Matrix

Matrix Total Control

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Powerful Process Automation MTL has been a leading supplier of process I/O and intrinsic safety products to many of the world’s top process automation companies for over thirty years. MTL Open System Technologies (MOST), a member of the MTL Instruments Group, has combined this experience with leading open market technologies to provide Matrix, an open process automation system that’s both powerful and flexible. Matrix Total Control delivers the performance that you expect from a distributed control system at a price that is normally associated with a programmable logic controller. Matrix has been successfully deployed worldwide in many diverse process applications, including power generation, gas plant control, chemicals and petrochemicals, pulp and paper, water and waste water, pharmaceutical, oil and gas pipeline, cement, and food and beverage. Matrix’s rugged open control platform is tightly integrated with Wonderware’s market leading FactorySuite A2, providing a field proven solution. Matrix’s comprehensive process management tools provide a unified environment for visualization, plant historian, batch management, device communications and instrument maintenance. While many systems only provide proprietary communication networks, Matrix incorporates Modbus TCP with built-in Fault Tolerant Ethernet (FTE) for redundant communications and interfaces with popular asset management software packages for regular status monitoring of smart plant instruments. Matrix’s open architecture enables you to cost effectively upgrade your system as new technologies emerge on the market. You no longer need to make critical business decisions based on traditional proprietary solutions that are costly and lock you into a single solution from a single vendor. Matrix is a compelling alternative to the DCS and PLC solutions that are being considered in today’s process applications. Matrix’s robust field mountable control platform incorporates interfaces with smart field devices and an elegant redundancy solution, providing a superior approach to most DCS and PLC solutions. Unlike other systems that determine software licensing by complicated and costly tag structures, Matrix has a single one-time affordable license for its control software that is independent of tag count, providing significant value to end users and system integrators in both small and larger applications. Customers worldwide are choosing Matrix for their process control needs. We offer extensive post installation support ranging from simple upgrade services, hotline support to 24/7 assistance. See how Matrix can provide a compelling advantage for your next project. Your satisfaction is not only our goal, it is our guarantee! 3

Gas Plants

Oil and Gas

When process I/O is installed in remote locations, it needs to be reliable, environmentally hardened and simple to maintain. Matrix’s I/O modules and process controllers meet this challenge by providing the industry’s most extended temperature range, corrosion protection, and availability. Controllers and modules can be “hot-swapped” under power without taking other modules out of service, and they are conformally coated to meet ISA’s stringent G3 corrosion standards to protect your system from harsh chemicals and solvents.

Matrix is designed for use in the difficult environment of oil and gas operations. Its –40 °C to +70 °C (-40 °F to 160 °F) temperature range and optional intrinsic safety means that it can be mounted directly in these operations’ harsh and hazardous locations. The Matrix availability in these harsh conditions can be easily increased by using redundant controllers, power supplies and network cables. Redundant communications are provided with each controller – it’s not an option! We also can easily add a redundant controller – just plug it in – no programming or engineering is required. The demand for both process and discrete control strategies typically associated with this type of application is no challenge for Matrix. The system provides advanced function block programming in addition to all five IEC61131-3 languages.

"Gas plant operating staff reductions and high gas prices make efficient, reliable plant operation a challenge. The Matrix control platform has demonstrated very reliable service at a remote, unmanned gas plant for more than a year. Matrix also integrates well with the existing gathering and pipeline SCADA systems. Matrix is an effective platform for our Advanced Control applications for enhanced gas processing performance. Matrix has proven to be well suited for natural gas processing applications."

“Matrix supplied a total solution! The I/O modules with integrated intrinsic safety saved us cost and space. The system’s wide operating temperature range let us mount the control platform directly in the field. The integrated Modbus interface made the connection with existing compressor skids very easy. The system supports open standards, simplifying the integration necessary for future expansion requirements. We discovered a new very flexible DCS technology, which is ideal for our applications!"

