Automation, ways to more productivity and quality - festo.ir · PDF fileFesto AG&Co KG, Esslingen, Germany Teheran, October 27th, 2009 ... FEC systems • Since 2001:electrical actuators

Abteilung/Name Projektname 27.10.2009 1

Iran’s first International Conference on Industrial Automation

Sharif University of Technology

Dr. Eckhard RoosFesto AG&Co KG, Esslingen, GermanyTeheran, October 27th, 2009eMail: [email protected]

[email protected]

Automation, ways to more productivity and quality

mailto:[email protected]

ABTEILUNG/Name

Festo – An independent family owned company

Festo AktiengesellschaftAutomation and Didactic

€ 1.6 billion annual turnover (2008)

in 176 countries worldwide

Innovative

2,800 patents granted worldwide

Approx. 100 innovations each year

R&D budget: 7.5% of turnover

Self-motivated learning

12,800 employees worldwide

Training budget: 1.5% of turnover

Environmentally-friendly and dedicated

to quality

Quality and environmental certificates

(ISO 9001, VDA 6.1/6.4, ISO 14001

Founded in 1925 by Gottlieb Stoll in Esslingen/ Germany

• 1925: high-quality wood-working machines

• Since 1956:pneumatic actuators and pilot valves

• Since 1978:electrical ON/ OFF systems, FEC systems

• Since 2001:electrical actuators

ABTEILUNG/Name

Automation

Components Systems

and

services

Didactic

Training

and

Consulting

Learning

systemsMachines

and systems

People and

organisation

Increasing the

efficiency of

and

Solutionsby

Solutionsby

Productivity begins with training

Festo – Supplier of automation and training solutions


Partner for professional Training and Consulting

Festo Didactic

Global solutions for professional training

Learning systems for Automation and Mechatronic Applications

Training & Consulting 3.600 Seminars in 56 Countries in 27 languages > 42.000 participants Pneumatic, Hydraulic, Robotic,

PLCs, Sensoren, .. E-learning

T/Dr. Eberhard Veit Automation 2008 3. Juni 2008

Automation at Festo: Factory Automation with seamless transition to

Process Automation

Process Discrete

En

erg

y

Re

fin

ery

Wa

ter

Ch

em

ica

ls

Oil

& G

as

Pu

lp &

Pa

pe

r

Ce

me

nt

& G

lass

Me

tal/

Min

ing

Ph

arm

ace

uti

cals

Foo

d &

Be

vera

ge

Au

tom

oti

ve

Ele

ctro

nic

s

Factory Automation is the automation ofdiscrete processes for the processing ofgoods

Process Automation is the automation ofbatch- and continuous processes, mainly withgas, fluids and solids

5


Factory Automation

„ compact production, low physical spread

„ Indoor-plants

Low requirements on temperature ranges as well as mechanical and temperature protection of single components

Process Automation

„ Production sites, often with large physical spread

„ often Outdoor-plants

High requirements for temperature ranges to be covered as well as protection of single components including specialities like protection against animals

Characteristics of production plants – environmental conditions


Factory Automation

„ discrete processes

„ frequently (scheduled) shut downs

„ cyclic movements with high clock rate and large numbers of pieces

„ dynamic, but precise positioning of sometimes large parts of machines

„ production plant consists often out of several machines of various producers with independent automation concept

Priorities

high productivity (speed)

low investment costs

real time processing of data

Characteristics of production plants - production


Process Automation

„ continuous or batch processes

„ longer operation periods without shut downs

„ closed production systems

„ slow to no process condition changes, when looking at continuous plants, e.g. refineries

„ less dynamics in the production process compared to FA

„ Integration of Package Units in PA with varying specifity

Priorities

security

availability

transparency in production data and history

Characteristics of production plants - production


Factory Automation

„ move

„ transport

„ sucking (vacuum technology)

„ handling…

Large portion of components for condition detection and processing are binary values (>95%)

Process Automation

„ transport

„ heat

„ mix…

Continuous process control, higher degree of analogue value processing (partially >40%)

Characteristics of production plants – tasks


Speciality of Process Automation

„ Explosion protection

„ SIL (Safety Integrity Level)

