ARC's Dave Woll Process Automation Systems @ ARC Industry Forum 2010

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ARC's Dave Woll Process Automation Systems @ ARC Industry Forum 2010 in Orlando, FL.
Time to Rethink Process Automation Systems (CPAS 2.0)
Top 10 Automation Business Drivers
1.Create proactive culture
2.Improve asset utilization
3.Enhance human reliability
4.Improve equipment reliability
5.Unify business and operations
6.Respond to uncontrollable external variables
7.Responsible care requirements
8.Prevent cyber security threats
9.Deal with loss of experienced staff
10.What is the potential value

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ARC's Dave Woll Process Automation Systems @ ARC Industry Forum 2010

  1. 1. Time to Rethink ProcessAutomation Systems(CPAS 2.0)Dave WollVP ConsultingARC Advisory Groupdwoll@arcweb.com
  2. 2. 2© ARC Advisory GroupFrom CPAS to CPAS 2.0CPAS conceived in 2005 Issue: The introduction of internet technology to manufacturingforced most of the suppliers to change their Control LAN andultimately innovate their entire systems. Users asked what to value“everything looked the same” Purpose: Develop an ARC vision of the ideal evolution of currentprocess automation systems. The Collaborative Process AutomationSystem (CPAS) Deliverable: A detailed Outlook StudyCPAS 2.0 conceived in 2009 Issue: There has been an absence of real innovation in both thesystem and field devices. Users have asked how to value what isneeded next Purpose: Develop an ARC forecast of the ideal functional evolutionof process automation systems Deliverable: A detailed Outlook Study
  3. 3. 3© ARC Advisory GroupTop 10 Automation Business Drivers1. Create proactive culture2. Improve asset utilization3. Enhance human reliability4. Improve equipment reliability5. Unify business and operations6. Respond to uncontrollable external variables7. Responsible care requirements8. Prevent cyber security threats9. Deal with loss of experienced staff10.What is the potential value
  4. 4. 4© ARC Advisory GroupCPAS Guiding PrinciplesROAOperationalExcellenceFlawless ExecutionAutonomous AutomationCommon InfrastructureContinuous ImprovementProactive ExecutionCommon Actionable ContextSingle Version of the TruthAutomate every thing thatshould be automatedFacilitate Knowledge WorkersManage All AutomationRobust, based on StdsPrecisionExtraordinary PerformancePrinciples CPAS Response
  5. 5. 5© ARC Advisory GroupCPAS Looks at Automation HolisticallyTo…From…Single Model with Distributed Processing and Shared ServicesBusinessSystemSensors, Actuators and Logical DevicesISA S95ISA S88ManufacturingWorkProcessesReal-TimeControl &EventsProductionManagementTransactions OperationsManagementEnterprise System
  6. 6. 6© ARC Advisory GroupWe Need Smarter Field Devices 50 -75% of device downtime is caused by lackof confidence in measurement Most field devices do not quantify health orestimate remaining usable life Precludes operations from deciding run/shutdown. Lost critical measurement usually results inshut down Active research, dearth of Products• One product based on SEVA (self evaluatingtechnology BSI 7926)
  7. 7. 7© ARC Advisory GroupSystems Need to Become Truly Distributed Current leading Distributed Control Systemsand the original CPAS are not true DCSs Current DCSs are based on IEC61131-3 whichspecifies programming languages andarchitecture The architecture is limited to a single domainwith all resources operating in unison Resources cannot act autonomouslyCurrent DCSs are a single model with distributedprocessing and shared services
  8. 8. 8© ARC Advisory GroupSystem Resources Need to Operate AutonomouslyWhen Necessary Functionally changes the control level(reconfigure) at run-time Provides the foundation for “zero downtimeautomation systems” and sustainableoperations Supports the utilization of high levelautonomous agent (FIPA), reasoning andmodelingPotentially offers the highest value
  9. 9. 9© ARC Advisory GroupIEC Standard 61499 Supplements IEC 61131FieldbusIEC 61158DCSIEC 61804PLCIEC 61131-3Open ConnectivityConfigurabilityDistributed FunctionalityFunction BlocksConfigurabilityStandard Programming LanguagesIndustrial ProcessMeasurementand Control Systems(IPMCS)IEC 61499Truly Distribution ReasoningAutonomyHigh LevelFunctionBlocks Single Model with Distributed Processing andIndependent Services Example: The Smart Watchdog from IntelligentMaintenance Systems IMS)
  10. 10. 10© ARC Advisory GroupControl Strategies are not Tied toSpecific Hardware Control Strategies Must TranscendHardware Required to support autonomy andreconfiguration Eliminates the need to position functionsinto highly secure system levels Runs across disparate platformscomplimented single size resource scaled bynumber Provides the opportunity to optimizehardware cost and performance
  11. 11. 11© ARC Advisory GroupSecure On-Line Version Upgrades At least one major versionupgrade every year Now requires a shut-down or atleast a major vendor supportedcustom revision ARC supports a three step on-line version upgrade Three step has crucial valuedetermining the new version isoperating predictably beforecommitting to the processRevertGoAbortLoadAcceptEvaluateFinishedRevertGoAbortLoad NewVersionAcceptEvaluateFinished
  12. 12. 12© ARC Advisory GroupNeed Business and Operations Unification– Business to Planning Normally the integration of disparate informationis largely custom work This is the case when integrating SCM targets tooperations planning Reference standards can eliminate the majority ofthis customization. Specifically: The SCOR model has been accepted as theprimary SCM reference model S95 has been accepted as the primaryOperations Management reference model There is a high correlation between the two This integration will deliver higher Business toPlanning performance
  13. 13. 13© ARC Advisory GroupNeed Business and Operations Unification– Real-time Planning to ProductionLP PlannerRTOModelUpdate(10/Day)LP PlannerLP PlannerDynamic PlannerLP PlannerRTOOperator involvement:- On/Off- Operating BandLP PlannerLP PlannerRTORTODynamic PlannerMarket SignalsSupervisoryController 1(DMC)LP PlannerSupervisoryController 2(DMC)SupervisoryController 3(DMC)Real-TimeOptimizationCapable/Profitable toPromise in Real-time24/7 Optimization,Minimal Human InvolvementAutonomous TransitionManagementShort Term Production Planning Based on MarketDemand and Production Capabilities
  14. 14. Thank You.For more information, contact the author atdwoll@arcweb.com or visit our web pages atwww.arcweb.com

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