The Mystery of PACs
January 25, 2011 Samuel M. Herb, PE owner
ISA—International Society of Automation • The confusion over PAC Monster……….
• The Acronym Monster…..
• The Configuration Monster………………
• The Network Monster….
• The Fieldbus Monster………………………. What System to Select?
PAC? What’s That?
Build me a wonderful control room… …all on a tight budget! What are the Issues?
? ! ?
No Project is Simple Real Goal for Plant Control System
PRODUCTIVITY!!!
! Buying Decision Factors for Process Products
4%-Delivery 11%-Operational Safety 32%-Operational Efficiency
13%-Spares Availability
18%-Price 22%-Ease of Maintenance Control System Issues
• Problems of open standards • Impact of fieldbuses • Configuration made easy • Significance to batching functions • Inclusion of safety systems • Challenge of advanced control methods • Wireless capabilities with security • Complexity of cyber security • Confusion of system names • Tie-in with plant business systems • Coordinate with other plants Process vs. Discrete Industries Process Discrete Products Fluids Devices, objects Operations Continuous, Batch Job Shop, Batch, Repetitive Product Design Done in Labs Done with CAD/CAE Equipment Uses Processes Uses Machines Equipment Cost Very High\ Medium to High Labor Cost Low High Sensors Numerous Analog & Discrete Mostly Discrete Control Products DCSs, PLCs, SLCs, PCs PLCs, CNCs, Robotics, PCs Supervisory Process Optimization. Cell Control, Scheduling Control Scheduling Business Mgmt. In-house, MRP II, MES, ERP MRP II, MES, ERP Implementation Bottom up Top Down All Process Control is an ART !
The key in process control is REPEATABILITY! Poor Accuracy; Poor Precision
No Repeatability Poor Accuracy; Good Precision
Repeatability, but no accuracy Good Accuracy; Good Precision
Repeatability with accuracy …But control rooms were nearly all manual! What is going on here?
Feedback Control! Evolution: These Were Distributed
Touring the plant Pneumatic transmission
Electronic miniaturization DDC -- Direct Digital Control
Computer Process
Analog Computer Back-up Tracking • Advantages: • Disadvantages: – Sophisticated control – Computer reliability – Flexible control – Redundant computer or – Data acquisition & alarm controllers – Wiring complex & extensive – HMI required high level operators – Expensive DDAC -- Supervisory Control
Analog Computer Process Panel
• Advantages: • Disadvantages: – High reliability – Complex wiring & – Human-machine interface installation adequate – Difficult to make strategy – Data acquisition & alarms changes – Sophisticated control – Expensive – Complete redundancy From Central to Distributed Control • Central CENTRAL CONTROL ROOM – Many wires
– Programmed COMPUTER – Vulnerable
CONTROLLER DATA CONTROLLER HIWAY CONTROLLER Distributed Data highway Configured
CONTROLLER Less risk
CENTRAL CONTROL ROOM Functional
UNIT CONTROL ROOM Physical Control System Comparisons ANALOG DIGITAL
PROCESS PROCESS
(Dedicated) (Centralized) • System organization Familiar Unfamiliar • Operator interface Rigid Flexible • Risk of failure Distributed Central • Diagnostics Limited Extensive • Sophisticated control Complicated Program • Record keeping Awkward Built-in • Plant computer interface Difficult Inherent • Ability to change Complex Reprogram Control System Comparisons ANALOG DIGITAL DCS
PROCESS PROCESS PROCESS (Dedicated) (Centralized) (Distributed) • System organization Familiar ------<— same • Operator interface ------Flexible <— same • Risk of failure Distributed ------<— same • Diagnostics ------Extensive <— same • Sophisticated control Objects ------Config • Record keeping ------Built-in <— same • Plant computer interface ------Inherent <— same • Ability to change ------Modular Traditional DCS - PLC - Computers: & Warning! Generalizations Here! Typical Strengths Typical Weaknesses DCS Distributed Risk Entry Level Cost Real-Time Throughput Proprietary Network Advanced Control Strategy Proprietary Operator Station PID (3-mode control) Complex Interlocks Operator Interface Control Room Environment Low Integration Cost PLC Environmental Human Interface Uptime Integration Cost Sequencing Rapid Repetition of Actions Reporting Complex Interlocks Application Software Logic Steps Easy to Do Recipe Handling Central Data Acquisition Programmed Advanced Control Strategy Environmental Limits Computer Database Storage Costly Redundancy History & Trending Real-Time Throughput Networking Traditional Scan Time Considerations Warning! Generalizations Here!
Scan Time Typical Function Likely System 1 Month . Corporate Update of Plant Computer . Operations Summary 1 Day, Shift . Production Report 1 Hour . Off-line Optimization . Batch Management DCS . Batch Scheduling 1 Minute . Unit Process Optimization DCS 1 Second . Display Update . Analog Control . Process Calculations . Batch Sequencing 100 mSec . Flow Control 20 mSec . High Speed Sequencing PLC . Interlocks 1 mSec . Sequence of Events DCS vs. PLCs with PCs as a System Typical PLC System Configuration:
Some Proprietary Network that passes as de facto Physical & PC Communication Standard as HMI PLC PLC PLC PLC Each Individually Configured Must configure to communicate with each PLC, to link views, etc.
Typical DCS System Configuration:
PC as ―Add-on‖ Proprietary Network, often based upon a HMI configured Workstation Physical Standard separately as HMI Controller Controller Controller Controller
Single database configured for all stations Traditional PLC Vendor Supply Model End User Buys from: …AND …Indirectly From Suppliers:
Component Implementer Provider Manufacturer(s)
OEM Distributors Software System Value Added Drive Integrator Resellers PLC Engineering Manufacturers Motion Contractor Representatives Sensor
HMI Manufacturer Traditional DCS Vendor Supply Model End User Buys from: …OR …Directly From Supplier:
Capabilities DCS Manufacturer System System design Integrator IT integration Services Process Project Management Engineering optimization Engineering Contractor Performance Field services guarantees Technical call Platform in Consulting Software Single Source Control Supply I/O Global support DCS - PLC - PC/PLC Report Card
Warning! Generalizations Here! DCS PLC PC/PLC Control Capabilities: Process I/O A A A Multivariable Regulatory Control A C C Complex Interlocking C A A Sequencing B D C Recipe Handling A D B Batch Process Control B D C User Interface: Ease of Configuration (links & displays) A C D Ease of Operator Use A D B Ease of Creating Custom Displays A C B Cost: Hardware C A B Installation A C D Application Programming A B C Additional Considerations: Ease of Expansion (interactive functions) A D D Flexibility A D C Redundancy A C C Reliability B A C Hardware Maintainability B A B Software Maintainability B C D Then What is Hybrid?