„ define measures to control risks

„ takes a complete Control-loop under consideration

„ quantitative calculation of the probability of failure (PFD ) in case of demand

actually uncertainties in the implementation

quantitative calculations still uncertain due to missing/insufficiant input database

high priorities in proven technology/components

Characteristics of production plants – security


Factory Automation

„ Interlock of control- and drive concepts

„ scalability, usability, flexibility

„ real-time data processing capability

„ no changes in performance due to extensions

„ changeability due to shorter life cycle of the produced products

Priorities

data processing speed

minimal effort for changing the production for new products

horizontal as well as vertical integration

Characteristics of production plants – DCS, PLC, Field equipment

Quelle: Siemens


Process Automation

„ Compatibility and ability to integrate of individual process sections (e.g. Package units)

„ Integration of Safety components and systems (PLC, Bus)

„ Ability to upgrade the system during plant life cycle

„ Asset Management Tools for monitoring of components and systems during plants life cycle

Prioritäties

Life cycle costs

protection of the investment

security and availability

horizontal and vertical integration

Characteristics of production plants – DCS, PLC, Fieldequipment

Quelle: PNO


Process Water / Chemicals/ Biotech / Mining Energy Pulp & Paper Food

Industry Sewage Petrochemicals Pharma

Process Industry – the industry segments

… is a variety of segments with • different requirements for products and solutions • different technical specifications and regulations

Process

Industry

TS-M/CLU / LTB Projektstruktur "Wassermarkt" Entwurf Vertraulich

Resource Water – Synergies and Contradictions

GeographicConflicts

Products/Technologies

Watermarket

Efficiency of applications

Economic Growth

External Pusher/Environmental conditions

StructuralChanges

Waste water volumes

Quality and Analytic

Factors of future development of water- and waste water treatment

DevelopingCountries

Security

Sweatwater reservoir Mega Cities

Source TechnologiyRoadmap Automation 2015+ (IZT/ZVEI 2006)


Resource Water – Flash [1]

„ UN: „In 20 years 2/3 of the worldwide population will not have access to natural waterresources“

„ Also Europe will face lack of water (until 2025 an increase of demand of + 25%)!

„ Eastern Europe has resources, but these are partly contaminated (Deficiency: Water

treatment!)

„ Worldwide a various number of regional problems exist cause by different reasons

„ Insufficiant quality of water for potable water, food and Bio/Pharma industry

„ Europe‘s industry needs 11times more water compared to the US industry (Mentality of

consumption)

„ Strong political as well as financial pressure for industrial water recycling (closed loops)

„ Mega cities require new facilities and modernization of existing water infrastructure

+++ Water +++ AGUA +++ вода +++ 水 +++ VODA +++ WASSER +++


„ World market potential water: > 300 Bio. US $/a

„ Europe & US: 9 % yearly growth for industrial water treatment, in Asia: country specific up to 50%

„ Global Players strenthen their position (e.g. RWE bought Thames Water, Siemens bought US Filter Corp.)

„ Insufficiant and missing water infrastructure avoids industrial growth (China, India)

„ Mega Cities are new challenges for water supply. Mid 2007: first time in history more people live in urban areas than in rural areas Tokyo ‟ 35 Mio. people ( Kanada = 32.3 Mio.) produce 40 % of all Japanese goods and services

Bangkok ‟ 6.5 Mio. people produce 35 % of all Thai goods and services

Paris ‟ 13.7 Mio. people produce 30% of all French goods and services

„ Intensive agriculture generates increase in water demand

„Water is the Oil of the 21st century“

+++ Water +++ AGUA +++ вода +++ 水 +++ VODA +++ WASSER +++

Source: Roger Radke, Siemens Water Technologies(VDI-Nachrichten 12. Mai 2006)

Resource Water – Flash [2]


Future Trends

Future trends are dominated by:

„ Increase of population and water consumption„ Increasing Mega cities„ Bottleneck in food production„ Lack in infrastructure„ Overloaded resources„ Increasing climatic catastrophies

„ Contaminated water

„ Old infrastructure„ New technolgies

Infrastructure

Quality

Quantity

Infrastructure

„ Chances and risk

Demographic changes

Healthcare

Old Infrastructure

Liberalisation?


