IIoT for manufacturing

industry
Key concept :
Situational
Awareness
This is our
mantra number
2
Connected factory: the
right information, in the
right way, to the right
person, at the right time,
anywhere is needed
Situational Awareness…
Examples:
• on-shift information directly sent to
the assigned specialist for each
operation

• problem solving and decision making

in real time: connection with
vendors, clients, etc.
 Collaborative manufacturing
• Collaboration allows everyone involved in the
value stream to have the right information, at
the right time, at the right place
• Collaboration among software applications (agents)
• Collaboration among machines
• Collaboration among people
• Collaboration among people, machines and agents
 Collaborative manufacturing
• The system directs the right response
alternatives to the available on-shift
worker to prioritize and execute the
corrective action
• Workers can take care about
continuous improvement: focus on
plant improvement, less in normal
operation
• In the information level, the system
collects data and identifies patterns:
models

• In the knowledge level: root-cause

analysis, corrective actions
• The understanding stage is
engineered in the form of simulations
and predictive models for
accurately planning and executing to
meet customer demands
The more time a system
takes to convert data from
the physical process or
operations workflow to
event information, the less
value the response action
brings.
 IT / OT
Integration
Until recently, information technology (IT) and operational technology
(OT) have for the most part lived in separate worlds.

IT supports connections to the Internet along with related data and

technology systems and is focused on the secure flow of data across an
organization.

OT monitors and controls processes on physical operational systems:

assembly lines, utility distribution networks, production facilities and
many more.

Typically, IT did not get involved with the production and logistics of
OT environments.
The benefit of IT and OT working together is a more efficient and
profitable business due to reduced downtime, lower costs through
economy of scale, reduced inventory, and improved delivery times.

When IT/OT convergence is managed correctly, IoT becomes fully

supported by both groups.

This provides a “best of both worlds” scenario, where solid industrial

control systems reside on an open, integrated, and secure technology
foundation
95
Many ISA standards are related to IIoT:

ISA5.1: Instrumentation Symbols and Identification

ISA12: Electrical Equipment for Hazardous Locations
ISA18: Instrument Signals and Alarms
ISA20: Instrument Specification Forms
ISA37: Measurement Transducers
ISA60: Control Centers
ISA95: Enterprise-Control System Integration
ISA84: Safety Instrumented Systems (SIS) & Functions (SIF)
ISA88: Batch Execution and Recipe Management
ISA106: Procedure Automation of Continuous Processes
ISA99: Industrial Automation and Control Systems Security
ISA100: Wireless Systems for Automation
ISA101: Human-Machine Interface
ISA103: Field Device Tool Interface
ISA104: Device Integration
ISA108: Intelligent Device Management
ISA111: Building Automation
ISA112: SCADA Systems
• ISA-95 is an international standard from
the International Society of Automation for
developing an automated interface
between enterprise and control
systems.

• It was developed to be applied in all

industries, and in all sorts of processes.

• Consistent terminology, information models,

and operation models
Enterprise Model
 The basic concept in
level 1 & 2 is:

Measurement
and Control
Levels 1 & 2 are critical to:
• quality
• safety
• reliability
• efficiency
To be able to use signals’
information correctly, the operation
of sensors, and the nature of
signals they produce, must be well
understood.
 Measurement
• Measurement is everywhere. It is arguably the most
important scientific activity
• Measurement establishes a relationship between a
phenomenon and a group of symbols, in order to
create the most reliable representation
possible.
• Measurement may help to guarantee the
quality of goods/services, meeting legal
standards.
• The term instrumentation refers to any systems
which help us measure variables and maintain
control of a process.
• For our purposes, the following terms can be singled
out:
• measurement systems: these are instruments
used to acquire data concerning the tested
object.
• control systems: in addition to measuring, these
instruments are also used to exert control.
• A signal is any variable with characteristics which vary
in time.
• Computer-driven interpretation requires converting the
source signal to electric voltage or current.
• The quantity to be measured, which we call m, is
converted into an electrical variable called s.
• The measurement s can be an impedance, an electrical
charge, a current, or a difference of potential. The
function s = F(m) depends on:
• physical law determining the sensor;
• sensor’s environment.
• F(m) may be estimated by calibration. By using a
reference, we determine for different values of m (m1,
m2…mi…) the electrical signals sent by the sensor (s1,
s2… si…) and we trace the curve s = F(m) , called the
sensor calibration curve
• For many years, industrial measurements were
mostly DC analog electric current in the range
of 4–20 mA.
• This convention was defined by ISA 50.1 in 1966
• A current signal was chosen so that, within
constraints, wire length and resistance were not
relevant.
• The 4 mA lower limit was found to be the minimum
current, with a 12-V power supply, that could power
electronic instruments of that time.
20 mA

