Optimize Control with an Array of Embedded Advanced Control Applications

Manufacturers are being asked to do more with less: improve process performance with fewer engineers, increase reliability with lower maintenance budgets, and guarantee quality during changing conditions. Advanced control has proven to be an effective tool in optimizing operations, reliability, and quality but can be expensive to implementation and maintain on traditional control systems.

DeltaV Advanced Control provides a full array of applications including model predictive control, loop monitoring and adaptive tuning, quality prediction, and constrained optimization. Unlike other control systems, DeltaV Advanced Control is embedded in the system, using the same engineering environment, configuration database, and controller platform for unprecedented availability and ease of use.

DeltaV Embedded Advanced Control products include:

• DeltaV InSight for control loop performance monitoring and tuning
• DeltaV Adapt for closed loop adaptive PID control
• DeltaV Fuzzy for non-linear single loop control
• DeltaV Neural online soft sensor for non-linear property estimation
• DeltaV PredictPro for multi-variable model predictive control (MPC) and optimization.

Reduce Process Risk — Use Embedded Alarm Operations and Analytic Applications

DeltaV system alarm operations and analytic applications are ready for use from the moment they are licensed, unlike general-purpose layered alarm management systems that require extra hardware and software to engineer and maintain.

DeltaV Alarm Help gives operators one-click access to consequence of inaction, time to respond, recommended action, probable cause and other alarm guidance — from the alarm banner, alarm list, or faceplates — for quick consistent operator responses.

DeltaV Alarm Mosaic provides a configuration-free layer of protection against alarm floods, presenting active alarms in an icon graphical view optimized to reduce operator stress, increase situational awareness and aid in root cause identification. With one mouse click, the operator can switch between the active alarm view and a historical view, to review previous alarm floods and the control actions that were taken; ideal for real-time situation management, shift transition reviews, and post-flood forensics.

DeltaV Analyze continuously monitors alarm-system performance. Key performance indicators recommended in the ISA-18.2 and EEMUA-191 standards are automatically calculated. Alarms that chatter, remain active for excessive periods, or exhibit other bad behaviors are automatically identified. Intuitive point-and-click webpages allow easy ad-hoc analysis of alarms, events, and user actions.

The core DeltaV system provides a superior level of visibility to inhibited and altered alarms. Built-in schedulable configurable alarm audit reports identify discrepancies between actual and approved alarm settings. Alarms requiring maintenance can be marked out of service without interference with dynamic or manual shelving operations. Reasons for shelving or removal from service, done manually or by logic, can be viewed in alarm lists, audit reports, and detail displays.

Emerson alliance partner product SILAlarm™ from exida LLC provides extensive alarm rationalization capabilities tailored to the DeltaV system— to efficiently manage the process of qualifying and specifying alarm design criteria. SILAlarm supports the native DeltaV bulk edit system to easily bi-directionally transfer or compare alarm settings with the DeltaV system, including advanced alarm settings and alarm help information.

Minimize Risk to Quality by Using Consistent, Integrated Batch Processes

Batch manufacturing often involves coordinating sophisticated sequencing across a plant while ensuring the use of proper equipment for the task. Emerson’s DeltaV Batch is modular and scalable to meet needs — whether a relatively simple pilot plant or a very complex production facility. This S88-compliant structure enables you to develop a library of software modules that can be reused – significantly reducing testing efforts. The batch functionality can easily be scaled to support multi-product facilities with multi-stream recipes that span many controllers.

All batch control logic for a unit, including phases, is executed in the DeltaV controllers.

The DeltaV Batch Executive is the engine which coordinates all batch processing activity, creates detailed batch history records, and schedules recipes and resources.

Recipe Studio is a powerful yet simple–to–use application for recipe configuration.

Campaign Manager optionally manages the recipe, formula, equipment, and number of batches that are to be run within a campaign and can be accessed via a web service.

Batch Historian automatically collects and displays recipe execution and process management event data.

The History Analysis application enables web–based access to process management event information from anywhere.

Recipe Exchange provides an open, programmatic interface to the DeltaV recipe management system. Recipe Exchange is based on an XML schema that provides the ability to programmatically import and export DeltaV recipes. All of this functionality can also be provided via a web service.

The DeltaV system provides integrated configuration tools along with integrated operator interface in DeltaV Operate. The Batch Analytics solution facilitates in-batch quality prediction along with identification of process faults in real-time.