George Bozant, Sr. Project Consultant, Barry D. Payne & Associates, Inc. Gas Plant Control Specialist, Houston, TX, USA

Fusco Luciano, Project Manager, Edison Gas Company, Collalto, Italy

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Boiler Control

Biotech and Pharmaceutical

Matrix combines industry-leading open components – operator interface (HMI), engineering tools and industrial control hardware with pre-written advanced boiler control functions such as combustion control, steam, O2 trim, and water header pressure controls to provide a cost-effective solution. Matrix has successfully replaced many installations that had used single loop and mature DCS solutions. With our boiler control expertise, your control system will be quickly commissioned, significantly reducing the engineering time required on the project. Your boiler will operate more efficiently with an optimum air/fuel mix, reducing your fuel costs and providing a rapid system payback.

Matrix meets the demands of regulated industries that must comply with U.S. Food & Drug Administration (FDA) requirements, specifically 21 CFR Part 11. The advanced function block control strategies included with the system support the Wonderware InBatch Flexible Batch Management System thus eliminating countless hours of engineering and programming associated with phase and unit operations, saving considerable time and money. Detailed audit tracking of users and software revision control combined with the advanced reporting and documentation features of the Matrix programming environment eliminate the many issues faced by end users and system auditors.

"Matrix is really easy to work with. Our requirements called for a "single-point" of data entry. With an easy single step configuration, the Matrix Workbench, incorporating Wonderware's .NET-based ArchestrA, seamlessly configured the Control Application, HMI and Historian. This helped us complete our testing quicker, which helped us achieve 21 CFR Part 11 compliance faster."

"Advanced Boiler Control Services (ABCS) chose Matrix for boiler control at the Crawfordsville Electric Light and Power because it enabled us to cost effectively deliver a redundant control system with advanced boiler control strategies, which has significantly reduced operating costs."

Guhan Prabhu, Systems Engineer MAVERICK Technologies Houston, TX, USA

Robert Burrink, President, Advanced Boiler Control Services, Orland Park, IL, USA

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Chemical and Petrochemical Processing

Cement Plants Matrix is used in cement plants that require special functionality for cement manufacturing, including specialized motor control. Application specific control blocks have been created to optimize performance in cement plants and further accelerate the program development time. Matrix’s robust environmental specifications are essential in this environment, where its extensive corrosion resistance is needed to withstand the ever-present dust particles.

Matrix is environmentally hardened to withstand the harsh and hazardous areas of chemical and petrochemical plants. The control platform meets ISA’s stringent G3 corrosion requirements and incorporates intrinsic safety when required. Matrix’s batch software provides a cost effective and flexible recipe management solution for specialty chemical plants. For Class I Division 1 hazardous areas, Matrix provides the most cost effective solution available by integrating intrinsic safety and sensor signal conditioning in a single module, eliminating costly barriers and significantly reducing wiring, engineering and installation costs.

"Matrix Process Software's advanced functionality enabled us to quickly implement our system. Motor Control function blocks enabled us to quickly set up our plant operations with safety interlocks while the process control blocks enabled us to readily control all of the ingredients needed in cement manufacturing. This control software saved us significant program development time and has also been easy to maintain."

"We were looking for an open system for a hybrid application at our specialty chemical plant and selected the Matrix system as the best of breed solution. Matrix ensures reliable operation in a harsh process environment and is a cost saving solution, not only in initial hardware and engineering cost but also with ongoing maintenance costs."

Jeff Meurin, Process Software-Electronics Technician Texas Industries, Inc. (TXI) New Braunfels, TX, USA

Mr. Yin Zuwei, Vice General Manager, Wuxi He Cheng Chemical Industry Co. Ltd. Wuxi, China

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Water and Waste

Safety Systems

Distributed field mounting makes Matrix ideal for use in the water industry where I/O is clustered in each part of the process. Its wide temperature range means that I/O cabinets do not need heating and ensures that the control platform can be mounted directly in the process, providing significant savings in field wiring. Matrix supports the Modbus RTU protocol for easy interface to remote mounted RTUs and provides dual redundant RS-485 connections for reliable serial communications.

