Process Automation Market and Trends...April: mobiLink TBA Launch August: TBA March: June: Webinar...
Transcript of Process Automation Market and Trends...April: mobiLink TBA Launch August: TBA March: June: Webinar...
18th June 2018, Haar Thomas Hilz, Program Marketing Manager Process Automation
Process Automation – Market and Trends
Copyright © 2018 Softing Industrial. All rights reserved. 2
Table of Contents
1.
2.
3.
Characteristics of Process Automation
Market Size and Growth
Break – Market Survey Questions
4. Eco System and Stakeholders
Introduction
5. Trends in Process Automation
6.
Introduction
Summary & Q/A
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Partner Webinar – Schedule
Q1 Q2 Q3 Q4
April:
mobiLink
Launch
August:
TBA
March:
Webinar
Kick-off
Continuous feedback from Channel Partners
Embedded market surveys
(not more than 5 closed multiple
choice questions)
Oct:
TBA
May:
DN-Gateways
for Process
Automation
June:
PA Market
Overview
July:
mobiLink
PA
Upgrade
Sept:
TBA
Nov:
TBA
X2 Webinars per month: Monday 9am CET & 4pm CET
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Webinar: Calendar
• IA DN PA Webinar: March (19th)
• 2. IA DN PA Webinar: April (17th)
• 3. IA DN PA Webinar: May (14th)
• 4. IA DN PA Webinar: June (18th)
• 5. IA DN PA Webinar: July (16th)
• 6. IA DN PA Webinar: August (20th)
• 7. IA DN PA Webinar: September (17th)
• 8. IA DN PA Webinar: October (15th)
• 9. IA DN PA Webinar: November (19th)
Scheduled Webinars
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Table of Contents
1.
2.
3.
Characteristics of Process Automation
Market Size and Growth
Break – Market Survey Questions
4. Eco System and Stakeholders
5. Trends in Process Automation
6. Summary & Q/A
Introduction
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Components and Tasks of Process Automation (= Process Industry = Process Manufacturing) Measuring, control and automation
technology used in plants of process industries
For measuring, regulating, controlling and interlocking process-related processes, e.g. heating, cooling, evaporating, condensing, separating, mixing, stirring and analyzing
Includes sensors, actuators, analyzers (e.g. gas and liquid analysis), process control, communication and interface technology; and planning, management; and monitoring software
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Process Control
The process control technology provides means and methods for controlling, regulating and safeguarding process engineering plants.
Requirements and solutions for automation technology in the manufacturing and process industries differ so much that one can speak of two worlds.
Many providers only serve one of the two worlds. Only recently have some companies ventured into foreign territory.
There are hardly any communication solutions that are suitable for both worlds (PROFIBUS-DP + PROFIBUS-PA or PROFINET + PROFIBUS-PA only).
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Process Industry vs. Discrete Manufacturing
Process Industry Discrete Manufacturing
Substance conversion, treatment, recovery Fabric transformation (forming, separating, joining)
Continuous or discontinuous (batch) processes Discrete (synchronized) manufacturing and assembly processes
Batch production (weight, volume) Lot size production (piece)
Recipes Parts lists
Production process can usually not be stopped Production process can usually be stopped at any time
Safe state is process-dependent (exothermic reactions)
Safe state = plant shutdown
Long operating phases and very long plant utilization periods
Short operating phases (shift) and average system utilization periods
4..20 mA, HART, FF, PROFIBUS-PA CAN, PROFIBUS-DP, Modbus, DeviceNET, ControlNET PROFINET, EtherCAT, EthernetIP
Process industry processes substances and materials in chemical, physical, biological or other technical methods and processes.
Segments
Chemical
Oil & Gas
Pharmaceuticals
Food & Beverage
Pulp & Paper
Glass
Steel
Cement
(Energy)
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Continuous Process
A process in which there is a continuous (uninterrupted) transformation (synthesis, chemical reaction) to produce the final product.
High capacity, low flexibility, advantageous for large products
Examples:
Catalyst in a vehicle (fixed bed reactor, substances are continuously supplied and extracted)
Division of crude oil into various products in the distillation tower of a refinery
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Batch Process
A process that leads to the production of limited quantities of substances by subjecting quantities of inputs to an orderly sequence of process activities using one or more facilities within a defined period of time.
Low capacity, high flexibility, advantageous for specialty products
Set-up times for cleaning and refilling the reactor vessels
Examples:
Cook noodles or bake cakes (stirred tank reactor)
Brew beer or burn liquor
Production of pharmaceuticals, fine chemicals, paints
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Hybrid Industries
Combination of continuous or batch processes with (downstream) discrete manufacturing processes to produce the final product.
