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Distributed Control Systems Worldwide Outlook Supplier Profiles

Rockwell Automation
Key Products

PlantPAx Process Automation System


North America; Europe, Middle East & Africa; Asia; China; India; Latin America; Brazil

Rockwell Automation is a global provider of industrial automation control and information solutions. The company focuses on addressing customers business needs to form automation and information solutions through partnerships with a large network of local companies in distribution, services, and software around the world. To this end, Rockwell Automations message to its served markets includes reducing time-to-market and total cost of ownership, asset optimization, and providing business risk management. With headquarters in Milwaukee, Wisconsin, Rockwell Automation has two major product lines, Allen-Bradley and Rockwell Software, which offer a comprehensive suite of automation solutions that include control and information platforms, industrial components, intelligent motor control and global manufacturing support services. Additionally, it offers a wide range of services including design, implementation and post-sale support services.
DCS Business




Rockwell Automation


building the solutions with PlantPAx, the companys process automation system. PlantPAx combines the plant-wide control technologies and unmatched scalability of Integrated Architecture with the core capabilities expected in a world-class DCS. PlantPAx is based on a combination of core Rockwell Automation Integrated Architecture technologies (Logix, View and FactoryTalk) and extensions, such as batch management, process
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Distributed Control Systems Worldwide Outlook Supplier Profiles

information management functionality, APC, or SIL 3 process safety, as customer needs dictate. PlantPAx can also utilize functionality developed through co-investments with partners, such as Endress+Hauser, OSIsoft, On-Line Development Corp.,








Technologies, and others. The Logix platform batch provides a unified, common and control discrete

infrastructure that addresses continuous applications as well as traditional applications. and sequencing, motion, FactoryTalk encapsulates the supervisory and

production management environment and includes applications such as operator interface/visualization, batch control, batch management, asset management, and integration with enterprise resource planning (ERP) systems. PlantPAx incorporates and standards such as IEC 61131-3 programming, EDDL, FDT/DTM, Foundation Fieldbus, HART, EtherNet/IP, DeviceNet, ControlNet. ISA-88 hierarchies are implemented in the system, as are structural and transactional elements of the ISA-95 standard. Security is in conformance with the ISA-99 standard. Rockwell Automation is building on its core strengths that have long been demonstrated in process, hybrid, and discrete industries. The goal is to supply users with a process automation
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Distributed Control Systems Worldwide Outlook Supplier Profiles

system that suits their needs in terms of scalability, ease of use, and a plantwide view of control. Current customers tend to use small to medium size systems, according to ARCs definition. PlantPAx is capable of meeting those requirements as well as the requirements for large systems. PlantPAx Provides Unified Engineering & Configuration Design and configuration for PlantPAx are done through an integrated environment for creating, modeling, and programming production processes. tools, users manage conceptualization, With PlantPAxs integrated engineering the full control application simulation, lifecycle: testing, development,


deployment and maintenance. The PlantPAx configuration environment covers process control, motion, safety, discrete control, and drives applications, enabling information to be provided in context to the users or other applications in the environment. Rockwell Automations configuration supports the IEC 61131-3 languages, which can work with each other in a control application, enabling function blocks to call ladder routines, sequential function charts (SFCs), structured text, and so on; this is a unique ability for Rockwell Automation. PlantPAx Provides Single HMI Environment PlantPAx has a common HMI environment, which is integrated with the Logix control layer. The Rockwell Automation Integrated Architecture offers additional visualization options which can be applied within the overall solution. Operators, supervisors, maintenance personnel, and others connected to a PlantPAx solution have access to data and information from other Rockwell Automation or third-party supervisory control and production management, or maintenance management applications. Users can be delivered supporting information, in a useful context, so that they can make effective routine and critical production decisions. PlantPAx Open Hardware Environment for Controllers & I/O PlantPAx can scale from a single controller, associated I/O, and workstation focused on a local unit operation, up to a system with