M-series DCS System Hardware
M-series hardware for traditional I/O offers flexibility during installation and is built for reliability and availability. M-series hardware supports a wide range of I/O for your existing field devices and is built rugged to mount almost anywhere.

S-series DCS System Hardware
DeltaV S-series hardware adds I/O on Demand functionality to the proven technology found in M-series hardware.

S-series Electronic Marshaling with CHARMs
DeltaV S-series Electronic Marshalling with CHARMs lets you land field cabling wherever you want, regardless of signal type or control strategy.

Save Time and Effort with Standards-Based Data Connections

Data management has serious implications on a plant’s operations and productivity. Data from field devices must be communicated throughout control systems, manufacturing execution systems, and enterprise business systems. If data is lost or blocked at any step in the data-chain, the plant’s profitability will suffer. Also, if data mapping is too difficult and requires too much maintenance, costs will continue to pile up.

The DeltaV system makes it easy to connect data in the field. At the device level, the DeltaV system provides plug-and-play capability for runtime and diagnostics in a variety of standard protocols: Wireless HART, HART, FOUNDATION fieldbus, DeviceNet, and Profibus DP. DeltaV SIS, although a separate architecture, integrates seamlessly with the DeltaV system to provide process safety that is managed from the same engineering, operations, and maintenance tools.

The DeltaV system makes it easy to connect to enterprise business systems. Industry standard OPC along with SOA web services have been built-in to provide connections to Emerson’s MES, Syncade™, and other systems anywhere on the network.

Data Integration with the DeltaV system provides data between the field and business systems with minimal setup time. Decision makers at every level in the plant from engineering, operations, and production can get the critical data they need, reliably, securely, and in real time.

Make DeltaV Installation and Maintenance Trouble Free Using Purpose Built DeltaV Workstations

In a non-DeltaV environment, success in installing software and maintaining computers is often elusive — and expensive in time, effort, and money — due to incompatibilities between computer hardware and software.

DeltaV has solved these issues by providing a variety of purpose built computers specifically manufactured and tested to support DeltaV applications.

Our DeltaV Workstations are configured with the hardware – NIC cards, memory and hard disk size — required to support the DeltaV applications. Using images to install the operating system ensure that only the DeltaV required applications are installed and the system is properly configured to provide the robustness and performance required in a mission critical system.

Using DeltaV manufactured computers for DeltaV Workstations eliminates the potential software incompatibility headaches involved in implementing and maintaining control workstations.

DeltaV Workstations are only available from Emerson and are required to be used for all DeltaV workstation deployments.

Meet Project Deadlines More Easily Using Intuitive Engineering Tools

Emerson's Human Centered Design (HCD) efforts help eliminate work, reduce complexity, and embed knowledge. This focus has resulted in unprecedented ease of use within the DeltaV system:

• Drag-and-drop functionality
• Ribbon-bar interface
• Single-environment configuration (i.e. alarms, batch, advanced control, safety, and historian)
• Out-of-the-box templates
• Modular configuration library capability to redeploy configuration, reduce testing, and provide consistency

The DeltaV system provides ultimate scalability for all size projects from 25 to over 1 million I/O. It gives you the flexibility to implement your system how you want, when you want, where you want. The DeltaV system provides an offline, global configuration database to enable easy implementation of geographically distributed project teams.

The DeltaV system provides the industry's first bidirectional, supported solution integrated with Intools. This functionality enables flexibility to meet changing project requirements during implementation by automatically updating process PI&D drawings in AutoCAD with the project DCS database and vice versa. Eliminate work, ensure consistency, and improve productivity.

Efficiently Collect Process Data with Fully Integrated DeltaV Historians.

System alarms, events, and user actions are automatically captured in the DeltaV Event Chronicle. They are time stamped at the lowest possible level in the system for precise analysis of process disturbances and equipment failures.

Dependable collection of essential process data is easy to establish and maintain over the lifetime of the system with the fully integrated set of DeltaV Continuous, Advanced Continuous, and Enterprise Historians. Configuration of history data collection is an integral aspect of the system control engineering environment.

The DeltaV Advanced Continuous and Enterprise Historians employ OSIsoft PI Server technology for top-performance for the most highly demanding history data collection and integration applications.

DeltaV history client applications provide a broad and dependable range of methods to access event, continuous, and batch history information — both on and off the system.