Depends upon who you ask… • Defined by Industry (ARC Research) • Defined by Input & Output Capability – Analog + Discrete I/O • Defined by Function (Batch Capability) • Defined by Architecture – Advantages of both PLCs & DCSs – Few disadvantages of either Automation Architecture Migration
Process Hybrid Discrete Industries Industries Industries ABB Emerson Mitsubishi Omron Honeywell Petrochemical Pharmaceutical Automotive Invensys Refining Fine Chemical Aerospace Rockwell Power Food & Beverage Machining Schneider Siemens Pulp & Paper Consumer Yokogawa Packaged Goods Siemens Rockwell GE?? GE??
From ARC Advisory Group Strategies – June, 2001 Hybrid Architecture Emerging System Configuration:
Choice of Open Network Flexibility Workstation or Proprietary Network Security as HMI
Control Control Control Control
User Choice; Single distributed control strategy: Uploads control • Single configuration database for: • Created on any PC away from system • Screen Views • Use any PC as a simulator • Trends • History BUT… Suppliers bundle THEIR PC now… • etc. soooo… ARC Group calls this “PAC” – Process Automation Control PC-based vendors call it Programmable Automation Control Now PLC vendors use this definition too! Emergence of PC as a Controller
• Robustness still a serious concern – “Industrial strength” for processes is far more severe than factory floor where some replace PLCs – Corrosive atmosphere & vibration significant • Potential to “liberate” end user from being proprietary hostage • All serious vendors already growing into selling software rather than hardware • Not likely to make control “shrink-wrapped” • Standards still an obstacle System Size Considerations
Warning! Generalizations Here!
Over Large DCS Large DCS 150 Large with with DCS Medium PLCs Large PLCs Loops of 30 Small DCS Small DCS Modulating to Small with with Control 150 DCS Medium PLCs Large PLCs Small PLC Medium PLC Large PLCs Under w/PC with PC with 30 or or Integrated PC & SLCs with SLCs Workstation
LoopPAC Under 200 200 to 600 Over 600 Strategies? Systems Channels of Discrete I/O Hybrid = PAC – Process Automation Control?
ARC Advisory Group’s definition says • PAC consists of multi-domain functionality, including logic, motion, drives, and process on a single platform. Attributes: • Single, multi-discipline development platform incorporating common tagging and a single database • Software tools that allow the design by process to flow across several machines or process units • Open, modular architectures that mirror industry applications from machine layouts in factories to unit operations in process plants • De facto standards for network interfaces, languages, and the like, allowing data exchange as part of networked multi-vendor systems” Clearly not all suppliers who claim to have PACs can do process control. - Many do only motion control and PLC functions - Not everyone easily meets this definition of PAC in its entirety - Nearly every system is still evolving from its proprietary origins. Process Automation Controller (PAC)*
* Some call this Programmable Automation Controller …especially if their product competes with PLCs Acronym Monsters Some more maddening acronyms • BCS – Basic Control System • CDAS• – Collaborative Discrete Automation System • CIF – Control in the Field • CNC – Computerized Numeric Control • CPAS – Collaborative Process Automation System • DAC – Data Acquisition & Control • DAQ – Data Acquisition • DCS – Distributed Control System • ECS – Enterprise Control System • ERP – Enterprise Resource Planning • FCS – Fieldbus Control System • FPGA– Field-Programmable Gate Array; (controller on a chip for OEMs) • PAS – Process Automation System • PC Controller – Personal (Professional) Computer Controller • SBC – Single Board Computer (Controller) • SCADA – Supervisory Control and Data Acquisition • SLC – Single Loop Controller Multi-Functional Controller Platforms
• Bundled functionality & scope of products w/services offered by traditional automation suppliers into unified solutions to include Collaborative Production Management (CPM) applications, advanced control, safety systems, application-specific systems.
• CPAS—Collaborative Process Automation Systems – Large PACs with “process focus” & ECS
• CDAS—Collaborative Discrete Automation Systems – Large PACs with “manufacturing focus” & ECS
• Enterprise Control Systems (ECS) connecting production floor operations with business systems. What is SCADA?
Meaning of the word & ambiguity • Supervisory • Control • And • Data • Acquisition • vs. Data Acquisition & Control (The PC connected to a PLC) Discrete vs. Process Applications Typical Control Combined PC + PLCs PAC System Approach: from various suppliers process control system Application area Production / devices Process / ―fluids‖ Production type Assembly w/ machines Conversion w/ processes Automation type More open-loop control More closed-loop control Process dynamics Typically fast Typically slower Process values Many binary values Many analog values Operator action – HMI req. Little / rarely – Low Much / frequent - High HMI requirements Low High Availability requirements Low High Diagnosis / fault resolution Local Central Plant sections Stand-alone Networked Supervisory Control Scheduling Optimizing Plant Design Local / bottom- up Central / top-down Combined Systems vs. PAC Systems
Combined PC + PLCs PAC System • Components function/scope NOT • Components function/scope coordinated coordinated • Function extensions added in • System functions are included in components for system individual components performance • Frequently from various suppliers • From a single source • Integration work necessary • Integrated overall system • Product competence • Application/system competence • Individual product responsibility • System responsibility • Individually optimized • Optimally coordinated system components • Innovations coordinated • Innovation cycles not coordinated Combined Systems vs. PAC Systems
Combined PC + PLCs PAC System Component engineering Systems engineering . Data storage for each component . Central database . Multiple data entries . Data are only entered once . Individual programming tools . Uniform configuring tool . Individual communication modes . Uniform communication
Individual Component Uniform System . Quality assurance for each . Quality assurance as entire system . Documentation for each . Uniform documentation . Function tests for components, . Consistent function & system test . Then integration test in system . Low effort through validation . Validation involves large effort conformity Implementation Effort
Combined PC + PLCs PAC Control System
Alarms / messages Diagnosis Redundancy Documentation Access rights Customer Support
• Uniformity • Uniform functions not ensured • System performance • Additional effort by user without additional effort High integration effort needed Process Reliability Combined PC + PLCs PACSystem
Independently Implemented: Uniformly Implemented: Diagnosis concepts Process diagnosis Operator control System diagnosis Message concepts Message & archiving concept Cross-component performance must Startup behavior be programmed by user for each after system fault component Operator control & access concept System-wide Diagnostics System functions & image hierarchy must be programmed Economical over entire life cycle (total cost of ownership ) Combined System PAC from various manufacturers process control system Expansion costs Homogeneous configuring landscape Up-to-date documentation Expansion Scalable system hardware Expansion Maintenance costs Integrated service concept Maintenance Adapted versions Maintenance Engineering and startup System-wide config. tools Engineering Integration support Engineering HW/SW System costs HW/SW components System hardware components System software Investment in system performance is more than compensated through savings in engineering! The Configuration Monsters Traditional Process Control
Analog Loop Set point (SP) Process Output Variable (PV)
Process Shared Processing
Typical Distributed Control Loops
―Data Highway‖
(Digital Communications) Control Room Field Signals (Analog or Digital) Older Physical Controller Structure
Output Input Conditioning Data Base Algorithm (on some) Communication (External) Data Highway (Internal) • All “control loops” share several cards • Same sets for all • Function processing is distributed:
● I/O ● Control ● Data highway ● Communication Next Older Physical Controller Structure
Highway Bus Driver Diagnostics (some) Each Card Has one P for Algorithm, Data Base, etc. • Individual cards for each “control loop” • Different sets per order • Select card for each needed function:
● Loop ● Logic ● Data Acquisition ● Multifunction Control Function Executions
1 . Fixed “time slots” 2 . Fixed scan times 3 . Easier to configure & re-configure! 4 . Typically has algorithm card . Functions ―reused‖ during scan
1 . Variable “time slots” 2 . Scan time varies w/ density 3 . Can pack in more functions . Algorithms are packaged lines of 4 programs which are used once per scan Programming to Configuration
10110110 • Machine code 00000100 LOOP1 LDAA TEMP 00101100 SUBA #150 blt LOOP1 LDAA #$FF • Assembly language STAA MOTOR
I I I/I ( • Relay ladder logic I I ) • Boolean logicAND, OR, NOR,...
