D/3 Distributed Control System (DCS)

Future-Proof Automation

Futureproof-Automation

The Only Continuously Evolving Process Control System on the Planet Just Keeps Getting Better

The D/3 Distributed Control System maximizes the lifetime profitability of a process plant by combining bulletproof reliability, maximum application software configurability, and a Continuous Migration Path unmatched by any other automation vendor.  This balance of runtime performance and application agility allow a D/3-controlled facility to ensure product quality, speed development, ensure safe operations under all conditions, and deliver sustainable value over many decades of service.

Secure, Open and Fully Redundant Architecture

The D/3 utilizes off-the-shelf servers and network hardware along with our Process Controllers and 8000 Series I/O to create a remarkably reliable, scalable, Cyber Secure and fully redundant System Architecture.

Modular and Standardized Programming

D/3 uses Sequence and Batch Language (SABL) to manage sequential, batch and continuous processes together, allowing the complete integration of all process components into a single programming environment.  This makes changes much easier to develop and deploy than in distributed “Islands of Automation” topologies.   NovaTech Applications Engineers apply our own best practices and client’s corporate standards into programming standards that ensure the long term maintainability of all applications by incoming personnel.

Continuous Migration Path

D/3 is the only process control system to have never forced a platform migration on its end users. We’ve maintained backwards compatibility for user applications while continuously incorporating new technologies and capabilities in easy-to-manage, stepwise upgrades that can be implemented without process interruption.

“The D/3 has been controlling sterilizers, lypholizers, fluid bed dryers, coating pans, manufacturing tanks, air handling units, and much, much more on this site for over 30 years.  What other system… can make that claim?” – Gary D

System Capabilities

Integrated Continuous, Batch and Sequential Automation

The unit-relative and object-oriented SABL programming language offers a higher level of integration, granularity and application versatility compared to simpler control languages.  While new D/3 users may find it intimidating, experienced users often cite SABL as the most powerful and essential aspect of the D/3’s capability to handle the most complex process challenges, year after year. Users develop automation projects with graphical, object-oriented authoring of Master Device Logic for pumps, motors, valves. Thousands of devices can use (or “instance”) the logic of the master device, and users need only specify differences (such as tag name and I/O address) for each subsequent device, or “instance” the entire unit (including all of its logic) in “like” units, thereby using one set of programs for multiple units.  These features significantly reduce code generation, maintenance, and validation costs for new plants or plant expansions. As a result, new products developed faster, regulatory requirements are easier to meet, and products are manufactured consistently and at the lowest possible cost. FlexBatch users can develop, schedule, manage, document and centrally maintain recipes for globally distributed plants without engineering or IT personnel. FlexBatch exceeds the ISA S88 and IEC 61512 standards for batch control.

Visualization

Plant operators, engineers, and managers can easily create, modify, and access process data through a combination information-dense process graphics, intuitive browser-like system configuration and maintenance dialogues, and web and mobile KPI dashboards. TotalVision HMI screens can mimic older style production graphics alongside modern High Performance HMI screens, and users can drag-and-drop Smart Graphical Objects from a library of thousands or easily create their own.  The ProcessVision console provides engineers with browser-like system navigation from the entire plant down to a specific loop.  The D3Express is a read-only thin client optimized for mobile views that tracks specific loops and other KPIs on-the-go.

Alarming

Users can assign 256 alarm categories and 256 priorities, filter and sort alarms, display multiple alarm windows, inhibit downstream alarms and adjust alarm classifications based on the status of your process areas.  Systems are designed in accordance with ANSI 18.2 Alarm Management standards.  Additional audit and rationalization functions are available with our integration of PAS’ PlantStateSuite software.

Trending

The D/3 TrendR data historian securely and efficiently captures virtually any field related to TAG or batch or continuous plant operation into single or redundant archives.  Users track real time operational performance, analyze historical KPI data and create an unlimited number of trended data into meaningful displays.  Users can view multiple trend displays at each operator workstation and as embedded within TotalVision process graphics.

Reporting

Reports are manually generated or automatically triggered based on plant operational status. Batch reports may be automatically started at batch initiation to capture all KPI data for each vessel, unit operations, a log of all events including operator comments, program print statements, and any abnormalities in allocated equipment. Diagnostic, informational and shift reports can be scheduled or manually triggered to identify abnormal system characteristics, find where a specified tag is used, or find spare I/O modules.  Shift change reports identify all tags in manual mode, all off-scan tags, all forced tags, all devices in override, and all devices with faults so that an incoming operator is quickly informed and can make better decisions.