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Distributed Control Systems Worldwide Outlook Supplier Profiles

tens of thousands of I/O points, multiple servers, and many controllers. Rockwell Automation has been making control hardware for use in harsh industrial environments for years. Logix I/O and controllers are highly durable and can be mounted in harsh environments outside the control room. I/O is offered in multiple form factors with options for connectivity, giving users great flexibility for meeting their plant requirements. Many Rockwell Automation systems are in use today, which makes it easy to find people trained to program and maintain Rockwell Automation systems. EtherNet/IP Provides Common Control Network EtherNet/IP is the industrial Ethernet solution from ODVA Inc., an industrial consortium also known for its CIP networks DeviceNet, ControlNet and CompoNet. The common thread of these networks is the Common Industrial Protocol (CIP). The advantage of the CIP model is that the same command set is common to all CIP networks, enabling applications to cross networks without the need to translate protocols. As opportunities arise in the automation space, ODVA considers them and, if merited, adds capabilities and extensions to the network through the development efforts of its Joint Special Interest Groups working groups that focus on a particular technology or application need. Integrated Process Control and Safety Rockwell Automation provides the broadest portfolio of process safety products and solutions, using capabilities from its Integrated Architecture, as well as technology from the acquisition of ICS Triplex. Rockwell Automations technology is scalable and provides the application developer with options to meet end user standards or preferences and application requirements: Appropriate SIL level for requirements of the application: SIL1 through SIL3 requirements

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Distributed Control Systems Worldwide Outlook Supplier Profiles

Technology selection of common or diverse technology for Architectures for solution 1oo1, 1oo2, 2oo2, and 2oo3

BPCS and safety system (TMR) providing highest levels of fault tolerance available Level of integration between BPCS (Basic Process Control System) and safety system Rockwell Automation has the technology, expertise and project and support services to support the full system lifecycle for an initial safety system implementation as well as for legacy safety migration or conversion. Rockwell Automation Continues its Process Plan The company continues to invest in overall process automation development. Rockwell Automation identified six primary areas it wants to focus on as the company integrates this functionality seamlessly with PlantPAx. These include operations productivity, engineering productivity, field device integration, plant asset management, high availability and safety, and core process control functions. Rockwell Automation continues to build its solutions capability with acquisitions and new alliances. Following the 2009 acquisition of Hinz, of Canada, the company has acquired South African integrator (and product developer) Hiprom Technologies, a leading process control and automation systems integrator headquartered in Johannesburg, South Africa. Hiprom serves multiple industries, delivering customer solutions in the rapidly growing Sub-Saharan market, as well as globally in the mining, metals & minerals industries. 2011. A Truly Integrated System The PlantPAx roadmap is made up of a unified control and visualization solution. PlantPAx includes a reusable object library, built in trouble shooting features, such as breadcrumbs that allow users to trace sequence of events and perform root cause analysis. Rockwell Automation integrated its enterprise manufacturing intelligence (EMI) software product technology (acquired with
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This acquisition closed in early

Distributed Control Systems Worldwide Outlook Supplier Profiles

Incuity in 2008) into the FactoryTalk software suite.


functionality provides real-time intelligence and business decision support for improving operations and reducing production waste by providing manufacturers with management insight into their operations. system. Rockwell Automation continues to expand advanced process control capabilities within the Integrated Architecture and PlantPAx. Pavilion8 has been integrated with PlantPAx through Pavilion8 is the modular software platform with a Now known as FactoryTalk VantagePoint, this functionality serves as the supervisory layer in the PlantPAx


hybrid modeling engine at its core, and includes modules to control, analyze, monitor, visualize, persist, and integrate that are combined into high-value applications. Previously, these applications were run on a supervisory computer, connected with the PlantPAx environment. Recently, Rockwell Automation released PlantPAx ModelBuilder which allows use of the modelbuilding technology and encapsulation and deployment of the resulting real-time model into a Logix-based control application. Other advancements to the PlantPAx core system include enhanced redundancy and improved network resiliency. PlantPAx uses Ethernet in the automation system architecture, and implements a Device Level Ring (DLR) network topology network with embedded switch technology when more fault tolerance is desired from the network. Rockwell Automation automatic integrates centralized engineering operations on



supported devices, disaster recovery, and change management in its FactoryTalk AssetCentre Plant Asset Management offering. Safety System Integration In early 2010, Rockwell Automation announced integration of PlantPAx with the Trusted TMR and AADvance safety system platforms (acquired with ICS Triplex). The integration of safety system platforms goes beyond just process safety; including fire and gas detection, ballast control, and compressor and turbine controls. Fieldbus Rockwell Automation also participates in Foundation Safety Instrumented Functions (SIF) development.

