Hybrid Systems Hybrid Systems –– What Are They?What Are They?

Philadelphia Section ISANovember 15, 2000

Samuel M. Herb P.E.Siemens Moore Process Automation

Based on ISA book: Understanding Distributed Processor Systems for Control

DCS vs PLC vs Hybrid?

What are the Issues?What are the Issues?

? ! ?

NoProject

isSimple

Real Goal for Plant Control SystemReal Goal for Plant Control System

PRODUCTIVITY!!!

ChangesinWork

ForceSocial

Pressures

Government

egulationsEnergyCosts

Environment

R

Distributed Processor System IssuesDistributed Processor System Issues

• Problems of open standards• Impact of fieldbus• Configuration made easy• Significance to batching functions• Inclusion of safety systems• Challenge of advanced control methods

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

Process vs. Discrete IndustriesProcess vs. Discrete IndustriesProcess Discrete

Products Fluids Devices, objectsOperations Continuous, Batch Job Shop, Batch,

RepetitiveProduct Design Done in Labs Done with CAD/CAEEquipment Uses Processes Uses MachinesEquipment Cost Very High Medium to HighLabor Cost Low HighSensors Numerous Analog &

DiscreteMostly Discrete

Control Products DCSs, PLCs, SLCsPCs

PLCs, CNCs, RoboticsPCs

Supervisory Control Process Optimization,Scheduling

Cell Control,Scheduling

BusinessManagement

In-house Developed,MRP II, MES, ERP

MRP II, MES, ERP

ImplementationApproach

Bottom up Top Down

Evolution: These Were DistributedEvolution: These Were Distributed

• Touring the plant• Pneumatic

transmission• Electronic

miniaturization

From Central to Distributed ControlFrom Central to Distributed Control

• Distributed – data highway – configured – less risk

(functional, physical)

CENTRAL CONTROL ROOM

COMPUTER

CENTRAL CONTROL ROOM

UNIT CONTROL ROOM

CONTROLLER

CONTROLLER

CONTROLLER

CONTROLLER

DATAHIWAY

• Central– many wires – programmed – vulnerable

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

Typical Strengths Typical WeaknessesDCS Distributed Risk Entry Level Cost

Real-Time Throughput Proprietary NetworkAdvanced Control Strategy Proprietary OSPID (3-mode control) Complex InterlocksOperator Interface Control Room EnvironmentLow Integration Cost

PLC Environmental Human InterfaceUptime Integration CostReal-Time Throughput SequencingComplex Interlocks ReportingRLL Easy & Repeatable Application Software

Recipe HandlingCentralComputer

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

Scan Time ConsiderationsScan Time ConsiderationsWarning! Generalizations Here!Warning! Generalizations Here!

Scan Time Typical Function Likely System1 Month Corporate Update of Plant Computer

Operations Summary ⇓1 Day, Shift Production Report1 Hour Off-line Optimization

Batch ManagementBatch Scheduling

1 Minute Unit Process Optimization DCS1 Second Display Update

Analog ControlProcess CalculationsBatch Sequencing

100 mSec Flow Control20 mSec High Speed Sequencing PLC

Interlocks1 mSec Sequence of Events

DCS⇓

⇓

⇓

System Size ConsiderationsSystem Size ConsiderationsWarning! Generalizations Here!Warning! Generalizations Here!

Over150 Large

DCS

Large DCSwith

Medium PLCs

Large DCSwith

Large PLCs

Loops ofModulating

Control

30to

150SmallDCS

Small DCSwith

Medium PLCs

Small DCSwith

Large PLCs

Under30

Small PLCw/PC

orPC & SLCs

Medium PLCwith PC

orwith SLCs

Large PLCswith

IntegratedWorkstation

Under 200 200 to 600 Over 600

Channels of Discrete I/O

DCS - PLC - PC/PLC Report CardDCS - PLC - PC/PLC Report CardWarning! Generalizations Here!Warning! Generalizations Here! DCS PLC PC/PLC

Control Capabilities:Process I/O A A AMultivariable Regulatory Control A C CComplex Interlocking C A ASequencing B D CRecipe Handling A D BBatch Process Control B D C

User Interface:Ease of Configuration (links & displays) A C DEase of Operator Use A D BEase of Creating Custom Displays A C B