Matrix is TüV approved for use in SIL 2 applications, in compliance with IEC 61508, enabling you to use the same control platform for process control, emergency shutdown (ESD) and fire and gas (F&G) systems. Matrix’s common platform for these applications greatly reduces commissioning and ongoing maintenance costs. Matrix incorporates several test tools to evaluate your control logic, including an integrity analyzer and a cross reference analyzer. These productivity tools help users reduce the time and effort required developing IEC 61508 safety applications.

"We need to provide a redundant control solution in our large water and waste water applications. We prefer Matrix because it provides an easy-to-use and cost effective redundancy solution. Also, we like the fact that Matrix is designed around Wonderware's FactorySuite A2 for all HMI and plant historian functions."

"We used Matrix controllers on a British Petroleum training center in the Caspian Sea because it not only combined shutdown logic with DCS functionality in one controller, but the system’s rugged design enabled it to be remote mounted, which reduced commissioning time and did not require additional environmental protection.”

Sam Vandivort TMV Systems Engineering Phoenix, AZ, USA

Steve Coates, Engineering Manager Petrofac Engineering Ltd., Surrey, England

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Matrix Total Control Matrix can be optimized for your process automation needs today, addressing applications ranging from a few points to thousands of points. Its modular design assures easy upgrades and future expansion, while protecting your investment.

Matrix provides a comprehensive solution for both your process automation and functional safety needs. Matrix provides process automation solutions for regulatory, sequential and batch control applications while Matrix Safety Net, certified to IEC 61508 by TüV, provides safety related solutions for Emergency Shut Down and Fire and Gas applications.

Control Room

Single Monitor Operator Station

Multi Monitor Operator Station

Multi Monitor Operator Station

Network Printer

Matrix Process

RS485 Half-Duplex

Modbus RTU Device

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Matrix

The Matrix Workbench is integrated with Wonderware’s Industrial Application Server, ArchestrA®’s core application development platform. This architecture extends the life of legacy systems by leveraging the latest software technologies and enables applications to be developed more quickly, providing an easy interface to the open Matrix system.

Matrix offers extensive redundancy choices, including system servers, controllers, control networks and system power supplies. You can choose some or all of these options for increased system availability.

Business LAN

Server/Network Equipment Room Network connection to handle server redundancy

Industrial Application Server Engineering Workstation Primary Real Time Industrial Application Server

Backup Real Time Industrial Application Server

InSQL Server Historian/Reporting Server

DATA

Redundant Control System Network (Fault Tolerant Ethernet)

Discrete

Matrix SafetyNet

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Matrix Process Engineering Tools The Matrix Workbench provides an integrated project development environment that centralizes project engineering including I/O and control strategy configuration (process and discrete) and

project documentation. Matrix fully supports all five IEC 61131-3 programming languages and offers a comprehensive function block library for addressing advanced process control needs.

Process Engineering - The Workbench • Centralizes and coordinates all system engineering • Consistent Windows Explorer "Look and Feel" • Easy-To-Use Hierarchy of objects and folders • Comprehensive context sensitive help files

Matrix Process • Build process control logic diagrams using graphic interface - easy transition from P&IDs • Select the appropriate function blocks, assign symbolic tags, and connect them • Complete, proven library of function blocks provides powerful control logic capability • Resulting control logic diagrams provide self documentation of control strategies • Compile and download control program to control platform • On-line programming and troubleshooting

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Matrix Discrete (IEC 61131-3) • Supports all five IEC 61131-3 languages (Ladder Diagram, Sequential Function Chart, Function Block Diagram, Structured Text, Instruction List) plus Flow Chart • Concurrently executes programs in different languages – IEC 61131-3 and function block programming • Supports multiple configurations in a single programming environment • Supports user-defined function blocks, enabling users to create custom blocks that can be easily reused • Peer to peer communications links together multiple applications running in separate controllers