Product Tracking

Product tracking displays allow users to determine key start and stop times, what equipment or process units are being used for a batch or production run, what recipe is being used, targets and actuals for each recipe variable, and what step of the process each unit is in.

Data Integration

All process data is made available in industry standard formats like ODBC, DCE, OPC, and standard C++ data access techniques to Enterprise Resource Planning (ERP), Supply Chain Planning (SCP), equipment control and Laboratory Information Management Systems (LIMS). Legacy islands of automation within the plant can be accessed and integrated more easily than you might expect with the OrionLX automation platform.

I/O

NovaTech 8000 Series Ethernet I/O operates within a -40ºC to +70ºC temperature range and meets ISA G3 corrosion resistance, is HART capable and available in a 1-to-6 redundancy configuration. D/3 also directly supports I/O from Schneider and Siemens, and protocols include Modbus/TCP, EtherNet/IP, Foundation Fieldbus, and DF-1.

Compliance

Ensure compliance with such industry recognized standards as S72, ODBC, OPC, S88, and IEC-61512. I/O hardware offered with D/3® is UL, FM, and CE approved for use internationally.

Lowest Total Cost of Ownership

D/3 keeps automation costs at a minimum through a “No Hassle” licensing policy, standard programming methodologies, embedded simulation capabilities, and the ability to modify and upgrade software without process interruption.  

  • With the release of the D/3® Ethernet Multi-Protocol Controller (EMPC2) interface in version 12.2-3, Ethernet I/O has quickly become one of the most popular D/3® interfaces. This interface is used to communicate with NovaTech’s 8000 I/O and many common PLCs.

    August 16, 2009

  • D/3® PCM 4100 Datasheet

    The D/3® Process Control Module (PCM) is a real-time, microprocessor based computer that provides distributed automation and control capabilities for continuous and batch process plant operations…

    August 27, 2014

  • D/3® 8000 Series I/O Summary

    The NovaTech 8000 Series I/O is the remote I/O family native to the D/3® Distributed Control System (DCS). It is the preferred I/O for new installations and it can replace the older NovaTech 16000 series I/O in existing PCM cabinets, using existing field wiring connected to new termination panels with existing connectors.

    August 15, 2014

  • Paperless Procedures™ Datasheet

    Paperless Procedures (PLP) is a combination of software and services that integrate process control, operator training, documentation and compliance needs into a robust knowledge-retention architecture.

    August 26, 2014

  • D/3® ProcessVision Console Datasheet

    ProcessVision™ Console software is the easy and secure way to monitor, analyze and adjust continuous and batch processes running on the D/3® DCS System.

    August 26, 2014

  • D/3® USB Keyboard Process Control Functions Datasheet

    The D/3® USB Keyboard is an environmentally hardened operator’s keyboard with keys dedicated to process control functions. It communicates at 12 mbps via an available USB 1.0/2.0 port on an OCM, DCM or CDCM.

    August 26, 2014

  • D/3® System Architecture Datasheet

    The D/3® Distributed Control System (DCS) is a completely scalable solution to meet your current and future process control needs. NovaTech D/3 products are currently employed by customers with as few as 50 and as many as 40,000 tags — with room to grow to over 100,000 tags. The D/3 consists of four major components: OCMs, DCMs, PCMs, and I/O.

    August 26, 2014

  • D/3® Distributed Control System Datasheet

    D/3® is a leading-edge Distributed Control System (DCS) that incorporates a full suite of intuitive software tools designed to improve product quality, maximize throughput and increase profits for process manufacturing companies. Featuring a flexible, open architecture and the familiar Microsoft Windows environment, D/3 is easy to use, maintain and configure—saving both time and money.

    August 26, 2014

  • D/3® Keeps it Cool at Major Particle Accelerator

    DESY relies on D/3®, FlexBatch®, and TotalVision® Process HMI for 24/7 operation of refrigeration plant. The German Electron Synchrotron (DESY) – located in Hamburg and Zeuthen – is one of five large accelerator centers in the world at which physicists study the world of elementary particles. Several hundred men and women work together on experiments in international groups, where, over the course of years of collaborative effort, they design, build, and operate complex measuring instruments the size of buildings and evaluate millions of items of data. Four such groups are currently working at DESY at the large underground Hadron Electron Ring Accelerator (HERA).