Cost:Hardware C A BInstallation A C DApplication Programming A B C

Additional Considerations:Ease of Expansion (interactive functions) A D DFlexibility A D CRedundancy A C CReliability B A CHardware Maintainability B A BSoftware Maintainability B C D

DCS vs PLCs with PCs as a SystemDCS vs PLCs with PCs as a SystemTypical PLC System Configuration:

PLC

Some Proprietary Network that passes as de facto Physical & Communication Standard

PLC PLC PLC

Controller

Proprietary Network, often based upon a Physical Standard

PC asHMI

Workstationas HMI

Controller Controller Controller

Typical DCS System Configuration:

PCas HMI

Each Individually ConfiguredMust configure to communicate with each PLC, to link views, etc.

“Add-on”configuredseparately

Single database configured for all stations

Latest ApproachLatest ApproachEmerging System Configuration:

Workstationas HMI

Control Control Control Control

Choice of Open Network Flexibility or Proprietary Network Security

User Choice;Uploads controldatabase for:

• Screen Views• Trends• History• etc.

Single distributed control strategy:• Single configuration• Each Controller stores its own

• configuration• documentation• tag names & HMI “calls”• peer-to-peer links for complex strategies• “bridge software” to populate HMI database

Hybrid SystemsHybrid Systems

I/O

SLC

I/O

Controller

I/O

PLC

I/O

Controller

Workstation

I/O

PLC

Controller

Plant Computer

Workstation Workstation

PLC PLC Local O/I

I/O

I/ORemote

I/O I/O I/O

UNIX - Windows95 - WindowsNTUNIX - Windows95 - WindowsNT

Generalities: UNIX vs NT is currently a standoff“If you don’t know why you need NT, you probably don’t need it!”- Bill Gates

All of above is oversimplified in effort to compare what is far more complex than any chart can show!

Technical Issues UNIX™ Windows95™ WindowsNT™Hardware Needs Highest; Multiprocessors

• Multiple platformsLower; 486 w/ 8-16Mb• Intel only

Higher; Pentium w/ 16-32Mb• Multiple platforms

Scalability Yes, favors larger systems No Yes, favors smaller systemsData Warehouse Excellent Little Good & improvingClient/Server Central server in larger

systemsClient Local server or client

(in large systems)SoftwareCompatibility

High; relative to use, butmany different “flavors”

Higher, but office-based Lower, but growing

Hrdwre & DeviceCompatibility

High; relative to use, butmany different “flavors”

Higher Lower, but promised

Install & Deployment Most by far in Industrialapplications

Comprehensive butdesk-top

Less so; mostly for officedesk-tops, but also industrial

Plug ’n Play Functions Designed for Mission-critical

Built-in but for desk-top None (promised with Cairo)

Performance Higher Lower HigherReliability, Stability Excellent More than DOS, Win 3.1x GoodEase of Use Complex Simple SimpleEase of Administration Complex Simple Not so simpleSecurity Robust Weak GoodCost High Low Medium; grows when more

functions required (like UNIX)

Emergence of PC as a ControllerEmergence of PC as a Controller

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

far more severe than factory floor– Corrosive Atmosphere & vibration significant

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

• All serious vendors preparing to grow into selling Software rather than hardware

• Process control unlikely to be “shrink-wrapped”• Standards still an obstacle

Future Distributed EvolutionFuture Distributed EvolutionOperator Functions

Historical /Archiving

Statistical Process Control

Relational DataBase Manager ETC.

I/O

Controller Controller Controller Controller Controller

I/O I/O I/O I/O I/O I/O I/O I/O Local Operator Interfaces

I/O I/OSensors Analyzers Valves Drives ETC.

Fieldbus link

Control Room AreaTo Plantwide

Proprietary Data Highway

Migration of Functions

(connecting traditional DCS)

OperatorInterface

Ethernet-type link

ETC.

