How companies that rely on multiple OEMs can achieve process optimization with a smart distributed control system (DCS).
Differing network, interface and equipment standards can cause integration problems. This can lead to expensive project delays for manufacturers who depend on multiple OEMs. Complex DCS integration can add 50-70% to the cost of the equipment.
Complex DCS integration can add 50-70% to the cost of the equipment.
The stakes are even higher for the tightly regulated life sciences industry where integrated alarming and reporting are critical. Flexible single-use facilities need equipment that can be easily connected or disconnected from the production control system. Flexible single-use facilities need equipment that can be easily connected or disconnected from the production control system.
THE HIGH COST OF CUSTOM INTEGRATION
High integration costs often happen when customers accept the OEM network and interface standard as is. They do not notice the cost impact until the integration phase.
Once the equipment arrives, a system integrator or EPC can bridge it to the DCS protocol directly or via an OPC-type server. In both cases, integration typically involves additional hardware and software, custom data mapping, duplicate HMI configuration and additional licensing.
Each interface is usually custom – resulting in more time, money, risk and additional service requirements.
THREE STRATEGIES FOR PROCESS OPTIMIZATION
1. Proactively approach system development. Working with OEMs or an EPC early helps define network protocols and interface needs. It makes on-site integration easier.
Defining a common network protocol, such as Ethernet/IP, is a good start. Consider:
- What commands will be sent and what inputs/outputs are expected regarding process and/or equipment status?
- What’s the proper alarm configuration?
- What are the security requirements?
2. Base your integration strategy on a smart DCS. A connected DCS streamlines integration with open communication protocols. When using Ethernet/IP, the system can talk to many controllers in the plant. It does not need OPC bridges or custom interfaces. This means you can add the skid-based controller as the base controller to the system with a standard equipment interface.
With the smart DCS, the equipment can share common resources. This includes user accounts and security settings. Plus, it provides a consistent operator experience and centralized batch reporting.
3. Put your equipment’s intelligence to work. Today’s life science processing tools like clarification systems, chromatography, bioreactors and mixers are more advanced and intelligent than ever.
Rockwell Automation offers a connected approach using an integrated DCS. This approach respects the OEM’s intellectual property and allows customers to benefit from the skid’s intelligence right from the beginning. With the control platform in place, smart skids can be delivered with completed factory acceptance testing (FAT). They will be properly connected and easily integrated with the DCS.
Take the next step
A modern DCS positions companies to use embedded intelligence for more robust, contextualized datasets. You can take advantage of technologies such as process optimization, predictive analytics, adaptive machine control and AI. It only takes a phone call, so let’s talk! Call 1-800-247-1410 to find out how you can use Rockwell Automation’s distributed control system for process optimization.