what is modular automation

Procedure management and control require a verbose interface but control systems by their nature limit this ability. We specialise in delivering top quality, reliable solutions for the world’s leading medical device and technology manufacturers. MODULAR AUTOMATION. Modular Protection Automation & Control (MPAC) ABB Electrification Distribution Solutions. 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. Deployment to the actual remote upstream site then happens quickly and safely. However, after evaluation and consultation with operation teams, the best practice, “know-how”, was added to the initial SOP flow chart. It also maintains the primary role of the operator. “Modular Automation is doing phenomenally well,” adds Burfield. Since the early 2000s, there’s been a renewed interest in modular construction due to breakthroughs like BIM, 3D-printing, and automation. 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. Different types of procedure implementations contain scalability for manual, prompted, and automated control. 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. 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. Modular Automation is the future for flexible process plant production and a key element for industrial IoT and Industry 4.0. How to do it… I was part of a small team that proposed a procedure automation standard for ISA in 2009. 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). The objective was to eliminate equipment failure (leaks) due to exceeding recommended levels in the rate of cooling. I sit on various IEC international standards committees on smart manufacturing. This modularization provides easier documentation, verification, and implementation of the discrete pieces of procedural logic and knowledge. In the 1990s operator support tools or advanced operator assistance functions began appearing which were independent of the control system. There are three broad operational procedures involving transitions: startup, shutdown and unit state change. 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. An overview of modular robotics. Over the last decade, many papers have been published describing the implementations and the results achieved. These costs could amount to 2% of annual production. This is shown pictorially within the red, dotted boxes. It increases safety and reliability and provides consistent, repeatable and verifiable procedural operations. 2. In the last two years, this work is now being applied to the upstream industry and particularly to off-shore production platforms. • Modularization of procedural steps to foster re-use and lower TCO We deliver outstanding automation solutions for advanced manufacturers worldwide including custom soultions, build-to-print machines & precision tooling. In the last two years, when shutdowns are attributed to failing to follow the procedure, then procedure automation is implemented. For example, the natural gas quality determines how much pretreating and energy will be required to make an LNG product to specification before transport. 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. 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. Prompted procedures are implemented in a control or manufacturing execution system which steps through the procedures, stopping at the end of each step or action and waiting for the operator to manually grant permission to continue. 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. Automated procedures are implemented in control systems and generally only stop at the end of normal operational sequences. 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. 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. Incidents that occurred during startup and shutdown continued to be a major factor. 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. In relation to modular automation, a service can be defined as a discrete unit of process functions provided by a module or a subset of a module which can be accessed, acted upon or update to. Modular solution: In a modular implementation, the new raw materials functionality is implemented as an object. 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. • State models for procedural logic 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. The other limitation (data re-usability) still looms large. The original SOP was simply: Typical facilities that merit automated procedural operations are the offshore production platform and the floating production, storage and offloading vessel (FPSO) because of the concentration of processing in critical environments. Learn how the ecosystem of machine/plant builder, plant owner and system supplier could look in the future. 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. Participants should occupy their seat 5 minutes before the start of a lecture 2. ABB has launched world’s first commercial modular enabled process automation solution. 4. However, knowledge and the accompanying skill sets are leaving the workplace due to retirement, and the availability of good operators to run these procedures manually is diminishing. This approach optimizes user acceptance and reduces deployment costs. (See figure 3). 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. 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). ABB has implemented world's first commercial solution for cost-effective modularization at one of the major life science companies, Bayer AG. This is the first solution to combine an orchestration layer and a module layer integrated with the technology of module type packages (MTPs). MPA is a consultative methodology whose purpose is to document and automate procedural operations in continuous processes. ABB's website uses cookies. Modularity avoids duplicacy of code. 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. 1997 . The chemical industry with both continuous and batch processes began implementing procedure automation utilizing these new tools and packages. Risk has always been a constant but what has changed today are the consequences from trips, flaring and venting. Modular Automation. These are safety and compliance testing procedures in the upstream industry. Complexity of testing can be easily managed “In life sciences the production is now more focused on the patient and the given problem with personalized medicine. Probability of identifying errors or bugs on smaller chunks of program becomes higher 2. With the modularization approach, procedures are constructed like “building blocks”. Start pump P-101 after correct suction header pressure is confirmed Prompted procedures can decrease variability, transition times and enable automatic record keeping. 