Instrumentation and Control Systems
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Whole Number 216 Instrumentation and Control Systems Lifecycle total solution Integrate latest leading hardware and software and application know-how, future-oriented system development with evolution. This is the lifecycle concept of MICREX-NX. MICREX-NX realizes optimal plant operation in all phases of system design, commissioning, operation and maintenance. At renewal phase, MICREX-NX provides maximum effect with minimum capital investment. The MICREX-NX lifecycle total solution offers cost reduction and long-term stable operation with constant evolution and variety of solution know-how. The new process control system Instrumentation and Control Systems CONTENTS Present Status and Fuji Electric’s Involvement with 2 Instrumentation and Control Systems New Process Control System for a Steel Plant 8 New Process Control Systems in the Energy Sector 13 Cover photo: Instrumentation and control sys- Network Wireless Sensor for Remote Monitoring of Gas Wells 17 tems are anticipated to become sys- tems capable of considering carefully the comfort and safety of society and the global environment while contrib- uting to the stable manufacture of high quality products with the desired productivity. Fuji Electric strives to provide a total optimal system with vertically and horizontally integrated solutions Fuji Electric’s Latest High Functionality Temperature Controllers 21 that link seamlessly various compo- PXH, PXG and PXR, and Examples of their Application nents and solutions required on the shop fl oor. The cover photograph represents an image of instrumentation and con- trol system organized by the MICREX- NX new process control system, fi eld devices, receivers, and the like. Head Office : No.11-2, Osaki 1-chome, Shinagawa-ku, Tokyo 141-0032, Japan http://www.fujielectric.co.jp/eng/company/tech/index.html Present Status and Fuji Electric’s Involvement with Instrumentation and Control Systems Yuji Todaka Toshiyuki Sasaya Ken Kakizakai 1. Introduction again improved and enhanced the element technolo- gies of the instrumentation and control system, i.e., The investment environment surrounding the in- the main constituent elements of control technology, dustrial system sector is continuing to grow due to in- engineering technology and device manufacturing tech- creased public demand for capital investment. Accord- nology, and constituent components such as measuring ing to medium-range forecasts, the market for electric instruments. measurement equipment will continue to experience This paper presents Fuji Electric’s vertical and mild growth overall during the period from 2006 to horizontal integration solution, and described the pres- 2009; government-based demand will continue to be ent status of and Fuji Electric’s involvement with the limited and will level off; exports will be centered on abovementioned constituent elements. China and other Asian countries and will continue to increase slightly, and public demand for investment 2. Market Trends and Challenges for Instrumen- to reduce the high cost of crude oil and to add value to tation and Control Systems products is expected. Instrumentation and control systems are antici- 2.1 Market trends and challenges for distributed control pated to become capable of considering carefully the systems (DCSes) comfort and safety of society and the global environ- In the 1990s, DCSes underwent a dramatic change ment while contributing to the stable manufacture of from specialized systems for DCS manufacturers to high quality products with the desired productivity. open-standard systems used with UNIX*1 and Win- Moreover, at plants where the manufacturing equip- dows*2, which are the de facto standards for operating ment is approaching the time for renewal, it is desired systems. SCADA (supervisory control and data ac- to utilize existing assets while migrating to a system quisition), a monitoring and control package that uses capable of supporting future technological innovations. Windows as its operating system, emerged fi rst, and Meanwhile, owing to the latest advances in IT (in- PC-based DCSes that use SCADA as middleware were formation technology) and personal computers, there introduced into monitoring and control systems. Then are plans to combine instrumentation and control Internet technology and OPC*3, the de facto standard systems with MES (manufacturing execution system), interface of Windows, and fi eld bus technology revolu- ERP (enterprise resource planning), SCM (supply chain tionized the DCS market. management) and other such core systems, or combine In the years since 2000, programmable logic con- them with intelligent fi eld devices, and there is de- troller (PLC) instrumentation systems have been intro- mand for a comprehensive