• “High” level [Y=(X1+X2+X3+X4+X5)/5] – Fortran – Cobol – Basic - C++ – Visual Basic
• Algorithms & soft wiring – Menu entry – Fill-in-the-blanks – Graphic blocks – Object oriented technology – IEC 1131-3 standard – Graphical configuration Software Structures & Direction • Fewer large blocks – Many features in each – Easy re-configuration
• Many small blocks – More flexible – Complex to create or change configuration
• Object oriented – Build layers of large blocks from smaller – Flexible but simple Object Oriented Programming saves effort • Mine & process the graphite • Ship to pencil company • Rubber insert • Grow trees, cut trees, trim • Metal tip • Run wood through lathe, trim, mold • Wooden barrel • Ship to pencil company • Graphite core • Mine ore, process metal, • Shape metal • Ship to pencil company • Grow rubber trees. Harvest • Process, shape rubber • Ship to pencil company • Prepare, trim, assemble pencil • Packaging, delivery, retail • Etc. All Capabilities in One Module
Function Blocks Ladder Logic PID I I I/I ( < I I ) PID
Sequential Function Charts
Structured Text FI_134:=FT_130 (PT_450)/(TT_673) • Continuous, discrete, sequential control • Four blended languages (IEC 61131-3) Hardware to Firmware (Function Blocks)
Multiply/Divide Mass Flow PID Ratio
Add/Subtract Square Root PID-GAP Totalize Combining Functions for Capabilities ADAPTIVE TUNING PV OUT RSP PID
Input A Any Gain Input B Function • PID gain can be continuously changed by any other function, such as: – Multiposition Switch – Ramp generator – Function generator Benefits of IEC 61131 Configuration Standard • Allows multiple languages – Pick best tool for job • Uniform programming – Easier to learn – Consistent Documentation • Structured Organization – Greater maintainability – Reusable configuration/program objects • Covers wider range of applications – Wider range of applications – No need to use DCS and PLC combined architectures Standard Languages
• Function block – Mostly continuous execution model – PID, math, continuous control • Ladder logic – Typical PLC logic – Continuous or sequential • Sequential function charts – Sequential control – Parallel sequences, transition logic etc. • Structured text – Pascal like program language • Instruction list – Low level - like assembler or machine code [For PLCs; rarely used in Hybrid Systems] Function Blocks
INPUTS FUNCTION OUTPUTS
ONE OR MORE STRUCTURED ONE OR MORE INTEGERS TEXT EQUIVALENT TYPE-FUNCTION REAL DEPENDENT BOOLEAN TIME LABEL
LABEL VAR VAR LABEL
LABEL VAR
LABEL VAR
EXTENSIBLE FUNCTION BLOCK Function Block Diagrams
PID
TANK_SP SP OUT MIN
TANK_LVL IN1 OUT PV
LVL01*2.7 IN2 A/M
IN3 Implementing Function Blocks
―Softwiring‖ Terminal Connection
Controller Inputs Output Derived Function Blocks (vendor tested)
TARGET Derived Function Nesting TEMP TEMP H FACTOR SP CONTROL
DERIVED
TIME Typical Function Block INPUTS FUNCTION OUTPUTS DIG TEMP • ONE OR MORE STRUCTURED • ONE OR MORE • INTEGERS TEXT EQUIVALENT • TYPE-FUNCTION DEPENDENT RECIRC • REAL (created inside) CONTROL • BOOLEAN • TIME LABEL Structured Text DERIVED VAR_INPUT LABEL VAR TEMP:REAL VAR LABEL K1:REAL LABEL VAR RUN:BOOL A START NO. 1 PUMP CYCLE:TIME LABEL VAR END_VAR EXTENSIBLE VAR_OUTPUT FUNCTION STOP BLOCK HF:REAL END_VAR M Ladder Logic IF RUN THEN HF:= HF+(K1*TEMP*CYCLE) END_IF Custom Function Blocks
• Standard function blocks or existing application libraries do not perform desired functions • Using existing standard languages requires substantial processing time or resources • Using existing structured text language would not protect algorithm intellectual property • Do not want to create stand-alone program Custom Function Block Benefits
• Appear and used same way as standard function blocks • Configured into control strategy same as standard function blocks • Communicate with other control modules using existing standard communication function blocks • HMI or application programs use consistent addressing syntax • Vendor equipment can test and verify configurations containing custom function blocks Potential Custom Function Blocks
• Multi-variable predictive controller algorithms • Adaptive controller algorithms • Sophisticated filter algorithms • Process material- and energy-balance algorithms • Statistical analysis algorithms • Loop behavior analysis algorithms • Specialized motor control logic algorithms • Specialized batch control algorithms • Process simulation algorithms Uniform Function Blocks • IEC61131 originally developed by consortium of European PLC suppliers, – incomplete from a process control standpoint. – Application software within Function Blocks was left up to each automation control supplier. • IEC committee looked at function blocks of the DCS fieldbus standard IEC 61158 to determine enhanced function block standard IEC 61804. • IEC 61804 from DCS world and IEC 61131 from the PLC world will be brought together to for the more universal IEC 61499. – This should meet the needs of both the process industries and the discrete industries, and as a result, the hybrid (batch processing with packaging) industries. – Many of the newer or newer versions of DCSs already follow an IEC 61131 approach. What’s this mean? Ladder Diagrams
• Simulates hard wired relay logic – Power rails on either side – Contacts are inputs to logic – Coils are outputs – Rungs carry power (Boolean data) – Branching and looping are provided by labels
INA INB OUT1 OUT1 = INA AND INE INC OUT2 OUT2 = INC OR IND IND
INE OUT3 OUT3 = NOT INE Sequential Function Charts
Ready • Graphical representation of: Start – Steps in a sequence Fill – Transition logic between steps True – Parallel operation – Relationship between parallel operations Mix Heat – Conditional flow/ looping of sequences Cool
STEP10 STEP1 0 OR A A D Empty STEP20 STEP20 B Skip B Loop Condition 1 STEP21 STEP21 & C Condition 2 OR D C
STEP31 STEP31 Sequential Function Charts (cont’d) . Skip sequence . Loop sequence . Divergence of sequence, one . Step 20 and step 21 will branch has no steps be executed as long as . If transition D becomes true transition C becomes true before A step 20 and step 21 before D will be skipped.