Example:
Beverage industry, pharmacy, fine chemicals: production (batch) and bottling (discrete)
Hybrid industries are of interest to Softing because of the need to converge and combine automation solutions for the manufacturing and process industries.
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Special Requirements of PA
Continuous operation
PA plants often run for several years without interruption, which leads to high demands on the availability of the automation components. Configuration changes must be made during operation (configuration in run), as well as device replacement in case of component failure.
Redundancy
The high availability requirements can only be achieved through redundancy (components are available multiple times). Typically, controllers and critical infrastructure components are duplicated. For very high requirements you will also find 2-of-3 systems.
Explosion Protection
Since flammable gases or liquids are often processed, special measures to prevent explosions must be taken. This also applies to all automation components that are subject to the corresponding approval procedures.
Functional Safety
Processes often have a high risk potential for humans and the environment (Bhopal, Seveso, ...), which is why Functional Safety plays an important role in plant design and automation technology.
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Distributed Control System (DCS)
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Transmitters (Sensors)
Temperatur Pressure
Flow Level
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Valves and Actuators
Pneumatic Valve with Positioner
Electric Valve
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Functional Hierarchies of Integrated Process Automation
IT
AT
Pla
nn
ing
Dat
a A
cqu
isit
ion
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Evolution of Industrial Communication
PA
RTE
FA
1975 1980 1985 1990 1995 2000 2005 2010
Ethernet
Modbus
FIP
PROFIBUS
DP
MAP
SINEC H1
INTERBUS sercos sercos II
sercos III
FF-H1
FF-HSE
PROFIBUS
PA
CC-Link
CAN
CANopen
DeviceNet
EtherCAT
Ethernet
POWERLINK
PROFINET IO
HART
Modbus TCP
Ethernet/IP
ISP
PROFIBUS
FMS
wirelessHART
ASi IO-Link
HART IP
WorldFIP
Modbus
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Applications for Industrial Communication
einf. Sensor
Sensor/Aktor
Remote IO
SPS / DCS
PC/IPC
ERP
Process Industry Manufacturing Industry
(HART)
FF-H1
PB-PA
FF-HSE
wirelessHART
PROFIBUS-DP-V1
OPC UA
PROFINET IO
etherCAT
sercos 3
POWERLINK
Ethernet/IP
PROFIBUS DP-V2
PROFIBUS DP
Motion Control
(Fast isochronous
communication)
Continous
Process
(e.g. Oil & Gas)
Fast processes in hybrid plants
(e.g. filling machines)
PROFIBUS DP
ASi
(4..20 mA)
(IO-Link)
Sercos 1+2
DeviceNet
Manufacturing Process
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Table of Contents
1.
2.
3.
Characteristics of Process Automation
Market Size and Growth
Break – Market Survey Questions
4. Eco System and Stakeholders
5. Trends in Process Automation
6. Summary & Q/A
Introduction
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World Market for Process Automation Grows Annually by 4%
175 184 192 195 201 209
218
0
50
100
150
200
250
2013 2014 2015 2016 2017 2018 2019
Billion €
Source: ZVEI
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Areas of Activities Over the Plant Life Cycle
Our business opportunities for gateways derive from considerations of the plant planning
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Almost 50% of the total market is attributable to three sectors
Source: ZVEI
5%
10%
15%
15%
9%
19%
7%
9%
8%
3%
Wasseraufbereitung und Abwasserwirtschaft
Minenwesen und Metalle
Energieerzeugung
Erdöl- und Erdgasgewinnung
Mineralölverarbeitung
Chemie
Pharma
Nahrungs- und Genussmittel
Maschinenbau
Paper und Zellstoff
Water and Waste Water
Mining and Metals
Energy
Oil and Gas Exploration
Oil Processing
Chemical
Pharmaceutical
Food and Beverage
Machine Building
Pulp and Paper
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Slight Growth Impulses from Oil & Gas
Especially "non-cyclical" industries like
• Pharma,
• Water / sewage and
• Food and beverage
with continuous growth
In addition, electric power generation offers good business opportunities
Above-average growth (> 3%) in field buses and especially Industrial Ethernet
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Regional Distribution of Process Industry Investments
Source: ZVEI
27,1%
19,5%
8,5%
6,7% 3,5%
2,5%
3,0%
3,0%
26,2% China
USA
Deutschland
Japan
Südkorea
Großbritannien
Frankreich
Italien
ROW
China
USA
Germany
Japan
South Korea
Great Britain
France
Italy
ROW
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Distribution of Field Level Protocols
Source: Softing Estimations
7,87%
1,82%
2,78%
44,79%
0,24%
0,12%
26,63%
7,26%
8,47% PROFIBUS DP in Process Automation
PROFIBUS PA
FOUNDATION fieldbus H1
HART
WirelessHART
ISA 100.11a
pure 4 … 20mA
Pneumatic
Proprietary
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Table of Contents
1.
