ISA—International Society of Automation

Samuel M. Herb, PEowner

January 25, 2011

The Mystery of PACs

• The confusion over PAC Monster……….

• The Acronym Monster…..

• The Configuration Monster………………

• The Network Monster….

• The Fieldbus Monster……………………….

What System to Select?

PAC?

What’s That?

Build me a wonderful control room…

…all on a tight budget!

What are the Issues?

No

Project

is

Simple

? ! ?

Real Goal for Plant Control System

PRODUCTIVITY!!!

!

32%-Operational Efficiency

22%-Ease of Maintenance18%-Price

13%-Spares

Availability

11%-Operational Safety4%-Delivery

Buying Decision Factors for Process Products

Control System Issues

• Problems of open standards• Impact of fieldbuses• Configuration made easy• Significance to batching functions• Inclusion of safety systems• Challenge of advanced control methods• Wireless capabilities with security• Complexity of cyber security• Confusion of system names• Tie-in with plant business systems• Coordinate with other plants

Process vs. Discrete Industries

Process Discrete

Products

Operations

Product Design

Equipment

Equipment Cost

Labor Cost

Sensors

Control Products

Supervisory

Control

Business Mgmt.

Implementation

Fluids

Continuous, Batch

Done in Labs

Uses Processes

Very High\

Low

Numerous Analog & Discrete

DCSs, PLCs, SLCs, PCs

Process Optimization.

Scheduling

In-house, MRP II, MES, ERP

Bottom up

Devices, objects

Job Shop, Batch, Repetitive

Done with CAD/CAE

Uses Machines

Medium to High

High

Mostly Discrete

PLCs, CNCs, Robotics, PCs

Cell Control, Scheduling

MRP II, MES, ERP

Top Down

All Process Control is an ART !

The key in process control is REPEATABILITY!

Poor Accuracy; Poor Precision

No Repeatability

Poor Accuracy; Good Precision

Repeatability, but no accuracy

Good Accuracy; Good Precision

Repeatability with accuracy

…But control rooms were nearly all manual!

What is going on here?

Feedback Control!

Evolution: These Were Distributed

Touring the plant

Electronic miniaturization

Pneumatic transmission

DDC -- Direct Digital Control

• Advantages:– Sophisticated control

– Flexible control

– Data acquisition & alarm

• Disadvantages:– Computer reliability

– Redundant computer or

controllers

– Wiring complex & extensive

– HMI required high level

operators

– Expensive

Computer Process

Analog

Back-up

Computer

Tracking

Computer Analog

Panel

DDAC -- Supervisory Control

• Advantages:

– High reliability

– Human-machine interface

adequate

– Data acquisition & alarms

– Sophisticated control

– Complete redundancy

• Disadvantages:

– Complex wiring &

installation

– Difficult to make strategy

changes

– Expensive

Process

From Central to Distributed Control

Distributed

• Central– Many wires

– Programmed

– Vulnerable

CENTRAL CONTROL ROOM

COMPUTER

CENTRAL CONTROL ROOM

UNIT CONTROL ROOM

CONTROLLER

CONTROLLER

CONTROLLER

CONTROLLER

DATA

HIWAY

Data highway

Configured

Less risk

Functional

Physical

• System organization

• Operator interface

• Risk of failure

• Diagnostics

• Sophisticated control

• Record keeping

• Plant computer interface

• Ability to change

(Dedicated)

Familiar

Rigid

Distributed

Limited

Complicated

Awkward

Difficult

Complex

(Centralized)

Unfamiliar

Flexible

Central

Extensive

Program

Built-in

Inherent

Reprogram

PROCESS

ANALOG

PROCESS

DIGITAL

Control System Comparisons

• System organization

• Operator interface

• Risk of failure

• Diagnostics

• Sophisticated control

• Record keeping

• Plant computer interface

• Ability to change

(Dedicated)

Familiar

---------

Distributed

--------

--------

--------

--------

--------

(Centralized)

--------

Flexible

--------

Extensive

--------

Built-in

Inherent

--------

(Distributed)

<— same

<— same

<— same

<— same

ObjectsConfig

<— same

<— same

Modular

Control System Comparisons

PROCESS

ANALOG

PROCESS

DIGITAL

PROCESS

DCS

Traditional DCS - PLC - Computers: &Warning! Generalizations Here!

Typical Strengths Typical Weaknesses

DCS Distributed Risk Entry Level CostReal-Time Throughput Proprietary NetworkAdvanced Control Strategy Proprietary Operator Station PID (3-mode control) Complex InterlocksOperator Interface Control Room EnvironmentLow Integration Cost

PLC Environmental Human Interface

Uptime Integration Cost

Rapid Repetition of ActionsSequencing

Complex InterlocksReporting

Logic Steps Easy to DoApplication SoftwareRecipe Handling

Central

Computer

Data Acquisition ProgrammedAdvanced Control Strategy Environmental LimitsDatabase Storage Costly RedundancyHistory & Trending Real-Time ThroughputNetworking

Traditional Scan Time ConsiderationsWarning! Generalizations Here!

Scan Time Typical Function Likely System

1 Month Corporate Update of Plant Computer Operations Summary

1 Day, Shift Production Report1 Hour Off-line Optimization

Batch Management Batch Scheduling

1 Minute Unit Process Optimization DCS1 Second Display Update

Analog Control Process Calculations Batch Sequencing

100 mSec Flow Control

20 mSec High Speed Sequencing PLC Interlocks

1 mSec Sequence of Events

DCS

DCS vs. PLCs with PCs as a System

Typical PLC System Configuration:

Typical DCS System Configuration:

Controller

Proprietary Network, often based upon a

Physical Standard

PC as

HMIWorkstation

as HMIController Controller Controller

PLC

Some Proprietary Network that passes as de facto Physical &

Communication StandardPC

as HMI

PLC PLC PLC

Each Individually Configured

Must configure to communicate with each PLC, to link views, etc.

Single database configured for all stations

―Add-on‖

configured

separately

HMI Manufacturer

Traditional PLC Vendor Supply Model

Software

Drive

PLC

Motion

Sensor

OEM

System

Integrator

Engineering

Contractor

Implementer Provider

End User

Buys from: …AND …Indirectly From Suppliers:

Component

Manufacturer(s)

Distributors

Value Added

Resellers

Manufacturers

Representatives

System

Integrator

Engineering

Contractor

Traditional DCS Vendor Supply Model

End User

CapabilitiesSystem design

IT integration

Process

optimization

Performance

guarantees

Single Source

Supply

Global support

ServicesProject Management

Engineering

Field services

Technical call in Consulting

DCS Manufacturer

PlatformSoftware

Control

I/O

Buys from: …OR …Directly From Supplier:

DCS - PLC - PC/PLC Report CardWarning! Genera liza t ions Here! DCS PLC PC/PLC

Cont rol Capabilit ies:

P rocess I/O A A A

Mult ivar iable Regula tory Cont rol A C C

Complex In ter locking C A A

Sequencing B D C

Recipe Handling A D B

Ba tch Process Cont rol B D C

User In ter face:

Ease of Configura t ion (links & displays) A C D

Ease of Opera tor Use A D B

Ease of Crea t ing Custom Displays A C B

Cost :

Hardware C A B

Insta lla t ion A C D

Applica t ion Programming A B C

Addit iona l Considera t ions:

Ease of Expansion (in teract ive funct ions) A D D

F lexibility A D C

Redundancy A C C

Reliability B A C

Hardware Mainta inability B A B

Software Mainta inability B C D

Then What is Hybrid?