STEP10 STEP10 A A D STEP20 STEP20 B B STEP21 STEP21
C D C
STEP31 STEP31 Sequential Function Charts
• Rules of evolution – Must have an initial step – Must have alternating steps and transitions – Chart can be looped or terminated
CHART01
:=COND1 & COND2 Step STEP1 N ACTION1
Transition :=TRANS2 Step STEP2 N ACTION2
Transition :=COND3 & COND4
Looped Chart Sequential Function Charts
CHART001 Initial Step
Transition :=START Step FILL N FILL_A
:=TRUE Action Simultaneous Divergence HEAT LT#5S HEAT_A AGITATE LT#10S AGITATE_A Simultaneous Convergence :=TRUE COOL N COOL_A A B :=TRUE Loop DUMP N DUMP_A Convergence/Divergence :=TRUE X Y Actions
STEP10 Qualifier Action Body Feedback Variable
A AND LVL_LOW IN01 OUT N FILL_TANK_AC DONE FEED_OPN IN02 T
Can be Function Block ! N FILL_TANK_ACT DONE
INA INB OUT1 ACTION BODY INC OUT2 IND OR INE OUT3
OR Structured Text, etc. Actions In SFC’s and FBD’s Action is executed when step is active in SFC or…
STEP10 N FILL_TANK_ACT DONE
Action is executed when function block output (action input) is true
AND LVL_LOW IN01 OUT N FILL_TANK_ACT DONE FEED_OPN IN02
Function Block ! Structured Text
• PASCAL like
• Assignments := EXAMPLE • Arithmetic & logic VAR – Plus, minus, multi, P, PC, T, TC : REAL ; OR, AND, etc END_VAR • Conditionals (* Convert Pressures to psia *) – IF, ELSE, P := [PRESS] + 14.696 ; ELSEIF, THEN PC := [P_CAL] + 14.696 ; • Multi test case (* Convert Temperatures to Rankine *) – CASE OF, ELSE T := [TEMP] + 459.67 ; • Looping TC := [T_CAL] + 459.67 ; (* Orifice Calculation *) – FOR, WHILE.. DO, [FLOW] := [F_CAL] * ( ([HEAD]/[H_CAL]) REPEAT .. UNTIL * (P/PC) * (TC/T) ) ** 0.5 ; Instruction List
• Low level assembler like instructions • LD Load • ADD • ST Store • SUB • S Set • MUL • R Reset • etc. • AND • JMP Jump to label • OR • CAL Call function block • XOR • RET Return Mixing Languages
• Any or all languages can be used within a single controller • Derived blocks are used to encapsulate each application of a programming language – This also helps to organize the entire program • The various languages communicate or pass information to each other by ―wires‖ or variable or TAG names • Languages can co-exist within each other – E.g.. function blocks in ladder diagrams, structured text in function block diagrams, and any of the languages as an SFC action IEC 61131-3 Summary
• Structured methodology • Hierarchical design • Modern programming concepts refined and standardized • Use the best tool for task at hand • Reduced programming time • Easier to understand and troubleshoot another person’s program regardless of which venders hardware is used • Programs can be portable The Network Monsters Data Highways & Dirt Roads • Digital communications saves installation costs – Less wire, less connections – Less error in wrong connections! – BUT…avoid narrow bridges, toll booths, poor road surfaces & capacities… Network Topologies
Star Tree
Line (Bus)
Mesh Ring Types of Transmission
• Simplex: One direction Sender A Receiver B
• Half duplex: One direction at a time
Sender A Receiver B
Receiver A Sender B
• Full duplex: Both directions at once Sender A Receiver B Receiver A Sender B SDLC Format - Synchronous • Typical transmission example – Impact of “bits per second” on data rate modified by clever use of Information frame & reduction of overhead (all the other frames needed) Here is Here is my where I am message Message sending it (request/reply/etc.) Complete
Beginning Information Frame Ending Flag Address Control Check Flag 01111110 8 bits 8 bits any number 01111110 8 bits of bits 16 bits 8 bits
Listen This is Here is how to for from where confirm accuracy Message I am sending of transmission HDLC Response to “Scan Group” • Typical “scan group” could be all needed parameters of single control loop in one specific controller on network... – Amount of information determines scan group size – Assumes 1byte = 8bits; Assumes 1bit takes 2 µsec. Prefix Gap Flag Addr. Control Source Information CRC Flag
Scan Group
20 bytes
1byte
2 2 bytes
1 1 byte 1 byte 1 byte 1 byte
32 sec. 27 bytes @ 16 sec./byte = 432 sec. 2 sec.