Water consumption (2000)

Global needs :

10 % of water for living areas

70 % of water for agriculture

20 % of water for industry

■ living areas

■ agriculture

■ industry

Quelle:

FAO, 2000

ABTEILUNG/Name

Festo – innovative solutions for process automation

From the

SCADA level

to the

field area


Continuous Upgrades

Where are the original documents and data-logs?What about as built drawings?

Cost pressures

Prices decreases, overcapacity and pressure from competitors

Maintenance crew under pressure

Trouble shootingComplexityLess personnelNew technologies

Additional requirements

New standards for plant safety and product quality still await implementation:GMP / FDA / ISO 9000 - 2000

Unplanned Shut-downs

Down time kills productivity, minimize downtime requires instant response for spares, service and detailed diagnostics

Production capacity increases

Concentration of product plants are needed,flexibility and higher production rates, 3 shift manufacture, multi-purpose plants

Today's situation in a lot of process plants

ABTEILUNG/Name

„ TCO – Total Cost Of Ownership „

Source: Erasmus University Netherlands

Costs are like icebergsAnalysis of total costs:“TCO — Total Cost of Ownership” was developed in the 1980s and tested in practice. This analysis helps users to more effectively estimate their total costs during plant life cycle.

The results of this analysis show, that investment costs of materials and components are secondary when taking an overall life cycle view


Com

weeks

Install

weeks

Engineering

weeks

AssetManagement

ERPCMMS

DCS

Field

Production ControlProcess Control

Services

Life Cycle of Process Plants

Engineering Procurement InstallationOperation &Maintenance

Commissioning

Life cycle management is the issue

Operations

up to 25 years

Procurement

days

* Capital Expenditure**Operational Expenditure

ERP Enterprise Resource Planning System

CMMS Computerized Main-tenance Management

DCS Decentralized Control System

CAPex*

Maintenance & Operation Costs

Initial Costs

OPex**


Causes of Plant Incidents

Operator Error

21%

Accident/Nature

16%

Other/Unknow n

20%

Mechanical Failure

43%

Target availability/efficiency

Operation

Unplanned shut downs

Plant optimization

Predictive diagnostics and Condition monitoring leads

to productivity increase

EngineeringProcurementInstallationCommissioning

Optimization of plant availability is crucial

„ 43% of plant incidents are caused by mechanical failure

„ There are 2,500 machines in a typical process plant

„ Unplanned shutdowns are the largest cost in the process insustries


Vertical integration as success factor for Process Industry Endusers

Va

lue

ad

d f

or

the

cu

sto

me

r b

y

inte

gra

ted

so

luti

on

s

Process valves, field level single components e.g.

positioners, sensors,…

Process valve assemblies,solenoid valves and

valve terminals

Customized control

cabinets, integrated solutions, PLC, Field-

bus systems, Seminars (Didactic) & Services

The more integrated solutions are

delivered,

the more value add during life cycle can be achieved by the Endusers


From components to systems

Tech

nic

al C

om

pe

ten

ce

Added Value

Components

Systems

Assemblies

Customized Solutions


Benefits for PA customers by utilizing integrated solutions

„ Reduced engineering

„ Reduced supply management

„ Reduced technical risk by given compatibility of components

„ Fast product and solution supply

„ Standardized technical solutions plant/site wide

„ Reduced time to market

Engineering Procurement Installation CommissioningOperation

&Maintenance

Vertical integration as success factor for Process Industry companies

Festo delivers value to customers

http://adewww16.de.festo.net/cgi-bin/cgiWebLink.exe/10970k.jpg?Action=pic&b_Id=71804&Tran=00019549&folder=preview



„ Reduced assembly time and costs

„ Reduced commissioning effort by standardized solutions and compatible technical solutions

„ Faster start up by

„ Better diagnostic data of equipment

„ Reduced effort for failure/malfunction fixing

„ Reduced time to market


&Maintenance





„ Availability of diagnostic data for plant equipment

„ Reduced plant down-times applying intelligent maintenance strategies

„ Faster failure fixing based on detailed failure reports

„ Access to all relevant plant data for decision making at operator or management level