Depends upon who you ask…

• Defined by Industry (ARC Research)

• Defined by Input & Output Capability

– Analog + Discrete I/O

• Defined by Function (Batch Capability)

• Defined by Architecture

– Advantages of both PLCs & DCSs

– Few disadvantages of either

Automation Architecture Migration

Process

Industries

Hybrid

Industries

Discrete

Industries

Automotive

Aerospace

Machining

Pharmaceutical

Fine Chemical

Food & Beverage

Consumer

Packaged Goods

Petrochemical

Refining

Power

Pulp & Paper

ABB

Emerson

Honeywell

Invensys

Siemens

Yokogawa

Mitsubishi

Omron

Rockwell

Schneider

Siemens

From ARC Advisory Group Strategies – June, 2001

Rockwell

GE??

GE??

Hybrid Architecture

Workstation

as HMI

Control Control Control Control

Choice of Open Network Flexibility

or Proprietary Network Security

Emerging System Configuration:

User Choice;

Uploads control

database for:

• Screen Views

• Trends

• History

• etc.

Single distributed control strategy:• Single configuration

• Created on any PC away from system

• Use any PC as a simulator

ARC Group calls this “PAC” – Process Automation Control

PC-based vendors call it Programmable Automation Control

Now PLC vendors use this definition too!

BUT… Suppliers bundle THEIR PC now…

soooo…

Emergence of PC as a Controller

• Robustness still a serious concern– “Industrial strength” for processes is far more severe

than factory floor where some replace PLCs– Corrosive atmosphere & vibration significant

• Potential to “liberate” end user from being proprietary hostage

• All serious vendors already growing into selling software rather than hardware

• Not likely to make control “shrink-wrapped”• Standards still an obstacle

System Size Considerations

Warning! Generalizations Here!

Over150 Large

DCS

Loops ofModulating

Control

30to

150SmallDCS

Under30

Small PLCw/PC

orPC & SLCs

Medium PLCwith PC

orwith SLCs

Large PLCswith

IntegratedWorkstation

Large DCSwith

Medium PLCs

Large DCSwith

Large PLCs

Small DCSwith

Medium PLCs

Small DCSwith

Large PLCs

Under 200 200 to 600 Over 600

Channels of Discrete I/O

LoopStrategies?PAC

Systems

Hybrid = PAC – Process Automation Control?

ARC Advisory Group’s definition says

• PAC consists of multi-domain functionality, including logic, motion, drives, and process on a single platform.

Attributes:• Single, multi-discipline development platform incorporating common tagging and a

single database

• Software tools that allow the design by process to flow across several machines or process units

• Open, modular architectures that mirror industry applications from machine layouts in factories to unit operations in process plants

• De facto standards for network interfaces, languages, and the like, allowing data exchange as part of networked multi-vendor systems”

Clearly not all suppliers who claim to have PACs can do process control.- Many do only motion control and PLC functions- Not everyone easily meets this definition of PAC in its entirety- Nearly every system is still evolving from its proprietary origins.

Process Automation Controller (PAC)*

* Some call this Programmable Automation Controller

…especially if their product competes with PLCs

Acronym Monsters

Some more maddening acronyms• BCS – Basic Control System

• CDAS­ – Collaborative Discrete Automation System

• CIF – Control in the Field

• CNC – Computerized Numeric Control

• CPAS – Collaborative Process Automation System

• DAC – Data Acquisition & Control

• DAQ – Data Acquisition

• DCS – Distributed Control System

• ECS – Enterprise Control System

• ERP – Enterprise Resource Planning

• FCS – Fieldbus Control System

• FPGA– Field-Programmable Gate Array; (controller on a chip for OEMs)

• PAS – Process Automation System

• PC Controller – Personal (Professional) Computer Controller

• SBC – Single Board Computer (Controller)

• SCADA – Supervisory Control and Data Acquisition

• SLC – Single Loop Controller

Multi-Functional Controller Platforms

• Bundled functionality & scope of products w/services offered by traditional automation suppliers into unified solutions to include Collaborative Production Management (CPM) applications, advanced control, safety systems, application-specific systems.

• CPAS—Collaborative Process Automation Systems– Large PACs with “process focus” & ECS

• CDAS—Collaborative Discrete Automation Systems– Large PACs with “manufacturing focus” & ECS

• Enterprise Control Systems (ECS) connecting production floor operations with business systems.

What is SCADA?

Meaning of the word & ambiguity

• Supervisory

• Control

• And

• Data

• Acquisition

• vs. Data Acquisition & Control(The PC connected to a PLC)

Discrete vs. Process ApplicationsTypical Control System Approach:

Combined PC + PLCsfrom various suppliers

PACprocess control system

Application area Production / devices Process / ―fluids‖

Production type Assembly w/ machines Conversion w/ processes

Automation type More open-loop control More closed-loop control

Process dynamics Typically fast Typically slower

Process values Many binary values Many analog values

Operator action – HMI req. Little / rarely – Low Much / frequent - High

HMI requirements Low High

Availability requirements Low High

Diagnosis / fault resolution Local Central

Plant sections Stand-alone Networked

Supervisory Control Scheduling Optimizing

Plant Design Local / bottom- up Central / top-down

Combined Systems vs. PAC Systems

Combined PC + PLCs

• Components function/scope NOT coordinated

• Function extensions added in components for system performance

• Frequently from various suppliers

• Integration work necessary

• Product competence

• Individual product responsibility

• Individually optimized components

• Innovation cycles not coordinated

PAC System

• Components function/scope coordinated

• System functions are included inindividual components

• From a single source

• Integrated overall system

• Application/system competence

• System responsibility

• Optimally coordinated system

• Innovations coordinated

Combined Systems vs. PAC Systems

Combined PC + PLCs PAC System

Component engineering Data storage for each component

Multiple data entries

Individual programming tools

Individual communication modes

Systems engineering Central database

Data are only entered once

Uniform configuring tool

Uniform communication

Individual Component Quality assurance for each

Documentation for each

Function tests for components,

Then integration test in system

Validation involves large effort

Uniform System Quality assurance as entire system

Uniform documentation

Consistent function & system test

Low effort through validation

conformity

• Uniformity not ensured

• Additional effort by user

High integration effort needed

• Uniform functions

• System performance without additional effort

Alarms / messages

Diagnosis

RedundancyDocumentationAccess rights

Customer Support

Implementation Effort

Combined PC + PLCs PAC Control System

Independently Implemented:

Diagnosis concepts

Operator control

Message concepts

Cross-component performance must be programmed by user for each component

System-wide Diagnostics must be programmed

Uniformly Implemented:

Process diagnosis

System diagnosis

Message & archiving concept

Startup behavior after system fault

Operator control & access concept

System functions & image hierarchy

Process ReliabilityCombined PC + PLCs PACSystem

System costs System hardware System software

Engineering and startup System-wide config. tools Integration support

Maintenance costs Integrated service concept Adapted versions

Expansion costs Homogeneous configuring

landscape Up-to-date documentation Scalable system hardware

Engineering

Maintenance

Expansion

HW/SW components

PAC process control system

Combined System

from various manufacturers

Investment in system performance is more than compensated through savings in engineering!

