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FUTURE DIRECTIONSFUTURE DIRECTIONSOFOF
INSTRUMENTATION & INSTRUMENTATION & CONTROLCONTROL
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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).
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A few thoughts on...
The Future of I & CYour future in this industryTraining trends
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The Future of The Future of Instrumentation Instrumentation
and Controland Control
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Fairly Predictable Ethernet (and TCP/IP) & Fieldbus Safety Instrumentation Industrial IT (incl.
Security)/Supply Chain/E-Commerce & E-manufacturing)
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ETHERNET, TCP/IP & FIELDBUS
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UTP 10Base T System
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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
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Switch Types
Server
Segment Switch
Server
Private LAN Switch
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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
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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
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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
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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
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SAFETY INSTRUMENTATION
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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
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SUPPLY CHAIN, E-COMMERCE AND E-MANUFACTURING
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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
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And not so Predictable Trends…..
People required (ie YOU !)
see next section….
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Your Future in Your Future in this Industrythis Industry
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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?
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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?
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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?
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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?
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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?
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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?
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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?
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Training TrendsTraining Trends
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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?
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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?
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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?
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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?
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Summing it all Summing it all UpUp
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Good Luck !Good Luck !
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And now for And now for something something
completely different !completely different !
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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
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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 !
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Quiz Question No. 1
What are the main differences between the data communications
standards: RS-232 and RS-485 ?
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Quiz Question No. 2
Where would you use an OTDR as opposed to a power meter in
faultfinding of fibre optic cable ?
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Quiz Question No. 3
What is the difference in the functions of TCP and IP in the TCP/IP protocol ?
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Quiz Question No. 4
Why and where would you use the D or derivative term in control (with
the PID form of control) ?
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Quiz Question No. 5
Is Feedforward an Open or Closed Loop form of control ?
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Quiz Question No. 6How many tries has Jonah
Lomu scored against South Africa and where ?