&Maintenance



EZ-P/Matthias Dreher Competitive Advantages by Integrated Automation 10. Februar 2009

Festo – ePLAN: Successful Cooperation

32

ePlan fluid


Training and Diagnostics Unit: System Overview

33

Different types ofprocess valves

Remote I/Os + valveterminals

Processmeasurements forflow and pressure

Tank truck model forsimulation of filling

process

Centrifugal pump with frequency

converter

Local operatordisplay

PC-basedVisualization


Training and Diagnostics Unit: Piping & Instrumentation

34


Ethernet

System Configuration

1. CPX Remote I/O with integrated PLC (Master)

2. CPX/MPA Remote I/O and valve terminal (Slave)

3. Gate valve + solenoid valve

4. Instrument air supply

5. Electrical trigger signal

6. Diaphragm valve

7. Ball valve

8. Pneumatic trigger signals

9. Feedback signals

10. Process measuring devices

11. Local touch display

12. PC-based Visualization

13. Ethernet

35

4 8

8

9

9

91 2

3 67

12

13

10

5

11


Ethernet

Normal Operation: Triggering Process Valves

1. Commands for valve triggering

2. Valve open commands

3. Valves open

4. Feedback signals “valve open”

5. Forwarding of feedback signal

6. Changed valve status

7. Display of changed valve status

36


Ethernet

Failure: Gate Valve Blocked When Closing

1. Command for closing of gate valve

2. Valve close command

3. Gate valve does not close fully

4. Feedback signal “valve closed” is missing

5. Forwarding of feedback signal to master missing

6. Master detects failure and generates message for visualization system

7. Failure displayed on visualization system

37



8. Valve failure alarm is displayed in the alarm list

9. Button to activate electrical documentation

10. Affected valve is automatically selected in plant tree view

11. Easy navigation to P&ID via context menuy

12. Valve is automatically highlighted in P&ID

13. Easy navigation to pneumatic diagram via context menu

14. Valve is highlighted in pneumatic diagram

15. Easy Navigation to electrical diagram, valve is highlighted

38



8. Navigator with selected valve

9. Navigation to valve documentation via context menu

10. Valve documentation can be displayed online

39


Ethernet

Normal Operation: Processing of Measuring Values

1. Raw data is transmitted to controller

2. Data processing by controller

3. Processed data is sent to visualization system

4. Display of measuring value at visualization system

40


Ethernet

Failure: Broken Wire at Pressure Measurement

1. Transmission of raw data to controller is broken due to a broken wire

2. Master detects failure and creates message for visualization system

3. Message is sent to visualization system

4. Message is displayed at visualization system

41


Failure: Broken Wire at Pressure Measurement

8. Broken wire alarm is displayed in the alarm list

9. Button to activate electrical documentation

10. Electrical diagrams are opened, affected component is automatically highlighted

11. Navigation from electrical diagrams to P&ID

42


Failure: Automatic Printout

43

1. Broken wire alarm is displayed in the alarm list

2. Corresponding page of electrical diagram is printed automatically upon alarm occurrence


Benefits of integrated Automation Solutions

• Data created during engineering phase of projects are utilized for failure detection and fixing in the operational plant life cycle

securing investments

• Integration of data with diagnosis functions results in

• Reduced times for failure identification

• Direct access to documentation in context with the failure, documentation must not be searched for in various folders

• Reduced time for failure analysis and fixing

increased plant availability and capacity

• Improved database for decisions of management or operator

44


Festo …

… Passion for Process Automation!

Water / Chemicals/ Biotech / Mining Energy Pulp & Paper Food

Sewage Petrochemicals Pharma

Process

Industry

TR/ JBRE/Dr. Jan Bredau Diagnose in der Pneumatik/ Automation 2008 27. Mai 2008 geändert: 27. Mai 2008

Opportunities of diagnosis for pneumatic solutionsAnalogies and differences between Factory and Process Automation


End user

Increase of plant availability

„ Detection of failures

„ Localisation of defectcomponents

„ Data sampling, trend analysis

Improve reliability

„ Diagnosis for critical drives,

plant sections

„ new safety concepts

Customer benefits by improvedfuncionalities of machines

„ more efficient, powerful andintelligent components

Enhance of customer service

„ Remote diagnosis byspecialists

„ Support by local maintenanceteams

New business models

„ New services

„ Operator models…

Machine builder

Requirements of various target groups and contribution of automation

Improve productivity

„ Leakage detection

„ Consumption recording

„ Specific values for predictivemaintenance


Application example: packaging machines – which functionality is important?