Economical over entire life cycle (total cost of ownership )

Engineering

Maintenance

Expansion

HW/SW components

The Configuration Monsters

Traditional Process Control

Process

Variable (PV)Output

Set point (SP)

Process

Analog Loop

(Digital Communications)

―Data Highway‖

Shared Processing

Typical Distributed Control Loops

Control

Room

Field Signals (Analog or Digital)

Older Physical Controller Structure

• All “control loops” share several cards

• Same sets for all

• Function processing is distributed:

● I/O ● Control ● Data highway ● Communication

OutputInput Conditioning

Data BaseAlgorithm (on some)

Communication (External)Data Highway (Internal)

Next Older Physical Controller Structure

• Individual cards for each “control loop”

• Different sets per order

• Select card for each needed function:

● Loop ● Logic ● Data Acquisition ● Multifunction

HighwayBus Driver

Diagnostics (some)

Each Card Has one P for

Algorithm, Data Base, etc.

Control Function Executions

Fixed “time slots”

Fixed scan times

Easier to configure

& re-configure!

Typically has algorithm card

Functions ―reused‖ during scan

1

2

3

4

1

2

3

4

Variable “time slots”

Scan time varies w/ density

Can pack in more functions

Algorithms are packaged lines of

programs which are used once per

scan

• Machine code

• Assembly language

• Relay ladder logic

• Boolean logic

• “High” level – Fortran – Cobol – Basic - C++ – Visual Basic

• Algorithms & soft wiring– Menu entry – Fill-in-the-blanks – Graphic blocks– Object oriented technology – IEC 1131-3 standard– Graphical configuration

Programming to Configuration

I I

(

)I I I/I

10110110

00000100

00101100

LOOP1 LDAA TEMP

SUBA #150

blt LOOP1

LDAA #$FF

STAA MOTOR

[Y=(X1+X2+X3+X4+X5)/5]

AND, OR, NOR,...

Software Structures & Direction

• Fewer large blocks– Many features in each– Easy re-configuration

• Many small blocks– More flexible– Complex to create or

change configuration

• Object oriented– Build layers of large

blocks from smaller– Flexible but simple

Object Oriented Programming saves effort• Mine & process the graphite

• Ship to pencil company

• Grow trees, cut trees, trim

• Run wood through lathe, trim, mold

• Ship to pencil company

• Mine ore, process metal,

• Shape metal

• Ship to pencil company

• Grow rubber trees. Harvest

• Process, shape rubber

• Ship to pencil company

• Prepare, trim, assemble pencil

• Packaging, delivery, retail

• Etc.

• Rubber insert

• Metal tip

• Wooden barrel

• Graphite core

All Capabilities in One Module

• Continuous, discrete, sequential control• Four blended languages (IEC 61131-3)

Function Blocks

<PID

PID

Ladder Logic

Structured Text

Sequential Function Charts

FI_134:=FT_130 (PT_450)/(TT_673)

I I

(

)I I I/I

Hardware to Firmware (Function Blocks)

Ratio

TotalizePID-GAP

Mass Flow

Square RootAdd/Subtract

Multiply/Divide PID

Combining Functions for Capabilities

• PID gain can be continuously changed by any other function, such as:– Multiposition Switch

– Ramp generator

– Function generator

ADAPTIVE TUNING

PV

RSP PIDOUT

Input A

Input BAny

Function

Gain

Benefits of IEC 61131 Configuration Standard

• Allows multiple languages– Pick best tool for job

• Uniform programming– Easier to learn– Consistent Documentation

• Structured Organization– Greater maintainability– Reusable configuration/program objects

• Covers wider range of applications– Wider range of applications– No need to use DCS and PLC combined architectures

Standard Languages

• Function block– Mostly continuous execution model– PID, math, continuous control

• Ladder logic– Typical PLC logic– Continuous or sequential

• Sequential function charts– Sequential control– Parallel sequences, transition logic etc.

• Structured text– Pascal like program language

• Instruction list– Low level - like assembler or machine code

[For PLCs; rarely used in Hybrid Systems]

Function Blocks

LABEL

VAR

VAR

VAR

VAR

LABEL

LABEL

LABEL

LABEL

EXTENSIBLEFUNCTIONBLOCK

TYPE-FUNCTION DEPENDENT

FUNCTION

STRUCTURED TEXTEQUIVALENT

INPUTS

ONE OR MORE

INTEGERS

REAL

BOOLEAN

TIME

OUTPUTS

ONE OR MORE

Function Block Diagrams

MIN

PID

IN1 OUT

IN2

IN3

SP

PV

OUT

A/M

TANK_LVL

LVL01*2.7

TANK_SP

Implementing Function Blocks

Controller

OutputInputs

―Softwiring‖

Terminal Connection

Derived Function Blocks (vendor tested)

A

M

START

STOP

NO. 1 PUMP

H FACTOR

DIG TEMP

TARGET

TIME

TEMPSP

TEMPCONTROL

DERIVED

DERIVED

RECIRCCONTROL

VAR_INPUTTEMP:REAL

K1:REAL

RUN:BOOLCYCLE:TIME

END_VAR

VAR_OUTPUT

HF:REAL

END_VAR

IF RUNTHEN HF:= HF+(K1*TEMP*CYCLE)END_IF

Derived Function Nesting

Ladder Logic

Structured TextLABEL

VAR

VAR

VAR

VAR

LABEL

LABEL

LABEL

LABEL

EXTENSIBLEFUNCTIONBLOCK

• TYPE-FUNCTIONDEPENDENT

FUNCTION

STRUCTURED TEXTEQUIVALENT

(created inside)

INPUTS

• ONE OR MORE

• INTEGERS

• REAL

• BOOLEAN

• TIME

OUTPUTS

• ONE OR MORE

Typical Function Block

Custom Function Blocks

• Standard function blocks or existing application libraries do not perform desired functions

• Using existing standard languages requires substantial processing time or resources

• Using existing structured text language would not protect algorithm intellectual property

• Do not want to create stand-alone program

Custom Function Block Benefits

• Appear and used same way as standard function blocks

• Configured into control strategy same as standard function blocks

• Communicate with other control modules using existing standard communication function blocks

• HMI or application programs use consistent addressing syntax

• Vendor equipment can test and verify configurations containing custom function blocks

Potential Custom Function Blocks

• Multi-variable predictive controller algorithms• Adaptive controller algorithms• Sophisticated filter algorithms• Process material- and energy-balance algorithms• Statistical analysis algorithms• Loop behavior analysis algorithms• Specialized motor control logic algorithms• Specialized batch control algorithms• Process simulation algorithms

Uniform Function Blocks

• IEC61131 originally developed by consortium of European PLC suppliers,

– incomplete from a process control standpoint.