Field Interfaces

Domain of Control SystemsDomain of Control Systems

Continuous Batch Discrete

Computer

Control Room

Communications

Local Operators

Control

Input/Output SENSORS

MANAGEMENT INFORMATION

SYSTEMS

<< F

IELD

BU

S IN

FLU

ENC

E >>

<< A

DVA

NC

ED C

ON

TRO

L TE

CH

NO

LOG

Y IN

FLU

ENC

E >>

STAND-ALONE CONTROLLERS

PERSONAL COMPUTERS

AN

ALY

ZER

SPERSONAL COMPUTERS

DCS

PLC

HybridHybrid

Control System Market DynamicsControl System Market Dynamics

DCSDCS

PLCPLC

Processonly

MIS

PC

SLC

Only thatdone also inWorkstations

Growth from new markets due toimproved capacity

power, etc.

DCS WorldDCS World--wide Marketplacewide Marketplace

North America30.2%

Europe36.9%

Asia15.2%

Japan13.6%

Rest of World4.1%

Source: 1997 DCS Process Control Market Analysis - ARC Advisory

US Process Automation MarketUS Process Automation MarketEnterpriseEnterpriseEnterprise$4.0 B Billion

Enterprise Resource Planning SystemsManufacturing Execution Systems

Plant LevelPlant LevelPlant Level$5.0 BillionDistributed Control SystemProgrammable Logic Control

Field LevelField LevelField Level

Field InstrumentsField Instruments

$1.3 BillionField InstrumentsExcluding Analyzers & Valves

Batch vs ContinuousBATCHRecipe DrivenFrequentTransient StateSmallerShorterSharedNot clearly knownHighFewLarge numberComplexComplexComplex

CONTINUOUSSet point DrivenOccasionalUsually Steady StateLargerLongerDedicatedMore clearly knownHigh when abnormalManySmaller numberSimplerSimplerSimpler

ControlProduct Grade ChangesOperationsProduct VolumeProduction Life CycleProcess EquipmentProduct ChemistryOperator involvementAnalog control loopsInterlocksSequential ControlTracking & schedulingOperations Management

Parts of a Batch Operation

The Schedule

The Equipment

QR6

Make a batch of QR6 Execution

The Report

The Recipe

The Batch

Batch Occurs in Many Industries

M

M

M

M

LiquidsM

M

M M

M

Powders

zone 3 zone 2 zone 1

Solids

Each With Their Own RequirementsApplication Industry

Small quantities of product;different grades in small quantity

Dyestuffs and SpecialtyChemicals

Slow reacting process; reactantheld in vessel long time

Food industry; fermentation ofbeer and wine

Complex reaction not easy tocontrol

Chemicals resins manufacturing

Chemical reaction does not takeplace immediately

Pulp & paper industry; batchdigester

Large number of shades orgrades

House paints

Products or feedstock that cannotbe handled continuously

Solids or highly viscous materialsin iron ore beneficiation and waxseparation

Precise quality control indispensing raw materials;production practices andhistorical documentation

Pharmaceuticals

Each Operation is DifferentSingle-ProductSingle-Stream

One Product

Multi-ProductSingle-Stream

Several Products

Multi-ProductMulti-Stream

Several Products

Single-ProductMulti-Stream

One Product

AvoidOvershoot !!!

AvoidOvershoot !!!

…BUT they made it ON TIME !!

CorporateCorporate--wide Systemswide Systems

Control System Must Link to PlantProductionInformation

Management

RecipeManagement

ProductionPlanning andScheduling

Controllers

Automation System

Data(Batch Record)

ControlControlDomainDomain

ProcessManagement

UnitSupervision

ProcessControl

Safety Protection

InformationInformationDomainDomainMES Instructions

(make a batch)

Disparate Computing Communities:

Enterprise Resource Plan

Data

Control SystemControl System

Information !

Control People understand Plant Floor Complexity– Enterprise is some cloud…..

Business People understandEnterprise Complexity– Control system is a little box...

B u s in e s sP la n

C o n tro l S y s te m

Competitive LandscapeCompetitive Landscape

DISCRETE HYBRID CONTINUOUS

DCS LandHoneywell TDC/TPS

ABB/Bailey/H&BInvensys/FoxboroFisher-Rosemount

.PRoVOX – RS3. Yokogawa

PLC LandABBGE

Siemens S7RockwellSchneiderMitsubishi

Omron

THE BATTLEFIELD

PLC/DCSSiemens PCS7

Foxboro Micro I/AHoneywell PlantScape

ABB AC800 FFisher-Rosemount DeltaV

Siemens APACS+Rockwell ProcessLogixYokogawa Centum1000

Siemens ProcidiaRTP 2000

USDATAIntellution

WonderwareCitect

StandaloneHMI

Business Dynamics Business Dynamics in process automationin process automation

• Hardware margins continue to shrink• Users struggle to keep pace with new

technologies• Small vendors lack resources to service

clients around the world • Hardware suppliers challenged to manage

fast paced software & solutions business• Rising cost of software development• User need for customized solutions