Focus:

Packaging machines

Ne

w b

usi

ne

ssm

od

els

Ima

ge

, Im

pro

vem

en

to

fm

ach

ine

fun

ctio

na

lity

Wa

rra

nty

, co

nfi

rma

tio

no

ffu

nct

ion

ali

ty

Lo

we

re

ne

rgy

con

sum

pti

on

,

en

erg

ym

on

ito

rin

g

Incr

ea

seo

fa

vail

ab

ilit

y/r

eli

ab

ilit

y

Imp

rove

dse

curi

ty

An

aly

sis

an

da

rch

ivin

go

ftr

en

dd

ata

An

aly

sis

of

tre

nd

s, p

red

icti

vefa

ilu

reco

gn

itio

n

Ex

act

fail

ure

sid

en

tifi

cati

on

Fast

fa

ilu

red

ete

ctio

nin

ca

seo

fd

istu

rbe

nce

s

Be

ne

fits

/Im

po

rta

nce

of

Dia

gn

osi

s fu

nct

ion

ali

ty

Very

important

Important

Relevant

Less

Relevant

No

relevance

Focus

Packaging machines

Co

mm

issi

on

ing

sup

po

rt


Example – Energy monitoring

Costs of leakages in plants*Energy costs of a typical production plant*

(app. 80 pneumatic actuators)

* - 6 bar operating pressure,

2 shift operation - 250 days, 2 ct/m³ costs for compressed air

4 assembly cells = 270m³/d

Energy costs per day: 5,5 €

Energy costs per year: 1375 €

equivalent diameter of leak in mm

Costs in EUR p. year

Co

sts

in E

UR

p.

ye

ar

Flo

w i

n l

/min

Flow in l/min

TR/ JBRE/Dr. Jan Bredau Diagnose in der Pneumatik/ Automation 2008 27. Mai 2008 geändert: 27. Mai 2008 50

Failures in Automation Systems

Ethernet

Fieldbus

Air Supply

Drives/

Process valves

Valve Terminal

Air

preperation

units

• Communication failures

(fieldbus connectivity, break of wires, …)• Energy

(electrical power supply, operating airpressure …)

• Device failures

(defects, wear)• Accessories

(sensors, fittings, tubes, …)• …

Symptoms in pneumatics indicating failures orworn out components

Leakage, high airconsumption

Open and closing times

of process valvesSwitchung behaviour

of valves

Remaining failures (e.g.

oscillation of air pressure)


Examples of typical problems

Failure/indication Reason

System/Media air/

Air preparation devices

Problems in the air supply (compressor, feed tubes), High air consumption due to leakagesReduced air quality, e.g. humidity ratio, lubricated air, particlesContaminated or worn out filters

Linear drive/Rotary

drive/ Valve

Worn out piston-/ piston rod sealing, increased frictionLoad changesTolerances at actuators, break of shaft

Solenoid valve Delayed switching of solenoid valves due to leakagesWorn out of sealings, contaminated silencerFailures in the electronics (short circuit, power supply)

Tubes/Accessories Leaky fittings, break of tubes, crimpsContaminated silencer, embrittlement, icingDeadjustment of throttles


Components for diagnosis

1. Pressure- and flow sensors, positioningindicators, camera systems

2. PLC Controller as stand alone or integrated

3. Air preparation units with sensors

4. Valve terminals with diagnosis functionality

5. Drives pneumatic and electric

6. Vacuum- and gripper technology

7. DCS (Decentralized Control Systems)

52


Example: Automation terminal CPX with MPA-Valve terminal

53

Concepts for failure detection:

Valves

• Valve not installed, short circuit, undervoltage

• Monitoring of air pressure

• Counting of switching cycles

Electrical Input-/Outputmoduls

• Short circuit, power supply

• Wire break

• Undervoltage

Controller FEC and Fieldbusmoduls

• Calculation and analysis of data/ Webserver

technology

• Data transfer utilizing proven fieldbus protocols


Stepwise approach for system diagnosis

54

Se

rvices

(En

gin

ee

ring

, Co

mm

ission

ing

,O

pe

ratio

ns)

System diagnosis(localisation of failures)„ Valve or drive„ Leakage detection

Monitoring(failure detection)„ Feed pressure, flow, „ Air consumption, energy„ opening and closing times

Diagnosis of component(Failure identification)„Load, friction„ internal/ ext. leakage„ switching failures„ ….