– Application software within Function Blocks was left up to each automation control supplier.

• IEC committee looked at function blocks of the DCS fieldbus standard IEC 61158 to determine enhanced function block standard IEC 61804.

• IEC 61804 from DCS world and IEC 61131 from the PLC world will be brought together to for the more universal IEC 61499. – This should meet the needs of both the process industries and the

discrete industries, and as a result, the hybrid (batch processing with packaging) industries.

– Many of the newer or newer versions of DCSs already follow an IEC 61131 approach.

What’s this mean?

Ladder Diagrams

• Simulates hard wired relay logic

– Power rails on either side

– Contacts are inputs to logic

– Coils are outputs

– Rungs carry power (Boolean data)

– Branching and looping are provided by labels

OUT1INBINA

INC

IND

OUT2

INE OUT3

OUT1 = INA AND INE

OUT2 = INC OR IND

OUT3 = NOT INE

OR

OR

Sequential Function Charts

• Graphical representation of:

– Steps in a sequence

– Transition logic between steps

– Parallel operation

– Relationship between parallel operations

– Conditional flow/ looping of sequences

STEP10

STEP20

STEP21

A D

B

C

STEP31

STEP1

0

STEP20

STEP21

A

C

B

D

STEP31

Skip Loop

Ready

Fill

Mix Heat

Cool

Start

True

Empty

Condition 1

&

Condition 2

Sequential Function Charts (cont’d) Skip sequence

Divergence of sequence, one

branch has no steps

If transition D becomes true

before A step 20 and step 21

will be skipped.

STEP10

STEP20

STEP21

A D

B

C

STEP31

Loop sequence

Step 20 and step 21 will

be executed as long as

transition C becomes true

before D

STEP10

STEP20

STEP21

A

C

B

D

STEP31

Sequential Function Charts

• Rules of evolution

– Must have an initial step

– Must have alternating steps and transitions

– Chart can be looped or terminated

CHART01

STEP1

:=COND1 & COND2

Step N ACTION1

:=TRANS2

STEP2 N ACTION2

Transition

Step

:=COND3 & COND4 Transition

Looped Chart

Sequential Function Charts

CHART001 Initial Step

Transition

FILL

:=START

Step N FILL_A

Action

HEAT LT#5S HEAT_A AGITATE AGITATE_ALT#10S

Simultaneous

Divergence

Simultaneous

Convergence

COOL N COOL_A

:=TRUE

:=TRUE

DUMP N DUMP_A

:=TRUE

:=TRUE

Loop

BA

YX

Convergence/Divergence

Actions

N FILL_TANK_ACT DONE

ACTION BODY

OR

OUT1INBINA

INC

IND

OUT2

INE OUT3

OR Structured Text, etc.

Qualifier Action Body Feedback VariableSTEP10

AN FILL_TANK_AC

T

DONE

AND

OUTIN01

IN02

LVL_LOW

FEED_OPN

Can be Function Block !

Actions In SFC’s and FBD’s

STEP10 N FILL_TANK_ACT DONE

Action is executed when step is active in SFC or…

Action is executed when function block output (action input) is true

N FILL_TANK_ACT DONE

AND

OUTIN01

IN02

LVL_LOW

FEED_OPN

Function Block !

Structured Text

• PASCAL like

• Assignments :=

• Arithmetic & logic

– Plus, minus, multi,

OR, AND, etc

• Conditionals

– IF, ELSE,

ELSEIF, THEN

• Multi test case

– CASE OF, ELSE

• Looping

– FOR, WHILE.. DO,

REPEAT .. UNTIL

EXAMPLE

VAR

P, PC, T, TC : REAL ;

END_VAR

(* Convert Pressures to psia *)

P := [PRESS] + 14.696 ;

PC := [P_CAL] + 14.696 ;

(* Convert Temperatures to Rankine *)

T := [TEMP] + 459.67 ;

TC := [T_CAL] + 459.67 ;

(* Orifice Calculation *)

[FLOW] := [F_CAL] * ( ([HEAD]/[H_CAL])* (P/PC) * (TC/T) ) ** 0.5 ;

Instruction List

• Low level assembler like instructions

• LD Load

• ST Store

• S Set

• R Reset

• AND

• OR

• XOR

• ADD

• SUB

• MUL

• etc.

• JMP Jump to label

• CAL Call function block

• RET Return

Mixing Languages

• Any or all languages can be used within a single

controller

• Derived blocks are used to encapsulate each application

of a programming language

– This also helps to organize the entire program

• The various languages communicate or pass information

to each other by ―wires‖ or variable or TAG names

• Languages can co-exist within each other

– E.g.. function blocks in ladder diagrams, structured

text in function block diagrams, and any of the

languages as an SFC action

IEC 61131-3 Summary

• Structured methodology• Hierarchical design• Modern programming concepts refined and

standardized• Use the best tool for task at hand• Reduced programming time• Easier to understand and troubleshoot another

person’s program regardless of which venders hardware is used

• Programs can be portable

The Network Monsters

Data Highways & Dirt Roads• Digital communications saves installation costs

– Less wire, less connections

– Less error in wrong connections!

– BUT…avoid narrow bridges, toll booths, poor road surfaces & capacities…

Network Topologies

Star

Line (Bus)

Ring

Tree

Mesh

• Simplex: One direction

• Half duplex: One direction at a time

• Full duplex: Both directions at once

Types of Transmission

Receiver BSender A

Receiver BSender A

Sender BReceiver A

Receiver BSender A

Sender BReceiver A

SDLC Format - Synchronous• Typical transmission example

– Impact of “bits per second” on data rate modified by clever use of Information frame& reduction of overhead (all the other frames needed)

Beginning

Flag

01111110

8 bits

Address

8 bits

Control

8 bits

Information

any number

of bits

Frame

Check

16 bits

Ending

Flag

01111110

8 bits

Listen

for

Message

Here is

where I am

sending it

This is

from where

I am sending

Here is my

message

(request/reply/etc.)

Here is how to

confirm accuracy

of transmission

Message

Complete

HDLC Response to “Scan Group”• Typical “scan group” could be all needed parameters of

single control loop in one specific controller on

network...

– Amount of information determines scan group size

– Assumes 1byte = 8bits; Assumes 1bit takes 2 µsec.

Prefix Gap Flag Addr. Control Source Information

Scan Group

CRC Flag

2 sec.

32 sec.

1 b

yte

1byte

1 b

yte

1 b

yte

20 b

yte

s

2 b

yte

s

1 b

yte

27 bytes @ 16 sec./byte = 432 sec.