32 + 2 + 432 = 466 sec. = Total message length Complete Transaction on Network • Several factors must be considered in considering transaction time on network: – Request message length – Media access time; Transit time – Turn-around time (find, process reply) – Response message length – Transit time for return – Processing time of originator
Operator Station Controller Controller Response Operator Station Request Message Turn-around Message Processing 200 sec 80 sec 466 sec 320 sec Transit = 15 sec/10,000’ Transit = 15 sec/10,000’ Transaction time = 776 sec ……Time between transactions = 1.096 sec Modulation Types in Modems • Phase modulation 1 0 1 1 0 1 1 0 1 0 1 1 0 1 1 0 Modem 180 phase shift • Amplitude modulation CPU 1 1 1 1 1 0 0 0 Serial I/O 1 0 1 1 0 1 1 0 Modem
Modem • Frequency Shift Keying (FSK) 1 0 1 1 0 1 1 0 1 0 1 1 0 1 1 0 Modem Communication F1 F2 F1F1 F2 F1F1 F2 Network Access Protocols
2.CSMA-CD 3.Token Bus
1.Traffic Director • Three popular methods found on distributed systems • Used to gain access to communication network Response Time of Two Access Protocols
102 CSMA/CD (Ethernet) 10
(log scale) (log 1 Token Passing
-1 Mean Time to Respond to Time Mean 10 0 25% 50% 75% 100% Percent Load Industrial vs. Office Networks Industrial is more distributed architecture
OFFICE PLANT FLOOR ARCHITECTURE
Centralized Racks & Distributed, lower port Switch Closets count Switches & Hubs Office vs. Factory Ethernet Applications
Office Plant Floor • 80% clients (Workstations) • 20% Clients (Operator Stations) 20% Servers (Printers & 80% Servers (Controllers, PLCs, Computers) Drives, I/O, Robots, etc) • Operates during normal business • Operates continuously (24X7). hours 9 to 5 • Often mobile and move in wide • Systems usually fixed in one area or are frequently location. reconfigured. • Network downtime is only • Network downtime unacceptable; nuisance; problems may take a rapid restoration solutions day to solve. required. • Network Equipment is housed in • Network equipment installed easy to access and defined areas. near electrical equipment in • Local workers not encouraged to distributed enclosures. solve networking problems. • Local workers responsible for solving networking issues (fieldbus problems). “Traditional” Ethernet 10Base-2
• Historical network • All stations hear all others • Only one conversation at a time • Collisions can occur (CSMA/CD) • Bus or Star topology • 10 Base-T & 100 Base-T
HUB Network Architectures • Routers – provide both network isolation and Firewall protection from both external and internal interference.
• Hubs – inexpensive; physically links all devices to common line; used where single device is polling information.
• Switches – provide much greater performance as individual connections are established between devices.
• Managed Switches – switch maintains knowledge of connected device IP address. Switched Base-T Ethernet
• Allows multiple simultaneous communications (increased bandwidth) • Can connect 10Mbps to 100Mbps (speed buffering) • Allows larger network
SMART HUB
Smart hub “knows” network layout so it can route messages to proper port Large Ethernet Network
• Full duplex communications between switched hubs • Multiple simultaneous conversations w/o interference • Little chance for collisions to delay signals
SMART HUB SMART HUB
Smart hubs in networks allow any two stations to talk without interference Fault Tolerant Mesh Control Network
• Fault tolerant, ―self healing‖ network can recover from multiple faults • Higher data throughput for large plant-wide real-time application needs •High speed (100Mb/1Gb) •Data routing for more efficient data throughput • Longer distances supported, for large plant-wide networks • Variety of topologies – ring, star, tree.; fiber is standard Redundant Mesh WS1 Ethernet CP1 Network WS2 CP2 Control Processors Work Stations Devices (work stations, control processors, etc.) will each connect to two switches.
COTS = Commercial, Off-The-Shelf lowers costs 16-Port Managed Ethernet Switch Mesh Network Fault Tolerance
Bus Traditional bus architecture tolerates failure on WS WS WS either A or B network A A B B CP CP CP CP Mesh network provides multiple-fault tolerance by managing alternate communication paths between devices. Each switch has connections to two different switches in layer above. Rapid Spanning Tree (RSP) Root switches
1st layer WS WS
2nd layer
3rd layer
CP CP CP RSP tree topology in switches automatically manages connection paths to avoid unnecessary data flow. Mesh Network Fault Tolerance Mesh network provides multiple-fault tolerance by managing alternate communication paths between devices. SELF DIRECTING with NO PROGRAMMING!
Rapid Spanning Tree (RSP) Root switches A 01 B 01
1st layer A 11 B 11 WS1 X WS2 X 2nd layer A 21 B 21 A 22 X B 22 X 3rd layer A31 B 31 A 32 B32 X CP1 CP2 CP3 Compatible vs Compliant - MAP
• MAP compatible: – Each brand shares token, BUT can talk only to same brand; cost is $X over non-compatible…for ( m )
A A A B B B C C C m m m m m m m m m
MAP compliant: Each brand shares token AND talks to any other; cost is $10X over non-compliant…for ( M )
A A A B B B C C C M M M M M M M M M Node A OSI Reference Model by ISO Node B Function User program User program Layer 7 Provides all services to the Application program Layer 7 Application (e.g. Windows) Application Layer 6 Restructures data to/from standardized form Layer 6 Presentation Presentation Layer 5 Provides user-to-user connections Layer 5 Session (e.g. Winsockets, NetBios, NetX) Session Layer 4 Provides transparent data transfer-Node to Node Layer 4 Transport (e.g. TCP/UDP, NetBeui, IPX/SPX) Transport Layer 3 Provides routing of data through the network Layer 3 Network (e.g. IP) Network Layer 2 Provides link access control and reliability Layer 2 Data Link (e.g. token pass, CSMA/CD, etc.) Data Link Layer 1 Provides an interface to the physical medium Layer 1 Physical (e.g. connectors, cable type, impedance) Physical Physical transmission medium ( e.g. coaxial, twinaxial cable) OSI Analogy: Mailing Letter
OSI Layer Postal System Equivalent 7-Application Letter contents within envelope
6-Presentation Format & language of letter, including proper translation into another language, if needed 5-Session Name, address, zip code of both sender & receiver
4-Transport Certified or registered mail; verification to sender that letter arrived at correct destination 3-Network Distribution transfer to outside local system to another city or country 2-Data Link Distribution within same local system, or within local system in that other city or country 1-Physical Conveyance: postman, truck, train, plane….. Node A OSI Reference Model Node B
User program User data User program Layer 7 Layer 7 Application User data Application Layer 6 Layer 6 Presentation User data Presentation Layer 5 Layer 5
Session User data Session Headers... Layer 4 Layer 4
Transport User data Footers …& Transport Each Layer Adds More More Adds Layer Each Layer 3 Layer 3 Network User data Network Layer 2 Layer 2 Data Link User data Data Link Layer 1 Layer 1 Physical User data Physical Physical transmission medium ( e.g. coaxial, twinaxial cable) LAN Interconnection Devices
Layer 7 Gateway - Protocol conversion device to interconnect Application networks or devices which uses different communications protocols. Gateways function at all seven layers. Can be Layer 6 used to connect DECnet device to TCP/IP device. Presentation Layer 5 Session Layer 4 Transport Router - Connects to several networks and forwards data Layer 3 packets using the Network Level addresses. Can connect Network two LANs of different topologies but same protocol. Layer 2 Bridge - Interconnects LANs, but only forwards data destined Data Link for device on other side of bridge. Can only connect two similar LANs. (such as Ethernet) Layer 1 Repeater - Connects two or more LANs of same technology Physical or extends distance of a LAN. TCP/IP • Transmission control protocol/internet protocol • Developed by U.S. Department of Defense in 1974 • De facto standard network protocol to connect UNIX systems • IP : Network layer (layer 3) - routes data over network to correct LAN address • TCP : Transport layer (layer 4) - segments data into packets and verifies that message got to its destination intact • TCP/IP does not extend to physical and data link layers, hardware interface is beyond its scope. Since TCP/IP is media independent it has been implemented on variety of media. • UDP : User datagram protocol - alternative to TCP • UDP does not require acknowledgments of messages, less overhead, higher performance relative to TCP/IP What are differences between Ethernet, TCP/IP and address IP?