Inte

gra

tion

into

existin

gA

uto

ma

tion

Syste

ms

(PLC

, HM

I, SC

AD

A)


Pneumatic Circuit

55

Position indicator

Valve ‟control signal

pQpressure- and

flow sensorswithin thefeed line

Monitoring of

basic values

Localisation of failures

(subsystem, component)

Detailed failure

identification

Additional sensors


Diagnosis functionality for automation applications

Factory Automation Process Automation

Counting

Switching cycles of valves

Stroke counter for linear drives

Rated capacity, reverse of direction

Operating hours

Monitoring of process values/parameters

Operating pressure, volumetric flow rate and

air consumption of the system

Travel times of linear drives

Switching time of valves

Pressure, flow, position of actuators

Supply pressure, operating pressure

Open- and closing times of process valves

Temperature (electronic devices, process)

Seat of valve (upper and lower stop)

deviation of process control parameters

electronic devices (voltage supply, over- and

undervoltage, voltage fluctuation)

System diagnosis for localization of failures

Evaluation of flow profiles vs. process states (Leakage detection, failure allocation to components)

Diagnosis of components

Load-, friction detection at linear drives

Internal, external leakage at linear drives

Switching fault of valves

Break-away torque, torque reserve

Leakage of the drive/valve

Friction (packing gland, spindle)

Tolerance in mechanics, break of spring


Example: Flow Rate and air consumption analysis

Measured

Reference

Flow Rate

Air consumption

deviation

Flo

w R

ate

in

No

rmli

ters

/min

Time in sec

Air

Co

nsu

mp

tio

nin

No

rmli

ters


Example: Load- and friction monitoring at a linear drive application

5858

1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 34

4.5

5

5.5

6

6.5

7x 10

5

Dru

ck

2

time

pB1r

ef

pB2

Externe Kraft (F-)

Drr

uc

k in

Arb

eit

sk

am

me

r p

B [b

ar] Ausfahren

AB

1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 35.4

5.6

5.8

6

6.2

6.4

6.6

6.8

7

7.2x 10

5

Dru

ck

2

time

pB1r

ef

pB2

Referenz

Referenz

Einfahren

BA

F F

6.2

6.6

7.0

5.8

5.0

5.5

6.0

4.5

4.0

6.5

1.0 2.0 3.0Zeit [s]

Externe Lastkraft (F+)

5.4

1.0 2.0 3.0Zeit [s]

AB BA

External force (F-) External force (F+)

Time in secTime in sec

Pre

ssu

rein

ch

am

be

rsP

bin

ba

r


Estimation of safety factors and position of process valves

1

1

)(

A

N

A

N

A

A

AAEXTA

p

p

A

p

p

p

pAxVtotQQ

x

QEXT

pA pB

Q0

=QA

=QB( )p0

QEXT

AA AB

Indirect calculation of position using pressure and flow:

Mass balance equation

Equation for pressurization

00 KompressExtA QQxAQQ

pVp

QKompress

Pre

ssu

re(b

ar,

rel)

Vo

lum

e f

low

(Nl/

min

)Time in sec

Diff. Pressure

Flow

Rotating angle

TR-F/Jan Bredau Diagnose Überblick 11. November 2008 geändert: 11. November 2008

11

0)(

A

NormA

Norm

A

A

AAtotLEAK

p

pA

p

p

p

pAhubVQQx

Example: Estimation of position based on p-Q-signal

Mass balance:

Equ. for pressurization

0KompressLeakANA QQxAQQ

A

AAKompress p

VpQ

Filling of chamber AA

Example: Detailed diagnosis with pressure and flow sensors

back

„ Estimation of position withoutleakage out ofp - Q - Sensors (pressure-flow)

„ Leakage estimated by comparing theposition with reference/measuredposition

time [s]

Lea

kag

e [

Nl/

min

]

Po

siti

on

[m

m]

Leakage measured

Indirect estimated leakage

Estimated andmeasuredposition


Application: packaging machine


Packaging maschine: pneumatic functionality with monitoring

Foil take-off unit

• Linear drive for

contact pressure

of the conveyors

(contact pressure

+ conveyor friction)

Lateral sealing with

cutting knife

• Gripper move –

electric drive

• Cutting knife –

pneumatic linear

drive

(cutting time,

pressure profile)

Cooling air

• Valve – typ MPA

(flow rate of

cooling air)

Longitudinal Sealing

• Linear drive for

contact pressure

(travel times, travel

counter)

General:

• Air consumption,

Energymonitoring

• Monitoring of operating

pressure

• Valve switching


Packaging machine: Technical solution

VisualizationMachine Panel

PLC

Profibus

Diagnosis of Automation

Valve terminal withController

Optional:- Visualization- Remote access

Diagnosis results(Status, values …)

Ethernet - Digital I/O for Valvesand Actuators

- State of Process, Operations (Teach-In, …)

2. Air consumption of system

(flow sensor)

3. Travel times of actuators

(position switches, controlsignals)

4. Position and pressure ofdeduction unit

(Position indicator 50 mm andpressure sensor)

1. Pressure of air supply

(pressure sensor)


Diagnostic controller with

Software

Integration into an overall automation solution

Customer specific SCADA, HMI

Customer specific PLC

fieldbus/ ethernet

Standard pneumatic

Servo-pneumatic

Electrical drive

Sensors, camera

64


Festo …




Process

Industry


• Electrical drives are well established in water-/waste water plants

• Pneumatic drivres have clear advantages, which will be recognized and honoured from the market in future

• Technical University if Braunschweig executed detailed investigation electrical drives vs pneumatic drives with respect to life cycle costs.

• Utilization and transfer of scale effects from FA to PA will bring additional value to endusers and suppliers

6

Example water plant: advantages of pneumatic drives compared to electricdrives during the life cycle of a water plant

NB-H / Dirk Thamm Systems world SAP modul ‟ Get started presentation 18. August 2003 67

Valve automation with pneumatic in the water and waste water business

PLC

Fieldbus

Process control system

Valve terminal

NB-H / Dirk Thamm Systems world SAP modul ‟ Get started presentation 18. August 2003 68

Cost comparison Pneumatic – Electric actuators

Business Plan 2 PA 27/10/2009 69

Technical comparison: Electric / Pneumatic - Actuators

„Dimension/Weight

„Operation cycles/Maintenance

„Permanent operation/duty cycles (power-on time)

„Connection/Installation

„I/O signals

„Power consumption


Operation cycles Maintenance Permanent load Power-on time

„2 Mio cycles

„ Maintenance free, lifetime lubrication

„ overload proof, no thermal load

„100% duty cycle

„20.000 cycles, Open/close operation, SA

„200.000 cycles, controlled operation, SAR

„Overload protection, thermal load

„Operating mode S2 or S4


Connection Installation I/O-signals Power consumption

„ 400 VAC/3-phases

„ Connection to low voltage power supply

„ More than 10 I/O-signals

„ e.g. 375 VA, SA 07.5 (60 Nm)

„2 tubes, 1 cable for proximity switch 24 VDC

„Connection to control cabinet

„ Max. 2 Input / 2 Output signals

„Max. 2,4 W, valveterminal


Pneumatic actuator

Compressor Air tank Air preparation unit

Valveterminal

Solenoid valve

Actuator

Proximity switches

Positioner

Local controller

Way measuring unit

Accessories (silencer, fitting)

