Smarte Feldgeräte Die Basis für Industrie 4.0 Vortragsreihe Automatisierungstechnik 2017

Transcription

1 Smarte Feldgeräte Die Basis für Industrie 4.0 Vortragsreihe Automatisierungstechnik 2017 siemens.com/digitalplant

2 From Industrie 1.0 to Industrie 4.0, an initiative of the German industry sponsored by the German Government First Industrial Revolution Second Industrial Revolution Third Industrial Revolution Fourth Industrial (R)Evolution Characteristics driven by Digitalization, Integration and enhanced Flexibility Humans, devices and systems are connected along the entire value chain All relevant information is available in real-time across suppliers, manufacturers and customers 1784: First mechanical loom 1870: First conveyor belt, Cincinnati slaughterhouse, 1908: Ford T-Model 1969: First programmable logic controller (PLC) Modicon 084, Parts of the value chain can constantly be optimized with respect to different criteria, e.g., cost, resources, customer needs Time Page 2

3 Digitalization is the next level to yield productivity within Process Industries Process Industries Electrification, Automation and Digitalization as levers to increase productivity Technological driver Computing power Communication New sensors Virtualization Cloud computing Digitalization Digital Enterprise Integrated Engineering and Integrated Operations Next level of productivity Simulation Automation Electrification Time Page 4

4 Customer wishes are driving next level of productivity Advanced data analytics will be key level to increase productivity Digital innovation power speeds up chemical R&D Modularization of production is becoming key for higher operational efficiency Modelling and simulation are reducing the need for real world testing Collecting data from fragmented sources for efficient analytics The efficiency of plant life cycle processes will be significantly by a seamless interoperable tool landscape Information, not data, will be the gold of the 21 st century Page 6

5 Customer wishes are driving next level of productivity Advanced data analytics will be key level to increase productivity Digital innovation power speeds up chemical R&D The efficiency of plant life cycle processes will be significantly by a seamless interoperable tool landscape Modularization of production is becoming key for higher operational efficiency Smart Field Device Enabler for next level of productivity? Modelling and simulation are reducing the need for real world testing Collecting data from fragmented sources for efficient analytics Information, not data, will be the gold of the 21 st century Page 7

6 Smart Sensors the basis for optimization of engineering, processes, operation, maintenance and logistics Scenarios for Sensoren 4.0 in process industries Plant Asset Management Flexibility Device Integration Information for optimization Planning of revision example control valve Access to diagnostic data e.g. motion profile Cross linking of information for optimization of diagnostics => Lifetime prediction Multi purpose distillation plant unit to increase plant flexibility Information is basis for decisions Matching: Process requirements and specification of the plant unit Smart functions simplify sensor usage and enable plug and play functionality Fast, secure commissioning Self-x Self diagnostics Self calibration Self configuration Procurement of raw materials and product sales Cross-linking of information Procurement, logistics, order management, plant availability Ubiquitous Information Quelle: VDI/VDE Namur, Technologie-Roadmap Prozesssensoren 4.0 Page 8

7 Smart Sensors: basis for plant asset management Example control valve Plant Asset Management Planning of revision example control valve Access to diagnostic data e.g. motion profile Cross linking of information for optimization of diagnostics => Lifetime prediction Interactivity and connectivity Smart sensors provide measurement data and context information Linking with information out of the environment Link Valve position with pressure and flow cavitation detection Turbidity and ph-sensor abrasion and corrosion detection Serviceability Data collective to derive valve state and predict remaining lifetime Quelle: VDI/VDE Namur, Technologie-Roadmap Prozesssensoren 4.0 Page 9

8 Smart Sensors Sensor information is basis for flexibility Example plant availability Flexibility Multi purpose distillation plant unit to increase plant flexibility Information is basis for decisions Matching: Process requirements and specification of the plant unit Virtual description / simulation Matching of engineering requirements with plant specifications, incl. sensors. Digital specification and information availabiltiy is basis for decision Interactivity, connectivity Necessary, optimized application parameters can be accessed from the net Traceability, serviceability / condition Data collective is basis for plant unit status and prediction of condition Quelle: VDI/VDE Namur, Technologie-Roadmap Prozesssensoren 4.0 Page 10

9 Pre condition for new automation structures Smart Sensors as enabler Connectivity Serviceability Traceability Virtuality Interactivity Quelle: VDI/VDE Namur, Technologie-Roadmap Prozesssensoren 4.0 Expectation for a smart sensor Plug and Play, automated integration in plant structure Self calibration, diagnosis, prediction Communication (sensor-sensor/sensor-dcs) Multi Sensor / multi variable Source: Survey Smart Sensors Namur Hauptversammlung 2015 Drivers Less skilled and less people available for plant operation and maintenance Central operation of plants Maintenance and service is outsourced More information of process state, trend and quality Central optimization of logistic processes Page 11

10 Virtual Description Virtuality Integration in simulation and planning tools Engineering Maintenance Training Automation Service Technical specification Digital, harmonized description of functionalities and attributes Basis for seamless engineering and commissioning Digital models 3D models, virtual functional description for engineering, commissioning, operation and training as well as for maintenance and service. Models for plant and automation simulation Quelle: VDI/VDE Namur, Technologie-Roadmap Prozesssensoren 4.0 Page 12

