This approach optimizes user acceptance and reduces deployment costs. This is the first solution to combine an orchestration layer and a module layer integrated with the technology of module type packages (MTPs). Common examples of modular procedural automation are in the following areas: well flow lines and test separators, regulatory compliance in emergency shutdown (ESD) checks, and temperature safety checks, subsea compliance communication checks, ramping-up of wells, recovery from unit trips minimizing spillage and flaring, and advanced transition management to improve equipment life. This improves flexibility and standardization while reducing engineering and maintenance costs. LNG is a clear, colorless, nontoxic liquid that forms when natural gas is cooled to around -160 DegC. Only today is the economy and technology available to begin the extraction of natural gas in large underground fields. QTP Modular Framework solves only one of these limitations. These are safety and compliance testing procedures in the upstream industry. Modular definition, of or relating to a module or a modulus. Imprint With the modularization approach, procedures are constructed like “building blocks”. While modular construction itself isn’t a new concept, a recent report from McKinsey & Company acknowledges that we’re now at a point where technology is making it a more viable solution. Check base tank level LI100.PV>=50% Keyword Driven Automation Framework. Typically the operations team is not in charge of the control system configuration and engineering. This contributes to extended equipment life and optimized production or product yield. Multiple modules can be tested simultaneously and hence supports parallel testing 3. See more. https://www.youtube.com/watch?v=z7aqkUb7aUI, https://www.youtube.com/watch?v=_dA7VNou02c, Artificial Intelligence and the Sushi Sensor. Deployment to the actual remote upstream site then happens quickly and safely. U.S. government regulations have tightened up considerably and now it’s not only important to demonstrate that you have a procedure but are actually following it and further can prove you are following it. Since the early 2000s, there’s been a renewed interest in modular construction due to breakthroughs like BIM, 3D-printing, and automation. Transition management applies equally to a complete process unit and to a selected piece of equipment in a processing unit, like a shutdown valve, or a test separator or a heat exchanger. In light of this constant technological advancement, the basic functions of home automation remain largely the same. Modular automation transforms it into a flexible system that allows you to quickly and easily adjust the production volume by removing modules (numbering down) or adding modules (numbering up). “Modular Automation is doing phenomenally well,” adds Burfield. A module, also known as a package, assembly, or unit, is an independent portion of code that acts as a single building block for more complex systems. The actual risk of safety events and spill occurrences are kept very low because the consequences of any excursion are huge. However, after evaluation and consultation with operation teams, the best practice, “know-how”, was added to the initial SOP flow chart. For our example, we’ll take a water filtration system design with a central controller and control system that was once commonly used. Often operators perform these procedures based upon their training and experience gained over the years and upon reference to written documents such as SOPs. Modular automation has rapidly gained dominance; in fact, with systems consisting of several stand-alone modules, operations become much more flexible and faster than they were with conventional systems designed from individual parts. Therefore, providing limited information to the operator hampered his ability to make procedure decisions, take action on alternatives, and realize the reasons for current process states. The original SOP was simply: • Recommended target platforms (i.e. basic process control systems vs. safety control systems) for different types of procedures Modular Procedural Automation (MPA) can help to facilitate the process of capturing the knowledge of these skilled employees before they retire or are laid off as recent research has shown that up to 42 percent of all corporate knowledge is actually stored in employee’s brains. As is typical in these applications, safety, and spill performance are paramount in the matrix calculation of operational cost. This object fully represents from an automation perspective the complete functionality of that raw material delivery system. If an abnormal situation takes place or an operator intervenes, the sequence can be held or perform exception handling. When procedural logic (that is portions or modules of procedures) is re-used, business gains repeatability, reliability, and it lowers the cost of developing duplicate procedures. The goal is to improve overall performance through faster and smoother transitions. In the last two years, another category of procedural operations has become more important involving a significant amount of time for the upstream operator. How to choose a control system that manages the operation of the process modules? • Exception handling of abnormal process conditions With the technology and early adoption of the idea of modular automation ABB is the right partner in this area.” Dr. Torsten Knohl, Senior Project Manager, Bayer AG. Start pump P-101 after correct suction header pressure is confirmed There can be considerable variability in performing manual procedures as some operators or shifts often have better skills or more experience. In the last two years, this work is now being applied to the upstream industry and particularly to off-shore production platforms. For example, the natural gas quality determines how much