Maximize profitability and operational

efficiency with EcoStruxure Process Expert

schneider-electric.com
Hybrid Industry Market Challenges
Market trends like agile operations and digitized products (for more product personalization) have
increased the demands on automation systems to deliver these complex production requirements.
Flexibility is required in the automation system, and of its users, to ensure that continuous operation
of the manufactured products are delivered at the expected quality, while optimizing operations,
energy efficiency and expenditure. With these evolving process complexities, plant managers are
expecting an automation system that is productive in design with a superior operation environment
to monitor the process. EcoStruxure Process Expert answers these market challenges.

Improve Manage the

CAPEX/OPEX
operations & energy life cycle of
spending
efficiency the product

Aging /
Manage regulatory
inexperienced
requirements
workforce

Design, engineer and maintain your

plant with a single system
EcoStruxure Process Expert is a single automation system to engineer, operate, and maintain your
entire plant. The system enables users to achieve operational profitability from design engineering
to meeting the demands of modern day production.

The industry-leading EcoStruxure architecture is based on a three-tiered technology stack,

bringing energy, automation, and software together.

EcoStruxure Process Expert is positioned at the Edge Control

layer of the EcoStruxure Plant Architecture

EcoStruxure Process Expert 2

Maximize your operational profitability
EcoStruxure Process Expert can increase the business results by efficiency
improvements in four areas.

Reduce project execution time

Reduce engineering of the project by 25%, to get your production started earlier.

Possible Business Results

Efficiency improvement EcoStruxure Process Expert contribution

Reduce time-to-market by 25% A productive engineering approach to deliver faster

Embedded services to move from reactive to proactive

Reduce unplanned downtime to 2%
maintenance, leading to less maintenance costs

Business intelligence for faster decisions thanks to a

Increase the operational visibility comprehensive integration of the process data with apps,
analytics and services

Embedded services to compute the energy consumption and

Reduce energy use by 30%
master the energy within the plant

Improve profitable reliability

Moving from reactive to prescriptive maintenance can reduce unplanned downtime to almost zero.
Downtime costs the average plant 5% of production, so let’s conservatively assume increased
maintenance maturity can reduce this to 2% unplanned downtime. In addition, maintenance
staff could waste less time performing needless maintenance tasks, which could save in
maintenance costs

Improve process visibility

Accessing data and turning it into actionable business intelligence delivers enhanced process
visibility, which can result in 0.5 to 3% of revenue improvement a year and 3 to 10% of potential
margin impact.

Improve energy utilization

Mastering and improving your industrial facilities process energy use can yield savings of up to
30% in annual costs.

EcoStruxure Process Expert 3

Interconnect and manage
automation architecture
EcoStruxure architecture and interoperable technology platform bring together energy, automation,
and software. It delivers enhanced value around safety, reliability, efficiency, sustainability, and
connectivity. It opens the digital world to users across key end markets, enabling them to be
competitive in today's Digital economy.

Improving efficiency, accelerating

startup and reducing risk
A productive engineering approach
EcoStruxure Process Expert is an innovative multi-engineering environment to improve the
efficiency throughout the engineering phase of a plant and commissioning, accelerating start-
up and minimizing project risk. The engineering environment is scalable with a collaborative
architecture that allows multiple engineers to configure a process automation system, from
hardware configuration, communication, controls and mimics for the supervision.

Configure-once philosophy
As an asset centric system, it enables a single-entry point for all configuration for faster system
design, reduced errors, system consistency and quality. Asset information data is introduced
only once and the design of system follows the Control Instrumentation Diagram, making controls
design, installation, and commissioning easier.

EcoStruxure Process Expert 4

Central Repository
EcoStruxure Process Expert centralizes all system configuration in a global and single database.
This single database enables active services to share information across all automation system
components as well as share real-time engineering data with all the users. This centralized
repository for the whole system makes engineering and maintenance easier.

