Rethink What You Should Expect From

Your Distributed Control System

2 | Rethink What You Should Expect From Your Distributed Control System

Introduction
Today, process industry professionals face difficult challenges. How can we adhere to
increasingly tighter compliance requirements while competing for market share in today’s
globalized economy? How can we meet the continuous demand for new sources of productivity
and margin growth while using the same automation approach and control system strategy we
have been using for decades? A modern Distributed Control System (DCS) is designed to help
you address these challenges.

Typically, automation is accomplished by a mixture of diverse systems and tools specifically

developed for the tasks they control based on limitations of the technology that is available.
Manufacturing uses one system for process control, another for discrete control, and yet another
for power control. For example, specific functions in a plant with high speed, discrete logic might
be controlled using dedicated Programmable Logic Controllers (PLCs). While DCSs are used
when multiple controllers and multiple points of access need to be connected and accessible
throughout the plant. The main process area in a facility is typically automated using a dedicated
DCS. Integration of the DCS with the automation systems used in the balance of plant is often
costly and engineering intensive. Maintaining multiple disparate automation systems is straining
operations and support resources, restricting flexibility and responsiveness.

What is needed is a modern approach--one that delivers all of the core capabilities of a DCS to
address the requirements of process control, but is built on contemporary technology that easily
integrates with other automation systems, operators’ activities, and critical business systems.

A modern DCS is built using plant-wide control technologies. Today, process control, discrete
control, power control and safety control no longer have to be a choice of separate technologies.
Today, manufacturers can choose to implement a plant-wide control system.

A DCS has specific requirements, such as the capability to handle thousands of I/O with a highly
reliable architecture, known performance, and a deep set of process control programming
functions. With a modern DCS, common technologies (e.g. servers, workstations, controllers, and
networks) are applied in a prescribed way to meet these requirements. These same automation
technologies can be designed and configured to automate all other control functions
throughout the plant.

The use of common automation technologies enables seamless integration of the modern DCS
with plant-floor and business systems, creating more opportunity for plant-wide optimization.
Furthermore, using common technologies lowers the total cost of ownership of a modern DCS.

A modern DCS provides:

• All the core capabilities expected of a DCS, while enabling plant-wide control and optimization
• Scalability and modular architectures to match exact requirements
• Open, information-enabled, and secure architectures
• Flexibility in the delivery and support for the system
 Rethink What You Should Expect From Your Distributed Control System | 3

DCS Architecture

Process Automation
Asset Management Engineering Operator System Servers
Workstation Workstations

Process Control Motor Control

EtherNet/IP Centers

Variable Speed Drives

Integrated I/O Network

Process Skids EtherNet/IP
Process
Controllers

OK OK
LINK 1 LINK 1
LINK 2 LINK 2
DEVICE DEVICE
PORT PORT

! !

1783-ETAP 1783-ETAP

00:00:BC:5B:BB:99 00:00:BC:5B:BB:99
Etherent Address Etherent Address

EtherNet/IP EtherNet/IP

1 2 1 2
(front) (rear) (front) (rear)

Local, Distributed, and Intelligent I/O

Valves and
Instrumentation
4 | Rethink What You Should Expect From Your Distributed Control System

Plant-Wide Control and Optimization

Plant-wide control and optimization delivers a seamless flow of information between all
automation systems, including process, discrete, safety, and power. Traditional DCS systems
require large amounts of capital on custom integration between them and the disparate control
systems used in the balance of plant. A modern DCS uses scalable, multi-disciplined control
technology to provide a common automation platform for seamless integration between it and
balance of plant. For example, a Modern DCS controller can communicate directly with other
controllers in your plant, without the use of OPC bridges or other custom interfaces, even across
system boundaries. These same controllers can be scaled to handle all automation systems, from
small packaged systems to large process applications. (See illustration below.)

This approach provides improved productivity, lowers energy consumption and reduces total
cost of ownership.

Improved Productivity
Productivity is absolutely critical for any industrial company and crucial for investment growth.
Its objectives cascade throughout the organization, beginning with the CEO. But while
productivity is a key driver from the top levels of a company to the plant floor, each segment
within the organization views productivity—and the automation investments that drive it—from
a different perspective.
 Rethink What You Should Expect From Your Distributed Control System | 5