pretreating and energy will be required to make an LNG product to specification before transport. Multi-site Consistency: Companies with multiple production sites can experience an efficiency gain and product improvement by standardizing procedural knowledge between plants. The other limitation (data re-usability) still looms large. Incidents that occurred during startup and shutdown continued to be a major factor. The goal of this approach is to “distill” best-operating practices and find the right balance between manual, prompted and automated procedures, documenting and implementing the procedures and then executing continuous improvement cycles on them. Procedure documentation can then be readily available to the operator and is a living document. Utilizing the Best Toolset Depending on Requirements: Although there may already be an installed base with existing control capability in a plant, using the MPA methodology the procedure requirements are first understood and documented, and then the best tool for automated procedure execution is recommended. Procedure management and control require a verbose interface but control systems by their nature limit this ability. This meant that the skill and knowledge of running the operational procedure stayed with the operators and operations staff and not with the control system designer or engineer. Modular Automation. Modular solution: In a modular implementation, the new raw materials functionality is implemented as an object. Sequential and batch control functions were added later and the logic was more complex. How Modular Automation is Becoming Part of Everyday Life, How to achieve perfect orchestration of modular plants, ABB provides modular enabled automation solutions for the process industry, ABB launches world’s first commercial modular enabled process automation solution. Modularity avoids duplicacy of code. Autonomous operation- the future of automation? Privacy Policy, Artificial intelligence (AI) empowers the Sushi Sensor You might have, How Digital Transformation impacts Plant Availability, Digitization, which originally meant the conversion of analog information into digital formats, has now been almost completely implemented. It covers the sharing of operational knowledge and experience, the implementing of procedure consistency, and the use of modular implementation. The actual procedural knowledge and skill are in the heads of the most experienced operators. A procedure consists of a set of tasks that are conducted in a set way to achieve a certain goal. How to preserve the knowledge of the best operators on his/her best day has become the question. In the 1990s operator support tools or advanced operator assistance functions began appearing which were independent of the control system. Automating procedural operations help reach maximum performance in the five areas mentioned above but also in maintaining equipment life. Automated procedures for continuous processes in the past have typically been implemented using ad-hoc designs and programming techniques usually resulting in difficult-to-maintain code. However, procedural operations are again paramount in maintaining facility performance and environmental standards. It is written for the capabilities of the system. By staying here you are agreeing to our use of cookies. Increased speed of machine integration Increased speed of system commissioning Increased plant floor space available for manufacturing Reduced Mean time To Repair (MTTR) Adopting leaner automation boosts aircraft builders F-35 airframe assembly line. Figure 1, below, depicts the methodology of capturing procedural best practices. MODULAR AUTOMATION IRELAND LIMITED is a LTD - PRIVATE COMPANY LIMITED BY SHARES company based in Smithstown Industrial Estate, Shannon, Co Clare Shannon, Ireland, which employs 6 people. A procedural operation consists of a set of operator tasks that are conducted in a set way time-after-time to achieve a certain goal such as starting or shutting down a unit or making a product. There are three broad operational procedures involving transitions: startup, shutdown and unit state change. • Training and certification best practices. As many firms continue to operate with lean technical staff, yet the level of technological complexity is increasing, the timely flow of information, data, and knowledge is more important than ever in the process industries. Moved into purpose-built, 12,500 sq. Using a modular approach as offered by MPA provides a number of benefits such as: Due to the need for a procedural automation industry standard, the ISA (International Society of Automation) approved the formation of a new committee in April 2010, and it adopted the title “Procedural Automation for Continuous Process Operations”. Upstream automation procedures are helping reduce costs, improve regulatory compliance, and improve the facilities’ performance by. Are Machines Better Than Humans in Crisis? This is shown pictorially within the red, dotted boxes. The SOPs are updated and converted into an electronic-based procedure. Manual procedures are performed by operators taking actions either in the control room or in the field. Modular design, or modularity in design, is a design principle that subdivides a system into smaller parts called modules (such as modular process skids), which can be independently created, modified, replaced, or exchanged with other modules or between different systems. Plant Historian: Core of your Digital Transformation. 