Concurrent Engineering
Multiple design teams can work in parallel during the engineering phase, which reduces design
time and cost dramatically. EcoStruxure Process Expert enables concurrent engineering in the
same system with consistency management. The transparent check-in/check-out mechanism
optimizes engineering design, and shares, in real time, all the work performed across the different
engineering workstations.

EcoStruxure Process Expert 5

Comprehensive change tracking
EcoStruxure Process Expert provides out-of-the-box engineering traceability and revision control
by recording any system configuration changes. This feature helps to support the verification of
changes to comply with the requirements of regulated industries.

An Object Base Automation System

Standardization driven Automation System
An end-to-end automation object model to drive standardization across plants and enterprise.
With ready-to-use process application libraries, standards can be established resulting in reduced
engineering, plant operator training and maintenance tasks. An open object mode approach to
reduce project and operation cost, driving consistency and quality. Additionally, the openness
of the automation platform, enables encapsulation of customer standards in application assets,
which are created once as templates, and re-used consistently across the plant and multiple
enterprise sites.

The model represents the physical equipment, containing all the different points of view of the
equipment: control logic, graphical representation, data acquisition, alarms, trends, system
security, access control, external interfaces, etc.

Save you time and cost

• Centralized hardware and software configuration is uniform throughout the platform
• A single, global database and configure-once philosophy
• Pre-configured, tested and validated application template to simplify asset configuration
• Reuse of existing application templates to simplify the duplication of equipment

EcoStruxure Process Expert 6

Running the plant at the peak performance
Over the past few decades, industrial trends have created a universal set of challenges for process
control. Today’s operators work in more centralized operating rooms, are responsible for more
areas of the plant, and have more graphics, alarms, and data available to them than ever before.
The consequence is the additional effort to filter the information to process into decision.

It is admitted that abnormal situation of an automation system is resulting by 40% from

human errors.

A predefined environment based on Situational awareness concepts

Situational awareness design of the operational 
environment delivers the ability to identify,
process and analyse the critical elements
of information about what is happening with
regards to the automation system. The ability
to provide operators with clear process
information is crucial to driving production
efficiency. EcoStruxure Process Expert
provides a consistent control and operational
interface with a real-time view of your process.
The system delivers operators all the services
and data they need to make timely and
accurate decisions.

Easily monitor the process

The layout of the operation workspace with menus,
contextual sub-menus and banners enable the
operator to access the data easily.

The color code information related to the criticality

of alarms and the filtering based on equipment
speed up the operator analysis and the decision.

The faceplate is how operators interact with assets.

Each faceplate is embedded with:

• A user interface for an operator to monitor

the assets
• Visibility into which missing interlocks are
causing problems
• Status and information about the assets
• Parameters associated with the assets (e.g. PID)

EcoStruxure Process Expert 7

Empower your workforce to
make business decisions
Allow plant staff to continuously improve operations ensuring the right people have the right
information in the right form at the right time.

Put real time plant operating information in the hands of those who need it the most.

Digitize plant operations, Get the information at your fingertips

With EcoStruxure Process Expert, the right person gets the right information at the right time.
Problems can be diagnosed and solved faster. You can access any data in real time for any
asset or equipment in your system. This includes the control device running in the controllers,
all documentation, event historian, asset management, and internet links.

The advanced diagnostic with Runtime Navigation Services is a native service provided by
EcoStruxure Process Expert Objects during runtime. These powerful diagnostic services allow
the user to access different points of view for each asset, including monitoring control logic,
documentation, topological localization, alarms and trends. This innovative service reduces
commissioning time, as well as downtime, by quickly identifying the root cause of any issues

EcoStruxure Process Expert 8

Enhance Alarm Management
An efficient alarm management allows operators to distinguish critical alarms from routine alarms,
and take timely corrective action, thereby reducing plant downtime.

The layout of the operation workspace delivers the alarm information at a glance and the
EcoStruxure Process Expert alarm system provides you detailed information about the status
of your plant.

