Product category:
Process Control and Monitoring Systems
News Release from: Rockwell Automation Anorad
Edited by the Processingtalk Editorial
Team on 02 May 2008
Enhanced process portfolio at Rockwell
Automation
Rockwell Automation has an established platform to deliver robust process solutions through its Integrated Architecture, FactoryTalk Suite and Plant-Wide Manufacturing Execution Systems interface
Now this process capability has been further enhanced by specialist capabilities arising from three acquisitions and a technology partnership As technology advances blur the distinctions between discrete and analogue control systems, Rockwell Automation automation solutions demonstrate the ability of Integrated Architecture to be used in traditional DCS environments
This article was originally published on Processingtalk on 3 Jul 2008 at 8.00am (UK)
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Today, many companies use different control and information systems for each type of production discipline.
This approach means difficult and expensive system integration, but even more importantly, decisions are made based on the limitations and boundaries of these disparate systems, diminishing the ability to make timely, fully informed decisions and take action.
Rockwell Automation expertise in the areas of drives, high-speed motion, safety, and discrete automation gives the company a significant established presence in process facilities.
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Sugar plant process integration with Rockwell
A major automation project at the largest US sugar processing complex means that the company is now the most automated, making it more cost effective and more competitive in international markets
Tools for more efficient machine design
The Connected Components offering from Rockwell Automation delivers a simple, affordable control solution for machine builders and OEMs
Market demand expands Rockwell training business
Over 60 new instructor-led courses, ControlLogix Certificate Programme and safety seminars have been added to help companies better train their workforce, as the qualified labour pool shrinks
The ability to integrate high-speed discrete drives and motion control applications with process applications opens up a new realm of facility-wide optimisation for its core industries.
The multi-discipline, plant-wide solutions based on the Integrated Architecture platform are particularly successful within the so-called hybrid industries - those which operate both discrete and process manufacturing, where limitations of interoperability in systems and interfaces are most marked.
This capability has in recent times been further enhanced by the acquisitions of:.
* ICSTriplex - safety capability and critical control.
* ProsCon - process technology.
* Pavilion - advanced process control.
There is also a key partnership with Endress+Hauser over process instrumentation.
Collectively, these developments confirm Rockwell Automation as having one of the most powerful process control offerings available.
The advanced capability of the safety systems can address the most demanding applications with confidence.
The Pavilion model predictive control technology has been proven to increase efficiency and profits significantly.
The partnership with Endress+Hauser provides tools to simplify integration and improve plant performance, while both ProsCon and ICSTriplex provide the engineering capability to deliver complete turnkey installations.
MARKET OPPORTUNITY.
Within the traditional DCS environments, the first generation of process automation systems are starting to reach the end of their natural lives.
ARC Advisory Group believes that the next few years are a critical opportunity for control system suppliers to win market share: "Many end users are in the process of deciding who their new control system supplier will be for the next 10 or 20 years, and the suppliers that get their foot in the door today will succeed in the long term".
ARC predicts 7% market growth year-on-year through to 2010 as these ageing Process Automation Systems are replaced.
"Control system migration continues to be an important issue for manufacturers faced with ageing of Process Automation systems, combined with the compelling value proposition of information technology available from today's automation suppliers".
Whether customers need to migrate, upgrade or replace equipment, Rockwell Automation will test, stage, and implement the project without causing a major disruption to production.
The experienced project teams at Rockwell Automation can ensure the migration is at a pace that is acceptable for the individual customer and their budget.
With assistance from Rockwell Automation, customers can quickly migrate to newer technology while minimising downtime and maximising operational success.
INTEGRATED ARCHITECTURE.
Rockwell Automation Integrated Architecture is the only true plant-wide solution that can address all the requirements of process, discrete, motion control and integration with information systems.
Unlike conventional architectures, it provides fully integrated, scalable solutions, able to optimise production, respond more quickly to customer or market demands and reduce costs.
Real-time information exchange between production and the rest of the enterprise is critical for making business decisions that improve responsiveness, increase productivity, reduce costs and assure regulatory compliance.
Unlike traditional architectures, the Integrated Architecture reduces total cost of ownership by using a single control infrastructure for the entire range of factory automation applications, large or small.
This enables companies to re-use engineering designs and practices to reduce development time and cost, quickly respond to customer or market demands, reduce maintenance costs and downtime and easily access plant and production data from business systems.
Integrated Architecture, which includes the Logix control platform and FactoryTalk suite, allows manufacturers to install a single automation system across the plant, based on the key standards in the automation industry.
This supports the needs of batch operations, continuous operations and discrete control, including machine control and motion.
By emphasising third party connectivity, interoperability and use of open industry standards, the Integrated Architecture provides seamless information integration with the rest of the site or enterprise.
It provides the connectivity and control for all operations, including field instrumentation, pumps and conveying systems, valve control and process monitoring.
It also provides a single interface for programming changes and helps bridge the gap between the enterprise level and the plant floor.