11 Virtual description Data and information consistency of virtual and real world Next level of productivity Virtual description Simulation models Technical data for engineering Properties Approvals Quelle: VDI/VDE Namur, Technologie-Roadmap Prozesssensoren 4.0 Page 13

12 Example: Seamless integration of Smart Field Devices in Digital Engineering Tools Virtuality Customer Challenges and Potential Smart Sensor Solution? Engineering Which device fits to my measuring requirement High effort for selection fitting devices for measuring points High effort for integration of device data into planning tool Automated purchasing process increases Purchasing efficiency required More and complex product information at high quality required Interface from virtual field device to digital engineering tools Product configuration, comparison, and selection Seamless integrated inside the engineering environment Consistent and up-to-date data in all planning stages Significant effort reduction and quality increase in the engineering phase Page 14

13 Example: Specific simulation models for field devices allow detailed plant simulation Virtuality Customer Challenges and Potential Smart Sensor Solution Efficient use of automation equipment High test effort of Smart Sensor functions First testing of automation behavior with final HW high risk of reengineering Basic functionalities for digitalization Virtual Commissioning: test original automation software and smart field device functionality Operator training: train the interaction with original software Simulation models of virtual field devices Faster commissioning: automation engineering tested early w/o final hardware; including specific field device functions Higher engineering quality: early detection of errors and more comprehensive automation checks Lower costs: avoiding re-engineering and shorter commissioning time Reliable automation set-up will prevent errors and will safe time and money Page 15

14 Connectivity Smart sensors are the major data source Connectivity Digital connection of smart sensors to the environment Engineering Maintenance Logistic Automation Service Context information Different user groups have the need for different kind of information, context information are the basis to convert sensor data into information User interface to standard hardware Access to all data via standard tools and hardware Ensure compatibility to existing IT infrastructure Data security and availability Communication has to be standardized and secure Any kind of information must be accessible from any place at any time for every authorized person Quelle: VDI/VDE Namur, Technologie-Roadmap Prozesssensoren 4.0 Page 16

15 Example: Connection to additional information and functions of a smart field device Connectivity Customer Challenges and Potential Smart Sensor Solution Generic faceplates support only standard device functions High integration effort for specific device functions Risk of data inconsistencies Efficient engineering Access to additional device functions Avoid inconsistency for device parameters Specific faceplates for efficient use of connectivity Simplified checks due to easy access to special functions in the device e.g. partial stroke tests Analysis of status via integrated diagnostics Improved plant operation due to one single view with all necessary parameters Significant reduction in engineering, commissioning, cost for testing, and increased performance Page 17

16 Example: Description of functionality by use of integration standards Connectivity Customer Challenges and Potential? Smart Sensor Solution EDD DTM FDI Different tools and systems for Parameterization Diagnostics Commissioning Maintenance, Service Higher efficiency required for commissioning and overview of plant wide diagnosis Field device access Mobile accessibility in the field Smart functionality Field device description via EDD, DTM, FDI Support of all standard field device integration technologies Support of the common device integration technology FDI Tested interoperability for all integration packages Smart Sensor capabilities require harmonized and powerful field device descriptions Page 18

17 Example: Interoperability ensures smooth integration Connectivity Customer Challenges and Potential? Smart Sensor Solution!!! Big variety of Field devices DCS Infrastructure components Integration tools Smart Sensor functionalities Today even further Increase of the communication types Increase of product variants Increase of communication protocol versions and types Customer frustration about integration Pretested Interoperability Substantial interoperability test to ensure perfect integration into standard DCS systems Assured and optimized compatibility of infrastructures components Guaranteed interoperability reduces effort and cost Page 19

18 Smart Sensors enabler to merge business processes Horizontal and vertical integration Planning Operation and Maintenance Engineering Automation Training Maintenance Service Logistic Field Smart Sensors Connectivity Serviceability Traceability Virtuality Interactivity Page 22 Quelle: VDI/VDE Namur, Technologie-Roadmap Prozesssensoren 4.0

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32 Traditional sensors provides measurement data Traditional field device mA Measurement Data Page 41

33 Smart Sensors the information broker and basis for digitalization Traditional field device mA Smart Sensor Information broker Measurement Data Measurement Data + Context data Tech Data 3D Models Simulation Trace data Certificates Documentation Digital Communication Remote access Remote HMI Security Smart functions Self-x Condition Monitoring Page 42

34 Siemens realizes Digital Enterprise for Process Industries through Integrated Engineering and Integrated Operations Digital Enterprise for Process Industries Focus of Siemens Breadcrumb Topic Integrated Engineering optimizes engineering and life cycle management Digital Twin Integrated engineering tools Simulation Common data model Thanks for your attention! Questions? Cloud-enabled services and analytics Next generation of Control Digitalization of field level Reliable connectivity Integrated Operations improves productivity and flexibility Product design Process & plant design Engineering & commissioning Operation Service Page 43