future directions of instrumentation & control. presented by…. steve mackay of idc...

FUTURE DIRECTIONSFUTURE DIRECTIONSOFOF

INSTRUMENTATION & INSTRUMENTATION & CONTROLCONTROL

Presented by….

Steve Mackay of

IDC Technologieswith Warren Mitchell

assisting….Copyright acknowledgement to IDC Technologies and to ARC Advisory Group on material presented taken from Plant Automation Support Survey (June’02).

A few thoughts on...

The Future of I & CYour future in this industryTraining trends

The Future of The Future of Instrumentation Instrumentation

and Controland Control

Fairly Predictable Ethernet (and TCP/IP) & Fieldbus Safety Instrumentation Industrial IT (incl.

Security)/Supply Chain/E-Commerce & E-manufacturing)

ETHERNET, TCP/IP & FIELDBUS

UTP 10Base T System

100-MBit Ethernet

Defined in IEEE802.3u standard

Uses CSMA/CD media access Ethernet frame format High speed interface on:

100Base-TX for Cat 5 wiring100Base-FX for Fibre Optic

Switch Types

Server

Segment Switch

Server

Private LAN Switch

TCP/IP & InterNetworking

NetworkIBM Compatible

IBM Compatible

IBM CompatibleIBM Compatible

IBM Compatible

Laser printer

Network Backbone

IBM Compatible

Apple LaserWriter

Mac Classic

Mac Classic

UNIX Server

London - England

Sydney - Australia

INTERNET CONNECTION

Internetworking with TCP/IP Networks generally do not exist in

isolation, and need to be interconnected

An increasingly popular suite of protocols to handle this is TCP/IPTCP - Transmission Control

Protocol….a reliable transport service

IP - Internet Protocol….a delivery service

Fieldbus and DeviceNetworks

CNCPC/VME

VME/PC

PLC DCS

AreaController

Ethernet/TCP/IP TCP/IP/Ethernet

PROFIBUS-FMS

PROFIBUS-DP PROFIBUS-PA

Factory level

Bus CycleTime

< 1000 ms

Cell Level

Bus CycleTime

< 100 ms

Field Level

Bus Cycle-Time

< 10 ms

FOUNDATION FIELDBUS

SCADABRIDGE

H1

ANALYZER

PLCH1… Lower Speed Fieldbus• 31.25 Kbps• Replaces 4 to 20 mA• 2 - 32 Devices• Power & Communications• Intrinsically Safe• Twisted-pair• 1900 m length

PLC

SERVER GATEWAY

ETHERNET

H2

HSE… High Speed E t h e r n e t• 100 MBps• TCP/IP and standard Ethernet

SAFETY INSTRUMENTATION

Changes after Commissioning

21%

Operation & Maintenance

15%Installation &

Commisioning6%

Design & Implementation

15%

Specification44.1 %

Changes after Commissioning

21%

Operation & Maintenance

15%Installation &

Commisioning6%

Design & Implementation

15%

Specification44.1 %

Based on 34 investigated incidents in the UK : “Out of Control”, HSE

Accidents Caused by Control and Safety System Failures

SUPPLY CHAIN, E-COMMERCE AND E-MANUFACTURING

Industrial IT, Supply Chain, E-Commerce, E-manufacturing

Computers exchanging commercial information

Suppliers tied closely to your site Customers tied closely to your site Manufacturing/Process Control (eg

via SCADA) tied to business systems

And not so Predictable Trends…..

People required (ie YOU !)

see next section….

Your Future in Your Future in this Industrythis Industry

GrowStay SameShrinkDon't Use

Which of these disciplines that currently perform AUTOMATION SUPPORT in your plant are likely to GROW, SHRINK or STAY THE SAME size in the next 5 YEARS? - Control Engineers

302520151050

Grow

Stay Same

Shrink

Don't Use

48.1 %

34.6 %

11.5 %

5.8 %

Will ‘Control Engineers’ Shrink or Grow in Support Role in 5

Years?

GrowStay SameShrinkDon't Use

Which of these disciplines that currently perform AUTOMATION SUPPORT in your plant are likely to GROW, SHRINK or STAY THE SAME size in the next 5 YEARS? - Technicians

302520151050

Grow

Stay Same

Shrink

Don't Use

32.7 %

46.2 %

17.3 %

3.8 %

Will ‘Technician’ Shrink or Grow in Support Role in 5

Years?

