Enterprise hybrid control with distributed server architecture - 'out-of-the-box'

April 2001 System Integration & Control Systems Design

To meet the ever-challenging demands of industrial automation customers, control systems need to be plant-ready ie out-of-the-box ready, simple to get started and functionally rich.

They must be truly open and scaleable to keep pace with process requirements that may change or grow as business requirements change. They must also provide fully integrated solutions that span the full spectrum of requirements for process and discrete manufacturers.

Honeywell's PlantScape hybrid control system combines these multiple control disciplines in a single system. The system provides regulatory (PID), sequential and fast logic control in a single controller, compliant with IEC 1131. Taking a look at the distributed server architecture (DSA) debate: Honeywell says that a level of integration previously only seen within a single DCS installation is now possible across units, plants, sites and across an entire enterprise. PlantScape is claimed to be the only true hybrid control system on the market today integrating continuous, batch, high-speed discrete (PLC), true scada, shutdown, HVAC, security and access control. DSA seamlessly integrates the PlantScape system incorporating any or all of these functions. It enables seamless global access to points, alarms, interactive operator control messages and history without costly, error-prone and limiting database duplication. In essence, DSA allows applications and operator stations to subscribe not only to local points and alarms, but also to points and alarms on other PlantScape Servers, all within a single global namespace. Global historical and realtime trending is also supported.

According to Honeywell, DSA is aimed at extending the PlantScape infrastructure and architecture to allow core DCS functions and behaviours to transparently span multiple distributed PlantScape installations in a robust and efficient fashion.

PlantScape is delivered with more than 300 pre-built displays, saving the user considerable programming time and/or thousands of rands in outside engineering fees. Honeywell application packages and patented technology (SafeBrowse, SiteDocs, Knowledge Builder, SkillBuilder, Recipe Manager, SPQC) are also embedded in the system, making the system a valuable addition to plant operations 'right out of the box.' Because it is based on open standards, the PlantScape system can extend its reach throughout a plant, enveloping existing software applications and devices, preserving a manufacturer's existing investments. Further, as the system is based on Microsoft's Windows NT, it can run most 32 bit Windows-based applications.

Control schemes can be easily implemented by snapping together PlantScape's drag-and-drop control modules, composed of configurable function blocks. These control modules can be saved and re-used increasing their value and reducing time and costs still further.

PlantScape, according to Dependra Ambelal, Manager of the PlantScape Product for Honeywell Southern Africa, combines many features that can only be found on separate DCS and PLC systems.

"For example, users can choose between a process control processor or a high-speed logic processor that utilises a common family of components, including racks, I/Os, power supplies and communication modules. This interchangeability allows the customer to mix and match control features to fit their application in a very simple and cost-effective manner. In a nutshell, PlantScape with DSA is a total, cost-effective enterprise hybrid control solution in a box!"

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