Many industrial facilities operate established Emerson distributed control system (DCS) environments while relying on PLC-based subsystems for packaged equipment, utilities and specialist processes. Integrating these PLCs into the DCS is crucial for ensuring safe, efficient, and reliable plant operation. For existing Emerson DeltaV DCS sites, selecting Emerson PLCs and applying the NAMUR Module Type Package (MTP) standard provides a clear path to reduce integration costs, time, and risk compared to sourcing and integrating alternative PLC brands.

Modern production plants are highly automated, yet many still suffer from “islands of automation”. While the primary process is typically controlled by a DCS, skids and OEM equipment, such as centrifuges, filtration units, and packaging systems, are often controlled by local PLCs. These systems are frequently supplied by different vendors using various automation platforms, making integration particularly challenging.

Traditional DCS and PLC integration relies on manual data mapping, custom code, hardwired interfaces and repeated testing. This approach is labour intensive and increases project schedules and engineering costs. Operators may also be forced to move between multiple HMIs to access critical operating and diagnostic information. Changes after commissioning require updates on both the DCS and PLC sides, which increases the risk and ongoing support effort. When third-party PLC brands are introduced, coordination between vendors adds further complexity and uncertainty.

The Solution

MTP, defined by NAMUR NE 148, addresses these challenges by providing a standard, vendor-neutral method for integrating PLC-based equipment with a DCS. MTP allows PLC configurations to be exported as a structured package and imported directly into the DCS. This package includes process data, alarms, HMI elements and functional descriptions.

Figure 1: Traditional manual PLC/DCS integration methods (upper diagram) are time-consuming and may involve multiple iterations for complete implementation. MTP integration automates and simplifies the task. 

For existing Emerson DCS sites, integrating Emerson MTP-capable PLCs delivers additional benefits. The PLCs and DCS are designed and tested to work together, supporting a straightforward export and import process. Once connected, communication occurs over standard Ethernet using secure OPC UA. The DCS automatically generates operator graphics, alarms and data structures without the need for custom code or extensive manual configuration.

Figure 2: Skids and other PLC-controlled subsystems are part of the PEA, the lower section. Using MTP, they can communicate via a shared architecture network with their respective DCS, and also with other parts of the network if desired.

By integrating Emerson PLCs into an existing Emerson DCS using MTP, plants can reduce integration effort by half or more compared with traditional methods. Engineering time, testing cycles and commissioning activities are significantly reduced, lowering project cost and shortening schedules. Risk is also reduced, as the platforms are proven to operate together, and changes can be implemented more easily after startup.

Figure 3: When a chemical manufacturer built a new production unit by specifying Emerson’s MTP-capable DeltaV DCS and PACSystems RX3i PLCs, they benefited from advanced integration, while expending only half of the effort typically involved with traditional methods.

Operators gain clear, centralised visibility of all plant assets from the control room, supporting safer and more consistent operations. OEM equipment can be added or modified with less disruption, providing greater flexibility for future expansions. For Emerson DCS users, choosing Emerson PLCs with MTP offers a streamlined, lower-risk integration method, reducing complexity and uncertainty often associated with multi-vendor setups.

Figure 4: DCS and PLC integration based on MTP delivers many execution benefits, including speeding the time-to-market for new and retrofit projects.

For further details or to discuss tailored solutions for your business, contact IPD today.