Study Title Executive Overview

Rockwell Automation
http://www.rockwellautomation.com/solutions/process/ DCS Offerings

PlantPAx Process Automation System

In 2008, Rockwell Automation announced the new umbrella name for the companys process automation portfolio PlantPAx Process Automation System, which covers all the systems and solutions investments the company has made in process automation. PlantPAx Process Automation System has a defined A and

characterized core of Integrated Architecture (Logix + Factory

PlantPAx

Talk) as well as the ability to add integrated extensions, such as 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 System based on a combination of the two core Rockwell Automation PlantPAx leveraged technologies, from Logix and FactoryTalk, partners and those as co-investments with such

Endress+Hauser, OSIsoft, and acquired companies such as ICS Triplex, Pavilion Technologies, ProsCon and others.

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The two primary layers of the PlantPAx Process automation are the Logix control platform and the FactoryTalk suite of applications. The Logix platform provides a unified and common infrastructure that can address continuous applications as well as traditional includes resource batch the other and discrete such applications. as batch FactoryTalk control, batch encapsulates production management environment and

applications (ERP)

management, asset management, and integration with enterprise planning systems. PlantPAx incorporates and standards such as IEC 61131-3 programming, EDDL, FDT/DTM, Foundation Fieldbus, HART, EtherNet/IP, DeviceNet, ControlNet. ISA-88 hierarchies are implemented in the system, as are structural and transactional elements of the ISA-95 standard. Security is in conformance with the ISA-99 standard. Rockwell Automation is focusing on its core strengths that already 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 PlantPAx is capable of systems, according to ARCs definition. systems.
PlantPAx Provides a Unified Engineering & Configuration Environment

meeting those requirements as well as the requirements for large

Design and configuration for PlantPAx in process applications is done through an integrated environment for creating, modeling, and programming production processes. PlantPAx provides automation control programming, allows users to set up and propagate reusable equipment, order and define products, and allows for process development, simulation, and deployment. 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 provided in context to the users or other applications in the environment. Rockwell Automations configuration supports the IEC 61131-3 languages, and they are

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Study Title Executive Overview

integrated with each other, enabling function blocks to call ladder routines, sequential function charts (SFCs), structured text, and so on. In ARCs view, this is a unique ability for Rockwell Automation.
PlantPAx Provides Single HMI Environment

PlantPAx has a common HMI environment, which is integrated with the Logix control layer. key requirement.
PlantPAx Provides Single Open Hardware Environment for Controllers & I/O

ARC feels that a common HMI

environment where users have a consistent interface to data, is a

PlantPAx can scale from a single unit controller, associated I/O, and workstation up to a system with tens of thousands of I/O points, multiple servers, and multiple controllers. One of Rockwell Automations 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 control 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 standards such as IEC 61508 and IEC 61511 has led to the need for solutions to meet these new non-prescriptive The risk requirements. Adoption of the standards has required quantifying the risk and reducing it to an acceptable level. (SILs). the risk. One way to mitigate risk is through use of an independent Safety Instrumented System (SIS). To meet these new requirements, Rockwell Automation had TV certify ControlLogix for use in up to SIL 2 applications. Rockwell Automation has developed a SIL 3rated 1oo2 offering called GuardLogix. The company provides a redundant version of ControlLogix 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 requirement is quantified as one of four Safety Integrity Levels Process safety standards such as IEC 61511 and its predecessor ANSI/ISA-84 identify layers of protection to mitigate

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Study Title Executive Overview

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 engineering 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 runtime 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

EtherNet/IP is the industrial Ethernet solution from the Open Device Vendors 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 Automation) 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 development 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

fundamental synchronization method used by CIP Sync.

Today, Rockwell Automation is in Phase III of its overall process automation solution development. Phase I involved developing a good core platform, and phase II involved acquiring the necessary

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expertise and functionality to have a fully functional process automation and safety portfolio. systems and solutions umbrella. industry customers. Phase III includes integrating many of the capabilities the company gained through acquisition, including the purchase of plant performance software supplier, Incuity: safety system supplier, ICS Triplex; and advanced control and optimization supplier, Pavilion. Rockwell Automation identified six primary areas it wants to focus on as the company integrates this functionality seamlessly with PlantPAx. These include operations productivity, engineering productivity, field device integration, plant asset management, high availability and safety, and core process control functions. Of course, all this must be implemented with some solutions expertise, which is why Rockwell Automation has been steadily building alliances. its solutions capability with acquisitions and new The company acquired Calgary oil and gas industry Rockwell Automation expanded its Phase III is to take all these To date, the company has capabilities and develop a unified portfolio under a common invested over $500 million to deliver greater value to its process

systems integrator, Rutter Hinz, in early 2009, which brought an additional 212 employees. partnership footprint with German system integrator ProLeit, which has considerable expertise in the brewing industry, overall beverage industry, and other consumer markets. In addition, just recently, the company formed an alliance with Italian engineering firm, Elsag Datamat. because the If the name Elsag seems familiar, it is is owned by Italian conglomerate company