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Distributed Control Systems Worldwide Outlook Supplier Profiles

AADvance I/O from ICS Triplex has also been integrated into PlantPAx for high availability control systems. Logix controllers are already SIL 2 certified out of the box by TV Rhineland. Field Device Integration While Rockwell Automation supports EtherNet/IP as its control network backbone, the company is neutral when it comes to support of device level networks, such as Foundation Fieldbus, Profibus PA, HART, and Wireless HART. Through its support of FDT technology, Rockwell Automation is working toward a solution for unified device configuration for HART, PA, and Foundation Fieldbus devices in a common environment. The companys alliance with Endress+Hauser has been a key part of the companys PAM strategy. Rockwell Automation continues to release integration information and application code for EtherNet/IP devices from Endress+ Hauser. In addition to its longstanding alliance partnership with

Endress+Hauser, Rockwell Automation has relationships with Pepperl+Fuchs for their corrosion measurement devices and other products, and Mettler Toledo for analytical products, through its Encompass Partners program. has formed alliances with Masoneilan. Support of Virtualization on VMware Rockwell Automation also announced support of virtualization of automation software based on VMware. program. Competitive Conversions and Migration Portfolio Competitive control system migration/conversion continues to be a strategic focus for Rockwell Automation. Rockwell Automation provides conversion or migration to PlantPAx or to the Integrated Architecture-based solutions from: Field-proven Allen-Bradley and Rockwell Automation controllers, I/O and systems. Legacy systems from ABB, Honeywell, Invensys, and Emerson.
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For control valves, the company Metso Automation and Dresser

The company will

validate many of its software offerings under the VMware Ready

Distributed Control Systems Worldwide Outlook Supplier Profiles

Legacy PLC users from platforms, such as Modicon, Texas Instruments, IPC, and others.

The company develops enabling tools and services and works with partners to provide products to convert or migrate legacy systems, including: Preservation of existing wiring or marshalling cable Preservation of complete I/O subsystems scanner cards Migration/conversion Preservation of of control process and and visualization production solutions and swingarm swapout for some I/O families, including redundant communications applications historical information System-to-system integration

Partnerships and Acquisitions

Partnerships: None to report. Acquisitions: None to report.

Strengths and Challenges


Rockwell Automation has taken advantage of the

growth opportunities provided by the global process automation market. PlantPAx is a fully functional process automation system that conforms to ARCs CPAS model in key areas, from engineering and configuration to a common hardware platform to presenting information in context to the right people at the right time from any point within the system. The major process automation system players should consider Rockwell Automation as a formidable competitor in the years ahead, in North America and globally. Rockwell Automations background in the discrete industries and its large presence in the markets for drives, PLCs, discrete sensors, and motion control provide the company with some unique advantages when it comes to addressing the process automation space, particularly for its core target industries, such as life sciences, food & beverage, consumer products, fine chemicals, and oil & gas. These industries typically involve a significant amount of discrete and motion control processes that
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Distributed Control Systems Worldwide Outlook Supplier Profiles

are not typically integrated into a single automation system framework. It is this unified framework across multiple domains of automation that is enabled by PlantPAx . Challenges: As a relative newcomer to the DCS world, Rockwell Automation still has its work cut out for it. In the process automation system marketplace, the top tier of suppliers control well over two thirds of the market. The company, however has continued to strengthen its offering to the process industries beyond a fully functioning DCS, with its substantial abilities in safety instrumented systems (SIS), it abilities in plant asset management (PAM), and advanced process control (APC). It must provide a superior business value proposition and continue to live up to its release schedule and invest heavily in research and development.
Key Industries

Rockwells strongest installed base in the process industries continues to be in the life sciences, food and beverage, and consumer products industries. The company has been expanding into more traditional heavy process industries such as power generation, chemicals, and upstream oil and gas.

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