PES: An Innovative Approach to Process Automation Development and Energy Management

John Cavalenes, End User Product Management

Frank Prendergast, System Architect

Key Trends in Automation

●Workforce Crisis● Skills shortage● Need simpler tools

●Cost Pressure● Produce more with less● Energy is a key part of cost

●Flexibility● Customer needs change rapidly● Maintain uptime

Implications of Trends and Needs●Less funds available●Reduced workforce (less resources to develop in-house solutions or no core activities)

●Need to produce more with less●Minimize design time●Optimize project cost●Operating cost reduction●Maintenance cost reduction

HybridProcess

PharmaFine ChemicalFood & Bev.

WaterMining/Metals

The Conventional Solutions

Continuous Process

PetrochemicalRefiningPower

Pulp & Paper

Manufacturing

AutomotiveMachinery

Complex ProcessLoops

Hi-AvailabilityProcess Language

DiscreteInterlocking

Electrician language

DistributedControl (DCS)

ProgrammableController (PLC)

Industry Answer?

DistributedControl (DCS) ?

ProgrammableController (PLC) ?

Hybrid Control System(HCS)?

Process AutomationController

(PAC)?

CollaborativeAutomation Systems?

●Simple to:●Design●Operate●Maintain

● Troubleshooting● Remote access● Intuitive

●Simple to modify, improve and expand ● Reuse● Online changes● Future proof technologies

●Easy interaction with other systems (MES/Energy/Instruments)

Users need a system...

Integration

Single interface

Powerful diagnostics

World class products features…

Flexibility

Openness

Ease of use

a new generation of process automation system…

World class software features…

PlantStruxure PES

World class of energy management…

PlantStruxure PES

LoadsheddingReal-time dashboards

Optimization

Represents a real application

Crushing

Mill

Flotation

Homogenization Yard / Stacking

Water Treatment

Products Yard

Schneider Mine

Reclaiming

Crushing

Mill

Flotation

Homogenization Yard / Stacking

Water Treatment

Reclaiming

Products Yard

Schneider Mine

The System Translates Each Operation

P&ID Diagram

Application

● Model the application as it is in the real world and improve the reusability

Process

One Single Environment/Package

Supervision

System Configuration

ProcessDesign

Logic

Alarms

Concurrent Engineering● Facilitate communication about design

enhancements and process adjustments

● Delegate sections of PROCESS to various stakeholders, not sections of CODE

● Tear down barriers between Maintenance and Engineering departments to get up and running fast

● Several users can work on the same libraries and applications simultaneously from different work stations

● Check-in and check-out features are managed by the system and the user is always informed about the status of the applications

Single Distributed Configuration

Configure the network

architecture

Configure the controllers

Configure the control room

Configure the devices & I/Os

Object Oriented

An integrated object offers consistent functionality throughout the system

The model is open and extensible so engineers can build their own objects if needed

The system takes care of the application lifecycle, managing the changes needed throughout the plant life

Ensures consistency across your system and drives operational efficiency

Object Oriented

●Dedicated Libraries●Control Devices

● Drives, motor starters, power meters, energy consumption, etc.

●Process control ● Signal conditioning, process loop,

sequence logic, motor control, etc.

● Users can modify and/or create their own libraries

● With diagnostic and maintenance information for operators and maintenance staff

●User guides, maintenance procedures, etc.

Dedicated Process Libraries

Automate Energy ManagementDirect into your process

Control

Operations

FieldProcessdevices

Energydevices

Processcontrol

ProcessSCADA

EnergySCADA

Energycontrol

Combine data from process & power

Automate Energy ManagementMake your energy productive

Real time dashboard

Optimization capabilities

Load shedding

A Demo of the Software that Powers the System

Starting a project

Building a process hierarchy

Starting an area

Declaring the real devices

Customizing the devices

Determining the real devices interactions

Creating the logic and interlocks

Creating the supervision

Creating the architecture

Operator navigation

Trends Energy Management

Intelligent Motor

Control

AdvancedProcess Control

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