Plant iT multi-platform Plant iT gebaseerd op Siemens Plant iT gebaseerd op Rockwell Plant iT gebaseerd op Mitsubishi brewmaxx

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: Multi-platform system brochure (pdf)

: Multi platform architecture

Plant iT multi platform

Process control technology available for the world market leaders’ hardware platform

There is an increasing demand for process control technology with integrated MES functionality in process industries. More and more, operating companies require the implementation of process control systems instead of conventional
automation solutions. The process control systems in turn have to fulfill the technology-specific requirements of their processes and maintain the flexibility for modifications simultaneously.
The answer is an open, PLC-based process control system with parameterizable technological functions.

Focus on Technology

Classical process control systems form a homogeneous unit of finely tuned hardware and software components in combination with a very extensive technical integration right down to the field device. They are normally designed for the implementation of capacious and complex solutions, meeting highest standards of safety and availability (e.g. for power plants). Normally, technology-orientated special functions are not available. Because of the system’s high safety standard, this can very often only be done by the system suppliers.

Many users in the process industry – e.g. fine chemicals or food and beverage production – need classic process control technology as well as the openness and flexibility of conventional automation solutions at the same time.

This means:

Parameterizable system functions instead of application-specific individual
software
Adaptability to the characteristics of their own production processes
Possibility for step-by-step migration of existing automation systems
Flexibility for extensions and modifications during running operation
Openness for interfacing with existing automation systems to be retained
Scalability from a single-station system to a factory-wide integrated solution
Low total cost of ownership

Process control technology alone is not enough

The users increasingly require additional functionality that can seamlessly be combined with the process control system. To fulfill this requirement the number of autarkic systems and the amount of interfaces between them need to be as small as possible. The additional functions required have to be available as integrated functions of the process control system. To meet these requirements the emphasis is placed on:

Production data management
with consistent data acquisition that goes beyond the application scope of the process control system into upstream and downstream process areas with their own automation systems, whether it be process technology, discrete manufacturing or a mixture of both (hybrid processes).
Process-orientated material management
for the administration of materials and storage locations as well as for monitoring all relevant material movements as a basis for tracking and tracing.
Communications
for bi-directional exchange of information between the process control systems and external systems.

Added value multi-platform

For the user, the level of acceptance and the value of an installed automation system platform are largely determined by the technical know-how the staff has in handling the installed technical infrastructure. For that reason, very often the
existing staff has reservations with regard to changing the system platform. The solution providers are expected to provide a system with the required functionality that uses the existing control hardware at the same time.

Therefore, a process control system with selectable hardware platform offers benefits for both sides:

The operating company

saves training costs for the technical staff,
requires lower investment costs for the modification of existing PLC hardware including electrical installation,
avoids some of the costs that are normally due to limitations in production (modifications, commissioning),
has a reduced project risk because of higher flexibility in migration strategies and
can choose the optimal hardware platform customized to requirements.

The supplier

saves training costs for his staff, because the engineering can mainly be done independent of the hardware platform,
can build upon the acquired technological know-how of his staff and use it, independent of the hardware platform,
attains easier access to markets which are dominated by a PLC platform that has not been used yet
is in a position to compete worldwide since more effi cient engineering gives a competitive edge.

The multi-platformprocess control system

Plant iT is an integrated software platform that is well established in the market. It consists of different components that can be flexibly combined.
The seamless integration of various functions – ranging from automation to
process control technology and production data management up to interfacing with superordinated ERP systems – allows the implementation of homogeneous solutions even for the most complex tasks. The consistent application
of the principle “Parameterization instead of Programming” for all system components results in a unique combination of flexibility, transparency, safety and availability that is required particularly by process industries.

Plant Direct iT – The process control system

Plant Direct iT is an open, PLC-based process control system, whose client-server architecture is consistently implemented on the Microsoft platform. Based on this architecture on the one hand and the centralized, database-orientated engineering on the other hand, almost unlimited system scalability is possible from a single station system to multi-server solutions. Graduated redundancy concepts – from simple RAID solutions to hot-standby server systems –
can meet the competing requirements of economic efficiency and safety of the
entire system.

With its class concept (technical and technological automation objects with capsulated functionality) Plant Direct iT provides a future-proof solution for the many challenges controls and process technology offer.

The core functionality of Plant Direct iT is available for the hardware platforms of the world market leaders:

Siemens Simatic S7
Mitsubishi MELSEC System Q
Rockwell ControlLogix

When implementing process control systems or in case of the migration of automation systems, the controllers of different suppliers can be used simultaneously in a plant.

Plant Acquis iT – Production data management

Plant Acquis iT is a powerful production data management system supporting trans-sectoral applications even for hybrid processes, i.e. processes combining both process technology and discrete manufacturing.

Process, operational, machine and energy data can be acquired continuously, event-triggered or by manual input.
Online acquisition is preferably carried out with the help of standardized interfaces on the technical (OPC) and technological level (Weihenstephan standards for production data acquisition in beverage packaging lines). But it can also be used for all other plant-specific machine and plant control systems.
With the help of an analysis module thepurely time-related – but also shift, order or batch related – analysis of acquired data can be done.
Plant Acquis iT provides a number of add-ons like remote messaging, parameterizable reports, job control, or statistical functions for performance analysis (e.g. OEE). All of them can expand system capacities profoundly.

Plant iT material – Process-orientated material management

Plant iT material offers a close-to-process material management system. It is an optional extension and can be combined with all other components of Plant iT. Therefore, the following core functions regarding processes that require material-related operation are available for process control applications
based on Plant Direct iT as well as for pure production management (Plant
Acquis iT):

Management of master data for materials, storage locations and bookings of material movements
Transaction-accurate recording of all material movements based on a warehouse model that can be parameterized in a flexible way according to process requirements
Inventory management
Views and analyses with direct access to detailed information on any storage transaction

In combination with superordinated order management, Plant iT material is a very efficient tool for tracking and tracing.

Plant iT connect – The parameterizable communication interface

With the help of Plant iT connect, the engineering of interfaces becomes parameterizable. It is used for the implementation of communication connections between Plant iT and other systems like ERP and LIMS systems, but also measuring devices (e.g. inspection systems, analytical equipment).