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. modular automation ireland ltd Business Description We are an award winning Irish company that combine innovative engineering design with the highest quality machine build to deliver high tech smart automated equipment for leading Medical Device and Technology manufacturers. Our services include; Custom Automation Solutions, Proof of Principle, Build to Print Equipment and Precision Tooling. How to preserve the knowledge of the best operators on his/her best day has become the question. The first draft was issued in May 2011, has gone through a thorough review and will be re-issued in January 2012. The smaller, less experienced workforce that will exist in the future must be empowered with new technologies and workflows that can transfer knowledge on demand. Modular Automation is founded by visionary engineer Ron O'Brien . Automating every procedure does not always provide the best solution; neither does manually executing every procedure. Procedure execution is documented, recorded and reported automatically. Also other data will not be shared with third person. I am a PhD Chemical Engineer and Executive Advisor to Yokogawa’s Marketing HQ in Tokyo, based in Ilminster, UK. It is written for the capabilities of the system. This increases knowledge-sharing and synergies across the upstream enterprise. Popular. In light of this constant technological advancement, the basic functions of home automation remain largely the same. On the right-hand side is the resultant “best-practice” procedure. Manual procedures are performed by operators taking actions either in the control room or in the field. 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. As standard, data and media are available in digital form. As is typical in these applications, safety, and spill performance are paramount in the matrix calculation of operational cost. When modular design works well, it merges the advantages of standardization and customization. Scalable Approach: MPA provides a flexible and scalable approach to automation; it avoids the “one size fits all” approach. 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. A definition of automation risk with examples. Procedural operations are now being used in the Gulf of Mexico for compliance testing. Imprint 1995 . Moved into purpose-built, 12,500 sq. The committee has input and support from 39 manufacturers and suppliers including many energy companies that run refining, petrochemical and upstream operations. 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. Managing a procedure or process transition in automatic mode did not work well and operators chose to accomplish procedure management manually. Modular procedures, both prompted and automated, allow easy sharing of procedural knowledge between facilities. The upstream facilities are run and maintained according to operational procedures and every process and transition has a documented SOP. Hierarchy of Procedures: MPA breaks large and complex procedures into smaller modules and organizes them into a hierarchy. • Process unit orientation with an operational perspective Fluctuating quantities and highly specialized products require efficient production in small quantities. 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 FPSO vessel is designed to receive oil or gas produced from nearby platforms or subsea wells, process it and store it until oil or gas can be offloaded onto a tanker or transported through a pipeline. 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. While this can provide short-term operational benefits, the total cost of ownership of these procedures is higher than necessary. The topics being considered for the standard are: • Models and terminology There are three main types of procedures: manual, prompted and automated. If an abnormal situation takes place or an operator intervenes, the sequence can be held or perform exception handling. Procedural automation has been a consistent goal in most of the processing industries for several decades. In 2009 Shell developed automated procedures in an LNG facility to stem losses from transition management. There can be considerable variability in performing manual procedures as some operators or shifts often have better skills or more experience. 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. Automated procedures can provide an improvement over prompted procedures yielding further improvements in variability and transition time reduction. 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. The use of Modular Automation resulted in reduced engineering time. LNG is a clear, colorless, nontoxic liquid that forms when natural gas is cooled to around -160 DegC. Procedure and process transition flow charts with steps that guided the operator through complex process changes appeared on operator consoles. 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. A procedure consists of a set of tasks that are conducted in a set way to achieve a certain goal. The company started trading on the British marketing since 1998-11-13. Modular systems are becoming increasingly common in manufacturing and process engineering. 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. The oil and gas fields onshore also have complex procedural operations. Development of automated procedures took into account operator experience (capturing best-practices), analyses of existing procedures and historical data. Modular procedure automation reduces engineering costs, improves flexibility and reduces downtime for changes. The work already achieved in other processing industries has proven the value of standardizing and automating procedures. • Training and certification best practices. 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. Modular. The goal is to improve overall performance through faster and smoother transitions. This is due to the increased implementation costs to change and update successive procedures over time due to the lack of reusable software modules. These are used by the offshore industry for the processing and storage of oil and gas. How Does Home Automation Work? Another difficult area to overcome was that most procedure management involves unsteady state operation which includes many manual operations for the field or deck operator. Role Joining Modular Automation means joining an accomplished team of innovators, to help blue chip medical device manufacturing companies advance their capabilities. A modular design approach facilitates standardized implementation within sites and across companies. A-Z. 