    August 20, 2014

  • D/3® PCM 4200 Process Control Module Datasheet

    The D/3® Process Control Module (PCM) is a real-time, microprocessor based computer that provides distributed automation and control capabilities for continuous and batch process plant operations. The PCM 4200 is form-factor compatible with earlier cabinets and provides an upgrade path for PCM I, PCM II, PCM III, and PCM 2000 micros.

    August 15, 2014

  • D/3® 8000 Series I/O Product Catalog

    The full catalog of NovaTech’s 8000 Series I/Os. The 8000 Series is the remote I/O family native to the D/3® Distributed Control System (DCS). It is the preferred I/O for new installations and it can replace the older NovaTech 16000 series I/O in existing PCM cabinets, using existing field wiring connected to new termination panels with existing connectors.

    August 15, 2014

  • D/3® Distributed Control System Overview Brochure

    The D/3® Distributed Control System (DCS) is a leading edge process control system that includes a comprehensive suite of software applications, networks, and computing hardware. D/3 features system-wide redundancy and the ability to upgrade without stopping plant operations.

    September 24, 2013

  • FlexBatch® ISA-88 Batch Software Adds Revenue

    Major Dye Manufacturer Increases Monthly Production by 300,000 Pounds of Product, Adding More Than $23 Million in Annual Revenue. The customer in this scenario is a leading company dedicated to…

    August 1, 2012

  • Paperless Procedures™ Overview Brochure

    Paperless Procedures™ (PLP) is a patented software product and methodology that simplifies the creation , execution, and maintenance of Standard Operating Procedures (SOPs) across the entire process enterprise.

    June 26, 2012

  • FlexBatch® ISA-88 Batch Management Overview Brochure

    FlexBatch® integrates recipe management with the manufacturing process by making the automation procedure part of the recipe. Developers, engineers and production staff can quickly develop and modify documented recipes, and immediately schedule them for production.

    September 11, 2012

  • D/3® V14.0 Enhancements At-A-Glance Datasheet

    D/3 Version 14 delivers numerous important security, configuration, optimization, system, and 8000 Series I/O enhancements that improve product quality, operational efficiency and enhance your bottom line.

    March 28, 2011

  • D/3® TotalVision® HMI: A4

    TotalVision® provides an unparalleled display of real time process information. Custom graphics, built using dynamic objects from our extensive library, make it easy for the operator to control the process, enter information, and interact with sequence programs.

    December 21, 2010

  • D/3® PCM 4200 Process Control Module Datasheet: A4

    The D/3® Process Control Module (PCM) is a real-time, microprocessor based computer that provides distributed automation and control capabilities for continuous and batch process plant operations. The PCM 4200 is form-factor compatible with earlier cabinets and provides an upgrade path for PCM I, PCM II, PCM III, and PCM 2000 micros.

    December 21, 2010

  • FlexBatch® Recipe & Batch Control Datasheet: A4

    Control of batch manufacturing and product recipes represents a plant’s biggest challenge and greatest opportunity for competitive advantage. After all, efficiency and uniformity impact yield and ultimately R.O.I. Now, you can integrate recipe management and the manufacturing process with FlexBatch®.

    December 21, 2010

  • D/3® System Architecture Datasheet: A4

    The D/3® Distributed Control System (DCS) is a completely scalable solution to meet your current and future process control needs. NovaTech D/3 products are currently employed by customers with as few as 50 and as many as 40,000 tags — with room to grow to over 100,000 tags. The D/3 consists of four major components: OCMs, DCMs, PCMs, and I/O.

    December 21, 2010

  • D/3® Distributed Control System Datasheet: A4

    D/3® Loop Optimizer is designed to provide a highly intuitive and effective platform for all PID loop tuning on a D/3 system. It solves common problems associated with tuning PID control loops and it allows users to model, analyze, and tune PID control loops quickly, accurately, and consistently.

    December 21, 2010

  • D/3® TotalVision® HMI Datasheet

    TotalVision® provides an unparalleled display of real time process information. Custom graphics, built using dynamic objects from our extensive library, make it easy for the operator to control the process, enter information, and interact with sequence programs.

    November 17, 2010

  • FlexBatch® ISA-88 Batch Management Software Datasheet

    Control of batch manufacturing and product recipes represents a plant’s biggest challenge and greatest opportunity for competitive advantage. After all, efficiency and uniformity impact yield and ultimately R.O.I. Now, you can integrate recipe management and the manufacturing process with FlexBatch®.