4 mA

20 ºC 80ºC

Range: (20 ºC, 80 ºC)

Span: 80-20 = 60 ºC
Actuators
Actuators receive some type of control signal (commonly an
electric signal or digital command) that triggers a physical
effect, usually some type of motion, force, etc.
Micro-Electro-Mechanical Systems (MEMS)

Micro-electro-mechanical systems (MEMS) can integrate

electric and mechanical elements, such as sensors and
actuators, on a very small (millimeter or less) scale.

Microfabrication technique is similar to what is used for

microelectronic integrated circuits.

The combination of tiny size, low cost, and the ability to mass
produce makes MEMS an attractive option for a huge number
of IoT applications: they are embeddable in objects!
A surface micromachined electro-statically-actuated micromotor fabricated by the
MNX. This device is an example of a MEMS-based microactuator.
Basic Measurement and Control Loop
Process

Sensing Element

Final Control Measuring

Element Element Transmitter

Transmit
Element

Control Element
Basic Measurement and Control Loop

Set point

Controller
Transmitter

Fluid Fluid

Flow Sensor
Process and Instrumentation
Diagrams or simply P&IDs are the
“schematics” used in the field of
instrumentation and control

P&IDs are used by field techs, engineers,

and operators to understand the process
and how the instrumentation is
interconnected.
Standard
ISA S5.1
Alarm: A device or function that signals the existence of an
abnormal condition by means of an audible or visible discrete
change, or both, intended to attract attention.

Instrument: A device used directly or indirectly to measure

and/or control a variable. The term includes
• primary elements
• final control elements
• computing devices
• electrical devices such as annunciators, switches, and
pushbuttons.
Identification: The sequence of letters or digits, or both, used
to designate an individual instrument or loop.
Local: The location of an instrument that is neither in nor on a
panel or console, nor is it mounted in a control room. Local
instruments are commonly in the vicinity of a primary element
or a final control element. The word "field" is often used
synonymously with local.

Loop: A combination of instruments or control functions

arranged so that signals pass from one to another for the
purpose of measurement and/or control of a process variable.
Panel: A structure that has a group of instruments mounted
on it, houses the operator-process interface, and is chosen to
have a unique designation. The panel may consist of one or
more sections, cubicles, consoles, or desks.

Relay: A device whose function is to pass on information in an

unchanged form or in some modified form. Relay is often used
to mean computing device. The latter term is preferred. The
term "relay" also is applied specifically to an electric,
pneumatic, or hydraulic switch that is actuated by a signal.
Sensor: That part of a loop or instrument that first senses the
value of a process variable, and that assumes a corresponding,
predetermined, and intelligible state or output. The sensor
may
be separate from or integral with another functional element of
a loop. The sensor is also known as a detector or primary
element
Shared controller: A controller, containing preprogrammed
algorithms that are usually accessible, configurable, and
assignable. It permits a number of process variables to be
controlled by a single device.
Shared display: The operator interface device (usually a
screen) used to display process control information from a
number of sources at the command of the operator.

Transmitter: A device that senses a process variable through

the medium of a sensor and has an output whose steady-state
value varies only as a predetermined function of the process
variable. The sensor may or may not be integral with the
transmitter.
Each instrument or function to be identified is
designated by an alphanumeric code or tag number as
shown in Figure 1. The loop identification part of the
tag number generally is common to all instruments or
functions of the loop
The instrument loop number may include coded
information, such as plant area designation.

It is also possible to set aside specific series of

numbers to designate special functions; for instance,
the series 900 to 999 could be used for loops whose
primary function is safety-related.
Each instrument may be represented on diagrams by a
symbol. The symbol may be accompanied by a tag number.
The functional identification of an instrument or its
functional equivalent consists of letters from Table 1
and includes one first-letter (designating the measured
or initiating variable) and one or more succeeding-
letters (identifying the functions performed).

The succeeding-letters of the functional identification

designate one or more readout or output functions.
A modifying-letter may be used, if required, in addition
to one or more other succeeding-letters.

Modifying-letters may modify either a first-letter or

succeeding-letters, as applicable.

Thus, TDAL contains two modifiers. The letter D

changes the measured variable T into a new variable,
"differential temperature“. The letter L restricts the
readout function A, alarm, to represent a low alarm
only. The total number of letters within one group
should not exceed four.
Basic Measurement and Control Loop