TRIPLE ISOLATION: Protect Data Equipment from Surge Disasters

Ilinx RS-232/422/485 and fiber converters boast superior isolation for rugged industrial applications. Isolated data ports. 10-48VDC operation. 2000V I/O, 10-48V isolated power. Removable terminal blocks. DIN cases. CE, cULus. Pending: cUL, Cl1Div2. B&B Electronics: Your Serial and Data Communication Experts.

More Product Information

Kicking Automation up a Notch...

...with application software. At this stage of the process automation game, plant floor devices, sensors and control systems are pretty much nailed down. But, there is still a disconnect between the plant systems and the enterprise. This week, Invensys Process Systems hosted their Customer Conference in Dallas, Texas. More than 840 Invensys customers attended this event to see Invensys' new wares and share ideas, solutions and knowledge. The theme of this conference is “Know More. Act Faster.” with a primary focus on software.

First, let’s look at a plant automation timeline. In the 70’s through the early 90’s, we focused on operator efficiencies and simply ran the plants. In the 90’s and early 00’s, we focused on engineering efficiencies and optimized the plants. From 2005 and beyond, we’ll focus on plant business efficiencies and optimize the business. But, to do that we first need to get the right data, to the right person, at the right time and in the right context.

As automation professionals, most of us are familiar with the 5 layer automation model (triangle) where the bottom layer is Field Devices, the second layer is Automation Systems (PC, PLC, DCS, SIS), the third layer is Advanced Control & Optimization, the fourth layer is Plant Intelligence (MES) and the fifth layer is Enterprise Systems (ERP). In the “near” (not yet defined) future, we will most likely see this five layer model become three layers, where levels two, three and four will converge. This convergence is already starting to happen (or has happened) in some industries that are more regulated, (i.e. oil and gas, pharmaceutical) and software is playing a much larger role. Automation software has moved up the model.

At the same time, the cost for I/O will continue to go down, especially with the increased adoption of wireless technology. In essence, companies will be able to outfit their entire process, both local and remote, with full control and monitoring capabilities. With all these “senses” in place, companies will be able to see and control the entire process. But, seeing and actually making sense of all the data are two different things. Each discipline (engineering, operations, maintenance, etc.) within a company typically needs/wants the information presented in different ways so they can make decisions. Here lies the real need and challenge for the software.

Invensys believes, and I agree, that low-cost measurements will facilitate unprecedented growth in application software; and application software will facilitate the profitability of companies. In April, Invensys introduced InFusion, an Enterprise Control System built on the principles of Asset Performance Management. The premise of this software framework is to help process companies make better business decisions in real time, and subsequently improve plant productivity and profitability.

According to Invensys, InFusion gives companies a new way of doing business by making the plant visible to the enterprise and the enterprise visible to the plant. To accomplish this collaboration between disciplines within a plant, InFusion performs the following primary functions:

• Integrates data across multiple control sources (including competitors products) into one application environment
• Connects to legacy systems
• Links to ERP systems
• Allows easier implementation of advanced applications
• Allows creation and re-use of application objects
• Enables customized views for individual plant personnel

InFusion addresses a lot of functions that most process plants desperately need to be more efficient and productive. Plant-wide collaboration gives operators the ability to make decisions based on profitability, not expediency. Invensys already has a number of InFusion implementations and success stories. The technology and software is available. The question is…Are plants and their employees ready?

Implementation of such a software system will require a real cultural shift. Companies will first need to face the reality that a large percentage of their workforce will eventually retire and their intellectual property will walk out the door with them. Within the next few years, 40-50% of process control engineers will retire. Individuals with thirty-some years of plant operating experience have knowledge that is not documented and will be difficult to transfer to another person. Plant employees at all levels will need to buy into such an enterprise-wide automation system before it has any hope of success.

I expect some plants will be ready to take the leap and others will not. Like anything else, it’s an evolution that could take years. But, in this competitive global marketplace, every plant will eventually need to take action to improve profitability. Suppliers, like Invensys, are poised to help plants take this monumental step.

For other news from the conference, check out the other Announcements made by Invensys this week.

For more information on Invensys, read Jim Pinto's article - The Invensys/Foxboro Culture – Took a lickin’ & kept on tickin’.

Enjoy the rest of this eNews!

Rick Zabel
Vice President, Editor-in-Chief