Improve Productivity through Intuitive Operations

To improve business results and remain competitive, it is critical to optimize your plant operations, improve productivity, and increase process uptime.

Operations and maintenance experience is built into the DeltaV system. Intuitive design enables your staff to be more productive by using functions such as:

• Device dashboards to simplify device information for better decisions
• Color themes and pattern recognition to help the operator identity critical information
• Alarm help to embed knowledge with recommended actions and probable causes

DeltaV Operate gives users direct access to all operating information — including current process values, current operating displays, and all alarms with proper alarm priority and timestamp. Additionally, the DeltaV system provides high-resolution graphics, embedded historical trending, and system-wide security.

Gain a Competitive Advantage by Employing Reliable Equipment

In an increasingly competitive market, organizations are challenged to run their plants more profitably and with greater efficiency. Eroding condition of field equipment reduces throughput – or worse, halts production completely.

By integrating field diagnostic information with the control system, operators can quickly assess the condition of instruments, valves, and mechanical equipment in order to make real-time adjustments to sustain throughput and quality.

The DeltaV digital control system can receive critical machinery health alerts from the CSI 6500, providing actionable information for operators to protect the condition of mechanical assets.

Integration with AMS Suite allows operators to significantly reduce commissioning time during startups. When in operation, field device alarms and diagnostics are easily accessible to aid decision-making.

Gain Confidence in Secure Operations with Strong Monitoring and Protection Features

The DeltaV system provides the tools and services to help ensure that your system network is both robust and secured.

Emerson Smart Switches are built for purpose with security features to protect your network and come fully configured to plug-and-play in the DeltaV network. DeltaV Controller Firewalls further protect your controller from network based malware attacks. Our Emerson Smart firewall is specifically designed so you do not need to be an expert to add secure, robust, and reliable perimeter protection to your system.

To prevent physical intrusion on the control network, you can manage workstations to lock down USB ports from unauthorized users by using our “Easy Security” USB management solution. DeltaV Workstations are automatically hardened as the DeltaV system is installed to help protect against intrusions by disabling unused features that might provide access to unauthorized users.

Network alarms and diagnostics from our network devices are integrated in the DeltaV system along with other maintenance alerts so your operations staff, not your IT staff, can quickly address network and security issues.

Security patches and anti-virus updates are easily managed via the Guardian software update service. If you need help with network design, security assessments, and implementation our Advanced Services expertise can provide any level of support you require.

Achieve Operational Excellence through Development, Testing, and Training Simulation

Manufacturers are challenged to improve their operational excellence using advanced simulation capabilities. DeltaV Simulate delivers these capabilities for:

• Improved quality of DeltaV systems and solutions by providing tools to thoroughly checkout configuration, operator displays, and advanced applications before commissioning online.
• Reduced costs associated with engineering design, system configuration, and maintenance. Improve worker efficiency and minimize the equipment required to simulate and train.
• Increased productivity and improved Safety through rigorous training using a realistic training environment with the same plant configuration and operator displays.

DeltaV Simulate Suite consists of the following products:

Simulate Standalone: Allows you to run a DeltaV system on a single PC. This means you can work on your exact plant DeltaV configuration to test control strategies and operator displays, all from the comfort of your laptop.

Simulate Multi-Node: Allows you to simulate larger systems with multiple controllers and workstations. This is useful for engineering groups working on the same configuration or for training multiple operators. Simulate Multi-Node is licensed per workstation.

SimulatePro: Provides advanced features to coordinate simulation and support replay for multi-node systems. SimulatePro is available for both Simulate Standalone and Simulate Multi-Node workstations.

Simulate for SIS: Allows you to simulate safety instrumented systems without logic solver hardware, for both design checkout and operator training. Simulate for SIS is available both for both Simulate Standalone and Simulate Multi-Node workstations.

Take Automation Off the Critical Path with Smart Commissioning

Smart Commissioning is a technology-enabled process that drastically reduces commissioning time and effort decoupling the physical I/O design from the functional design — effectively streamlining the commissioning of field instrumentation. The advancements based on this decoupling are far reaching and improve the full commissioning process from system design, to device binding and configuration, to testing and documentation.

Positively impacting the overall project execution, Smart Commissioning helps automation projects meet strict and shifting deadlines by reducing trips to the field, eliminating tasks, and accommodating late project changes. Developments in the DeltaV™ distributed control system (DCS) using Electronic Marshalling with CHARMs technology and AMS Device Manager asset management software make the shift possible.