Challenges For Controls SuppliersChallenges 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

Decade of Controls Industry ChangesDecade of Controls Industry Changes

Standards are essential for “Open”Standards are essential for “Open”

SimulationDIPPRPDXISTEP

CAPE-Open

InternetOLE/ActiveX

JAVABrowsers

PlatformUNIX

WindowsNT

RelationalDatabases

ODBCSQL

DistributedApplications

DCOMOPC

HMIWindows

OLE/ActiveXCOM

ControlS88

IEC61131SP50

NetworksEthernet

SP50Fieldbus

RegionalStandardsCENELEC

ANSI/NEMAJIS/CNSCOPANT

Tonight we have systems to show

ABBFisher-Rosemount

HoneywellRTP

Siemens

Slide 1ISA Fieldbus Presentation Session 3

DeltaV ArchitectureDeltaV Architecture

HSE (High Speed Ethernet)HSE (High Speed Ethernet)

Slide 2ISA Fieldbus Presentation Session 3

DeltaV as a Hybrid SystemDeltaV as a Hybrid System• Main processor for regulatory and/or logic

– IEC 1131-3 standard– Function Block Diagramming– Sequential Function Charts– Structured Text

– Foundation Fieldbus Function Blocks• Co-Processors for

– Foundation Fieldbus– AS-I Bus– Profibus DP– Devicenet– General Purpose

– SOE– AGA– Steam– etc.

• HSE Control Network (Formally FF H2)– Open to HSE devices– OPC Data Structure for HMI of choice

DeltaV is built for busses…. Any device can be configured on the bus

Introduction

Architecture

Scalability

Controllers

Operator I/f

Alarming

Trending

Security

Reporting

Data Handoff

Engineering

Applications

Support

PlantScape

PlantScape Architecture

PressureTemperatureFlowValves

High AlarmLow AlarmComm. Err.

High AlarmLow AlarmComm. Err.

Control Room Ethernet

Redundant ControlNet

PlantScapeRedundantControllers

PlantScape Rack I/OPlantScape Rail I/O

FieldbusModule

PlantScapeOperatorStation [NT/98/95]

PlantScapeRedundantServer [NT]

I/O ControlNet (Local or Remote)

H1 Fieldbus

I/O ControlNet

Other Other Honeywell, Honeywell,

AllenAllen--BradleyBradley& 3rd Party & 3rd Party ControllersControllers

ERP, MES, Plant Historian,Third-party Application/System

Rotary Stations

Introduction

Architecture

Scalability

Controllers

Operator I/f

Alarming

Trending

Security

Reporting

Data Handoff

Engineering

Applications

Support

PlantScape

PlantScape - Architected for Usability• True Client/Server Architecture – modular & scaleable• Single Global Database• Composite Point Structure • Single Point of Build• Fully networkable…remote development, operation, and admin• Deterministic Control• Guaranteed Communication Performance• Employs a complete supervisory infrastructure, including

alarming, history , trending, security and reporting with over 300 standard displays

• Extensive 3rd party Controller, PLC and RTU integration• Integration with Security (XSM) & HVAC (Xfi) systems

•• Hierarchical Design StructureHierarchical Design Structure•• Object Oriented Software DesignObject Oriented Software Design•• HMI FriendlyHMI Friendly•• 1 msec. Time Stamping (SOE/Alarm)1 msec. Time Stamping (SOE/Alarm)•• Peer to Peer Data TransferPeer to Peer Data Transfer•• OnOn--line Logic Changesline Logic Changes•• Superior Analog Functionality Superior Analog Functionality

(Common Mode Rejection Ratio, Normal Mode Noise Rejection, Float(Common Mode Rejection Ratio, Normal Mode Noise Rejection, Floating Pointing Point--PID)PID)

•• Product Support For The Life of Your ProcessProduct Support For The Life of Your Process•• 3 Year Warranty + Non Obsolescence Policy3 Year Warranty + Non Obsolescence Policy

