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8/4/2019 Harsh Chitale-Global Trends in Process Automation the Way Forward for Indian Manufacturing
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Honeywell
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Honeywell
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Honeywell
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Honeywell
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Global trends in Process Automation
Harsh Chitale - VP, Strategy & MarketingHoneywell Process Solutions, USA
8/4/2019 Harsh Chitale-Global Trends in Process Automation the Way Forward for Indian Manufacturing
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Technology Milestones
smart
transmitter: 4-
20mA signal
transmission
1983
distributed
control systems
1974
automation vendor
to incorporate ASM
research
1999
2005
IEC 61508/61511safety standards
adopted
2003
TUV SIL3
Safety Systems
1993
FoundationFieldbus
WirelessIn
Automation
What has changed?
Just About Everything!
An order of magnitude more field data
An order of magnitude more users
Mobile users, desktop users, web users Open Standards
Architectures adopting standard platforms,networks, infrastructure
Application explosion Abnormal Situation Management, Asset
Management, Advanced Control, Businesss stem inte ration etc.
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New Business Challenges that are here to stay
Fewer skilled
peoplemust
respond faster,
handle more
complex processes,
make better
decisions,
with bigger
consequences
High attrition
rate of engineers
Fast changing technology
Production processes
increasingly complex
Supply chains more
integratedMust enhance safety,
security
More compliance, regulation
Global Project Resources
at a premium
Drive Energy Efficiency
Multiplegeographies,
Global Scales
Compressed
Schedules
Increase Uptime with
reduced maintenance
budgets
2006 2020THE FUTURE !!??!!
Automation is now being employed to solve this `Bigger Problem
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Reliability
Process Performance
Product Slate
Raw Material Selection
Reduce Utilities
Quality Give away
Parts/Supplies
Maintenance
Operators
Engineering
Reduce CAPEX
Life Extension
Inventory
Acct Rec / Acct Pay
DCS
Control System
Solu t ions w ou ld now so lve aSo lut ions w ou ld now so lve a Bigger ProblemBigge r Problem
IncreaseOperating
Margins
CapitalEfficiency
ReducedCosts
InstalledAssets
WorkingCapital
People
IncreaseRevenue
Material
ImprovedBusinessResults
Process Assets Business People
Business Solution
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Emerging Technologies for Emerging AutomationNeeds
New Sensors- MEMS
Knowledge SolutionsDecision Support Systems
Remote Monitoring
Abnormal Situation Management
Advanced Planning & SchedulingReal Time Enterprise
All pervasive
Wireless
Integrated Systems
Control
Security
Integrated Databases/ Data fusionAdvanced Process Controls
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the world of Smart-Dust
MICRO ELECTRO MECHANICAL SYSTEMS (MEMS)
MEMS A li i
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Nose-on-a-chip (MEMS sensor) can detect 400 species ofgases
Transmits signal indicating the level to a central controlstation (developed at Oak Ridge National Laboratory)
Nondestructive test scan of corrosion in an aluminumplate using an ultrasonic silicon sensor Blue represents a more distorted ultrasonic signal and
indicates severe corrosion / type
MEMS Applications
Inertial Sensors (Accelerometer, angular rate sensors)to revolutionize virtual reality for wider application areas
Accelerometer provides positional information, Angularrate sensors determine rotational position
Many more New Intelligent Sensors to measure more measurands, will enablebetter control of your business.
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Wireless
disconnected yet connected in free space
Wi l Ad
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Wireless Advantage
Reduced Cost & Speed of Installation
More sensor data,more controlled variables - enablingnew applications
One `integrated network for Data, Sensors, Surveillance,etc
Mobility: Roving operator / maintenance engineer
But what about?
Harsh industrial
environments License Free usage.
Countries ??
Everlasting power supply
Lack of standards/ protocolsfor Industrial applications
Data rate, Response time
Security, Reliability
World of Wireless in Industrial Automation has arrived.
GHz Wireless signal that can tunnel through
metal and better noise filters 2.4 GHz band. Unlicensed in 160 countries
Power scavenging, Now power sensors, powermanagement that gives 10 year life
ISA SP 100, Wireless HART High speed communication. Control ready
predictable communicate - 250 ms update rate
Security, Reliability
U l ki th V l f Wi l bl d
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Reliability- Continuous Equip Health Monitoring
- Automated Field Operator Rounds
Compliance- Emissions Monitoring
- Leak Detection & Repair
Unlocking the Value of Wireless-enabledApplications
Enabl ing Mul t ip le App l ica t ions in One Wire less Netw orkEnabl ing Mul t ip le App l ica t ions in One Wire less Netw ork
Safety & Security
- Safety Shower Monitoring- People/Asset Tracking
Optimization- Wireless I/O & Tools
- Better Data for Advanced Apps
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Multi-functional Industrial Wireless Network
One Wire less Net w ork Opt im ized for Many Appl ic a t ionsOne Wire less Netw ork Opt im ized for Many Appl ica t ions
BetterReliability
ProtectInstalled
Investment
Single NetworkOptimized for: Easy networkmanagement
Reduced infrastructureand overhead
ImprovedProductivity
Lower CostProjects
ImprovedCompliance
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Knowledge Solutions /Services
data to $$$$
What is now needed is
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Knowledge ServicesProviding Outcome basedservices for
-Improved business results-Sustained results
Field Devices
Distributed Control SystemPLC / Safety System
Advanced Process ControlReal time Optimization
Process Simulators
LIMS, HistorianPlant Information SystemsCondition Monitoring
Planning &Scheduling
Value
Chain Mgmt
Knowledge
Solutions
What is now needed isProcess Knowledge Solution .. Not just DCS
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Integrated Systems
unified, controlled, manageable
Integrated Systems
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Integrated Systems
Integrated Database
Synchronized database across the enterprise transcending singleunit : One Virtual system for entire plant / enterprise
Common database for Advanced Process Control, Real-time
Optimization, MES applications: Ease of engineering andmaintenance.
Safe & Secure production automation
Physical Security, System/Computer Security, Network Security Integrated Safety solutions & Process Control Solutions
Integrated Controls, Simulation & Optimization
Enables faster commissioning Enables getting optimization benefits earlier.
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Summary:
Tomorrows Automation solutions, will have:
More sensors,More integrated systems,More data being converted into knowledgelesswire
Would solve a Bigger problem
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