At the corporate level, productivity is defined within the context of achieving a Return on Assets
(ROA) or Return on Invested Capital (ROIC). Executives are focused on reducing costs, improving
cash flow and decreasing time to market—and often direct Operations to reach these targets
with existing and/or aging control systems and assets. To achieve these goals, Operations looks
for ways to improve asset utilization or inventory velocity.
Engineering is charged with keeping all assets running
at top capacity and maximum yield—and often must
ensure that their automation solutions are scalable and
maintainable so they can be deployed in multiple plants
and with diverse equipment.
“PlantPAx enabled our Engineering/Maintenance But these objectives are difficult to achieve with legacy or
team to pinpoint process issues quicker and disparate automation systems in place. Utilizing a modern
implement solutions where they will make the DCS to enable plant-wide control capabilities is often the
most positive impact on the plant operations. key to improving productivity. A modern DCS is able to
With the ability to monitor real-time data and deliver greater visibility into information-rich production
historical trending, along with plant-wide intelligence into ERP systems providing the visibility
visualization and standardization, this platform necessary to drive efficiency and productivity across all
enables us to put our resources where they are layers of the organization.
needed and reduce overall operation costs.”
Lower Energy Consumption
Source: C
 hief Technology Officer, The industrial sector consumes more energy than any
Medium Enterprise Food Company
other. Yet, energy usage is one of the most difficult costs to
manage in a production environment. The ability to control
those costs can result in significant savings.

Typical Energy Consumption In Chemical Sector

Other Facility Support

.11%
Onsite Transportation
.04%
Facility Lighting Conventional Electricity Generation
1.12% .26%
Facility HVAC (g) Other Nonprocess Use
Other 2.75% .11%
Process Use End Use Not Reported
1.08% Electro-Chemical 1.19%
Processes
4.5%

Conventional
Boiler Use
Machine Drive
20.16
16.48%

Process Cooling
and Refrigeration
3.31%
CHP and/or
Process Heating Cogeneration
23.40% Process
25.67%

Source: The Future of Energy

@ www.energyfuture.wikidot.com
6 | Rethink What You Should Expect From Your Distributed Control System

Most companies have a passive account of their energy usage which is costly in today’s economy.
They apply these costs as a burden or overhead cost and view it as a percentage of operating
cost to the company. The plant-wide control capabilities of a modern DCS can help optimize the
production and utilization of water, air, gas, electricity, and steam (WAGES), throughout the entire
manufacturing process. These capabilities provide the information to help you:
• Measure and monitor energy consumption data
• L everage collected data when deciding on
implementing energy management solutions
• P
 redict the impact of production changes on energy
use
83% of surveyed energy and utilities • Automate production for optimal energy use
customers realized the benefits of investing • P
 redict and plan for energy in production process cost
in the PlantPAx system in 3 to 6 months or less. (energy on the bill of material).
Because of its plant-wide control capabilities, the
Source: S urvey of 29 Energy and Utilities users of modern DCS is able to easily integrate with motor
Rockwell Automation - Industrial Solutions control devices. Since motors typically consume over
60% of the energy in any industrial facility, having
the ability to gather data from these critical assets
allows you to build an energy management strategy to
bring immediate and measurable impact on your operational efficiency—and efficiently running
equipment equates to great savings. For example, the more information you have to drive variable
torque loads in an application or reduce the inrush current of critical rotating assets, the greater your
ability to improve device energy consumption. The level of integration achieved between a modern
DCS and your motor control devices results in information that helps you drive improved plant
availability by reducing unplanned downtime as it can trigger manual or automatic intervention
before an occurrence—predictive and preventative measures.

The world’s largest office furniture supplier, Steelcase, set

aggressive goals for improving the company’s bottom line
through improved efficiencies and sustainability efforts. They
implemented a modern distributed control system with energy
management software to more cost-effectively operate their
boilers and gain better insight into company-wide energy
consumption. In doing so, they reduced energy consumption by
15 percent and shrunk their overall carbon footprint by 25 percent.
 Rethink What You Should Expect From Your Distributed Control System | 7

Reduced Total Cost of Ownership

Manufacturers who utilitize a modern DCS with plant-wide control capabilities help reduce
their total cost of ownership (TCO). If they take into account the lifecycle costs associated with
engineering, inventory, training, system maintenance & support, and future system expansions,
the savings can be substantial (see illustration below).

To further illustrate the impact of disparate controls

systems on the total cost of ownership, consider the
following:
• A
 re your control systems proprietary and require
specific vendor support? And what are those costs
“The PlantPAx System allows for lower cost and annually?
greater flexibility when production control • H
 ow many vendors are needed to support the dif-
changes are required and/or additional systems ferent control systems in your plant? Are they able
need to be integrated.” to provide on-site support in a timely manner?
• D
 o your engineers, operators, and maintenance
Source: V
 ice President, Small Business Chemicals Company professionals need training on all those systems?
And how often?
• D
 o you carry inventory/spare parts for each of your
control systems? What about spares for legacy
devices?
• D
 o the disparate systems integrate easily with your skid equipment or are excessive integration
time and resources necessary?
• C
 an you transfer real-time information across your facility with disparate systems? How does
that affect optimization and productivity?
• Are there added licensing fees associated with future system expansions?
These often overlooked factors result in higher costs over the lifetime of any control system. By
utilizing a modern DCS with plant-wide control capabilities, manufacturers can help reduce their
total cost of ownership.

