Keeping up with Industry 4.0. By Frederik Langenhoven

Transcription

1 Keeping up with Industry 4.0 By Frederik Langenhoven SAFA Symposium Emperors Palace, Kempton Park 24 May 2018

2 Agenda 1. Introduction 2. Process control architectures NAMUR Open Architecture (NOA) Open Process Automation (OPA) 3. How to make existing plants Industry 4.0 capable 4. The need for speed - Advanced Physical Layer (APL) 5. Conclusion SAFA Symposium Emperors Palace, Kempton Park 24 May 2018

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4 Introduction Internet of Things (IoT) is a term coming from IT technology It means that Each Thing has its own Internet address (URL) It is accessible via the Internet It can communicate with other Things via the Internet SAFA Symposium Emperors Palace, Kempton Park 24 May 2018

5 Introduction IoT vs IIoT Industry 4.0 IoT (Internet of Things) is based on concepts which are consumer oriented Entertainment electronics, Computers, Cars IIoT (Industrial Internet of Things) is based on concepts which are industry oriented Level measuring instruments in a process plant IIoT is a term coming from the US; the same is called in Europe Industrie 4.0 (German) or Industry 4.0 SAFA Symposium Emperors Palace, Kempton Park 24 May 2018

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7 Process control architectures NAMUR Open Architecture (NOA) European approach Open Process Automation (OPA) American approach SAFA Symposium Emperors Palace, Kempton Park 24 May 2018

8 NAMUR Open Architecture (NOA) SAFA Symposium Emperors Palace, Kempton Park 24 May 2018

9 NAMUR Open Architecture (NOA) Based on the current automation structure there will be An open Industry 4.0 interface from inside to outside A secure Industry 4.0 interface from outside to inside open secure ERP MES Automation level Field level SAFA Symposium Emperors Palace, Kempton Park 24 May 2018

10 NAMUR Open Architecture (NOA) The basic idea is that the Core Process Control remains as it is Data will be exported into the system world Monitoring + Optimization SAFA Symposium Emperors Palace, Kempton Park 24 May 2018

11 Open Process Automation (OPA) SAFA Symposium Emperors Palace, Kempton Park 24 May 2018

12 Open Process Automation (OPA) Initiator of this approach is ExxonMobile Currently further members are Shell, Total, BASF (USA), Aramco Services Company, Complete new idea which contains the following components: DCS, PLC Human Machine Interface Advanced Process Control Scope of OPA SAFA Symposium Emperors Palace, Kempton Park 24 May 2018

13 How to migrate existing plants to Industry 4.0 SAFA Symposium Emperors Palace, Kempton Park 24 May 2018

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15 Field Instrumentation Today Ethernet Operator Very often propriety Engineering Industrial Ethernet Plant Asset Management Control Room PROFIBUS DP, Modbus RTU, Ethernet PROFIBUS DP ma (HART?) ma (HART?) PROFIBUS PA Foundation Fieldbus Frederik Langenhoven 15

16 Industry 4.0 with conventional Barriers? Operator Station Mainten. Station Ethernet ETH RS ma 4 20 ma / HART Frederik Langenhoven 16

17 Industry 4.0 with conventional Barriers? In acc. With NOA with unaffected core automatization Operator Station M+O Ethernet ETH RS ma 4 20 ma / HART Frederik Langenhoven 17

18 Industry 4.0 using WirelessHART Operator Station Mainten. Station Ethernet 4 20 ma 4 20 ma / HART Frederik Langenhoven 18

19 Industry 4.0 using WirelessHART Parallel Architecture PLS System HCP Ethernet 4 20 ma Frederik Langenhoven 19

20 Application example HCP SAP Asset Intelligence Network Firewall Field device Dashboard 1 Asset Managm. Type- and Real time data of all instruments SAP HANA HCP IoT- Services Firewall SAP HANA Field devices with WirelessHART Bullet Field device vendor 2 Field device vendor 1 DCS system 4 20 ma Product data base Information about the instrument (Documents, instruction manuals, calibration data, certificates, models, Frederik Langenhoven 20

21 PROFIBUS DP Industry 4.0 with Remote I/O? A PROFIBUS DP Master class 2 is required which is supporting the HART on PROFIBUS protocol. This protocol must be supported by the bus coupler as well! ma (HART) Class 2 Master ETH HART on PROFIBUS Frederik Langenhoven 21

22 PROFIBUS DP Industry 4.0 and Fieldbus The required data are available within all fieldbus devices (FF and PA). With PROFIBUS the structure is the same as with Remote I/O Systems If a higher amount of data shall be transmitted the supported band width / transmission rate of FF or PROFIBUS PA is too small/low. e.g. Envelope curve of a microwave sensor Such data will be transmitted within the acyclic channel. Class 2 Master ETH Frederik Langenhoven 22

23 ERP The need for speed Advanced Physical Layer (APL) Field level Frederik Langenhoven 23

24 Requirements of NAMUR An Ethernet communication system for process automation shall: Enable the Integration of DCS technology and field devices Shall support 2-wire as well as 4-wire instruments Be usable in hazardous and non-hazardous areas Simple and robust connection technology High requirements regarding safety and availability NAMUR position paper Frederik Langenhoven 24

25 Ethernet for Process Automation The Initiative was started with the target to provide an Ethernet based communication platform for application in the Process industry 10 Mbit/s transmission rate (will be extended to 100 Mbit/s later) Usage of 2-wire cable type A (same cable as fieldbus) Full duplex transmission Same topology as fieldbus Possibility of intrinsic safe spurs (High Power Trunk Concept; FISCO comparable) 30 V / 500 ma of power provided to the trunk Frederik Langenhoven 25

26 Ethernet in the Field Principle Topology Switch Ethernet Power Supply Trunk Ex-e 2 wire with power supply 1000 m Field Switch Field Switch Zone 1 Spur: Ex-i 2 wire with power supply 200 m Zone 0 Field device Field device Field device Field device Frederik Langenhoven 26

27 General Specification Transparent for all Ethernet protocols including PROFINET and EthernetIP Switch based architecture Support of standard fieldbus cable (cable type A acc. to IEC ) Support of all common grounding concepts of fieldbus shield Connection via terminals or plugs (e.g. M8, M12) Phase 1: 10MBit/s Phase 2: 100MBit/s Auto-Negotiation for transmission rate and Power-Profile Development of conformance test tools Frederik Langenhoven 27

28 APL Fieldbus practical Example Switch APL PactWare FDI-i-DTM, CodeWrights 1000 m WLAN Router TabEx Web-Browser VEGAPULS Level E+H Micropilot Level Zone 0 APL APL E+H Cerabar Pressure Zone 1 P+F Temperature Input Fieldbus Up to 200 m Fieldbus Zone 2 Field-Switch Zone 1 Frederik Langenhoven 28

29 APL, organizational Structure Members as of 08/2017 PROFIBUS International (PI, PNO) has taken over the patronage for APL. The target is to standardize the transmission technology and to define the necessary specifications, standards and tests to enable the application within an interoperable environment. Frederik Langenhoven 29

30 Conclusion Sensors + Machines Connectivity Data Management Added Values Services Data Connectivity Visualisation Vendor Customer Connectivity User Frederik Langenhoven 30

31 Are you keeping up with Industry 4.0? Frederik Langenhoven 31

32 Are you keeping up with Industry 4.0? Frederik Langenhoven 32

33 Thank you for your attention By Frederik Langenhoven SAFA Symposium Emperors Palace, Kempton Park 24 May 2018