smarte feldgeräte die basis für industrie 4 - vde rhein … · smarte feldgeräte die basis für...

Smarte FeldgeräteDie Basis für Industrie 4.0Vortragsreihe Automatisierungstechnik 2017

siemens.com/digitalplantUnrestricted © Siemens AG 2017

Unrestricted © Siemens AG 2017 PD PA PI

From Industrie 1.0 to Industrie 4.0,an initiative of the German industry sponsored by the German Government

FirstIndustrial Revolution

SecondIndustrial Revolution

ThirdIndustrial Revolution

FourthIndustrial (R)Evolution

… driven by Digitalization, Integration and enhanced Flexibility

1784: First mechanical loom 1870: First conveyor belt, Cincinnati slaughterhouse,1908: Ford T-Model

1969: First programmable logic controller (PLC) Modicon 084,

1800 1900 2000Time

2025

Characteristics

• Humans, devices and systems are connected along the entire value chain

• All relevant information is available in real-time – across suppliers, manufacturers and customers

• Parts of the value chain can constantly be optimized with respect to different criteria, e.g., cost, resources, customer needs

Unrestricted © Siemens AG 2017Page 4 PD PA PI

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 • Simulation• …

Digital EnterpriseIntegrated Engineering and Integrated Operations

Electrification

Automation

Digitalization

Time

Next level of productivity


“The efficiency of plant life cycle processes will be significantly by a seamless interoperable tool landscape”

“Modelling and simulationare reducing the need for real world testing”

“Digital innovation power speeds up chemical R&D”

“Information, not data, will be the gold of the 21st century”

“Advanced data analytics will be key level to increase productivity”

“Modularization of production is becoming key for higher operational efficiency”

“Collecting data from fragmented sources for efficient analytics”

Customer wishes are driving next level of productivity


“The efficiency of plant life cycle processes will be significantly by a seamless interoperable tool landscape”

“Modelling and simulationare reducing the need for real world testing”

“Digital innovation power speeds up chemical R&D”

“Information, not data, will be the gold of the 21st century”

“Advanced data analytics will be key level to increase productivity”

“Modularization of production is becoming key for higher operational efficiency”

“Collecting data from fragmented sources for efficient analytics”

Customer wishes are driving next level of productivity

Smart Field DeviceEnabler for next level of productivity?


Smart Sensors – the basis for optimization of engineering, processes, operation, maintenance and logistics

Device IntegrationFlexibilityPlant Asset Management

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

commissioningSelf-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

Scenarios for Sensoren 4.0 in process industries

Quelle: VDI/VDE Namur, Technologie-Roadmap “Prozesssensoren 4.0”


Smart Sensors: basis for plant asset management

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

Example control valve


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


Smart Sensors – Sensor information is basis for flexibility

Flexibility

Multi purpose distillation plant unit to increase plant flexibility• Information is basis for

decisions• Matching: Process

requirements and specification of the plant unit

Example plant availability


Virtual description / simulation• Matching of engineering requirements with plant specifications, incl.

sensors. Digital specification and information availabiltiy is basis for decisionInteractivity, connectivity• Necessary, optimized application parameters can be accessed from the netTraceability, serviceability / condition• Data collective is basis for plant unit status and prediction of condition


Pre condition for new automation structuresSmart Sensors as enabler

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 variableSource: 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


Virtuality InteractivityConnectivity Serviceability Traceability


Virtual Description

Virtuality

Integration in simulation and planning tools


Technical specification• Digital, harmonized description of functionalities and attributes• Basis for seamless engineering and commissioningDigital 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

Service

Engineering

Training

Automation

Maintenance


Virtual descriptionData and information consistency of virtual and real world


Virtual description• Simulation models• Technical data for

engineering• Properties• Approvals

Next level of productivity


Customer Challenges and Potential Smart Sensor Solution

Example: Seamless integration of Smart Field Devices in Digital Engineering Tools

Virtuality

• Which device fits to my measuring requirement

• High effort for selectionfitting devices for measuring points

• High effort for integrationof 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

? Engineering


Example: Specific simulation models for field devices allow detailed plant simulation

Virtuality

• Efficient use of automation equipment

• High test effort of Smart Sensor functions

• First testing of automation behavior with final HW –high risk of re-engineering

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 timeReliable automation set-up will prevent errors and will safe time and money



Connectivity

Connectivity

Digital connection of smart sensors to the environment

Smart sensors are the major data source


Context information• Different user groups have the need for different kind of information, context

information are the basis to convert sensor data into informationUser interface to standard hardware• Access to all data via standard tools and hardware• Ensure compatibility to existing IT infrastructureData 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 personService

Engineering

Logistic

Automation

Maintenance



Example: Connection to additional information and functions of a smart field device

Connectivity

• 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 parametersSignificant reduction in engineering, commissioning, cost for testing, and increased performance


Customer Challenges and Potential

Example: Description of functionality by use of integration standards

Connectivity

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

?

DTM FDI

EDD

Smart Sensor Solution



Example: Interoperability ensures smooth integration

Connectivity

Big variety of • Field devices• DCS• Infrastructure components• Integration tools• Smart Sensor functionalities

Pretested Interoperability• Substantial interoperability test to ensure perfect integration

into standard DCS systems• Assured and optimized compatibility of infrastructures

componentsGuaranteed interoperability reduces effort and cost

Today even further• Increase of the

communication types• Increase of product variants• Increase of communication

protocol versions and types• Customer frustration about

integration

?! ! !


Smart Sensors – enabler to merge business processesHorizontal and vertical integration

Field – Smart Sensors

Operation and Maintenance

Service

Engineering LogisticAutomation

Maintenance

Planning

Training


Virtuality InteractivityConnectivity Serviceability Traceability


Traditional field device4 .. 20mA

Traditional sensors provides measurement data

Measurement Data


Traditional field device4 .. 20mA

Smart SensorInformation broker

Smart Sensors the information broker and basis for digitalization

Tech Data 3D Models

Documentation

Digital Communication

Measurement Data

Smartfunctions Self-x

Trace data Certificates

Measurement Data

Simulation

Remote accessRemote HMI

ConditionMonitoring

Security

Context data+


Breadcrumb Topic

Siemens realizes Digital Enterprise for Process Industries through Integrated Engineering and Integrated Operations

Digital Enterprise for Process Industries Focus of Siemens

Integrated Engineering optimizes engineering and life cycle management …

… Integrated Operations improves productivity and flexibility

Cloud-enabled services and analytics

Next generation of Control

Digitalization of field level

Reliable connectivity

Simulation

Common data model

Integrated engineering tools

Product design Process & plant design Engineering & commissioning Operation Service

Digital Twin

Thanks for your attention!Questions?

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