Process Automation Market and Trends...April: mobiLink TBA Launch August: TBA March: June: Webinar Kick-off Overview Continuous feedback from Channel Partners Embedded market surveys

18th June 2018, Haar Thomas Hilz, Program Marketing Manager Process Automation

Process Automation – Market and Trends

Copyright © 2018 Softing Industrial. All rights reserved. 2

Table of Contents

1.

2.

3.

Characteristics of Process Automation

Market Size and Growth

Break – Market Survey Questions

4. Eco System and Stakeholders

Introduction

5. Trends in Process Automation

6.

Introduction

Summary & Q/A


Partner Webinar – Schedule

Q1 Q2 Q3 Q4

April:

mobiLink

Launch

August:

TBA

March:

Webinar

Kick-off

Continuous feedback from Channel Partners

Embedded market surveys

(not more than 5 closed multiple

choice questions)

Oct:

TBA

May:

DN-Gateways

for Process

Automation

June:

PA Market

Overview

July:

mobiLink

PA

Upgrade

Sept:

TBA

Nov:

TBA

X2 Webinars per month: Monday 9am CET & 4pm CET

https://support.logmeininc.com/gotowebinar?c_name=prodselect

https://industrial.softing.com/de/wir-ueber-uns/distributor-login.html


Webinar: Calendar

• IA DN PA Webinar: March (19th)

• 2. IA DN PA Webinar: April (17th)

• 3. IA DN PA Webinar: May (14th)

• 4. IA DN PA Webinar: June (18th)

• 5. IA DN PA Webinar: July (16th)

• 6. IA DN PA Webinar: August (20th)

• 7. IA DN PA Webinar: September (17th)

• 8. IA DN PA Webinar: October (15th)

• 9. IA DN PA Webinar: November (19th)

Scheduled Webinars


Table of Contents

1.

2.

3.






6. Summary & Q/A

Introduction


Components and Tasks of Process Automation (= Process Industry = Process Manufacturing) Measuring, control and automation

technology used in plants of process industries

For measuring, regulating, controlling and interlocking process-related processes, e.g. heating, cooling, evaporating, condensing, separating, mixing, stirring and analyzing

Includes sensors, actuators, analyzers (e.g. gas and liquid analysis), process control, communication and interface technology; and planning, management; and monitoring software


Process Control

The process control technology provides means and methods for controlling, regulating and safeguarding process engineering plants.

Requirements and solutions for automation technology in the manufacturing and process industries differ so much that one can speak of two worlds.

Many providers only serve one of the two worlds. Only recently have some companies ventured into foreign territory.

There are hardly any communication solutions that are suitable for both worlds (PROFIBUS-DP + PROFIBUS-PA or PROFINET + PROFIBUS-PA only).


Process Industry vs. Discrete Manufacturing

Process Industry Discrete Manufacturing

Substance conversion, treatment, recovery Fabric transformation (forming, separating, joining)

Continuous or discontinuous (batch) processes Discrete (synchronized) manufacturing and assembly processes

Batch production (weight, volume) Lot size production (piece)

Recipes Parts lists

Production process can usually not be stopped Production process can usually be stopped at any time

Safe state is process-dependent (exothermic reactions)

Safe state = plant shutdown

Long operating phases and very long plant utilization periods

Short operating phases (shift) and average system utilization periods

4..20 mA, HART, FF, PROFIBUS-PA CAN, PROFIBUS-DP, Modbus, DeviceNET, ControlNET PROFINET, EtherCAT, EthernetIP

Process industry processes substances and materials in chemical, physical, biological or other technical methods and processes.

Segments

Chemical

Oil & Gas

Pharmaceuticals

Food & Beverage

Pulp & Paper

Glass

Steel

Cement

(Energy)


Continuous Process

A process in which there is a continuous (uninterrupted) transformation (synthesis, chemical reaction) to produce the final product.

High capacity, low flexibility, advantageous for large products

Examples:

Catalyst in a vehicle (fixed bed reactor, substances are continuously supplied and extracted)

Division of crude oil into various products in the distillation tower of a refinery


Batch Process

A process that leads to the production of limited quantities of substances by subjecting quantities of inputs to an orderly sequence of process activities using one or more facilities within a defined period of time.

Low capacity, high flexibility, advantageous for specialty products

Set-up times for cleaning and refilling the reactor vessels

Examples:

Cook noodles or bake cakes (stirred tank reactor)

Brew beer or burn liquor

Production of pharmaceuticals, fine chemicals, paints


Hybrid Industries

Combination of continuous or batch processes with (downstream) discrete manufacturing processes to produce the final product.