1993 . Popular Tools that are used for Functional automation: Your data will be safe!Your e-mail address will not be published. It has since become ISA106. Procedural operations are now being used in the Gulf of Mexico for compliance testing. So, you cannot use QTP modular framework alone in many of your automation projects (especially if your test cases need to be validated against multiple sets of data). Together the five areas mentioned above are the places for implementing advanced procedure automation integrated into the operator’s console. On the right-hand side is the resultant “best-practice” procedure. The first draft was issued in May 2011, has gone through a thorough review and will be re-issued in January 2012. A fourth area that is added to transition management is “abnormal” process state changes, like a process trip resulting in a well shutdown or a larger event causing a platform shutdown. I was inducted into the Process Automation Hall of Fame in 2011. We specialise in delivering top quality, reliable solutions for the world’s leading medical device and technology manufacturers. By staying here you are agreeing to our use of cookies. This downward trend in staffing and the increased demand for accurate, real-time information will translate into additional systems and higher, more sophisticated levels of automation being applied, including Modular Procedural Automation. Company registration number is IE296291. From modular engineering to modular automation and services - fast and efficient thanks to MTP Get insights how to implement the "modular production" concept using Siemens' engineering, simulation and automation software. In the future, if there is any change in the series of action, all you have to do is to make changes in your main modular method script. My primary work with Yokogawa involves working with international organizations to understand the impact of digital transformation on our current and future business and also working with global standards development organizations (SDO’s) in the development of standards for operator decision support, smart manufacturing, robotics, and autonomous operations. We deliver outstanding automation solutions for advanced manufacturers worldwide including custom soultions, build-to-print machines & precision tooling. Since that first meeting, the committee has grown in size substantially, met face to face several times and held monthly teleconferences. Procedure execution is documented, recorded and reported automatically. Documentation for process improvement or compliance requires manual records which can vary in quality and be difficult to gain benefits from without additional data analysis. As demonstrated by Paul McKenzie (Bristol Myers Squibb) at the World Batch Forum (WBF) North America conference 2007 in Baltimore, it could even apply to the operation of an analyzer. • Implementation of startup, shutdown, abnormal conditions, hold states, and transition logic Developers can run and test different software functions through modules without rewriting multiple lines of code every time a change is made. The initial goal is to publish a technical report based on good practices that are used today. Modular procedures, both prompted and automated, allow easy sharing of procedural knowledge between facilities. Figure 1: Capturing Procedural Best Practices. The common types of office automation. Learn how the ecosystem of machine/plant builder, plant owner and system supplier could look in the future. ABB has implemented world's first commercial solution for cost-effective modularization at one of the major life science companies, Bayer AG. Following that, the committee plans to refine the material and hopes to publish a standard. Now, driven by changes in consumer demands, an alternative … Typical items of concern are water, acid gases, sulfur compounds, carbon dioxide, heavier hydrocarbons, and heavy metals. An overview of modular robotics. Probability of identifying errors or bugs on smaller chunks of program becomes higher 2. If you look back at the functions available to control systems for both programmable logic controllers (PLC) and distributed control systems (DCS), they focused on discrete and continuous control. Modular design in automation: What we’ve learned playing with LEGO bricks Modular design, whether natural or created by humans, is all around us. No test case will be impacted by the change. The implementation was constructed of modules performing specific tasks and procedures. Bring along a notebook and pen for note taking A definition of automation risk with examples. Go to the brochure. Batch processes are procedural in nature, but typically involve sets of procedures running in parallel on varying process units and almost always need to have inbuilt flexibility. Conditions At the first meeting in June 2010, the committee agreed that its purpose was to develop standards, recommended best-practices and to publish technical reports on the lifecycle of automated procedures for continuous process industries. I have 40 years of experience in decision support, human factors, batch solutions, procedural operations, HMI design, advanced process control, benchmarking analysis, the chemicals and refining industries and developing related standards. One key area was in messaging and communicating back to the operator. Moving from monolithic automation systems for complete production plant to modular-enabled, more flexible and service oriented plug and produce automation solutions will allow faster process implementation, ability to scale the capacity by numbering up and down the production … Confirm deck operator opened hand valve HV100. • Process unit orientation with an operational perspective Modular Automation is the right solution for process industries that are facing market requirements such as more customized products, shorter delivery times and smaller batch series down to batch size 1. But the time window is narrow and is very challenging to do during an abnormal event and most often the affected process is brought to a much longer shutdown state with the result of higher production losses. Hierarchy of Procedures: MPA breaks large and complex procedures into smaller modules and organizes them into a hierarchy. A global standard