Integrated Architecture controllers and I/O also offer redundancy to provide high availability, supporting runtime modifications to the control system.
Standards supported by the Rockwell Automation Integrated Architecture system include IEC 61131-3 for programming and configuration and structures for batch and procedural applications.
ISA-95, the international standard for the integration of enterprise and control systems, is supported, as are ISA-S88 and S99.
In the realm of networking and device connectivity, Rockwell Automation supports Foundation Fieldbus, Profibus PA, HART, EtherNet/IP, DeviceNet, and ControlNet protocols, as well as being a member of the Field Device Tool (FDT) Group, and is represented at board level within their supporting organisations.
The company has also been a long-time supporter and board member of the OPC Foundation and embraces OPC UA (Unified Architecture) for open interoperability between the plant floor and the enterprise.
THUMBNAIL PROFILE - ICS TRIPLEX.
Safety and critical control is a key element of many automation systems in the process industries and moved to the forefront of essential topics for manufacturers in recent years.
An increased awareness of the importance of safety in automation systems has resulted in a boost in markets for both process and machine (discrete) safety components and solutions.
ICS Triplex is one of very few world class Safety Instrumented Systems (SIS) suppliers.
These safety and critical control systems combined with the Rockwell Automation Integrated Architecture provide a comprehensive solution for process applications.
ICS Triplex provides engineering services, products, and solutions for industries that demand high reliability and high availability from their safety systems.
From fail-safe to fault tolerant TMR and non-safety to SIL3, ICS Triplex has the expertise to build a solution to fit the customer's needs.
For over 40 years ICS Triplex has provided safety systems and services into a variety of industries including oil and gas exploration, production, transportation, and refining as well as chemicals and power generation.
The ICS Triplex flagship product, Trusted, and the recently released AADvantage provides fault-tolerant control to virtually eliminate spurious trips and are designed for real-world situations, where fixing a fault can rarely be done immediately.
Although developed to meet the highest safety requirements, wherever possible, the system will continue to control the process, even if multiple faults are present.
THUMBNAIL PROFILE - ENDRESS+HAUSER.
Endress+Hauser specialises in measurement instrumentation and automation solutions for industrial process engineering.
But field instruments are becoming more sophisticated and can now provide advanced diagnostics that allow predictive maintenance strategies.
The maximum benefit can only be gained if the information is available to the control system, operator workstations and asset management package.
Therefore, the alliance between Rockwell Automation and Endress+Hauser aims to combine system capabilities with field instrumentation, using fieldbus networks such as Foundation Fieldbus, Profibus PA and HART.
Joint research and development between the two companies encompasses fieldbus interoperability testing and software integration.
Working with Endress+Hauser, Rockwell Automation has developed software tools to integrate instrumentation and improve the performance of the control system.
This technology was once used only for very "high end" process application, but can now be cost effectively applied in sectors such as water and food and beverage.
THUMBNAIL PROFILE - PAVILION TECHNOLOGIES.
Headquartered in Austin, with offices in Europe and the Asia-Pacific region, Pavilion Technologies, a Rockwell Automation company, is a recognised leader in advanced process control, optimisation and environmental compliance solutions for process industries.
In a large plant, there may be hundreds of control loops.
Addressing each one individually will not optimise the overall process.
The Pavilion Technologies Model Predictive Control technology reduces process variability and drives up plant efficiency increasing productivity and reducing energy usage.
This technology has applications in many industries ranging from chemicals to food production.
Pavilion Technologies software products have been integrated into the Rockwell Automation FactoryTalk integrated production and performance suite, as well as the Logix control platform.
"In terms of technology, no-one comes close to Pavilion Technologies" said Colin Masson, AMR Research: "It has a stellar list of customers and has succeeded, where many others have struggled, in building a partnership with SAP".
Pavilion Technologies can also offer unique approaches for two critical needs in air emissions compliance and reporting: REM (Real-time Environmental Management) provides an active compliance, auditable system of record on emissions, with advanced capabilities that includes predictions on emissions based on inputs such as an operating plan.
It supplies broadly available information on emissions, compliance position and provides automatic alerts on issues.
THUMBNAIL PROFILE - PROSCON.
The Rockwell Automation acquisition of ProsCon, previously a privately held engineering firm headquartered in Cork, Ireland, offers proven and technically unique design solutions to the process industry.
ProsCon primarily 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 General Manager, Paul Green said: "By combining the ProsCon process industry knowledge with the technical expertise, broad product portfolio, distribution channels, and financial resources of Rockwell Automation, we strengthen our ability to serve customers".
ProsCon has special capabilities in modular design and fast track implementation.
The company offers full process design ability coupled with integrated automation to give their customers a true 'turnkey' solution.
This expertise has delivered process skids, super-skids, pilot plants, kilo-scale facilities and full scale production plants.
ProsCon also has recognised expertise in solvent recovery, distillation and separation processes design. Request free introductory details about products from Rockwell Automation Anorad ...
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