• Ethernet is the road to drive on.
• TCP/IP are the cars on the road.
• And the IP Address is used as the street address to which the car drives. Will the REAL Ethernet Please Stand Up! Industrial Ethernet – Has no standard definition; typically means Ethernet protocols independently developed for manufacturing data collection & control, such as:
• EtherCAT – Ethernet Control Automation Technology; primarily for motion control functions; can interoperate with normal TCP/IP-based networks like EtherNetI/P or PROFInet. • EtherNet/IP – ControlNet/DeviceNet objects on TCP/IP. • High-speed Ethernet (HSE) – FOUNDATION Fieldbus (FF) using standard Ethernet cabling; once called FF H2. Modbus/TCP – • Modicon Communication Bus packet within a TCP/IP packet; defacto standard for Ethernet on the plant floor. • PROFInet – PROFIBUS with Ethernet. Application Interface Options DDE vs API DDE (Dynamic Data Exchange) • Simple configuration • Simple interface • Low performance • Wide selection of servers available
Ethernet
API (Application Program Interface) • Programming • Full integration • High performance • Windows, WindowsNT, QNX, • OSF/1, HP/UX, VAX/VMS, • Alpha/VMS DDE - Dynamic Data Exchange • DDE: – Standard communication protocol – Allows several programs to share data Personal Computer Lotus 1-2-3 – Simple connection between applications Excel – Does not understand the data DDE • DDE server: HMI software – Allows other programs to access data DDE Server from controllers – Compatible with any "DDE-aware" programs such as Lotus 1-2-3, Microsoft Excel, and HMI software Controller(s)
DDE client: Can request data, send data, and send messages to controllers through DDE Server Controller - NetDDE Options Operator Station Manager 1 Manager 2 Excel DDE Server Excel NetDDE NetDDE
Ethernet
• NetDDE is extension of DDE • Using NetDDE, Windows applications in separate computers on network can share data via DDE as if they were in same computer • Communication between nodes is transparent to the user OPC for HMI Communication Why is OPC Needed?
Display Trend Report Application Application Application
Software Software Software Software Driver Driver Driver Driver How does OPC Solve the Problem?
Display Trend Report Application Application Application OPC OPC OPC
OPC OPC OPC OPC Software Software Software Software Driver Driver Driver Driver Typical Communication Models • Client/Server— Clients each independently request/receive data from Server
Server
Receives whatever data asked
• Publisher/Subscriber— Subscribers each independently receive updates as they occur
Publisher
Only selected stations receive assigned data The Fieldbus Monster Conventional vs Fieldbus Signals Digital instrumentation technology with analog communications technology?... or... digital communications technology!
Controller
Fieldbus Digital-to-Analog Analog-to-Digital Signal Conversion Signal Conversion 4-20 mA Microprocessor- Microprocessor- Based Based Transmitter or Instrument Fieldbus How Fieldbus Works
Subset of the ISO’s OSI Reference Model:
Device 1 Device 2
User User
7 Appl’n. Appl’n. 7
2 Data Link Data Link 2 1 Physical Physical 1 Field Based Control Example
Controller Cascaded ! Controller FOUNDATION Fieldbus itself can be controller
Fieldbus Open Network Flexibility ControlPC network Linkingas HMI device (Control Network) User Choice; Sensors Analyzer Valves Motors Multivariable Configures control Controller database and: Screen Views • Smart Transmitters, Sensors, End Elements: Trends • • Multivendor within same system History • • Common Function Blocks etc. • • configuration • documentation • tag names & HMI ―calls‖ • peer-to-peer links for complex strategies Process automation protocols • FOUNDATION Fieldbus • FINS - Omron's protocol for communication over • Profibus - by PROFIBUS International. several networks, including ethernet. • PROFINET IO • Host Link - Omron's protocol for communication • CIP (Common Industrial Protocol) - Can be over serial links. treated as application layer common to • Interbus - Phoenix Contact's protocol for DeviceNet, CompoNet, ControlNet and communication over serial links, now part of EtherNet/IP PROFINET IO • Controller Area Network utlised in many • Mechatrolink - open protocol originally developed network implementations, including CANopen by Yaskawa. and DeviceNet • MelsecNet/10 - supported by Mitsubishi Electric. • ControlNet - an implementation of CIP, • Modbus RTU or ASCII originally by Allen-Bradley • Modbus-NET - Modbus for Networks • DeviceNet - an implementation of CIP, • Modbus/TCP originally by Allen-Bradley • Modbus Plus • DirectNet (CCM protocol) - supported by • Optomux - Serial (RS-422/485) network protocol Automationdirect \ originally developed by Opto 22 in 1982. The • EtherNet/IP - IP stands for "Industrial Protocol". protocol was openly documented and over time An implementation of CIP, originally created by used for industrial automation applications. Rockwell Automation • SERCOS interface - Open Protocol for hard real- • EtherCAT time control of motion and I/O • EGD (Ethernet Global Data) - GE Fanuc PLCs • GE SRTP - GE Fanuc PLCs (see also SRTP) • Sinec H1 - Siemens • PoE, PoE+ - Power over Ethernet • SynqNet - Danaher. • HART Protocol • BSAP - Bristol Standard Asynchronous Protocol, • PieP - An Open Fieldbus Protocol. developed by Bristol Babcock Inc. Which path to take? Don’t want conflicting interests! Process Control User Layer Foundation Fieldbus has Process Control USER LAYER!