2.
3.
Characteristics of Process Automation
Market Size and Growth
Break – Market Survey Questions
4. Eco System and Stakeholders
5. Trends in Process Automation
6. Summary & Q/A
Introduction
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Engineering, Procurement and Construction (EPC) Contractor
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The MAC is a "super-system integrator" that acts as a "general contractor" for automation technology. Parts of the total offering can be provided by third-party, specialized service providers, such as
- Electricians
- Commissioners
- System integrators for special subsystems / topics
- …
All major system manufacturers in process automation have their own SI departments, which can also act as MACs.
Main Automation Contractor (MAC)
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System integrators are specialized companies, which market technical integrate (sub) systems in production facilities to create a production system.
They install the selected automation components, commission them and validate the functionality of the overall system.
The ultimate goal is for all plant elements to be isolated and functioning as an overall system according to the objective.
System Integrators (SI)
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SIs serve the entire life cycle, in particular in the process industry
From planning to installation, commissioning and acceptance to plant maintenance and decommissioning
New plants and plant extension
Total suppliers or specialists for partial services or specific topics
Often specialized in selected (system) providers; e.g. Siemens, Schneider Electric, ...
Focus on marketing own services
Source: Control Global
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List of Top 40 System Integrators – Top 50 Companies
Source: Control Global, 2018
https://www.controleng.com/events-and-awards/system-integrator-giants/2018-system-integrator-giants.html
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Selection of Organizations with Relevance to Process Automation
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Table of Contents
1.
2.
3.
Characteristics of Process Automation
Market Size and Growth
Break – Market Survey Questions
4. Eco System and Stakeholders
5. Trends in Process Automation
6. Summary & Q/A
Introduction
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Goals of Industrie 4.0 and IoT are also Valid for Process Automation
Realization of • Resource efficiency • Cost reduction (CAPEX and OPEX) • Increasing flexibility
require comprehensive integration and networking
for optimizing processes and equipment
with
digitization and "ethernetization" as a prerequisite
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NE 74
With Ethernet into Field (APL) APL Group exists of PNO, ODVA and Fieldcomm Group
Two-wire solution for the Ethernet communication in the field
Profibus PA cables as well as common shielding concepts can still be used
Phase 1: 10Mbps - Phase 2: 100Mbps (500m max)
PNO sees a solution package for the process industry consisting of PROFINET, PA profile for PROFINET, FDI and Ethernet in hazardous areas
OPC UA server with FDI device descriptions, operating and repair instructions in the field device.
Ethernet switch in zone 2 (max 50 devices), 1000 m long 2-wire solution with power supply ("Trunk") in protection class Ex e for zone 1, field devices in zone 0 via two conductors in up to 200 m ("lane ", Ex i)
Standardization pushed (IEEE taskforce for IEEE 802.3 extension)
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„Namur Open Architecture“ (NOA) with Two Communication Channels
Reduction in the complexity of DCS
Use of proven DCS
Complement to open interface for the use of dynamic technologies for e.g. data analysis
OPC UA currently "traded" as preferred communication technology
Core Process 4 … 20mA
BOM, MOM
DCS
(Condition) Monitoring
(Process) Optimization
Data Data
Information Information
Analytics Analytics
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Modular Automation for More Flexibility in Production
Particularly relevant for the production of small batches and for "multipurpose plants" (for example fine chemistry and pharmacy)
Responsibilities and expenses "migrate" from the system integrator to the module supplier
NE 148 knows i.W. two module types, autonomous (with own control) and those directly integrated via I / Os NE 148
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Modular Plants will Complement Existing Plants
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Table of Contents
1.
2.
3.
Characteristics of Process Automation
Market Size and Growth
Break – Market Survey Questions
4. Eco System and Stakeholders
5. Trends in Process Automation
6. Summary & Q/A
Introduction
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Marketing relevant conclusions
Our gateways and mobile interfaces have good cross-industry potential
System and device manufacturers remain our target group for technology integration and especially for the mobiLink for device parameterization
System integrators are the strategic target audience / strategic channel especially for our gateway business
SI-relevant organizations, trade fairs, web-publishers and conferences as well as the partner programs of the big manufacturers are the platforms to get in contact for solutions
Trainings and especially application support is the key to SIs success
Thomas Hilz Program Marketing Manager Softing Industrial – Data Networks Tel: +49 89 45 656 - 168 Mobile: +49 1577 141 2445 Email: [email protected]
Thank you very much for your attention! Any questions? Feel free to ask!
industrial.softing.com/en