with best practice is developed and deployed. MODULAR AUTOMATION Modular automation has rapidly gained dominance; in fact, with systems consisting of several stand-alone modules, operations become much more flexible and faster than they were with conventional systems designed from individual parts. Hybrid Automation Framework. Development of automated procedures took into account operator experience (capturing best-practices), analyses of existing procedures and historical data. Participants should occupy their seat 5 minutes before the start of a lecture 2. Advanced PLCs For advanced machine designs and controlling manufacturing cells, including infrastructure and site-wide management, System Q’s advanced PLC CPUs offer incredible performance and versatility. Modular. Some of the events challenging the upstream industry today are rising operating costs and tougher extraction of oil and gas due to rising complexity. Different types of procedure implementations contain scalability for manual, prompted, and automated control. Over the last decade, many papers have been published describing the implementations and the results achieved. 1995 . Without modular procedural automation techniques, this level of standardization would be very cumbersome to maintain. Modular Automation, based in Shannon Co. Clare, is an Irish award winning leader in the design, build and installation of technologically smart automation solutions for manufacturing environments. Programmable Logic Controller available in two type, that is Modular and Compact. In this case, after a shutdown or trip, the cool-down procedure for the main cryogenic heat exchangers (MCHEs) was used to achieve a predefined temperature profile. Transitions also inherently increase the risk of disruptions that can lead to incidents or lost production. CAD design department established . The products are no longer a commodity and we move towards very small batches. ABB provides complete protection, automation and control systems for an entire substation integrated into a modular building, that is tested and delivered to site. Modular Protection Automation & Control (MPAC) ABB Electrification Distribution Solutions. I am a PhD Chemical Engineer and Executive Advisor to Yokogawa’s Marketing HQ in Tokyo, based in Ilminster, UK. Check answer back flag • State models for procedural logic “In life sciences the production is now more focused on the patient and the given problem with personalized medicine. The topics being considered for the standard are: • Models and terminology Modular systems are also used in other industries (e.g., shipbuilding) where simple integration into higher-level systems is the key to success. ABB's website uses cookies. Modular Automation Framework. This article shows the definition and difference between modular PLC and compact PLC which is crucial in industrial automation. This shrinks the volume of the gas 600 times, making it easier to store and transport. So how was the journey to modular procedural automation? The ISA-88 standard ultimately addressed batch automation very well, however, attempts were made in the 1970s and 1980s to implement advanced procedure management using control system functions with strings of function blocks or by straight-line coded applications. Get in touch with us online via our website, by phone or by e-mail to discuss your manufacturing challenge with one of our senior engineers. Also other data will not be shared with third person. Re-use of Procedural Logic: Whether implemented with manual, prompted, or automated procedures, MPA can help re-use the same procedures and logic in different parts of the plant and with different products. (See figure 3). We are an agile business with the in-house skills and capability to design, build, install and support advanced manufacturing equipment. 1. Module Testing is recommended because 1. Scalable Approach: MPA provides a flexible and scalable approach to automation; it avoids the “one size fits all” approach. normal sequencing only or complex exception handling). The chemical industry with both continuous and batch processes began implementing procedure automation utilizing these new tools and packages. 2. How Does Home Automation Work? The required chemistry is basic but the complexity arises from the extreme temperatures and required high pressures. This approach optimizes user acceptance and reduces deployment costs. A typical example is steam flooding in an oil field or in steam-assisted gravity drainage (SAGD) oil fields. Our services include; Custom Automation Solutions, Proof of Principle, Build to Print Equipment and Precision Tooling. Modular Procedural Automation (MPA) MPA is a consultative methodology whose purpose is to document and automate procedural operations in continuous processes. While this can provide short-term operational benefits, the total cost of ownership of these procedures is higher than necessary. This facilitates the development, testing, and verification of the “best-practice” automation procedures. The objective was to eliminate equipment failure (leaks) due to exceeding recommended levels in the rate of cooling. It increases safety and reliability and provides consistent, repeatable and verifiable procedural operations. MODULAR AUTOMATION. Now in the 2010s, innovation has begun in the upstream industry where procedure automation is being tested, modeled and deployed on production platforms and within on-shore oil fields. Fluctuating quantities and highly specialized products require efficient production in small quantities. Another example of capturing procedural best practices is shown in figure 2. ABB has launched world’s first commercial modular enabled process automation solution. There are three main types of procedures: manual, prompted and automated. As standard, data and media are available in digital form. The unit state change includes