PROCESS AUTOMATION THE DNA OF DCS DEVELOPMENTS
In alignment with Valmet’s lifetime systems
compatibility promise, existing process automation customers can also benefit from the latest technology, and have a clear pathway to upgrade their existing systems
To meet the modern challenges of the processing industry, Valmet has launched the newest generation of its DNA distributed control system, designed to deliver cutting edge cybersecurity, user interface, data storage and management features
T
he evolution of the first Distributed Control Systems (DCS) can be traced back to the 1980s and 1990s, and they have been developed and modernised over time. This approach, although effective, essentially involves building upon the foundations laid by earlier systems.
However, over the last few years the requirements for a DCS have dramatically changed. The primary purpose of a distributed control system is to connect field devices to process controls, but digitalisation initiatives have pushed DCS towards higher levels of connectivity and automation. Today, DCS are increasingly web-based systems that must be able to share information securely with back- office IT systems, provide more autonomous operations, and still offer high availability. The processing industry has gone through a
significant transformation as well. With the mass exodus of long-time operators to retirement, a DCS is now required to be more automated, easy to configure, and intuitive to operate, even for less well-trained operators. DCS must also accommodate remote work and maintenance.
Recognising that the iterative process has limits and that the needs of the industry were changing, Valmet decided to rewrite its DNA – the company’s next-generation DCS system
18 APRIL 2025 | PROCESS & CONTROL
originally introduced to the market in 2000. The concept was to apply modern development programming languages and tools from the ground up, along with agile software development, which involves breaking the process down into smaller parts and frequently testing the software.
The new upgrade is further informed by the company’s experience in providing automation systems for pulp mills, energy production, marine and process industries worldwide. The result is Valmet DNAe, a fully web-based process control system the company says was “completely redesigned from the start.” The primary drivers were enhancing cybersecurity, streamlining the user interface and configuration tools, and advanced data management, reporting, and analysis. “Valmet DNAe comes with a new cybersecure system architecture, updated user interface, control software and hardware, and engineering and analytics tools, all of which are designed to help processors improve efficiency, productivity, sustainability, and safety of their operations,” said Petri Tiihonen, Product Manager, Platform R&D at Valmet.
Although there were many priorities, perhaps the most important was addressing cybersecurity with the most advanced tools
available on the market. A DCS must provide open and secure connectivity at all levels, as well as between OT (Operational Technology) and IT (Information Technology) systems. This poses a significant challenge, and securing the system requires sophisticated cybersecurity. Valmet approached the task by adopting the cybersecurity philosophy known as “security by design.” This school of thought emphasises incorporating security measures from the very beginning of a product’s development cycle rather than adding them later in response to threats.
At the core of the Valmet DNAe Distributed Control System is the Trusted Information Framework (TIF), which serves as the backbone for communication and data management. Built upon the TIF foundation, Valmet DNAe architecture is cybersecure by design, and it includes measures such as role-based access control, authentication, encryption, endpoint protection, and comprehensive audit trails. IT security integration helps security teams stay alert to potential threats, and the Valmet DNAe system also enables intrusion detection to be implemented.
Another focus for the Valmet design team was improving the UX, or User Experience, of the DCS. The urgency to provide an easy-to-use, intuitive, and insightful interface that requires less operator training is only increasing as seasoned professionals exit the workforce, leaving a knowledge gap that new hires in the same role struggle to fill. Attracting new recruits and keeping them is difficult, adding to the pressure to optimise and do more with less. Smaller and smaller teams need to be able to run processes in larger, more complex operations.
The Valmet DNAe User Interface, is a modern web-based interface that is fully compatible with earlier Valmet DNA system generations.
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