Ring line

Fieldbus

PLC

Fie

ldb

us

Ma

ste

r

Sub distribution line

Process control

level

Energy supply – low voltage plant


Electrical actuator

ActuatorControl unit

Fieldbus

Energy supply – low voltage plant

Emergency power generating set

PLC

Fie

ldb

us-

ma

ste

r in

terf

ace

Linear unit / spindle

Process

control level


Example Kleine Kinzig waterworks


„ Comparison based on data of an existing plant in Germany

„ Filtration unit of a water plant

„ 8 filter units, each with 8 process valves

„ 7 process valves in open/close operation, one in a controlled mode

„ The following costs were considered

„ Investment and operational costs

„ Costs for plant shut downs due to maintenance or failures

„ Depreviations during the Life Cycle of 25 years

R ohwasser

R einwasser

Spülwasser Ablauf

E rstfiltrat

Abluft

Schlamm

Spülluft

R ohwasser

R einwasser

Spülwasser Ablauf

E rstfiltrat

Abluft

Schlamm

Spülluft

17 m

26 m

19 m

4 m

2 übereinander

angeordnete Filter

Schaltschrank mit

Ventilinseln

Schaltschränke mit

SPS und

Niederspannungs-

verteilung

Kompressoren

Druckluftleitung Feldbusleitung Signalkabel

17 m

26 m

19 m

4 m

2 übereinander

angeordnete Filter

Schaltschrank mit

Ventilinseln

Schaltschränke mit

SPS und

Niederspannungs-

verteilung

Kompressoren

Druckluftleitung Feldbusleitung Signalkabel

7

Example water plant: advantages of pneumatic drives compared to electric drives during the life cycle of a water plant


Life Cycle costs

„ Pneumatic: 199.000,00 €

„ Electromechanic 295.000,00 €

Further technological advantages for the pneumatic solution are

„ Sizes/Mounting

„ # of cycles/Maintenance

„ ability to operate in emergency cases (no energy)

„ maximal permanent load

„ energy consumption

Vergleich Anfangs- zu Folgekosten

159.099,08

222.554,50

39.957,33

72.589,08

0,00

50.000,00

100.000,00

150.000,00

200.000,00

250.000,00

300.000,00

350.000,00

Pneumatik Elektromechanik

Le

be

ns

zy

klu

sk

os

ten

in

€ t

en

Folgekosten

Anfangskosten

Example water plant: advantages of pneumatic drives compared to electric drivesduring the life cycle of a water plant

7


Tool support for analysis of different variants as well as sensitivity studies

„ Estimation of the percentage of different kind ofcosts related to the total costs

„ relation of investment vs operational costsdepending on the operational data, e.g. numberof switchings per day

„ Sensitivity analysis with respect to

„ investment costs of drives

„ number of repairs/failures

„ Calculation of critical values

Vergleich Anfangs- zu Folgekosten

159.099,08

222.554,50

39.957,33

72.589,08

0,00

50.000,00

100.000,00

150.000,00

200.000,00

250.000,00

300.000,00

350.000,00


Le

be

ns

zy

klu

sk

os

ten

in

€ t

en

Folgekosten

Anfangskosten

Preisrabatt für elektrische Antriebe

0,00

50.000,00

100.000,00

150.000,00

200.000,00

250.000,00

300.000,00

350.000,00

0 10 20 30 40 50 60 70 80 90

Rabatt auf den Anschaffungspreis in %

Le

be

ns

zy

klu

sk

os

ten

in

€ d

Pneumatik

ElektrikAufteilung der Kosten

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%


Reparatur und Ausfall

Instandhaltung

Energie

Projektierung

Montage und Inbetriebnahme

Energieversorgung

Feldbusansteuerung

Antriebseinheit

Example water plant: advantages of pneumatic drives compared to electricdrives during the life cycle of a water plant

7


Summary

78

„ Integrated automation systems provide value byenabling end users to

„ reduce costs,

„ increase productivity and

„ secure investments

during plant life cycle

„ Diagnosis functionality supports

„ modern maintenance strategies likepredictive maintenance

„ to avoid unplanned plant shut downs whichis equal to increased productivity

Automation, ways to more productivity and quality


Festo …




Process

Industry

Documents

Automation, ways to more productivity and quality - festo.ir · PDF fileFesto AG&Co KG, Esslingen, Germany Teheran, October 27th, 2009 ... FEC systems • Since 2001:electrical actuators