Matrix SafetyNet • IEC 61508 certified by TüV for use in SIL 2 functional safety applications, including Emergency Shutdown and Fire & Gas • SIL 2 rating without requiring use of redundant I/O or redundant controllers • Add a second controller to provide greater system availability • Develop both process control and functional safety applications with the same control platform on a single workbench • Static analysis tools assist verification and validation of safety strategy

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I/O Database Configuration • Uses "Fill-In-The-Blanks" Template or Excel spreadsheet import, providing an open interface to other systems • Configure instrument I/O tags, field and panel wiring information • Configure controller and assign tags to I/O modules • Allows on-line configuration changes during testing, start-up, and maintenance phases • Eliminates expensive, laborious, and sometimes error prone manual engineering • Eliminates manual generation of design documents, bill of materials, wiring diagrams, and operator interface database

Project Documentation • Automatically generates as-built documents from control strategy diagrams, dramatically reducing project documentation time • Standard reports include: - System startup and testing information - I/O configuration reports - Cross reference analyses - Instrument index • User configurable reports address specific requirements

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Simulation and Tuning • View control logic diagram animation with simulated data or real-time process data • On-line and off-line control configuration and intelligent control schematics for modification and maintenance • Quick and easy verification of control loop integrity quickens system startup • Simulation accelerates operator training

System Diagnostics • Diagnostic tools for network configuration, controller statistics and individual modules • Extensive Process I/O diagnostics include module and channel status, high and low alarms and open circuit detection • Event logs provides detailed diagnostic data • On-Line Diagnostic Tools for evaluating system configuration, communications, execution times and control parameters

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Matrix Process Management Tools The system features process management tools and applications needed to control, optimize and manage process performance including operator

interface (HMI), plant historian, batch management and instrument maintenance (HART and Foundation Fieldbus).

Operator Interface (HMI) • Utilizes Wonderware’s InTouch, the market leading operator interface • Integrated with Industrial Application Server, an ArchestrA® software component • Provides a single integrated view of all control and information resources • Performs visualization, data access, extensibility to external components/systems, history, event handling, alarm logging, reporting and analysis • Connect to your process via standard Internet-enabled applications • Ease of use and power dramatically reduce commissioning and maintenance timing, with significant cost savings

Plant Historian • Integrated with IndustrialSQL Server Plant Historian • Integrates plant data with event, summary, production and configuration data • Acquires process data at full resolution including hourly, daily, weekly, monthly, etc. • Powerful suite of data analysis and reporting tools, including real-time and historical trending, database queries and report generation

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Batch Management • Integrated with InBatch flexible batch system • Integrated phase logic consistent with ISA S88.01 standard • Manages recipes, batches and complex decisions • Assigns process units to the recipe and sets schedule • Redundant servers for critical applications • Dynamic batch and equipment management • Batch history and reporting

Instrument Maintenance • Manages instrument configuration and calibration information • Monitors instrument status – alerts when status changes • Preventative maintenance will lower overall operating costs • Maintains maintenance and diagnostic history • Performs online and offline configuration • Supports conventional and HART devices – 4-20mA, 4 process variables and status • Modules with HART “passthrough” connect directly to asset management software

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Matrix Control Platform Power Supplies (not shown) • AC power or 24V dc input versions • Supplies power for I/O and controllers • Redundant power supply options • External mounting allows easy panel layout and simple installation • Power supply monitor alerts controller when a power supply fails

Controllers • Controls up to 64 sixteen channel modules • Redundant controllers with dual redundant Ethernet® and redundant RS-485 connections • Wide range of protocols including Modbus TCP and Modbus RTU • Regulatory and IEC 61131-3 software execute concurrently providing both process and discrete control • Provides process automation, sequential control and functional safety from a single control platform • On-line configuration and reconfiguration 16