Example:

Beverage industry, pharmacy, fine chemicals: production (batch) and bottling (discrete)

Hybrid industries are of interest to Softing because of the need to converge and combine automation solutions for the manufacturing and process industries.


Special Requirements of PA

Continuous operation

PA plants often run for several years without interruption, which leads to high demands on the availability of the automation components. Configuration changes must be made during operation (configuration in run), as well as device replacement in case of component failure.

Redundancy

The high availability requirements can only be achieved through redundancy (components are available multiple times). Typically, controllers and critical infrastructure components are duplicated. For very high requirements you will also find 2-of-3 systems.

Explosion Protection

Since flammable gases or liquids are often processed, special measures to prevent explosions must be taken. This also applies to all automation components that are subject to the corresponding approval procedures.

Functional Safety

Processes often have a high risk potential for humans and the environment (Bhopal, Seveso, ...), which is why Functional Safety plays an important role in plant design and automation technology.


Distributed Control System (DCS)


Transmitters (Sensors)

Temperatur Pressure

Flow Level


Valves and Actuators

Pneumatic Valve with Positioner

Electric Valve


Functional Hierarchies of Integrated Process Automation

IT

AT

Pla

nn

ing

Dat

a A

cqu

isit

ion


Evolution of Industrial Communication

PA

RTE

FA

1975 1980 1985 1990 1995 2000 2005 2010

Ethernet

Modbus

FIP

PROFIBUS

DP

MAP

SINEC H1

INTERBUS sercos sercos II

sercos III

FF-H1

FF-HSE

PROFIBUS

PA

CC-Link

CAN

CANopen

DeviceNet

EtherCAT

Ethernet

POWERLINK

PROFINET IO

HART

Modbus TCP

Ethernet/IP

ISP

PROFIBUS

FMS

wirelessHART

ASi IO-Link

HART IP

WorldFIP

Modbus


Applications for Industrial Communication

einf. Sensor

Sensor/Aktor

Remote IO

SPS / DCS

PC/IPC

ERP

Process Industry Manufacturing Industry

(HART)

FF-H1

PB-PA

FF-HSE

wirelessHART

PROFIBUS-DP-V1

OPC UA

PROFINET IO

etherCAT

sercos 3

POWERLINK

Ethernet/IP

PROFIBUS DP-V2

PROFIBUS DP

Motion Control

(Fast isochronous

communication)

Continous

Process

(e.g. Oil & Gas)

Fast processes in hybrid plants

(e.g. filling machines)

PROFIBUS DP

ASi

(4..20 mA)

(IO-Link)

Sercos 1+2

DeviceNet

Manufacturing Process


Table of Contents

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6. Summary & Q/A

Introduction


World Market for Process Automation Grows Annually by 4%

175 184 192 195 201 209

218

0

50

100

150

200

250

2013 2014 2015 2016 2017 2018 2019

Billion €

Source: ZVEI


Areas of Activities Over the Plant Life Cycle

Our business opportunities for gateways derive from considerations of the plant planning


Almost 50% of the total market is attributable to three sectors

Source: ZVEI

5%

10%

15%

15%

9%

19%

7%

9%

8%

3%

Wasseraufbereitung und Abwasserwirtschaft

Minenwesen und Metalle

Energieerzeugung

Erdöl- und Erdgasgewinnung

Mineralölverarbeitung

Chemie

Pharma

Nahrungs- und Genussmittel

Maschinenbau

Paper und Zellstoff

Water and Waste Water

Mining and Metals

Energy

Oil and Gas Exploration

Oil Processing

Chemical

Pharmaceutical

Food and Beverage

Machine Building

Pulp and Paper


Slight Growth Impulses from Oil & Gas

Especially "non-cyclical" industries like

• Pharma,

• Water / sewage and

• Food and beverage

with continuous growth

In addition, electric power generation offers good business opportunities

Above-average growth (> 3%) in field buses and especially Industrial Ethernet


Regional Distribution of Process Industry Investments

Source: ZVEI

27,1%

19,5%

8,5%

6,7% 3,5%

2,5%

3,0%

3,0%

26,2% China

USA

Deutschland

Japan

Südkorea

Großbritannien

Frankreich

Italien

ROW

China

USA

Germany

Japan

South Korea

Great Britain

France

Italy

ROW


Distribution of Field Level Protocols

Source: Softing Estimations

7,87%

1,82%

2,78%

44,79%

0,24%

0,12%

26,63%

7,26%

8,47% PROFIBUS DP in Process Automation

PROFIBUS PA

FOUNDATION fieldbus H1

HART

WirelessHART

ISA 100.11a

pure 4 … 20mA

Pneumatic

Proprietary


Table of Contents

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6. Summary & Q/A

Introduction


Engineering, Procurement and Construction (EPC) Contractor


The MAC is a "super-system integrator" that acts as a "general contractor" for automation technology. Parts of the total offering can be provided by third-party, specialized service providers, such as