32 + 2 + 432 = 466 sec. = Total message length

Complete Transaction on Network

• Several factors must be considered in considering transaction time on network:

– Request message length

– Media access time; Transit time

– Turn-around time (find, process reply)

– Response message length

– Transit time for return

– Processing time of originator

Operator Station

Request Message

Controller

Turn-around

Controller Response

Message

Operator Station

Processing

200 sec 80 sec 466 sec 320 sec

Transit = 15 sec/10,000’

Transit = 15 sec/10,000’

Transaction time = 776 sec ……Time between transactions = 1.096 sec

Modulation Types in Modems• Phase modulation

• Amplitude modulation

• Frequency Shift Keying (FSK)

180 phase shift

1 0 1 1 0 1 1 0

1 0 1 1 0 1 1 0 Modem

1 1 1 1 1 0 0 0

1 0 1 1 0 1 1 0 Modem

1 0 1 1 0 1 1 0

F1 F2 F1F1 F2 F1F1 F2

CPU

Serial I/O

Modem

Communication

Network

1 0 1 1 0 1 1 0 Modem

Access Protocols

• Three popular methods found on distributed systems

• Used to gain access to communication network

2.CSMA-CD 3.Token Bus

1.Traffic Director

Response Time of Two Access Protocols

0 25% 50% 75% 100%

Token Passing

CSMA/CD

(Ethernet)

Mean T

ime to R

espond

(log s

cale

)

102

10

1

10-1

Percent Load

Industrial is more distributed architecture

PLANT FLOOR

Distributed, lower port

count Switches & Hubs

OFFICEARCHITECTURE

Centralized Racks &

Switch Closets

Industrial vs. Office Networks

Office vs. Factory Ethernet Applications

Office• 80% clients (Workstations)

20% Servers (Printers & Computers)

• Operates during normal business hours 9 to 5

• Systems usually fixed in one location.

• Network downtime is only nuisance; problems may take a day to solve.

• Network Equipment is housed in easy to access and defined areas.

• Local workers not encouraged to solve networking problems.

Plant Floor• 20% Clients (Operator Stations)

80% Servers (Controllers, PLCs, Drives, I/O, Robots, etc)

• Operates continuously (24X7).

• Often mobile and move in wide area or are frequently reconfigured.

• Network downtime unacceptable; rapid restoration solutions required.

• Network equipment installed near electrical equipment in distributed enclosures.

• Local workers responsible for solving networking issues (fieldbus problems).

“Traditional” Ethernet 10Base-2

• Historical network• All stations hear all others• Only one conversation at a time• Collisions can occur (CSMA/CD)• Bus or Star topology• 10 Base-T & 100 Base-T

HUB

Network Architectures

• Routers – provide both network isolation and Firewall protection from both external and internal interference.

• Hubs – inexpensive; physically links all devices to common line; used where single device is polling information.

• Switches – provide much greater performance as individual connections are established between devices.

• Managed Switches – switch maintains knowledge of connected device IP address.

Switched Base-T Ethernet

• Allows multiple simultaneous communications(increased bandwidth)

• Can connect 10Mbps to 100Mbps(speed buffering)

• Allows larger network

SMART HUB

Smart hub “knows” network layout

so it can route messages to proper port

Large Ethernet Network

• Full duplex communications between switched hubs• Multiple simultaneous conversations w/o interference• Little chance for collisions to delay signals

SMART HUB SMART HUB

Smart hubs in networks allow any two stations to talk without interference

Fault Tolerant Mesh Control Network

• Fault tolerant, ―self healing‖ network can recover from multiple faults

• Higher data throughput for large plant-wide real-time application needs

•High speed (100Mb/1Gb)

•Data routing for more efficient data throughput

• Longer distances supported, for large plant-wide networks

• Variety of topologies – ring, star, tree.; fiber is standard

COTS = Commercial, Off-The-Shelflowers costs

16-Port Managed Ethernet Switch

Redundant

Mesh

Ethernet

Network

Control

Processors

CP2

CP1

Work StationsDevices (work stations, control processors, etc.) will each connect to two switches.

WS1

WS2

Mesh Network Fault Tolerance

Traditional bus architecture tolerates failure on

either A or B networkWS

CP CP

WS WS

CP CP

Bus

AB

AB

Mesh network provides multiple-fault tolerance by managing alternate communication

paths between devices. Each switch has connections to two different switches in layer

above.

RSP tree topology in switches automatically manages connection paths to avoid unnecessary data flow.

CP CP CP

Rapid Spanning Tree (RSP)Root switches

1st layer

2nd layer

3rd layer

WSWS

Mesh Network Fault Tolerance

Rapid Spanning Tree (RSP)

Mesh network provides multiple-fault tolerance by managing alternate

communication paths between devices.

WS2WS1

X

Root switches

1st layer

2nd layer

3rd layer

X

XX

CP1 CP2 CP3

X

A01 B01

A11 B11

A21

A31

B21

B31

A22 B22

A32 B32

SELF DIRECTING with NO PROGRAMMING!

Compatible vs Compliant - MAP

• MAP compatible:

– Each brand shares token, BUT can talk only to same brand; cost is $X over non-compatible…for ( )

MAP compliant:

Each brand shares token AND talks to any other; cost is

$10X over non-compliant…for ( )

A A A BBB C C C

mm m m m m m m m

m

A A A BBB C C C

M

M M M M M M M M M

OSI Reference Model by ISO

Provides all services to the Application program(e.g. Windows)

Function

Physical transmission medium ( e.g. coaxial, twinaxial cable)

Restructures data to/from standardized form

Provides user-to-user connections(e.g. Winsockets, NetBios, NetX)

Provides transparent data transfer-Node to Node(e.g. TCP/UDP, NetBeui, IPX/SPX)

Provides routing of data through the network(e.g. IP)

Provides link access control and reliability(e.g. token pass, CSMA/CD, etc.)

Provides an interface to the physical medium(e.g. connectors, cable type, impedance)

Layer 6

Presentation

Node A

Layer 7

Application

Layer 5

Session

Layer 4

Transport

Layer 3

Network

Layer 2

Data Link

Layer 1

Physical

User program

Layer 6

Presentation

Node B

Layer 7

Application

Layer 5

Session

Layer 4

Transport

Layer 3

Network

Layer 2

Data Link

Layer 1

Physical

User program

OSI Analogy: Mailing Letter

OSI Layer Postal System Equivalent

7-Application Letter contents within envelope

6-Presentation Format & language of letter, including proper

translation into another language, if needed

5-Session Name, address, zip code of both sender & receiver

4-Transport Certified or registered mail; verification to sender

that letter arrived at correct destination

3-Network Distribution transfer to outside local system to

another city or country

2-Data Link Distribution within same local system, or within

local system in that other city or country

1-Physical Conveyance: postman, truck, train, plane…..

OSI Reference Model

Physical transmission medium ( e.g. coaxial, twinaxial cable)

Layer 6

Presentation

Node A

Layer 7

Application

Layer 5

Session

Layer 4

Transport

Layer 3

Network

Layer 2

Data Link

Layer 1

Physical

User program

Layer 6

Presentation

Node B

Layer 7

Application

Layer 5

Session

Layer 4

Transport

Layer 3

Network

Layer 2

Data Link

Layer 1

Physical

User programUser data

User data

User data

User data

User data

User data

User data

User data

Each L

ayer

Adds M

ore

Headers

...