PA PROFIBUS
DeviceNet Function Blocks FIP “Mode” “Status” Device Alarm SDSnet Description Support LONworks Language Trend Support etc. FF Fieldbus PHS D-L Appl. User. Layer Layer Layer Layer Fieldbus Hierarchy HIGH
(BIT)
(BYTE) Network Speed Network
(BLOCK) LOW HIGH Cost – Function – Data – Complexity
Figure A.18 Example of field bus trade-offs Digital Networks for Control Systems
X
X HSE
Source: Control Engineering Magazine Past, Present, Future Use of Fieldbuses, Network Methods Ethernet
4-20 mA
DeviceNet
CONTROL magazine survey 132 respondents who buy, HART recommend or specify PROFIBUS-DP industrial networks
FF – H1 PROFIBUS-PA FDT/DTM Used in 2003 Installed 2005 Plan for 2006 Fieldbus AND Ethernet market shares– 2009
(Process & Discrete) Exclusively Process Industrial network development– 2009
Technology Development Growth
1975 1985 1995 2008 Fieldbus - User Group Focus
Europe Petro & Chemistry Pulp & Paper India Food & Beverage Japan SEA
Canada USA India Brasil Food & Beverage SEA Chemistry Water / Waste Argentina RSA Fieldbus - meets the Customer needs
DCS System ***** **** PLC * ***** Solids * *** Waste- / Water ** **** Food & Beverage *** ***** Industry Chemistry i.s. ** ***** Chemistry non i.s. *** *** Petrochemical ***** **** Power ** **** Availabilty ** ***** Reliability **** ***** Costs ** **** Technical features ***** **** (*****) = best suitable Fieldbuses in Process Industry
• Large installed base – >2/3 of all “smart” instruments shipping are HART capable – >20 million HART-enabled devices installed world-wide – >700,000 FF compliant devices; 10,000 systems – >700,000 PROFIBUS PA compliant devices • Mega-systems (>10K devices) becoming common • Companies standardizing on fieldbus for control – Higher availability, lower variability, reduced commissioning time – Mandated for new projects – Several use “control-on-the-wire” Which Fieldbus to use?
• Each have different strengths, limitations – Host system support! – Area classification – Distance limitations – Equipment cost – Signal mix – “analog” (numerical) vs. discrete – Facility history/legacy – Process needs & speed of response – Availability of devices capable of desired measurements • Best choice is often combination of buses – Different processes in different parts of operation – Different end uses = motor controls vs. process controls – Trade-off: system more complex with more buses Bottom Line Thoughts from Large User • Biggest potential return for fieldbus lies in – Reduction of process upsets – Maintenance costs through effective use of device data
• FDT is great enabler to obtain these functions! However… My Plant
• Runs continuously
• With many different field devices
• On several different networks
• With more than one control system… when a problem occurs
• No matter who responds
• No matter where their mind is at the time
• No matter how much their experience with THIS problem …or THIS equipment
• No matter how rarely it happens… my people QUICKLY need to
• Always see information the same way
• Know what is wrong
• Know how to act
• Be consistent …WHOEVER responds …WHENEVER they respond… with a SINGLE tool
• That works with any field equipment
• From any supplier
• That reduces device commissioning time
• Supplies meaningful Asset Management information
• On ALL my EXISTING systems EDDL • EDDL - Electronic Device Description Language – Descriptive characteristics of a device • In compressed binary format; cyber safe • Not executable code to not impact stability of operating system – Graphical elements for device maintenance and configuration • Specified by the Instrument Protocol foundations – Foundation Fieldbus – HART Communication Foundation – PNO - PROFIBUS • Required for instrument certification by the respective foundations • Foundations working to establish a common EDDL standard – ECT – “EDDL Cooperation Team” – IEC standard EDDL – Data Description
• The EDDL provides a texted description – Device #define LINEAR 0 – Block VARIABLE trans1_temperature_unit { – Parameters LABEL[digital_units]; HELP [temperature_unit_help]; CLASS CONTAINED; HANDLING READ & WRITE; TYPE ENUMERATED (2) { DEFAULT_VALUE 32; { 32, [degC], [degC_help] }, { 33, [degF], [degF_help] }, { 34, [degR], [degR_help] }, { 35, [Kelvin], [Kelvin_help] } IF (trans1_sensor_type == LINEAR) { { 36, [mV], [mV_help] }, { 37, [Ohm], [Ohm] }, { 39, [mA], [mA_help] }, } } } Another Solution…
FDT is an “open” standard for device integration that: – Is viewed on any windows workstation – Provides consistent graphic presentations – Is supplier, system, & protocol independent FDT based tools • Support Consistent workstation views FDT based tools • Compatible with existing & future automation equipment • Upgrade all your existing networks • Manage multiple generations of devices over life of plant • Graphical support for start up and commissioning • Intuitive HELP functions for troubleshooting • Monitor efficiency during operations • Same look & feel on every system • Best advanced diagnostics …specific know-how …from each device supplier …who can easily upgrade you with new information FDT connects with 12 different protocols
AS-interface INTERBUS ContolNet IO Link DeviceNet MODBUS SL/TCP EtherNet/IP PROFIBUS DP/PA FOUNDATION Fieldbus PROFINET I/O High Speed Ethernet HART CIP Annex configuration Endorsed by 66 users & suppliers and growing!
® VALIDATED user results show • 40% reduction in commissioning time Note! Commissioning is usually the CRITICAL path of the project! (Dow 9/07)
• 80% reduction for last minute engineering modifications (Dow 9/07)
• Much faster resolution of typical instrument problems during startup (example false echo’s with radar level meters)
• 60-70% reduction in scheduled plant downtime (Clariant GmbH 9/06) Feedback from commissioning team:
“Instrument Technicians LOVE this tool!”