I/O Modules • Wide range of I/O for virtually any process signal, including HART® Smart analog, thermocouple, RTD, potentiometer, high-speed counter, frequency, quadrature and sequence of events • Suitable for safe-area, non-incendive and intrinsically safe applications • Remote configuration and interrogation of smart devices • Maximum packing density – 1/4” (6mm) per channel • “Hot swapping” does not affect adjacent modules • Keying stops modules from being fitted in the wrong position • Isolation between I/O bus and field wiring • Diagnostic services for each channel, including status and alarms

Field Terminals • Unique, removable terminals for fast wiring and field replacement • Optional fuses and disconnects – no interposing terminals required • Field power provided at terminals – no daisy chained power connections • Integral tagging system

Carriers • Tough polycarbonate base – protects against shock and vibration • Choice of four module, eight module and controller versions • Cable ground and shield terminals along front edge • Reliable – no active components - so there is nothing to fail • Replacement modules are configured automatically, so maintenance is simplicity itself • Field power can be supplied through connectors on the back of the carrier 17

MATRIX Total Control – The Cost Effective Automation Solution for Process and Discrete Applications integration for connecting to HART and Foundation Fieldbus devices. Matrix control strategies, HMI and hardware are configured through a single unified engineering tool unlike HMI and PLC systems, which often require that the HMI and controller be configured separately.

Matrix Total Control is the cost effective automation solution for both process, discrete, batch and functional safety applications. A PLC is cost effective in small discrete applications while a DCS is well suited for large process control applications, but neither are effective solutions for complex process applications that also need discrete control. Users often have to use both a PLC and DCS to address these two different requirements. This is a difficult solution since it requires the user to manage different programming approaches, different communications protocols and an extensive integration effort to get data from one system into the other. Now there’s no longer the need to struggle with these difficult solutions. Matrix Total Control combines the best application features of a PLC and a DCS to address these complex applications.

Matrix is a scalable solution, able to address both small and large applications, which provides significant flexibility over DCS systems that are optimized for large applications. Its advanced function block programming combined with the IEC 61131-3 languages enables process control applications to also address discrete logic needs when required. The single Matrix Engineering Workbench is tag count independent, which provides you with a more cost effective solution that is easier to use – you will never have to buy more Workbench tags to complete your application.

Matrix is a superior choice over traditional solutions in process applications. The Matrix control platform is a field-mountable distributed control system that offers concurrent execution of process and discrete control applications, harsh environment operation, "hot swappable" I/O modules, extensive redundancy options, peer-to-peer communications and fieldbus

Matrix is a rugged process automation system that can be mounted much nearer the process plant than ever before, providing users with benefits of increased flexibility, greater scalability and a significantly lower cost of ownership. Why settle for traditional solutions? Matrix provides value across the entire automation spectrum.

MATRIX - Providing the Best of What a PLC and DCS Have to Offer PLC BASED SOLUTIONS

MATRIX SOLUTIONS

DCS BASED SOLUTIONS

IEC 61131 Programs

IEC 61131-3 Programs/ Advanced Function Blocks

Advanced Function Blocks

Workable Safety System

Safety and Process Control by same control platform

Independent SIL 2-3 Safety System

Loose Peer-to-Peer Communications

Tight Peer-to-Peer Communications

Tight Peer-to-Peer Communications

Minimal HMI Integration

Integrated HMI

Integrated HMI

Minimal Integrated I/O and Diagnostics

Quality for I/O and Communications

Quality Flags for I/O and Communications

Harsh Environmental Specifications

Harsh Environmental Specifications

Requires Controlled Environment

Low Initial Investment

Low Initial Investment

High Initial Investment

Scaleable

Scaleable

Not Very Scaleable

Open Protocols

Open Protocols

Propriety Protocols

Workable Device Redundancy

Seamless Redundancy

Seamless Device Redundancy

Intrinsic Safety Available Integral Hart Capability

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MTL Open System Technologies MTL Open System Technologies (MOST), a member of the MTL Instruments Group, provides industrial automation and information technologies to the process industries. Solutions encompass process automation systems including process controllers and robust I/O systems, operator interfaces, supervisory control and data acquisition (SCADA) systems, plant historians and batch management applications. Our solutions are proving themselves in many industries, including: oil and gas, petrochemical and petroleum refining, food and beverage, pulp and paper, power generation and utilities, metals and mining, water and wastewater, manufacturing and others.