…&

Foote

rs

LAN Interconnection Devices

Repeater - Connects two or more LANs of same technology

or extends distance of a LAN.

Bridge - Interconnects LANs, but only forwards data destined

for device on other side of bridge. Can only connect two

similar LANs. (such as Ethernet)

Router - Connects to several networks and forwards data

packets using the Network Level addresses. Can connect

two LANs of different topologies but same protocol.

Gateway - Protocol conversion device to interconnect

networks or devices which uses different communications

protocols. Gateways function at all seven layers. Can be

used to connect DECnet device to TCP/IP device.

Layer 5

Session

Layer 4

Transport

Layer 3

Network

Layer 2

Data Link

Layer 1

Physical

Layer 7

Application

Layer 6

Presentation

TCP/IP• Transmission control protocol/internet protocol

• Developed by U.S. Department of Defense in 1974

• De facto standard network protocol to connect UNIX systems

• IP : Network layer (layer 3) - routes data over network to correct LAN address

• TCP : Transport layer (layer 4) - segments data into packets and verifies that message got to its destination intact

• TCP/IP does not extend to physical and data link layers, hardware interface is beyond its scope. Since TCP/IP is media independent it has been implemented on variety of media.

• UDP : User datagram protocol - alternative to TCP

• UDP does not require acknowledgments of messages, less overhead, higher performance relative to TCP/IP

What are differences between Ethernet, TCP/IP and address IP?

• Ethernet is the road to drive on.

• TCP/IP are the cars on the road.

• And the IP Address is used as the street address to which the car drives.

Will the REAL Ethernet Please Stand Up!

Industrial Ethernet – Has no standard definition; typically means Ethernet protocols independently developed for manufacturing data collection & control, such as:

• EtherCAT – Ethernet Control Automation Technology; primarily for motion control functions; can interoperate with normal TCP/IP-based networks like EtherNetI/P or PROFInet.

• EtherNet/IP – ControlNet/DeviceNet objects on TCP/IP. • High-speed Ethernet (HSE) – FOUNDATION Fieldbus (FF) using

standard Ethernet cabling; once called FF H2. Modbus/TCP –• Modicon Communication Bus packet within a TCP/IP packet;

defacto standard for Ethernet on the plant floor. • PROFInet – PROFIBUS with Ethernet.

DDE vs API

DDE (Dynamic Data Exchange)• Simple configuration

• Simple interface

• Low performance

• Wide selection of servers available

API (Application Program Interface)• Programming

• Full integration

• High performance

• Windows, WindowsNT, QNX,

• OSF/1, HP/UX, VAX/VMS,

• Alpha/VMS

Ethernet

Application Interface Options

DDE - Dynamic Data Exchange• DDE:

– Standard communication protocol

– Allows several programs to share data

– Simple connection between

applications

– Does not understand the data

• DDE server:

– Allows other programs to access data

from controllers

– Compatible with any "DDE-aware"

programs such as Lotus 1-2-3, Microsoft

Excel, and HMI software

Lotus 1-2-3

Controller(s)

Excel

DDE Server

HMI softwareDDE

Personal

Computer

DDE client:

Can request data, send data, and

send messages to controllers through

DDE Server

• NetDDE is extension of DDE

• Using NetDDE, Windows applications in

separate computers on network can share

data via DDE as if they were in same

computer

• Communication between nodes is

transparent to the user

Manager 1Excel

DDE Server

NetDDEExcel

NetDDE

Manager 2

Ethernet

Operator

Station

Controller - NetDDE Options

OPC for HMI Communication

Why is OPC Needed?

Software

Driver

Software

Driver

Software

Driver

Software

Driver

Display

Application

Trend

Application

Report

Application

How does OPC Solve the Problem?

Software

Driver

Software

Driver

Software

Driver

Software

Driver

OPC OPC OPC OPC

Display

Application

Trend

Application

Report

Application

OPC OPC OPC

Typical Communication Models

• Client/Server—

• Publisher/Subscriber—

Server

Clients each independently request/receive data from Server

Publisher

Subscribers each independently receive updates as they occur

Only selected stations receive assigned data

Receives whatever data asked

The Fieldbus Monster

Conventional vs Fieldbus SignalsDigital instrumentation technology with analog communications technology?...

or... digital communications technology!

4-20 mA

Digital-to-Analog

Signal Conversion

Analog-to-Digital

Signal Conversion

Microprocessor-

Based

Transmitter

Microprocessor-

Based

Instrument

Fieldbus

or

Fieldbus

Controller

How Fieldbus Works

7

2

1

Device 1

User

Appl’n.

Data Link

Physical

Device 2

User

Appl’n.

Data Link

Physical

7

2

1

Subset of the ISO’s OSI Reference Model:

Field Based Control Example

Controller

Controller

Cascaded !

FOUNDATION Fieldbus itself can be controller

Sensors Analyzer Valves Motors

Fieldbus Open Network Flexibility

Smart Transmitters, Sensors, End Elements:

• Multivendor within same system

• Common Function Blocks

• configuration

• documentation

• tag names & HMI ―calls‖

• peer-to-peer links for complex strategies

MultivariableController

PC

as HMI

User Choice;Configures control

database and:

• Screen Views

• Trends

• History

• etc.

Control network

Linking device

(Control Network)

Process automation protocols• FOUNDATION Fieldbus

• Profibus - by PROFIBUS International.

• PROFINET IO

• CIP (Common Industrial Protocol) - Can be

treated as application layer common to

DeviceNet, CompoNet, ControlNet and

EtherNet/IP

• Controller Area Network utlised in many

network implementations, including CANopen

and DeviceNet

• ControlNet - an implementation of CIP,

originally by Allen-Bradley

• DeviceNet - an implementation of CIP,

originally by Allen-Bradley

• DirectNet (CCM protocol) - supported by

Automationdirect \

• EtherNet/IP - IP stands for "Industrial Protocol".

An implementation of CIP, originally created by

Rockwell Automation

• EtherCAT

• EGD (Ethernet Global Data) - GE Fanuc PLCs

(see also SRTP)

• PoE, PoE+ - Power over Ethernet

• HART Protocol

• PieP - An Open Fieldbus Protocol.

• FINS - Omron's protocol for communication over

several networks, including ethernet.

• Host Link - Omron's protocol for communication

over serial links.

• Interbus - Phoenix Contact's protocol for

communication over serial links, now part of

PROFINET IO

• Mechatrolink - open protocol originally developed

by Yaskawa.

• MelsecNet/10 - supported by Mitsubishi Electric.

• Modbus RTU or ASCII

• Modbus-NET - Modbus for Networks

• Modbus/TCP

• Modbus Plus

• Optomux - Serial (RS-422/485) network protocol

originally developed by Opto 22 in 1982. The

protocol was openly documented and over time

used for industrial automation applications.

• SERCOS interface - Open Protocol for hard real-

time control of motion and I/O

• GE SRTP - GE Fanuc PLCs

• Sinec H1 - Siemens

• SynqNet - Danaher.