    November 17, 2010

  • D/3® Ethernet I/O Network Configuration Reference Guide

    With the release of the D/3® Ethernet Multi-Protocol Controller (EMPC2) interface in version 12.2-3, Ethernet I/O has quickly become one of the most popular D/3® interfaces. This interface is used to communicate with NovaTech’s 8000 I/O and many common PLCs.

    August 24, 2009

  • TotalVision® 动态、灵活和复杂 Datasheet (Chinese)

    TotalVision® provides an unparalleled display of real time process information. Custom graphics, built using dynamic objects from our extensive library, make it easy for the operator to control the process, enter information, and interact with sequence programs.

    April 1, 2008

  • FlexBatch® 配方和批控制 Datasheet (Chinese)

    Control of batch manufacturing and product recipes represents a plant’s biggest challenge and greatest opportunity for competitive advantage. After all, efficiency and uniformity impact yield and ultimately R.O.I. Now, you can integrate recipe management and the manufacturing process with FlexBatch®.

    April 1, 2008

  • D/3® System Architecture 系统结构 可扩展、高效、冗余 (Chinese)

    The D/3® Distributed Control System (DCS) is a completely scalable solution to meet your current and future process control needs. NovaTech D/3 products are currently employed by customers with as few as 50 and as many as 40,000 tags — with room to grow to over 100,000 tags. The D/3 consists of four major components: OCMs, DCMs, PCMs, and I/O.

    April 1, 2008

  • D/3® Distributed Control System 分布式控制系统 强大、可靠、紧凑 (Chinese)

    D/3® is a leading-edge Distributed Control System (DCS) that incorporates a full suite of intuitive software tools designed to improve product quality, maximize throughput and increase profits for process manufacturing companies. Featuring a flexible, open architecture and the familiar Microsoft Windows environment, D/3 is easy to use, maintain and configure—saving both time and money.

    April 1, 2008

  • 8000 Series I/O 产品目录 Product Catalog (Chinese)

    The full catalog of NovaTech’s 8000 Series I/Os. The 8000 Series is the remote I/O family native to the D/3® Distributed Control System (DCS). It is the preferred I/O for new installations and it can replace the older NovaTech 16000 series I/O in existing PCM cabinets, using existing field wiring connected to new termination panels with existing connectors.

    June 1, 2007

  • PCM 4200 过程控制站 (Chinese)

    The D/3® Process Control Module (PCM) is a real-time, microprocessor based computer that provides distributed automation and control capabilities for continuous and batch process plant operations. The PCM 4200 is form-factor compatible with earlier cabinets and provides an upgrade path for PCM I, PCM II, PCM III, and PCM 2000 micros.

    April 1, 2008

  • Additional Datasheets, Application Notes, Customer Success Stories and other documents in our documentation library

  • This video introduces the D/3, the distributed control system trusted by many Fortune 100 companies to keep their global operations’ continuous and batch processes running smoothly and efficiently. Part one reviews the system architecture and configuration tools.

    December 21, 2014

  • D3v14 – D/3 Version 14.1 Webinar

    Original Air Date: 4/10/13

    A webinar presenting D3v14.1, outlining and demonstrating the newest features of the upcoming D/3®, ProcessVision™ Console, and FlexBatch® releases, and highlight meaningful product features to enhance value for all customers, including managers, engineers, and operators.

    December 21, 2014

  • ProcessVision™ Features Profile

    A brief overview of NovaTech’s D/3 DCS ProcessVision console, outlining the new features designed to deliver a modern yet familiar user experience that will delight new users and seasoned D/3 veterans alike.

    December 21, 2014

  • D/3 Express Mobile Client Introduction

    An introduction to the D3Express™ mobile application, providing read-only access from anywhere via your smartphone or tablet (with no additional licensing).

    December 21, 2014

  • This webinar covers ProcessVision, the state-of-the-art console that enhances the ability to easily and securely monitor, analyze, and adjust production processes running on the D/3® Distributed Control System.

    December 21, 2014

  • The First Twenty-Five Years of D/3

    The NovaTech D/3 Distributed Control System (DCS) is an open process automation system that controls a wide variety of industrial processes. This video, produced to commemorate its 25th anniversary, recounts its history with archival images and humorous employee anecdotes.

    December 21, 2014

  • ProcessVision™ Console Overview

    The ProcessVision Console is the new interface to the NovaTech D/3 Distributed Control System (DCS) that provides a wealth of system data and intuitive Windows navigation, right out of the box.

    December 21, 2014

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