Accurately Configure Devices in a Fraction of the Time
Reduce commissioning time for HART and Foundation fieldbus devices by up to 80%. Build configuration templates once and apply to common devices simultaneously. Use built-in validation reports to quickly identify discrepancies and reduce configuration errors. Learn more about device commissioning with AMS Device Manager.

Adapt to Late Project Changes with Ease
Smart Commissioning changes the way of executing automation projects because configuration of the control logic can be done independently of the I/O assignment for field devices.

Streamline the Process in a Safe Environment
Pre-tagged smart devices can be auto-sensed by DeltaV - which means the system finds and identifies all smart devices and uses their tags to automatically bind them to the configuration. That means no extra trips to the field for verification — save time and keep personnel safe.

Streamline Virtualization in an Integrated Environment Designed for Process Control

Process control systems often require many computers, which can be expensive to maintain and disruptive to upgrade. Emerson’s DeltaV Virtual Studio gives you the flexibility to easily create and upgrade your control system workstations. You don’t have to be a virtualization expert to deploy a virtualized automation platform. With DeltaV Virtual Studio you can keep your system up and running with little or no disruption or downtime for system upgrades, maintenance and security.

What if you could…

• Consolidate all of your workstations to run on just a few host servers, reducing maintenance, footprint and replacement costs?
• Create new virtual workstations with no prior virtualization experience?
• Consolidate multiple training and development systems on a single platform?
• Perform system upgrades when you need them –with less time and complication?
• Make your hardware and software updates independent?
• Recover from computer failures in a matter of minutes rather than hours?

Designed for Automation Engineers — DeltaV Virtual Studio is designed specifically for virtualization of process control systems, with a workflow and feature set that automation engineers can easily understand and use. Every DeltaV virtual machine you create comes with all the standard operating system settings and network connections to ensure consistent, error-free configuration and implementation.

Easily Implement and Maintain Your System — DeltaV Virtual Studio lets you reduce the number of physical computers you maintain, and makes it easier to replace hardware or update software when needed. With DeltaV Virtual Studio you can easily configure your virtual networks and create DeltaV virtual machines using prebuilt virtual machine templates.

Reduce System Downtime — DeltaV Virtual Studio high availability and disaster recovery options help you minimize downtime from disruptive events. Recover from hardware or software failures in a matter of minutes, not hours or days. Minimize downtime for system maintenance with Live Migration of critical applications off of affected hardware. With a layered approach for backup and recovery options, you can pick the level of availability your system needs.

Improve Productivity And Safety With Smart Wireless Networks and Services

The wireless solutions developed for plant operations include hardware, software, and services targeting applications which would normally require extra time, additional investment, and more resources, if done based on wired infrastructure.

The solutions are engineered according to customer needs and can deliver video, voice, and control system information based on a wireless infrastructure. Field operations and the connectivity to remote sites or process signals are also part of the Wireless Plant Network solutions portfolio.

The engineered solutions are scalable and based on very specific requirements which include:

• Bandwidth: High; multiple applications must share the service
• Security/Reliability: Industrial security and robust coexistence are essential
• Power Management: Devices can be line powered or recharged daily
• Standards: Driven by IT community (802.11, WIMAX, LTE...)

Our Smart Wireless architecture uses rugged wireless access points from Cisco to provide Wi-Fi coverage. The Smart Wireless Gateway 1552WU is part of the Cisco® Aironet 1550 Series Outdoor Wireless Mesh Access Points which are Class I, Div 2 (ATEX Zone 2) certified and support dual band radios compliant with IEEE 802.11 a/b/g/n standards, providing a universal standard network infrastructure for easy integration of all the wireless applications in your plant, including security and mobile workforce productivity solutions.

The architecture uses Cisco Prime Infrastructure and allows Network Managers to design, control, and monitor enterprise wireless networks from a single location, simplifying operations. It oversees a series of wireless LAN controllers, which are responsible for Network wide wireless functions such as security policies, intrusion prevention, RF management, QoS, and mobility. Cisco Prime itself facilitates load balancing and traffic management, policy provisioning, network optimization, troubleshooting, user tracking, and monitoring for end-to-end security.

Emerson offers comprehensive services to help you get started with your plant network applications. The Wireless Plant Network service portfolio includes:

• Site Survey
• Network Planning and Design
• Network installation and Commissioning
• Application Implementation
• Network Support and Management
• Project Management