GrowStay SameShrinkDon't Use

Which of these disciplines that currently perform AUTOMATION SUPPORT in your plant are likely to GROW, SHRINK or STAY THE SAME size in the next 5 YEARS? - IT

302520151050

Grow

Stay Same

Shrink

Don't Use

51.0 %

31.4 %

9.8 %

7.8 %

Will ‘IT (personnel)’ Shrink or Grow in Support Role in 5

Years?

GrowStay SameShrink

Which of these groups or functions are likely to GROW, SHRINK or STAY THE SAME size in the next 5 YEARS? - Specialists

35302520151050

Grow

Stay Same

Shrink

58.0 %

32.0 %

10.0 %

Are ‘Specialists’ Likely To Grow In 5 years?

GrowStay SameShrink

Which of these groups or functions are likely to GROW, SHRINK or STAY THE SAME size in the next 5 YEARS? - Outsourced Automation

403020100

Grow

Stay Same

Shrink

75.0 %

19.2 %

5.8 %

Is ‘Outsourced Automation’ Likely To Grow In 5 years?

NeverIncreaseStay SameDecrease

Which of these Plant OPERATIONAL FUNCTIONS in your plant w ill be likely to INCREASE, DECREASE or STAY THE SAME with regard to being OUTSOURCED in the next 5 YEARS? - Instrument Maintenance

2520151050

Never

Increase

Stay Same

Decrease

3.8 %

36.5 %

42.3 %

17.3 %

Will Instrument Maintenance ‘Outsourcing’

Change in 5 Years?

NeverIncreaseStay SameDecrease

Which of these Plant OPERATIONAL FUNCTIONS in your plant w ill be likely to INCREASE, DECREASE or STAY THE SAME with regard to being OUTSOURCED in the next 5 YEARS? - Control Network Maintenance

302520151050

Never

Increase

Stay Same

Decrease

5.8 %

51.9 %

32.7 %

9.6 %

Will ‘Control Network Maintenance’ ‘Outsourcing’

Change in 5 Years?

Training TrendsTraining Trends

NoneOJTISA Certif icateAssociates DegreeBS Engineering

What level of TRAINING for Automation Support is typically required? - Maintenance

454035302520151050

None

OJT

ISA Certif icate

Associates Degree

BS Engineering

3.8 %

61.5 %

13.5 %

19.2 %

1.9 %

Maintenance TRAINING for Support Currently

Required?

NoneOJTISA Certif icateAssociates DegreeBS Engineering

What level of TRAINING for Automation Support is typically required? - Technician

302520151050

None

OJT

ISA Certif icate

Associates Degree

BS Engineering

2.0 %

45.1 %

13.7 %

37.3 %

2.0 %

Technician TRAINING for Support Currently

Required?

NoneOJTISA Certif icateAssociates DegreeBS Engineering

What level of TRAINING for Automation Support is typically required? - Control Engineer

5550454035302520151050

None

OJT

ISA Certif icate

Associates Degree

BS Engineering

3.8 %

9.6 %

1.9 %

11.5 %

73.1 %

Control Engineer TRAINING for Support Currently

Required?

NoneOJTISA Certif icateAssociates DegreeBS Engineering

What level of TRAINING for Automation Support do you feel w ill be required in 5 years? - Control Engineer

605550454035302520151050

None

OJT

ISA Certif icate

Associates Degree

BS Engineering

3.8 %

5.8 %

0.0 %

9.6 %

80.8 %

Control Engineer TRAINING for Support Required In 5

years?

Summing it all Summing it all UpUp

Comments/Queries….? You can contact me at:

tech@idc-online.com

http://www.idc-online.com

Good Luck !Good Luck !

And now for And now for something something

completely different !completely different !

A quick Instrumentation and Control Quiz

Prizes are not mickey mouse…but practical, highly regarded and excellent books:

Two of the famous “Industrial Control Handbook”…. R2500 each

Four of the practical “EMC For Product Designers” at R800 each

De Beer da Rules... First person to put his hand up gets

to give his answer to the panel - ie to YOU !

Your peers will decide. Geoff Cragg’s decision will be final. You only get one chance !

Quiz Question No. 1

What are the main differences between the data communications

standards: RS-232 and RS-485 ?

Quiz Question No. 2

Where would you use an OTDR as opposed to a power meter in

faultfinding of fibre optic cable ?

Quiz Question No. 3

What is the difference in the functions of TCP and IP in the TCP/IP protocol ?

Quiz Question No. 4

Why and where would you use the D or derivative term in control (with

the PID form of control) ?

Quiz Question No. 5

Is Feedforward an Open or Closed Loop form of control ?

Quiz Question No. 6How many tries has Jonah

Lomu scored against South Africa and where ?