Hybrid Control SystemHybrid Control System

ABB Automation Slide: 1

Supporting the major international fieldbusstandards and HART

Supporting the major international fieldbusstandards and HART

IndustrialIT System Structure with AC800FEngineerIT Operate IT/ Produce IT InformIT

Control ITHSE

FF-H1

FIO 100

PB-PA

PB-DP

ABB Automation Slide: 2

ControlIT with AC800F

Best in class Fieldbus ManagementAll major Fieldbuses (FF, Profibus, HART)Engineering supports all configuration aspectsuserfriendly/ intuitive (FDT/DTM)online (auto-scan)/ offline (libraries)

RedundancyControllerFieldbus Master

Industrial ITIntegrated with OperateIT, ProduceIT, InformIT

Enables Asset OptimizationScalable,High Connectivity

OPC, HART, Serial (Modbus, IEC870)

s

© Siemens , 200027

QUADLOG The Safety PLC

APACS+ QUADLOG

NTWorkstation

Firewall

APACS+ QUADLOG

Supervisors Center

Engineering

ERPConnectivity

RemoteDial-in

Maintenance

Open ApplicationsServer

Profibus DP/PAField Products

Operations

Plant Network OPC Gateway

Expands

Siemens Energy & AutomationPCS7 Process Automation Solutions

s

© Siemens , 2000

PCS7 SystemPCS7 SystemOverviewOverview

CFCCFC

ETHERNET Terminalbus

TCP/IP Eng’ring

Operator Interface (Clients) Plantwide Operator InterfaceHMI based on WinCCWindows NT based Client/Server-ArchitectureOpen System environment

Engineering Station Functions blocks for continuous control (CFC)Ladder Logic for interlockings (LL)Sequential function charts (SFC)Structured Text (SCL)PDM

Control LevelDCS functionality, PLC capabilitiesFully redundant Controllerintegrated BATCH System

Field LevelProfibusI/O-Modules, HART-InterfaceH1/H2

Operator Interface(Server)

Open System Environment(ERP, MIS/MES)

System CommunicationRedundant SystembusRedundant Profibus

PROFIBUS PA

PROFIBUS PAField device

PROCESS FIELD BUS

Distributed I/OET 200

DP/PA-LinkDP/PA Coupler

PROFIBUS DP

4-20 mA / HARTField deviceI/O module

Redundancy

SFCSFC

SCLSCL

PDMPDMEthernet

e.g. PI/Aspentech

Siemens Energy & AutomationPCS7 Process Automation Solutions

s

© Siemens , 2000

Efficient integration with Efficient integration with SIMATIC PCS 7 SIMATIC PCS 7 plantwideplantwide engineeringengineering

PDMPDM

Process Device Managerfor fielddevices

Engineering

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WinCCWinCC

OS-Engineering with pre-builtoperator-interface/Faceplates

LibrariesLibraries

Pre-definedProcessFunction blocks

CFCCFC SFCSFC

Application Engineering

SCLSCL

User-definable Function blocks Engineering

SIMATIC Manager Database

STEP 7STEP 7

Network / CommunicationEngineering

System Engineering

© Siemens , 20001

ICS Architecture

CL1

Loop Si gn a tu r e

Graphics

HistoricalData

Analysis

WebBrowser

Controller

Internet/Intranet

Browser

Browser

ICS

© Siemens , 20002

Internet Control System (ICS)

Hybrid-controller category — Embeds graphical HMI data, historical data and loop signature information

within the physical controller.— Accessible from anywhere in the world via a simple internet web browser such as

Microsoft's Internet Explorer— Accessible through web enabled devices such as Personal Digital Assistant's.

The real benefit is the ability to transform the data into useful information. For example Application Service Provider (ASP) :— Can aggregate data & provide reports on operational efficiency

- compared to other user systems- compared to other similar systems in the database.

— From this data process optimization recommendations can be made- by the ASP- by third party experts- by end user himself."

Still Room to Grow

"What the hybrid industries such as pharmaceuticals really lack today." O’Brien says, "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

There are Never Simple Answers!!There are Never Simple Answers!!

• If there were...• all of this stuff would be

sold mail order, and... • talks like this would be

unnecessary!!