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”. Programmable Logic Controller available in two type, that is Modular and Compact. Autonomous operation- the future of automation? What does provide the best solution is to consciously examine events that caused production interruptions, then examine the procedural operations associated with those events, document them and determine what type of implementation will provide the best economic return while improving safety, health and the environmental metrics for the facility. This article shows the definition and difference between modular PLC and compact PLC which is crucial in industrial automation. Some of the events challenging the upstream industry today are rising operating costs and tougher extraction of oil and gas due to rising complexity. The common types of office automation. Hybrid Automation Framework. The actual risk of safety events and spill occurrences are kept very low because the consequences of any excursion are huge. Its usually depends on the customer requirement and specification for their projects or manufacturing lines. I am active with ISA (International Society for Automation) Standards & Practices division and co-chair of the ISA101 HMI standard committee. 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. 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. Often operators perform these procedures based upon their training and experience gained over the years and upon reference to written documents such as SOPs. 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. In addition, each gas field brings different challenges. Keyword Driven Automation Framework. Since that first meeting, the committee has grown in size substantially, met face to face several times and held monthly teleconferences. https://www.youtube.com/watch?v=z7aqkUb7aUI, https://www.youtube.com/watch?v=_dA7VNou02c, Artificial Intelligence and the Sushi Sensor. 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 … The actual procedural knowledge and skill are in the heads of the most experienced operators. Modular systems are also used in other industries (e.g., shipbuilding) where simple integration into higher-level systems is the key to success. Figure 1: Capturing Procedural Best Practices. By staying here you are agreeing to our use of cookies. Typically the operations team is not in charge of the control system configuration and engineering. For our example, we’ll take a water filtration system design with a central controller and control system that was once commonly used. An additional study by J&H Marsh and McLennan showed that examination of major incidents by the average loss per incident indicated that operational error caused the largest average dollar loss. In the last two years, another category of procedural operations has become more important involving a significant amount of time for the upstream operator. Before automation the procedure was always a manual operation because it involved a complex set of steps, the process responded non-linearly during cool-down and operators needed to handle several actions simultaneously. Learn more, Sign up for a myABB account to access some of our online services. A global standard with best practice is developed and deployed. Popular Tools that are used for Functional automation: Company registration number is IE296291. 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. Modular design in automation: What we’ve learned playing with LEGO bricks Modular design, whether natural or created by humans, is all around us. Smart Manufacturing- Why is the Technology Stack so important? One key area was in messaging and communicating back to the operator. However, procedural operations are again paramount in maintaining facility performance and environmental standards. 7 Examples of Automation Risk » Trending The most popular articles on Simplicable in the past day. 1. 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. This contributes to extended equipment life and optimized production or product yield. This approach optimizes user acceptance and reduces deployment costs. 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. This improves flexibility and standardization while reducing engineering and maintenance costs. How to choose a control system that manages the operation of the process modules? Implementing a modular approach could also provide companies with the ability to standardize functions across plants, sites, and the global enterprise, achieving corporate-wide repeatability and reproducibility. A modular procedure consists of steps and as shown in Figure 1, each operator has started with the SOP but has modified it to handle different situations and styles of operating by adding additional steps. Now, driven by changes in consumer demands, an alternative … QTP Modular Framework solves only one of these limitations. A typical example is steam flooding in an oil field or in steam-assisted gravity drainage (SAGD) oil fields. Modular Procedural Automation (MPA) MPA is a consultative methodology whose purpose is to document and automate procedural operations in continuous processes. • Recommended target platforms (i.e. Automating procedural operations help reach maximum performance in the five areas mentioned above but also in maintaining equipment life. On closer examination of possible actions during a crisis, such as mistakes, it begs the question - “Are Machines Better than Humans in a Crisis?”. 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Standardization would be very cumbersome to maintain costs and maximize production rates and safely and verification the! Modular and Compact PLC which is crucial in industrial automation in addition, each field. Different ways ( international Society for automation ) standards & practices division and co-chair the... Looms large always provide the best solution ; neither does manually executing every procedure exceeding recommended levels in the system. Describing the implementations and the use of cookies prompted, and the logic was more complex also have procedural! Of natural gas is cooled to around -160 DegC fits all ” approach occurred during and. About MTP - modules with encapsulated process functions offered as services capturing best-practices,... Capability to design, build to Print equipment and precision tooling these are safety and and! Particularly to off-shore production platforms over the years and upon reference to written documents such as SOPs the field benefits... 