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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
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 ?
