‟s cpmPlus Enterprise Connectivity, Matrikon‟s

The cpmPlus Enterprise Connectivity solution (ECS) provides a stream-

Matrikon‟s AlarmInsight for System 800xA provides a configurable inter-

The Intergraph Smart Plant Instrumentation (SPI) integration with System

The 800xA Evolution for HSM connectivity package enables supervision

800xA Controllers Receive Cyber Security Certification

(MUSIC) Foundation-level Certification. MUSIC certification means that

MUSIC Foundation and Advanced certifications both ensure critical infra-

Earlier in 2007, ABB announced that the Sys-

The Achilles testing process is rigorous. According to Wurldtech, the ma-

Wurldtech and its partners developed the Achilles Certification Program to

reliability, and robustness of a device's implementation of OSI layers 2 – 4,

Load-Evaluate-Go as a Path to High Availability Control

System 800xA supports on-line version upgrades. With

ration, online upgrades of the controller‟s firmware is accomplished by

System 800xA supports Load, Evaluate, Go for application modifications in

Freelance 800F System

Partnerships and Acquisitions

of Calgary, Canada. Ber-Mac specializes in industrial automation, electric-

Strengths and Challenges

ABB‟s comprehensive lifecycle support policy is designed to protect cus-

patches and downloads, and access to technical support specialists for

ABB‟s solutions for improving productivity are also formidable. As far as

One of ABB‟s primary challenges, however, lies in making these solutions

Emerson Process Management

Emerson utilizes industry stan-

The DeltaV Continuous Historian stores the wealth of information available

Emerson Process Management released version 8.4 of DeltaV system soft-

Key Enhancements to Version 10.3

Version 10.3 also includes a redundant Profibus DP card, which is a drop-in

DeltaV Smart Switch Provides Built In Security Features

Integrated Wireless Functionality

Making FOUNDATION Fieldbus Easier to Use

Ovation is designed to provide a flexible and easy-to-upgrade platform for

unique operational needs of the power generation and water/wastewater

Ovation incorporates an array of embedded software capabilities required

Recent Ovation Upgrades and Enhancements

The Ovation Security Center consists of a suite of security packages and

products allow operators to detect vulnerabilities in operating systems, con-

The Ovation Alarm Analysis tool performs statistical analysis by leveraging

Ovation System Transitions for Legacy ABB and Siemens Systems

Emerson/Mitsubishi Alliance for Turbine Retrofit Projects

Emerson Power & Water Extends Contract with Westinghouse Nuclear

will use Emerson‟s Ovation system to control power generation processes,

Emerson Develops Comprehensive Migration Program

Once the requirements are determined, the transition or migration products

All of this is done with an eye toward

as well as competitor legacy systems that allow for a flexible migration

FlexConnect is a method of connecting multi-conductor cables to the exist-

Emerson‟s migration program also includes expert platform-specific and

Partnerships and Acquisitions

Strengths and Challenges

Emerson must continue to penetrate new markets successfully with DeltaV

GE Fanuc Intelligent Platforms

The company‟s name change to GE Fanuc Intelligent Platforms in late 2007,

GE Fanuc Intelligent Platforms launched the Proficy Process System to pro-

dards to facilitate the sharing of data throughout a manufacturing organiza-