MTL Instruments Group PLC MTL Instruments Group PLC is recognized as a world leader in the development and supply of Process Control, Hazardous Area, and Surge Protection products aimed at process and discrete control spanning a wide range of industries, applications, and geographical regions. Many of the world’s safety-critical processes are monitored, controlled or protected by MTL products. The Group is distinguished by its global network of sales and support centers and by its acknowledged position as a leader in this high technology marketplace.

©2005 MTL Open System Technologies LP. All rights reserved. All brand names and product names are trademarks or registered trademarks of their respective companies.

The Americas United States

Latin America

MTL Open System Technologies LP 2450 South Shore Blvd. League City, TX 77573 USA Tel +1 281 334 3293 Fax +1 281 334 4324 Email: [email protected] www.mtlmost.com

MTL Open System Technologies LP 9 Merrill Industrial Drive Hampton, NH 03842 USA Tel +1 603 926 0090 Fax +1 603 926 1899 Email: [email protected]

Canada MTL Canada Safety Instrumentation Stonegate Plaza 511 Edinburgh Road, South Suite 202 Guelph, Ontario N1G 4S5 Canada Tel +1 800 835 7075 Email: [email protected]

Europe, Middle East & Africa

Italy

Asia

England

MTL Italia srl Via Fosse Ardeatine, 4, I - 20092 Cinisello Balsamo MI, Italy Tel +39 (0)2 61802011 Fax +39 (0)2 61294560 Email: [email protected]

Singapore

MTL Instruments Group plc Power Court, Luton, Bedfordshire, England LU1 3JJ Tel +44 (0) 1582 723633 Fax +44 (0) 1582 422283 Email: [email protected]

France MTL Instruments sarl Bâtiment 4, Parc d’Activités de Limonest 1rue des Vergers, 69760 Limonest, France Tel +33 (0)4 78 64 98 32 Fax +33 (0)4 78 35 79 41 Email: [email protected]

Germany MTL Instruments GmbH An der Gümpgesbrücke 17, D-41564 Kaarst, Germany Tel +49 (0)2131 718930 Fax +49 (0)2131.7189333 Email: [email protected]

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United Arab Emirates MTL Instruments P.O. Box 53234, Abu Dhabi, UAE Tel +971 2 645 2620 Fax +971 2 645 2630 Email: [email protected]

MTL Instruments Pte Ltd 128 Joo Seng Road #07-00 DP Computers Building Singapore 368356 Tel +65 6 487 7887 Fax +65 6 487 7997 E-mail: [email protected]

Australia MTL Instruments Pty Limited 9 Vinnicombe Drive, PO Box 1441, Canning Vale, Perth, WA 6155, Australia Tel +61 (0)8 9455 2994 Fax +61 (0)8 9455 2805 Email: [email protected]

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People’s Republic of China Tel +86 10 85625718/20/21 Fax +86 10 85625725 E-mail: [email protected] www.mtlmost.com/cn

India MTL India Pvt Limited 36, Nehru Street, Off Old Mahabalipuram Road, Sholinganallur, Chennai - 600119, India Tel +91 (0)44 2450 1660 Fax +91 (0)44 2450 1463 Email: [email protected]

Japan MTL Instruments KK 3rd Floor, Gotanda Masujima Building, 1-8-13 Higashi-Gotanda, Shinagawa-Ku, Tokyo 141-0022, Japan Tel +81 (0)3 5420 1281 Fax +81 (0)3 5420 2405 Email: [email protected]