- Electricians

- Commissioners

- System integrators for special subsystems / topics

- …

All major system manufacturers in process automation have their own SI departments, which can also act as MACs.

Main Automation Contractor (MAC)


System integrators are specialized companies, which market technical integrate (sub) systems in production facilities to create a production system.

They install the selected automation components, commission them and validate the functionality of the overall system.

The ultimate goal is for all plant elements to be isolated and functioning as an overall system according to the objective.

System Integrators (SI)


SIs serve the entire life cycle, in particular in the process industry

From planning to installation, commissioning and acceptance to plant maintenance and decommissioning

New plants and plant extension

Total suppliers or specialists for partial services or specific topics

Often specialized in selected (system) providers; e.g. Siemens, Schneider Electric, ...

Focus on marketing own services

Source: Control Global


List of Top 40 System Integrators – Top 50 Companies

Source: Control Global, 2018

https://www.controleng.com/events-and-awards/system-integrator-giants/2018-system-integrator-giants.html

















Selection of Organizations with Relevance to Process Automation


Table of Contents

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6. Summary & Q/A

Introduction


Goals of Industrie 4.0 and IoT are also Valid for Process Automation

Realization of • Resource efficiency • Cost reduction (CAPEX and OPEX) • Increasing flexibility

require comprehensive integration and networking

for optimizing processes and equipment

with

digitization and "ethernetization" as a prerequisite


NE 74

With Ethernet into Field (APL) APL Group exists of PNO, ODVA and Fieldcomm Group

Two-wire solution for the Ethernet communication in the field

Profibus PA cables as well as common shielding concepts can still be used

Phase 1: 10Mbps - Phase 2: 100Mbps (500m max)

PNO sees a solution package for the process industry consisting of PROFINET, PA profile for PROFINET, FDI and Ethernet in hazardous areas

OPC UA server with FDI device descriptions, operating and repair instructions in the field device.

Ethernet switch in zone 2 (max 50 devices), 1000 m long 2-wire solution with power supply ("Trunk") in protection class Ex e for zone 1, field devices in zone 0 via two conductors in up to 200 m ("lane ", Ex i)

Standardization pushed (IEEE taskforce for IEEE 802.3 extension)


„Namur Open Architecture“ (NOA) with Two Communication Channels

Reduction in the complexity of DCS

Use of proven DCS

Complement to open interface for the use of dynamic technologies for e.g. data analysis

OPC UA currently "traded" as preferred communication technology

Core Process 4 … 20mA

BOM, MOM

DCS

(Condition) Monitoring

(Process) Optimization

Data Data

Information Information

Analytics Analytics


Modular Automation for More Flexibility in Production

Particularly relevant for the production of small batches and for "multipurpose plants" (for example fine chemistry and pharmacy)

Responsibilities and expenses "migrate" from the system integrator to the module supplier

NE 148 knows i.W. two module types, autonomous (with own control) and those directly integrated via I / Os NE 148


Modular Plants will Complement Existing Plants


Table of Contents

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6. Summary & Q/A

Introduction


Marketing relevant conclusions

Our gateways and mobile interfaces have good cross-industry potential

System and device manufacturers remain our target group for technology integration and especially for the mobiLink for device parameterization

System integrators are the strategic target audience / strategic channel especially for our gateway business

SI-relevant organizations, trade fairs, web-publishers and conferences as well as the partner programs of the big manufacturers are the platforms to get in contact for solutions

Trainings and especially application support is the key to SIs success

Thomas Hilz Program Marketing Manager Softing Industrial – Data Networks Tel: +49 89 45 656 - 168 Mobile: +49 1577 141 2445 Email: [email protected]

Thank you very much for your attention! Any questions? Feel free to ask!

industrial.softing.com/en

Documents

Process Automation Market and Trends...April: mobiLink TBA Launch August: TBA March: June: Webinar Kick-off Overview Continuous feedback from Channel Partners Embedded market surveys