ARC's Dave Woll Process Automation Systems @ ARC Industry Forum 2010 in Orlando, FL. Time to Rethink Process Automation Systems (CPAS 2.0) Top 10 Automation Business Drivers 1.Create proactive culture 2.Improve asset utilization 3.Enhance human reliability 4.Improve equipment reliability 5.Unify business and operations 6.Respond to uncontrollable external variables 7.Responsible care requirements 8.Prevent cyber security threats 9.Deal with loss of experienced staff 10.What is the potential value

1. Time to Rethink Process
Automation Systems
(CPAS 2.0)
Dave Woll
VP Consulting
ARC Advisory Group
dwoll@arcweb.com

2. 2
© ARC Advisory Group
From CPAS to CPAS 2.0
CPAS conceived in 2005
 Issue: The introduction of internet technology to manufacturing
forced most of the suppliers to change their Control LAN and
ultimately innovate their entire systems. Users asked what to value
“everything looked the same”
 Purpose: Develop an ARC vision of the ideal evolution of current
process automation systems. The Collaborative Process Automation
System (CPAS)
 Deliverable: A detailed Outlook Study
CPAS 2.0 conceived in 2009
 Issue: There has been an absence of real innovation in both the
system and field devices. Users have asked how to value what is
needed next
 Purpose: Develop an ARC forecast of the ideal functional evolution
of process automation systems
 Deliverable: A detailed Outlook Study

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© ARC Advisory Group
Top 10 Automation Business Drivers
1. Create proactive culture
2. Improve asset utilization
3. Enhance human reliability
4. Improve equipment reliability
5. Unify business and operations
6. Respond to uncontrollable external variables
7. Responsible care requirements
8. Prevent cyber security threats
9. Deal with loss of experienced staff
10.What is the potential value

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© ARC Advisory Group
CPAS Guiding Principles
ROA
Operational
Excellence
Flawless Execution
Autonomous Automation
Common Infrastructure
Continuous Improvement
Proactive Execution
Common Actionable Context
Single Version of the Truth
Automate every thing that
should be automated
Facilitate Knowledge Workers
Manage All Automation
Robust, based on Stds
Precision
Extraordinary Performance
Principles CPAS Response

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© ARC Advisory Group
CPAS Looks at Automation Holistically
To…From…
Single Model with Distributed Processing and Shared Services
Business
System
Sensors, Actuators and Logical Devices
ISA S95
ISA S88
Manufacturing
Work
Processes
Real-Time
Control &
Events
Production
Management
Transactions Operations
Management
Enterprise System

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We Need Smarter Field Devices
 50 -75% of device downtime is caused by lack
of confidence in measurement
 Most field devices do not quantify health or
estimate remaining usable life
 Precludes operations from deciding run/shut
down.
 Lost critical measurement usually results in
shut down
 Active research, dearth of Products
• One product based on SEVA (self evaluating
technology BSI 7926)

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© ARC Advisory Group
Systems Need to Become Truly Distributed
 Current leading Distributed Control Systems
and the original CPAS are not true DCSs
 Current DCSs are based on IEC61131-3 which
specifies programming languages and
architecture
 The architecture is limited to a single domain
with all resources operating in unison
 Resources cannot act autonomously
Current DCSs are a single model with distributed
processing and shared services

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© ARC Advisory Group
System Resources Need to Operate Autonomously
When Necessary
 Functionally changes the control level
(reconfigure) at run-time
 Provides the foundation for “zero downtime
automation systems” and sustainable
operations
 Supports the utilization of high level
autonomous agent (FIPA), reasoning and
modeling
Potentially offers the highest value

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© ARC Advisory Group
IEC Standard 61499 Supplements IEC 61131
Fieldbus
IEC 61158
DCS
IEC 61804
PLC
IEC 61131-3
Open ConnectivityConfigurability
Distributed Functionality
Function Blocks
Configurability
Standard Programming Languages
Industrial Process
Measurement
and Control Systems
(IPMCS)
IEC 61499
Truly Distribution Reasoning
Autonomy
High Level
Function
Blocks
 Single Model with Distributed Processing and
Independent Services
 Example: The Smart Watchdog from Intelligent
Maintenance Systems IMS)

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© ARC Advisory Group
Control Strategies are not Tied to
Specific Hardware
 Control Strategies Must Transcend
Hardware
 Required to support autonomy and
reconfiguration
 Eliminates the need to position functions
into highly secure system levels
 Runs across disparate platforms
complimented single size resource scaled by
number
 Provides the opportunity to optimize
hardware cost and performance

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© ARC Advisory Group
Secure On-Line Version Upgrades
 At least one major version
upgrade every year
 Now requires a shut-down or at
least a major vendor supported
custom revision
 ARC supports a three step on-
line version upgrade
 Three step has crucial value
determining the new version is
operating predictably before
committing to the process
Revert
Go
Abort
Load
Accept
Evaluate
Finished
Revert
Go
Abort
Load New
Version
Accept
Evaluate
Finished

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© ARC Advisory Group
Need Business and Operations Unification
– Business to Planning
 Normally the integration of disparate information
is largely custom work
 This is the case when integrating SCM targets to
operations planning
 Reference standards can eliminate the majority of
this customization. Specifically:
 The SCOR model has been accepted as the
primary SCM reference model
 S95 has been accepted as the primary
Operations Management reference model
 There is a high correlation between the two
 This integration will deliver higher Business to
Planning performance

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© ARC Advisory Group
Need Business and Operations Unification
– Real-time Planning to Production
LP Planner
RTO
ModelUpdate(10/Day)
LP PlannerLP Planner
Dynamic Planner
LP Planner
RTO
Operator involvement:
- On/Off
- Operating Band
LP PlannerLP Planner
RTORTO
Dynamic Planner
Market Signals
Supervisory
Controller 1
(DMC)
LP Planner
Supervisory
Controller 2
(DMC)
Supervisory
Controller 3
(DMC)
Real-Time
Optimization
Capable/Profitable to
Promise in Real-time
24/7 Optimization,
Minimal Human Involvement
Autonomous Transition
Management
Short Term Production Planning Based on Market
Demand and Production Capabilities

14. Thank You.
For more information, contact the author at
dwoll@arcweb.com or visit our web pages at
www.arcweb.com