Finmeccanica, former owner of Elsag Bailey, which of course was acquired a number of years ago by ABB. Elsag Datamat has a large presence in the oil & gas, power, and other process industries and executes projects all over the world.
A Truly Integrated System

The first step in realizing Phase III of the PlantPAx roadmap is a unified visualization solution, and this is realized with the release of the PlantPAx Visualization Server and Visualization Client. PlantPAx Visualization includes specific architecture classes, a reusable object library, built in trouble shooting features, such as

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Study Title Executive Overview

breadcrumbs that allow users to trace sequence of events and perform root cause analysis. reusable object library. Rockwell Automation acquired software supplier, Incuity, a PlantPAx also now includes a

privately held company offering a full range of enterprise manufacturing intelligence (EMI) software. Incuity Software focuses on providing real-time intelligence of business decision support for improving operations and reducing production waste by providing manufacturers with management insight into their operations. system. Now known as FactoryTalk VantagePoint, the Incuity offering serves as the supervisory layer in the PlantPAx Pavilion 8 is also integrated with PlantPAx through Pavilion8 is a modular software platform with a FactoryTalk.

hybrid modeling engine at its core, and includes modules to control, analyze, monitor, visualize, persist, and integrate that are combined into high-value applications. Other advancements to the PlantPAx core system include fuzzy logic capabilities, enhanced redundancy, and improved network resiliency. PlantPAx offers a Device Level Ring (DLR) network topology network with embedded switch technology for a more fault tolerant network.
Safety System Integration

In early 2010, Rockwell Automation announced integration of PlantPAx with the ICS Triplex Trusted TMR and AADvance safety system platforms. The integration of the full suite of Triplex control platforms provides a deeper level of integration than just process safety; including fire and gas detection, ballast control, and compressor and turbine controls. ICS Triplex also participates in Foundation Fieldbus Safety Instrumented Functions (SIF) development. AADvance I/O from ICS Triplex has also been integrated into PlantPAx for high availability control systems. AADvance is also being packaged for specific applications such as subsea automation. PlantPAx and the Logix controllers are already SIL 2 certified out of the box by TV Rhineland.
Field Device Integration and Fieldbus

While Rockwell Automation supports EtherNet/IP as its control network backbone, the company is neutral when it comes to

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support of device level networks such as Foundation Fieldbus, Profibus PA, HART, and Wireless HART. The company supports HART in a new line of distributed I/O. Through its support of FDT technology, Rockwell Automation is also working toward a solution for unified device configuration for HART, PA, and Foundation Fieldbus devices in a common environment. The companys alliance with Endress+Hauser has been a key part of the companys PAM strategy. On the fieldbus front, the company is working toward a redundant Foundation Fieldbus solution by the end of 2010. diagnostics. The company also invests heavily in field The capability of the GEPA change management

software acquired by Rockwell Automation in 2007 is now part of the AssetCentre Plant Asset Management offering. At Rockwells annual Automation Fairs Process Solutions User Group (PSUG), the company announced the first instance of penetration of EtherNet/IP at the device level with the new Endress+Hauser ProMass flowmeter compatible with EtherNet/IP. In addition to its longstanding alliance partnership with Endress+Hauser, Rockwell Automation has relationships with Pepperl+Fuchs for their corrosion measurement devices and other products, and Mettler Toledo for analytical products, through its Encompass Partners program. has formed alliances with Masoneilan.
Support of Virtualization on VMware

For control valves, the company Metso Automation and Dresser

Rockwell Automation also announced support of virtualization of automation software based on VMware. program.
Rounding out the Competitive Migration Portfolio

The company will

validate many of its software offerings under the VMware Ready

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 Emerson. 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

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Study Title Executive Overview

Modicon 800 Series I/O racks with the ControlLogix I/O system without disturbing existing 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 December 2008. Conversion systems for other competitive PLC offerings are also on the way.
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 engineering 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 companys management team and approximately 220 employees have jointed Rockwell Automations 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 Xian, China, Xi'An Hengsheng Science & Technology Company Limited serves customers in the power, petrochemical, coal mining, chemical and oil markets. The company conducts 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.

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Key Industries

Rockwells strongest installed base in the process industries continues to be in the life sciences, food and beverage, and consumer products industries, but the company has been steadily pushing into more traditional heavy process industries such as power generation, chemicals, and upstream oil and gas.

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