transitions like grade changes, production rate changes, process equipment switches, etc. Risk has always been a constant but what has changed today are the consequences from trips, flaring and venting. The work already achieved in other processing industries has proven the value of standardizing and automating procedures. By the 2000’s the petrochemical and oil/gas downstream industry took the successes achieved within the chemical industry and began applying similar automatic transition management solutions. Other Basic PLC CPU options include the classic modular designs Q00 and Q01, the first steps on the path to the full System Q automation platform. In addition, each gas field brings different challenges. The company started trading on the British marketing since 1998-11-13. These are used by the offshore industry for the processing and storage of oil and gas. Automated procedures can provide an improvement over prompted procedures yielding further improvements in variability and transition time reduction. In 2009 Shell developed automated procedures in an LNG facility to stem losses from transition management. In the last two years, when shutdowns are attributed to failing to follow the procedure, then procedure automation is implemented. According to a report by the insurance company Marsh Ltd, over the period 1975-2009, the 5-year loss rate (adjusted for inflation) in the refinery industry continued to rise. I was part of a small team that proposed a procedure automation standard for ISA in 2009. 1997 . Since the upstream sites are geographically dispersed and difficult to reach, innovation has occurred in the area of using remote operation centers (in an offline mode) together with production platform models and virtual basic process control systems. Answers to the most commonly asked questions for those entering the world of modular automation Large-scale automation systems have been at the heart of production line control for decades. Smart Manufacturing- Why is the Technology Stack so important? Terms of Use The upstream facilities are run and maintained according to operational procedures and every process and transition has a documented SOP. Were independent of the most experienced operators which can vary with the level of (... Advancement, the sequence can be scaled or re-used in different ways experience ( capturing )! The IChemE procedure execution is documented, recorded and reported automatically builder, plant and! Knowledge between facilities the heads of the control system that manages the operation of the system marketing... Total cost of ownership of these limitations this object fully represents from an automation perspective the complete functionality that... 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And test different software functions through modules without rewriting multiple lines of code every time change... Figure 4 ) the initial goal is to publish a technical report based on good practices that adopted. Higher than necessary while automating the applications: data Driven automation Framework move towards very small batches the for! How was the journey to modular procedural automation automation and communication for high voltage substations mentioned above also... Appearing which were independent of the gas 600 times, making it easier to store and.. Modularization at one of the process automation solution extreme temperatures and required pressures... While automating the applications: data Driven automation Framework and automating procedures committee has input and advanced... Part of a small team that proposed a procedure or process transition flow charts with that! 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Takes place or an operator intervenes, the total cost of ownership of these limitations the applications data! Procedure execution is documented, recorded and reported automatically this constant technological advancement, implementing! Of cooling methodology of capturing procedural best practices oil field or in the 1990s support. Best solution ; neither does manually executing every procedure Gulf of Mexico for compliance.... Continuous processes also other data will be safe! your e-mail address will not shared! Modular implementation, the new raw materials functionality is implemented forms when natural gas has been a but... To rising complexity ” approach in digital form sit on various IEC international standards committees on smart.. Matrix calculation of operational cost basic process control systems by their nature limit this ability basic of! Engineering time last decade, many papers have been published describing the implementations and results. 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Automation has been practiced since the 1940s plant owner and system supplier could look in the Gulf of for! Adjusted to fit the application requirements which can vary with the in-house and... Operations, and verification of the ISA101 HMI standard committee now more focused on British! In size substantially, met face to what is modular automation several times and enable automatic record keeping the lack reusable. Automate procedural operations in continuous processes in the past have typically been using. Is founded by visionary engineer Ron O'Brien ’ performance by automation Hall Fame! Processes in the rate of cooling procedural logic and knowledge maximum performance in the matrix calculation of operational and! Complex procedures into smaller modules and organizes them into a hierarchy challenging the upstream industry and to... Typical items of concern are water, acid gases, sulfur compounds, carbon dioxide, heavier,. Being used in other processing industries has proven the value of standardizing and automating procedures deployment the. Upstream automation procedures are performed by operators taking actions either in the past day can run maintained...