Alarms can be filtered according to the equipment hierarchy and severity, with alarm-based
navigation, enabling the operator to easily zoom into an area of the plant.

Track activity within the system

The operator log enables a plant manager to track all the commands performed by an operator.
Information logged:

• Change of process values

• Bypass of interlock conditions
• User activities, like:
–– Manual reset following a failure
–– Consignment of a device; device simulation
–– Change of command mode, Operator-to-Program mode, or reverse

EcoStruxure Process Expert 9

EcoStruxure Process Expert Process libraries
EcoStruxure Process Expert brings out of the box reusable process libraries specifically designed
to reduce engineering costs, risk and time to operation. These libraries embed the know-how
of years of experience delivering solution on hybrid Industries, and have been tested, validated
and documented.

The process library is designed to provide the components that are required to engineer the core
of the automation process. In addition, these libraries enable the integration of Schneider Electric
and third-party devices via different open protocols. Automation infrastructure objects extend the
functionality beyond the classical automation layer to integrate smart connected products and
software applications within Edge Control. This brings the IIoT from concept to reality within the
distributed control system.

• Motor Starters (TesysU & TesysT ranges)

Schneider Electric motor and drive
• Progressive Starters (Altistart)
management
• Variable Speed Drives (Altivar ranges)

• Circuit Breakers (Masterpact & Compact ranges)

• Protection Relays (Sepam ranges)
Schneider Electric power management
• Power Meters (PM ranges)
• Smart UPS, Harmonic Filter

Connecting through industrial • Ethernet I/P & Modbus TCP

networks • Modbus Serial, Profibus, HART

• Analog Input (direct, processed or multiple)

• Analog Output (actuators, control valves, motorized valves,
Analog Devices pulse width)
• Analog Control (PID, ramp, split range, ratio, ramp, lead-lag,
3-step)

• Digital Inputs (limits or other discrete sensors)

Digital Devices • Motors (direct, dual direction, dual speed, variable speed)
• Valves (analog position and/or limit switches)

• Flow Control
Process Templates
• Pump Set Management

• Sequence Management (ISA88 - sequencing)

Sequence Templates • Process Management (ISA — equipment module)
• Batch Integration (InBatch phase management)

Hybrid Industry-specific libraries

Additionally, to the general-purpose process library, EcoStruxure Process Expert complements its
expertise in hybrid industries with a set of ready to use libraries to specific industries such as water
and waste water treatment, cement, mining and Food & Beverage.

Water Library Mining Library Cement Library

EcoStruxure Process Expert 10

Ready-to-use libraries for energy
management and process control
EcoStruxure Process Expert has dedicated libraries for power and energy management and
advanced process control. They can be combined with the general purpose and industry-specific
libraries to build applications with a consistent look and feel.

The Energy Management Library offers monitoring and measurement of electrical and non –
electrical process objects. The aggregation of energy (water, air, gas, electricity and steam) at each
level delivers information to users about the energy consumption data.

Low Voltage Power Control (LVPC) Library provides the ability to monitor the energy situation in
low voltage power circuits in a plant and retain the available energy for the most critical loads by
shedding the least critical ones.

Advanced Process Control Library targets monitoring and controlling complex processes, like a
furnace, in the plant.

Energy Management Low Voltage Advanced Process

Library Power Control Library Control Library

Typical applications
Mining Minerals Metals Power Generation
• Cement • Hydro Power
• Mining • Biomass
• Glass • Concentrated Solar
• Burners,
Boilers, Furnaces
and Compressors

Water & Waste Water Treatment Plant Oil & Gas

• Desalination Plant • Small OnShore
• Water Treatment Plant • Production Plant
• Waste Water • Tank Farms
Treatment • Compression Station

Food & Beverage Chemicals

• Liquid Food • Distillation
• Grain • Tank Reactor
• Oil
• Agro Business
(Silos, Sugar)

EcoStruxure Process Expert 11

Make the most of your energy
schneider-electric.com

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