145 Standards are essential for “Open”
Regional HMI Standards Windows CENELEC ANSI/NEMA OLE/ActiveX JIS/CNS COM COPANT Simulation DIPPR Internet Control PDXI OLE/ActiveX S88 STEP JAVA IEC61131 CAPE-Open Browsers SP50
Platform Relational Distributed Networks Databases Applications Ethernet UNIX ODBC DCOM SP50 Windows SQL OPC Fieldbus IEC61131 Configuration Standard
Function Blocks Ladder Logic
PID I I I/I ( ) < I I PID
Sequential Function Charts
Structured Text FI_134:=FT_130 (PT_450)/(TT_673)
• Continuous, discrete, sequential, batch control • Multiple languages in same controller Benefits of IEC 1131 Configuration Standard • Allows multiple languages – Pick best tool for job • Uniform programming – Easier to learn – Consistent Documentation • Structured Organization – Greater maintainability – Reusable configuration/program objects • Covers wider range of applications – Wider range of applications – No need to use DCS and PLC combined architectures Standard Languages • Function block – Mostly continuous execution model – PID, math, continuous control • Ladder logic – Typical PLC logic – Continuous or sequential • Sequential function charts – Sequential control – Parallel sequences, transition logic etc. • Structured text – Pascal like program language • Instruction list – Low level - like assembler or machine code [For PLCs; rarely used in Hybrid Systems] OPCUA Unification • OPC Unified Architecture provides a common view of the field instruments up to the enterprise level – Product data e.g. identification, I/O description, certifications – Diagnostic data e.g. device status information, events and alarms – Process data e.g. measurement data, set point Parameters, unit upper/lower limits – Maintenance data e.g. classification, description, spare parts, tools for maintenance • Uses EDDL or FDT information OPCUA FDI Unification
• FDI – Field Device Integration – ECT members participate [ECT = EDDL Cooperation Team] – FDT members participate [FDT = Field Device Tool] – OPCUA members participate • Define a common infrastructure – Device semantics – Device applications for maintenance and diagnostics • Retain full functionality of existing EDD applications • Retain full functionality of existing FDT applications • OPCUA becomes the communication infrastructure – One object model for device information – Use of OPCUA for maintenance and diagnostic applications OPC UA Early Adopter Companies • ABB • Metso Automation • Absynt Technologies Ltd • Microsoft • ascolab GmbH • OPC-F • Beckhoff • OSIsoft, Inc. • CAS • Prosys PMS Ltd • Rockwell • Cognex • SAP • Cyberlogic • Siemens • Helsinki University of Technology • SISCO • Honeywell • SMAR • Iconics • Softing AG • InduSoft LLC • Software Toolbox • Ing.-Buero Allmendinger • SRI International • Invensys/Foxboro • Tampere University of Technology • Invensys/Wonderware • Technosoftware AG • Kepware • VTT • Wapice Ltd • Matrikon • Yokogawa Electric Asia Batch vs Continuous
BATCH CONTINUOUS Control Recipe Driven Set point Driven Product Grade Changes Frequent Occasional Operations Transient State Usually Steady State Product Volume Smaller Larger Production Life Cycle Shorter Longer Process Equipment Shared Dedicated Product Chemistry Not clearly known More clearly known Operator involvement High High when abnormal Analog control loops Few Many Interlocks Large number Smaller number Sequential Control Complex Simpler Tracking & scheduling Complex Simpler Operations Management Complex Simpler Typical Batch Processes
M M M M
M M
M
Liquids Powders M
M
zone 3 zone 2 zone 1
Solids Types of Batch Processes
Single-Product Multi-Product Single-Stream Single-Stream
One Product Several Products
Single-Product Multi-Product Multi-Stream Multi-Stream
One Product Several Products Parts of a Batch Operation
Make a batch of QR6 Execution The Schedule The Report
The Equipment
QR6 The Recipe The Batch Domain of Control Systems
MANAGEMENT Computer INFORMATION SYSTEMS PERSONAL COMPUTERS Control Room
Communications DCS
PLC STAND-ALONE Local Operators CONTROLLERS PAC PERSONAL COMPUTERS
Control ANALYZERS
Input/Output SENSORS
<< FIELDBUS INFLUENCE >> INFLUENCE FIELDBUS << << ADVANCED CONTROL TECHNOLOGY INFLUENCE >> INFLUENCE TECHNOLOGY CONTROL ADVANCED << Continuous Batch Discrete Control System Market Dynamics
Only that done also in Workstations MIS PAC PLC
DCS Process PC only
Growth from new markets due to SLC improved capacity power, etc. Competitive Landscape
DISCRETE PAC CONTINUOUS
THE BATTLEFIELD DCS Land PLC Land Honeywell ABB PLC/DCS ABB GE Siemens PCS7 Invensys/Foxboro Siemens S7 Foxboro Micro I/A Emerson Rockwell Honeywell Experion . Yokogawa ABB AC800 F SchneiderStandalone Emerson DeltaV Mitsubishi HMI Omron USDATA Rockwell Pant PAx Intellution Yokogawa Centum1000 Wonderware GE IP Citect Decade of Controls Industry Changes 1990 1995 2000 2010 Honeywell Emerson (Intellution) Emerson ABB Honeywell ABB Emerson ABB Invensys (Wonderware) Fisher Controls Siebe Honeywell General Signal (L&N) Elsag Bailey Siemens Bailey Rockwell Rockwell Foxboro Westinghouse Neles Automation GE Fanuc Johnson Yokogawa Schneider Automation Fisher & Porter General Signal (L&N) Moore AEG Measurex Yokogawa Westinghouse Moore GE Fanuc (Intellution) Measurex Siemens Siemens GE Fanuc Johnson Yokogawa Wonderware [Order of US Mkt Shares] Moore AEG Schneider Applied Automation… …via H&B Challenges For Controls Suppliers
• Transition from Hardware to Software & Solutions • Development and Management of Open Architecture systems • Managing Customized Solutions to Customers • Build Global Sales & Service Infrastructure • Maintain Margins Selling Software & Solutions • Keep Pace with New Technologies Still Room to Grow
“What the hybrid industries such as pharmaceuticals… really LACK today… is effective enterprise optimization… because of the WALL that still exists… between the traditional processing realm of batch systems… and the traditional discrete realm… of PLC-based packaging systems.” ARC Research Director Larry O’Brien Industry Trends (ARC Advisory Group) • Market – Investment Shift to Asia-Pacific & Latin America – Deregulation & Privatization – Supplier-User Alliances & “Automation Outsourcing” – “BOOT” Agreements (Build, Own, Operate, & Transfer) • Technology – Standardization >> COTS (Commercial-Off-The-Shelf) Components – Dematerialization >> Less Hardware vs. More Software – Migration of Control to Field >> Smart Field Devices – Intersites / Plant Connection >> Internet / Intranet – e-Business / e-Commerce • Prices
– Continued Erosion >> …Sam -40% in past 15 years; expect –10% in next 5 years There are Never Simple Answers!! If there were... • all of this stuff would be sold mail order, and... • talks like this would be unnecessary!!
…Sam • The confusion over PAC Monster……….
• The Acronym Monster…..
• The Configuration Monster………………
• The Network Monster….
• The Fieldbus Monster……………………….