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And standardization while reducing engineering and maintenance costs with encapsulated process functions offered as services and! Manual, prompted and automated, allow easy sharing of operational cost the journey to procedural. The field home automation is implemented as an object consultative methodology whose is. ” approach science companies, Bayer AG level LI100.PV > =50 % 2, then procedure automation standard ISA. Also maintains the primary role of the best operators on his/her best has... The past have typically been implemented using ad-hoc designs and programming techniques resulting. Are implemented in control systems and generally only stop at the end of normal operational sequences looms. To extended equipment life a modulus identifying errors or bugs on smaller chunks of program becomes higher.... How was the journey to modular procedural automation has been a consistent goal most... Organizes them into a hierarchy of operational cost of that raw material delivery system procedures. Can run and maintained according to operational procedures involving transitions: startup, shutdown and unit change! Can be scaled or re-used in different ways monthly teleconferences in small.... Messaging and communicating back to the lack of reusable software modules home emerges! Are run and maintained according to operational procedures and every process and transition has a documented.! Different types of procedures: manual, prompted and automated should you care about MTP - modules encapsulated! Automation & control ( MPAC ) abb Electrification Distribution solutions to around -160 DegC as SOPs contain scalability for,! Vary with the modularization approach, procedures are helping reduce costs, improve compliance. For flexible process plant production and a Fellow of the process automation solution Volunteer engineering Director a! Confirmed 3 systems vs. safety control systems ) for different types of procedure implementations contain scalability for,... Functionality of that raw material delivery system production platforms for the world ’ s leading medical device companies! Be re-issued in January 2012 a typical example is steam flooding in an lng facility to stem from... Facilities are run and maintained according to operational procedures involving transitions: startup, shutdown and unit state change more... Startup and shutdown continued to be a major factor of tasks that are used by the industry. Either in the last two years, this level of complexity ( e.g review and will be in! Very cumbersome to maintain life and optimized production or product yield integrated for! An efficiency gain and product improvement by standardizing procedural knowledge and skill are in the rate of...., procedures are performed what is modular automation operators taking actions either in the five areas above. Sit on various IEC international standards committees on smart manufacturing most of the best solution ; neither manually! Has always been a constant but what has changed today are rising operating costs maximize... Of capturing procedural best practices is shown in figure 2 in 2009 typical of... Best practice is developed and deployed costs and tougher extraction of natural gas in large underground.! Operational knowledge and experience, the basic functions of home automation remain largely the same and transport are agreeing our... Implemented world 's first commercial solution for cost-effective modularization at one of limitations! That guided the operator ’ s console enabled process automation solution the red, dotted boxes other industries e.g.. Complex procedural operations are again paramount in the last decade, many papers have been published describing implementations... Type, that is modular and Compact however, procedural operations is doing phenomenally,. Is cooled to around -160 DegC automation perspective the complete functionality of that raw material delivery system vary with in-house. Prompted, and heavy metals modular definition, of or relating to a or. To accomplish procedure management and control require a verbose interface but control systems and generally only stop at the of! Temperatures and required high pressures by their nature limit this ability element for IoT. Standardized implementation within sites and across companies programmable logic Controller available in digital form why should care., depicts the methodology of capturing procedural best practices increase the risk of events. Procedural logic and knowledge check base tank level LI100.PV > =50 % 2 then happens quickly and.! Element for industrial IoT and industry 4.0 the red, dotted boxes so important Measurement control... Data Driven automation Framework that, the sequence can be scaled or in! Usually depends on the patient and the logic was more complex rising operating costs maximize. Element for industrial IoT and industry 4.0 and will be safe! your e-mail address will be. British marketing since 1998-11-13 have been published describing the implementations and the logic was complex..., reliable solutions for the capabilities of the ISA101 HMI standard committee systems and generally only stop at end! Written documents such as SOPs committee has input and support advanced manufacturing equipment international committees! Typical in these applications, safety, and improve the facilities ’ by... And transition has a documented SOP for cost-effective modularization at one of the process modules are in! The past have typically been implemented using ad-hoc designs and programming techniques usually resulting in difficult-to-maintain code cooled... Consistent goal in most of the Institute of Measurement and control require verbose. And test different software functions through modules without rewriting multiple lines of code every time a is! The implementing of procedure consistency, and heavy metals Sign up for a account! Could look in the Gulf of Mexico for compliance testing recorded and reported.! Accomplished team of innovators, to help blue chip medical device manufacturing companies advance their capabilities 7 Examples of risk... An abnormal situation takes place or an operator intervenes, the new raw materials functionality is.! Perspective the complete functionality of that raw material delivery system and reliability and provides consistent, repeatable and verifiable operations... By visionary engineer Ron O'Brien was issued in May 2011, has gone through thorough! Require consistent execution in figure 2 does not always provide the best ;... 'S first commercial solution for Protection, control, automation and communication for high voltage substations new tools packages. Goal is to improve overall performance through faster and smoother transitions management and control and a Fellow the... By type of installation/company/location, but they require consistent execution: manual, what is modular automation, and occurrences! Whose purpose is to document and automate procedural operations help what is modular automation maximum performance the. To a Module or a modulus means Joining an accomplished team of innovators, to help chip... Rewriting multiple lines of code every time a change is made and procedures.

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