Typical Modern DCS “Total Cost of Ownership” Customer Value Proposition

$18,000,000
Accumulated Total Cost of Ownership

$16,000,000

$14,000,000
TCO Savings
Choosing
$12,000,000 PlantPAx

$10,000,000
Traditional DCS
$8,000,000 TCO

$16,000,000
PlantPAx
TCO
$14,000,000

$2,000,000

$0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Year
8 | Rethink What You Should Expect From Your Distributed Control System

Scalable and Modular

Operational flexibility, quick changeover and simple operation are just a few of the benefits
of modular plant design. A skid-based approach allows the equipment and automation to be
assembled and tested prior to shipment to site, improving consistency and reducing time to
market.

Because traditional DCS systems were built at a time when plants were created from the ground
up, these systems were uniquely designed, closed, and non-scalable. They carried a high
minimum cost due to their use of dedicated servers and networks. Additionally, they typically
offered a single choice of controller designed to be optimal only for very large applications.

Integrating DCSs with disparate skid-based systems was, and still is, very expensive. This
integration typically involves additional hardware and software, custom data mapping (truth
tables), duplicate HMI configuration, and additional licensing. Each interface is custom, resulting
in greater risk and a higher premium for services.

Studies have shown that the cost to integrate is often 50-70% of the cost of the actual skid
equipment. Even after integration, the end user must deal with fragmented operator experience
between the traditional DCS and the skid equipment.

In contrast, a modern DCS is built for the needs of today’s end users, providing wider ranges of
architecture options and increased flexibility. A modern DCS combats the “single-size” controller
with a scalable control platform that provides the right-size control at the right cost. This helps
users avoid purchasing expensive control capacity that isn’t needed—a waste of valuable assets.
A modern DCS also provides scalable system capabilities, such as HMI, batch management
and data collection that does not require a server or workstation—perfect for process skid
equipment.

Skid Integration on a Modern DCS

• EtherNet/IP backbone
• No data remapping
• Common security
•C
 ommon library and HMI objects for
local panel and main control room
 Rethink What You Should Expect From Your Distributed Control System | 9

This design is ideal for modular implementations, providing wider ranges of build options and
increased flexibility. At the same time engineering costs are dramatically reduced when the same
programming tools are used, regardless of system size or I/O capacity. Scalable HMI displays,
alarms, data collection and batch management requirements can be provided at a small scale
without a workstation or server. This skid-based automation system can also become part of
the on-site control system network, connecting with the site-wide HMI, historian, and batch
management servers, and thus become quickly integrated with the modern DCS.

Open, Information Enabled,

and Secure
The DCS can no longer be an isolated operation.
As industrial organizations move toward gaining
“The PlantPAx system allows standardized code greater visibility into their operations, their need to
development both by internal and external establish a seamless flow of information from device
engineering resources, and allows integration to enterprise has become a requirement of modern
of both processes and machine control systems industrial automation systems.
within a common domain of software tools.” A traditional DCS is usually limited to a single choice
option for servers, workstations, and network
switches on closed networks. This makes it difficult
Source: E ngineering Manager, Global 500 Consumer Products to manage IT support and integrate with business
Company
systems. Newer IT technologies, including cloud
computing, mobile and virtualization, are often seen
as disruptive and are at odds with the traditional DCS
architecture. Improvised communication networks linking them to other systems on the plant
floor and across the enterprise can expose the traditional DCS to security breaches. Cyber risks
from both internal and external sources increase with each new connection, creating threats
capable of disrupting control system operations, safety, productivity and the ability to protect
equipment, assets, and confidential company information and intellectual property.

A modern DCS is open to commercial off-the-shelf servers, workstations, and servers, supporting
the adoption of the latest IT technology for automation. By rationalizing to a common IT
infrastructure, companies can mitigate security risks and improve uptime, while protecting
people, assets and information. The level of safety is easily reached by investing in secure
industrial control systems that are part of the
corporate-wide security program. A modern DCS
addresses industrial security from the individual
device on the plant floor to the enterprise, which
contrasts with the traditional approach of securing
plant and enterprise systems separately.
How has the PlantPAx system helped manage
information visibility within your organization? A modern DCS is designed upon a foundation
that utilizes open standards such as EtherNet/
“Being able to drill into the production data easier IP. EtherNet/IP is capable of handling the widest
has allowed business to target the harder-to-spot range of industrial applications, including process,
efficiencies in production which increases profits.” safety, discrete, power and motion control. It allows
the use of readily available, off-the-shelf products
because it complies with IEEE 802.3 and TCP/UDP/IP
Source: I T Director, Large Enterprise Enery and Utilities Company
standards and conventions. This helps Operations
10 | Rethink What You Should Expect From Your Distributed Control System