• BSAP - Bristol Standard Asynchronous Protocol,

developed by Bristol Babcock Inc.

Which path to take?

Don’t want conflicting interests!

Process Control User Layer

PROFIBUS

DeviceNet

FIP

SDSnet

LONworks

FF Fieldbus

etc.

PHS

Layer

D-L

Layer

Appl.

Layer

User.

Layer

Function Blocks

“Mode” “Status”

Alarm

Support

Trend

Support

Device

Description

Language

Foundation Fieldbus has Process Control USER LAYER!

PA

Cost – Function

– Data – Complexity

Netw

ork

Sp

eed

LOW

HIGH

HIGH

Figure A.18 Example of field bus trade-offs

Fieldbus Hierarchy

(BIT)

(BYTE)

(BLOCK)

Digital Networks for Control Systems

X

X HSE

Source: Control Engineering Magazine

PROFIBUS-PA

FDT/DTM

FF – H1

PROFIBUS-DP

HART

Installed 2005Plan for 2006

Used in 2003

DeviceNet

4-20 mA

Ethernet

Past, Present, Future Use of Fieldbuses, Network Methods

CONTROL magazine survey

132 respondents who buy,

recommend or specify

industrial networks

Fieldbus AND Ethernet market shares– 2009

Exclusively Process(Process & Discrete)

Industrial network development– 2009

1975 1985 1995 2008

Technology

Development

Growth

Fieldbus - User Group Focus

India

SEA

Canada

USA

Brasil

Argentina

Europe

India

SEA

Japan

Food & Beverage

Chemistry

Water / Waste

Petro & Chemistry

Pulp & Paper

Food & Beverage

RSA

Fieldbus - meets the Customer needs

(*****) = best suitable

Industry

System

Availabilty

Reliability

Costs

Technical features ***** ****** ****

**** ******* *****

* *********

PLC

DCS *****

Petrochemical

Power

Chemistry i.s.

Food & Beverage

Waste- / Water

*

********

****

*******

***********

***Solids *** ****

Chemistry non i.s. ******

Fieldbuses in Process Industry

• Large installed base– >2/3 of all “smart” instruments shipping are HART capable

– >20 million HART-enabled devices installed world-wide

– >700,000 FF compliant devices; 10,000 systems

– >700,000 PROFIBUS PA compliant devices

• Mega-systems (>10K devices) becoming common

• Companies standardizing on fieldbus for control– Higher availability, lower variability, reduced

commissioning time

– Mandated for new projects

– Several use “control-on-the-wire”

Which Fieldbus to use?

• Each have different strengths, limitations– Host system support!– Area classification– Distance limitations– Equipment cost– Signal mix – “analog” (numerical) vs. discrete– Facility history/legacy– Process needs & speed of response– Availability of devices capable of desired measurements

• Best choice is often combination of buses– Different processes in different parts of operation– Different end uses = motor controls vs. process controls– Trade-off: system more complex with more buses

Bottom Line Thoughts from Large User

• Biggest potential return for fieldbus lies in– Reduction of process upsets

– Maintenance costs through effective use of device data

• FDT is great enabler to obtain these functions!

However… My Plant

• Runs continuously

• With many different field devices

• On several different networks

• With more than one control system…

when a problem occurs

• No matter who responds

• No matter where their mind is at the time

• No matter how much their experience with

THIS problem …or THIS equipment

• No matter how rarely it happens…

my people QUICKLY need to

• Always see information the same way

• Know what is wrong

• Know how to act

• Be consistent

…WHOEVER responds

…WHENEVER they respond…

with a SINGLE tool

• That works with any field equipment

• From any supplier

• That reduces device commissioning time

• Supplies meaningful

Asset Management information

• On ALL my EXISTING systems

EDDL• EDDL - Electronic Device Description Language

– Descriptive characteristics of a device

• In compressed binary format; cyber safe

• Not executable code to not impact stability of operating system

– Graphical elements for device maintenance and configuration

• Specified by the Instrument Protocol foundations

– Foundation Fieldbus

– HART Communication Foundation

– PNO - PROFIBUS

• Required for instrument certification by the respective foundations

• Foundations working to establish a common EDDL standard

– ECT – “EDDL Cooperation Team”

– IEC standard

EDDL – Data Description

• The EDDL provides a texted description

– Device

– Block

– Parameters

#define LINEAR 0

VARIABLE trans1_temperature_unit{

LABEL[digital_units];HELP [temperature_unit_help];CLASS CONTAINED;HANDLING READ & WRITE;TYPE ENUMERATED (2){

DEFAULT_VALUE 32;{ 32, [degC], [degC_help] },{ 33, [degF], [degF_help] },{ 34, [degR], [degR_help] },{ 35, [Kelvin], [Kelvin_help] } IF (trans1_sensor_type == LINEAR){

{ 36, [mV], [mV_help] },{ 37, [Ohm], [Ohm] },{ 39, [mA], [mA_help] },

}}

}

Another Solution…

FDT is an “open” standard

for device integration that:

– Is viewed on any windows workstation

– Provides consistent graphic presentations

– Is supplier, system, & protocol independent

FDT based tools• Support Consistent workstation views

• Compatible with existing & future automation equipment

• Upgrade all your existing networks

• Manage multiple generations of devices over life of plant

• Graphical support for start up and commissioning

• Intuitive HELP functions for troubleshooting

• Monitor efficiency during operations

• Same look & feel on every system

• Best advanced diagnostics

…specific know-how

…from each device supplier

…who can easily upgrade you with new information

FDT based tools

FDT connects with 12 different protocols

AS-interface

ContolNet

DeviceNet

EtherNet/IP

FOUNDATION Fieldbus

High Speed Ethernet

HART

INTERBUS

IO Link

MODBUS SL/TCP

PROFIBUS DP/PA

PROFINET I/O

CIP Annex configuration

Endorsed by 66 users & suppliers and growing!

®

145

VALIDATED user results show• 40% reduction in commissioning time

Note! Commissioning is usually the CRITICAL path of the project! (Dow 9/07)

• 80% reduction for last minute engineering modifications (Dow 9/07)

• Much faster resolution of typicalinstrument problems during startup (example false echo’s with radar level meters)

• 60-70% reduction in scheduled plant downtime(Clariant GmbH 9/06)

“Instrument

Technicians

LOVE this tool!”

Feedback from commissioning team:

PlatformUNIX

Windows

RelationalDatabasesODBCSQL

DistributedApplications

DCOMOPC

NetworksEthernet

SP50Fieldbus

Standards are essential for “Open”

SimulationDIPPRPDXISTEP

CAPE-Open

InternetOLE/ActiveX

JAVABrowsers

HMIWindows

OLE/ActiveXCOM

ControlS88

IEC61131SP50

RegionalStandardsCENELEC

ANSI/NEMAJIS/CNSCOPANT

IEC61131 Configuration Standard

• Continuous, discrete, sequential, batch control• Multiple languages in same controller

Function Blocks

<PID

PID

Ladder Logic

Structured Text

Sequential Function

Charts

FI_134:=FT_130 (PT_450)/(TT_673)

I I

( )I I I/I

Benefits of IEC 1131 Configuration Standard• Allows multiple languages

– Pick best tool for job• Uniform programming

– Easier to learn

– Consistent Documentation• Structured Organization

– Greater maintainability

– Reusable configuration/program objects• Covers wider range of applications

– Wider range of applications

– No need to use DCS and PLC combined architectures

Standard Languages• Function block

– Mostly continuous execution model

– PID, math, continuous control

• Ladder logic

– Typical PLC logic

– Continuous or sequential

• Sequential function charts

– Sequential control

– Parallel sequences, transition logic etc.