optimized system structure, duced to the market, and the segregation of the instru- from the fi eld level to the level of production manage- mentation control domain among DCS manufacturers, ment and operation, based on a vertically and horizon- PLC manufacturers and SCADA manufacturers has tally integrated solution that seamlessly integrates the become even more complex. various components and applications required at the On the other hand, the focus on DCSes has production site. changed, from mere monitoring and control systems On the other hand, the so-called “year 2007 prob- to systems that are being reconsidered by users as lem” is one that Fuji Electric cannot avoid, and in es- an effective means for reducing the TCO (total cost of tablishing and executing a countermeasure policy, as a part of an effort to strengthen the rationale for an in- *1: UNIX is a registered trademark in the U.S. and other strumentation and control system that provides verti- countries, licensed through X/Open Company, Ltd. cal and horizontal integration solutions, and cognizant *2: Windows is a registered trademark of U.S.-based Micro- of the transmission of technology and of measures to soft Corporation. prevent the hollowing out of this industry, Fuji Electric *3: OPC is a standard interface specifi cation of Microsoft. 2 Vol. 53 No. 1 FUJI ELECTRIC REVIEW ownership) for the total lifecycle duration, from DCS especially China, and the enhancement of facilities in adoption until renewal, and with the introduction of IT, the basic materials industry, which is the main cus- as a way to optimize the operation of manufacturing tomer of measuring instruments. systems. Measuring instruments can be broadly categorized In this context, a DCS does not exist by itself, but as fi eld instruments such as transmitters and fl ow me- must be linked to an ERP, SCM or MES core busi- ters, receivers such as recorders and controllers, and ness system to form a system that operates effectively. analyzers. A noticeable recent trend among measuring Seamless integration and the provision of MES prod- instruments is the provision of functions that support ucts are huge challenges. networking. The fi rst example of a fi eld bus used in With longer service lives of equipment, DCSes are the fi eld was announced in 1998, and the necessity of being required to provide long-term maintenance and a fi eld bus has become a frequent topic in recent busi- protection. The extent to resolve the confl ict between ness discussions. Communication functions such as longer service life and higher versatility of general- Ethernet*4 support are now required in receivers as purpose products based on open standards remains a well. Moreover, the trend toward globalization of mea- huge challenge. suring instruments is remarkable, and for transmit- In the domestic Japanese DCS market, new plant ters, de facto standards are increasingly being used in demand is small, but the majority of demand arises the specifi cations, and the resulting low cost is often from the need to renew equipment in order to maintain the key to receiving orders. On the other hand, how- a plant. The challenge facing DCS manufacturers is ever, there is a growing demand for specialized devices achieve long-term operation while continuing to utilize for particular customers. a user’s assets and providing a revolutionary system. 3. Fuji Electric’s Involvement with Instrumenta- 2.2 Market trends and challenges of measuring instru- tion and Control Systems ments The market for measuring instruments has con- 3.1 Involvement with DCS tinued to diminish due to a reduction in capital invest- Fuji Electric possesses excellent core technology ment over the long-term and lower prices, but in the past few years, the market has recovered as a result of *4: Ethernet is a registered trademark of U.S.-based Xerox increased in capital investment in Asian markets and Corporation. Fig.1 MICREX system confi guration Enterprise resource Small and medium planning/supply chain Medium and large size systems size systems management (ERP/SCM) Existing system 5th generation Office LAN, Internet, intranet MICREX-NX 2nd & 3rd 4th generation Manufacturing - generation MICREX AX OS clients execution system MICREX-IX (MES) MICREX-PIII Terminal bus FOCUS DBS-1500 IDS-2500 AOS-2000 OS server ADS-2000 ADS-2000 Batch servers ES OS single user FL-net Process DPCS-F automation Plant bus (DCS) ACS-2000 AS AS MICREX-SX ICS-2000 ACS-2000 (JUPITER) ACS-2000 PCS-500 HDC-500 IPU DP - EGFMAC-SIRIUS PROFIBUS-DP IPU IPU P/PE link PROFIBUS Field level PROFIBUS-PA OS : Operator station ES : Engineering station MICREX-SX AS : Automation system Present Status and Fuji Electric’s Involvement with Instrumentation and Control Systems 3 in the distinct fi elds of electric (E), instrumentation Fig.2 MICREX-NX