and IT professionals collaborate on deploying and

maintaining a secure, reliable and robust network
infrastructure within the enterprise and throughout the
industrial environment. Utilizing EtherNet/IP increases
your flexibility, assures compatibility, and offers ease of
100% of surveyed CEOs of small device integration into new or legacy systems.
businesses improved visibility into By reducing the number of disparate technologies
production data with the PlantPAx system. on the plant floor and by providing open secure
networking, the Modern DCS facilitates the daunting
task of integrating the plant floor with the enterprise
Source: S urvey of 10 small business CEOs who use achieving a seamless flow of information that translates
Rockwell Automation - Industrial Solutions
to greater visibility into plant operations.

Flexible Delivery and Support Network

Traditional DCS systems are generally only implemented and serviced by the specific DCS vendor.
In some cases, this results in longer wait times for service, and higher costs. Furthermore, the
traditional DCS approach requires the plant to support several disparate automation systems and
the custom integration necessary for them to work together.

With a modern DCS, multiple choices for implementation and support are available. Different
integration routes may be selected depending on the scope of the project.
• I t may be beneficial for manufacturers to engage the specific vendor for commissioning the
modern DCS system. This often results when a very large user elects to deploy the “same” system
in several locations across a large geographic area.
• S maller manufacturers may select a local process system integrator because of an established
relationship and the availability of the local resources.
• A
 user may also rely on process equipment manufacturers to provide automation and equipment
to leverage their specific expertise.
In many cases, a combination of delivery partners
are required to meet the requirements and schedule
demands of a project. A modern DCS allows
manufacturers to choose from a vast global network
of local experts, including the modern DCS vendor
“‘I was blind, but now I see’ comes to mind when team, system integrators, partners, OEMs and process
I think of the contribution PlantPAx made to our professionals for design, implementation, maintenance,
facilities. The accuracy and timely data permits and support.
better decision making for all of production.” Following is a simplified table highlighting the attributes
of a modern DCS.
Source: E ngineer, Global 500 Electronics Company
 Rethink What You Should Expect From Your Distributed Control System | 11

Differentiation between a Modern DCS and Traditional DCS

Traditional DCS Modern DCS

Purpose built on disparate technology Purpose built on plant-wide technology

The balance of plant automation (e.g. The same automation technology can
ancillary systems, skidded systems, motor be used throughout the plant enabling
control) handled by disparate technology seamless integration, easy access to
– separate automation systems which are information, and easy modifications as
difficult to integrate. demand or products change.

Not scalable Scalable

System features one size for all applications. System capabilities are scalable, yet share
Automation on skidded equipment is common technology and development
difficult to integrate or the integration has tools. Can be easily integrated into a
to be done on the DCS system adding risk to distributed system on site, greatly reducing
the end customer and project schedule. startup time and risk improving time to
market.

Closed system Open, information enabled, and secure

Only proprietary, vendor-specific DCS Open to commercial off-the-shelf servers,
equipment is permitted on the Ethernet workstations, and servers. Allows rational
network. Servers, workstations, and zation of IT infrastructure and enables
network switches are limited to a single the use of the latest IT technology for
vendor-provided option, making it difficult automation. Integration with other systems
to manage IT support and integrate with can be added as needed.
business ERP systems.

Delivery and support by vendor only Flexible delivery and support

Implementation can only be commissioned Global delivery and support by the DCS
and supported by the DCS vendor, whose vendor. Vendor support enhanced through
resources are limited and not always a global network of local experts, including
readily available. Balance of plant systems system integrators, distributors, and OEM
supported separately. Integration between partners allowing the freedom to choose
systems are custom with no clear ownership what is best for their application.
of support.
 Rethink What You Should Expect From Your Distributed Control System | 12

The Modern DCS from Rockwell Automation

In today’s competitive world, manufacturers need to rethink what to expect from their DCS.
They need to choose a modern DCS that:
• Enables plant-wide control and optimization for lower total cost of ownership
• Provides system scalability and modularity for engineering flexibility and faster time to market
• Is open to enabling new technologies which improve operation and integration with the
enterprise
• Can be delivered and maintained by a support eco-system — whether the system vendor,
local distributor, system integrator, or OEM — chosen by the manufacturer.
The PlantPAx system is the Modern DCS from Rockwell Automation that delivers all of these
capabilities.

Publication PROCES-WP010A-EN-E – October 2014 Copyright ©2014 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.