• Structured text

– Pascal like program language

• Instruction list

– Low level - like assembler or machine code

[For PLCs; rarely used in Hybrid Systems]

OPCUA Unification

• OPC Unified Architecture provides a common view of the field instruments up to the enterprise level– Product data

e.g. identification, I/O description, certifications– Diagnostic data

e.g. device status information, events and alarms– Process data

e.g. measurement data, set point Parameters, unit upper/lower limits

– Maintenance data e.g. classification, description, spare parts, tools for

maintenance

• Uses EDDL or FDT information

OPCUA FDI Unification

• FDI – Field Device Integration– ECT members participate [ECT = EDDL Cooperation Team]– FDT members participate [FDT = Field Device Tool]– OPCUA members participate

• Define a common infrastructure– Device semantics– Device applications for maintenance and diagnostics

• Retain full functionality of existing EDD applications• Retain full functionality of existing FDT applications• OPCUA becomes the communication infrastructure

– One object model for device information– Use of OPCUA for maintenance and diagnostic applications

OPC UA Early Adopter Companies• ABB

• Absynt Technologies Ltd

• ascolab GmbH

• Beckhoff

• CAS

• Cognex

• Cyberlogic

• Helsinki University of Technology

• Honeywell

• Iconics

• InduSoft LLC

• Ing.-Buero Allmendinger

• Invensys/Foxboro

• Invensys/Wonderware

• Kepware

• Matrikon

• Metso Automation• Microsoft• OPC-F• OSIsoft, Inc.• Prosys PMS Ltd• Rockwell• SAP• Siemens• SISCO• SMAR• Softing AG• Software Toolbox• SRI International• Tampere University of Technology• Technosoftware AG• VTT• Wapice Ltd• Yokogawa Electric Asia

Batch vs Continuous

BATCH CONTINUOUS

Control Recipe Driven Set point Driven

Product Grade Changes Frequent Occasional

Operations Transient State Usually Steady State

Product Volume Smaller Larger

Production Life Cycle Shorter Longer

Process Equipment Shared Dedicated

Product Chemistry Not clearly known More clearly known

Operator involvement High High when abnormal

Analog control loops Few Many

Interlocks Large number Smaller number

Sequential Control Complex Simpler

Tracking & scheduling Complex Simpler

Operations Management Complex Simpler

Typical Batch Processes

M

M

M

M

M

M

M M

M

zone 3 zone 2 zone 1

Liquids Powders

Solids

Types of Batch ProcessesSingle-Product

Single-Stream

One Product

Multi-Product

Single-Stream

Several Products

Multi-Product

Multi-Stream

Several Products

Single-Product

Multi-Stream

One Product

Parts of a Batch Operation

Make a batch

of QR6

The Schedule

The Recipe

The Equipment

Execution

The Batch

The Report

QR6

Domain of Control Systems

Continuous Batch Discrete

Computer

Control Room

Communications

Local Operators

Control

Input/Output SENSORS

MANAGEMENT

INFORMATION

SYSTEMS

<<

FIE

LD

BU

S IN

FL

UE

NC

E >

>

<<

AD

VA

NC

ED

CO

NT

RO

L T

EC

HN

OL

OG

Y IN

FL

UE

NC

E >

>

STAND-ALONE CONTROLLERS

PERSONAL COMPUTERS

AN

ALY

ZE

RS

PERSONAL COMPUTERS

DCS

PLC

PAC

Control System Market Dynamics

DCS

PLC

Process

only

MIS

PC

SLC

Only that

done also in

Workstations

Growth from

new markets due to

improved capacity

power, etc.

PAC

Competitive Landscape

DISCRETE PAC CONTINUOUS

DCS LandHoneywell

ABBInvensys/Foxboro

Emerson. Yokogawa

PLC LandABBGE

Siemens S7RockwellSchneiderMitsubishiOmron

THE BATTLEFIELD

PLC/DCSSiemens PCS7

Foxboro Micro I/AHoneywell Experion

ABB AC800 FEmerson DeltaV

Rockwell Pant PAxYokogawa Centum1000

GE IP

USDATAIntellution

WonderwareCitect

StandaloneHMI

Decade of Controls Industry Changes1990Honeywell

ABB

Emerson

Fisher Controls

General Signal (L&N)

Bailey

Foxboro

GE Fanuc

Fisher & Porter

AEG

WestinghouseMeasurex

Siemens

Johnson Yokogawa

Moore

Applied Automation…

…via H&B

1995Emerson

Honeywell

ABB

Siebe

Elsag Bailey

Rockwell

Westinghouse

Johnson Yokogawa

General Signal (L&N)

Measurex

Moore

Siemens

GE Fanuc

Wonderware

AEG Schneider

2000 2010Emerson

ABB

Invensys

Honeywell

Siemens

Rockwell

Neles Automation

Schneider Automation

Moore

Yokogawa

GE Fanuc

[Order of US Mkt Shares]

(Intellution)

(Intellution)

(Wonderware)

Challenges For Controls Suppliers

• Transition from Hardware to Software & Solutions

• Development and Management of Open Architecture systems

• Managing Customized Solutions to Customers

• Build Global Sales & Service Infrastructure

• Maintain Margins Selling Software & Solutions

• Keep Pace with New Technologies

Still Room to Grow

“What the hybrid industries such as pharmaceuticals…

really LACK today…

is effective enterprise optimization…

because of the WALL that still exists…

between the traditional processing realm of batch systems…

and the traditional discrete realm…

of PLC-based packaging systems.”

ARC Research Director Larry O’Brien

Industry Trends (ARC Advisory Group)• Market

– Investment Shift to Asia-Pacific & Latin America

– Deregulation & Privatization

– Supplier-User Alliances & “Automation Outsourcing”

– “BOOT” Agreements (Build, Own, Operate, & Transfer)

• Technology

– Standardization >>COTS (Commercial-Off-The-Shelf) Components

– Dematerialization >> Less Hardware vs. More Software

– Migration of Control to Field >> Smart Field Devices

– Intersites / Plant Connection >> Internet / Intranet

– e-Business / e-Commerce

• Prices

– Continued Erosion >>

-40% in past 15 years; expect –10% in next 5 years

…Sam

There are Never Simple Answers!!

If there were...

• all of this stuff would be sold mail order, and...

• talks like this would be unnecessary!!

…Sam

• The confusion over PAC Monster……….

• The Acronym Monster…..

• The Configuration Monster………………

• The Network Monster….

• The Fieldbus Monster……………………….