FUTURE DIRECTIONS
OF
INSTRUMENTATION &
CONTROL
Presented by….
Steve Mackay
of
IDC Technologies
with Warren Mitchell
Copyright acknowledgement
to IDC Technologies and to ARC
assisting….
Advisory Group on material presented taken from Plant
Automation Support Survey (June’02).
A few thoughts on...
 The
Future of I & C
 Your future in this industry
 Training trends
The Future of
Instrumentation and
Control
Fairly Predictable
Ethernet (and TCP/IP) & Fieldbus
 Safety Instrumentation
 Industrial IT (incl. Security)/Supply
Chain/E-Commerce & E-manufacturing)

ETHERNET, TCP/IP &
FIELDBUS
UTP 10Base T System
100-MBit Ethernet
Defined in IEEE802.3u standard
 Uses CSMA/CD media access
 Ethernet frame format
 High speed interface on:
 100Base-TX for Cat 5 wiring
 100Base-FX for Fibre Optic

Switch Types
Segment Switch
Server
Private LAN Switch
Server
TCP/IP & InterNetworking
London - England
IBM Compatible
Laser printer
IBM Compatible
Network
IBM Compatible
IBM Compatible
IBM Compatible
INTERNET CONNECTION
Sydney - Australia
Apple LaserWriter
Mac Classic
Mac Classic
Network Backbone
UNIX Server
IBM Compatible
Internetworking with TCP/IP


Networks generally do not exist in
isolation, and need to be interconnected
An increasingly popular suite of protocols
to handle this is TCP/IP
 TCP - Transmission Control
Protocol….a reliable transport service
 IP - Internet Protocol….a delivery
service
Fieldbus and DeviceNetworks
Factory
level
Ethernet/TCP/IP
Bus Cycle
Time
< 1000 ms
Field
Level
Bus CycleTime
< 10 ms
TCP/IP/Ethernet
PC/VME
CNC
Cell
Level
Bus Cycle
Time
< 100 ms
Area
Controller
PROFIBUS-FMS
VME/PC
PLC
PROFIBUS-DP
DCS
PROFIBUS-PA
FOUNDATION FIELDBUS
ETHERNET
HSE… High Speed E t h e r n e t
• 100 MBps
• TCP/IP and standard Ethernet
SERVER
GATEWAY
H2
H1… Lower Speed Fieldbus
• 31.25 Kbps
• Replaces 4 to 20 mA
• 2 - 32 Devices
• Power & Communications
• Intrinsically Safe
• Twisted-pair
• 1900 m length
BRIDGE
SCADA
PLC
PLC
H1
ANALYZER
SAFETY INSTRUMENTATION
Accidents Caused by Control and
Safety System Failures
Specification
44.1 %
Changes after
Commissioning
21%
Operation &
Maintenance
15%
Design &
Implementation
15%
Installation &
Commisioning
6%
Based on 34 investigated incidents in the UK : “Out of Control”, HSE
SUPPLY CHAIN, E-COMMERCE
AND E-MANUFACTURING
Industrial IT, Supply Chain, ECommerce, E-manufacturing
Computers exchanging commercial
information
 Suppliers tied closely to your site
 Customers tied closely to your site
 Manufacturing/Process Control (eg via
SCADA) tied to business systems

And not so Predictable
Trends…..

People required (ie YOU !)

see next section….
Your Future in this
Industry
Will ‘Control Engineers’ Shrink or
Grow in Support Role in 5 Years?
Which of these disciplines that currently perform AUTOMATION SUPPORT in your plant are likely
Grow
Stay Same
Shrink
Don't Use
5.8 %
Don't Use
11.5 %
Shrink
34.6 %
Stay Same
48.1 %
Grow
0
5
10
15
20
25
30
Will ‘Technician’ Shrink or Grow
in Support Role in 5 Years?
Which of these disciplines that currently perform AUTOMATION SUPPORT in your plant are likely
Grow
Stay Same
Shrink
Don't Use
3.8 %
Don't Use
17.3 %
Shrink
46.2 %
Stay Same
32.7 %
Grow
0
5
10
15
20
25
30
Will ‘IT (personnel)’ Shrink or
Grow in Support Role in 5 Years?
Which of these disciplines that currently perform AUTOMATION SUPPORT in your plant are likely
Grow
Stay Same
Shrink
Don't Use
7.8 %
Don't Use
9.8 %
Shrink
31.4 %
Stay Same
51.0 %
Grow
0
5
10
15
20
25
30
Are ‘Specialists’ Likely To Grow
In 5 years?
Which of these groups or functions are likely to GROW, SHRINK or STAY THE SAME size in the ne
Grow
Stay Same
Shrink
10.0 %
Shrink
32.0 %
Stay Same
58.0 %
Grow
0
5
10
15
20
25
30
35
Is ‘Outsourced Automation’ Likely
To Grow In 5 years?
Which of these groups or functions are likely to GROW, SHRINK or STAY THE SAME size in the ne
Grow
Stay Same
Shrink
5.8 %
Shrink
19.2 %
Stay Same
75.0 %
Grow
0
10
20
30
40
Will Instrument Maintenance
‘Outsourcing’ Change in 5 Years?
Which of these Plant OPERATIONAL FUNCTIONS in your plant w ill be likely to INCREASE, DECREAS
Never
Increase
Stay Same
Decrease
17.3 %
Decrease
42.3 %
Stay Same
36.5 %
Increase
3.8 %
Never
0
5
10
15
20
25
Will ‘Control Network
Maintenance’ ‘Outsourcing’
Change in 5 Years?
Which of these Plant OPERATIONAL FUNCTIONS in your plant w ill be likely to INCREASE, DECREASE
Never
Increase
Stay Same
Decrease
9.6 %
Decrease
32.7 %
Stay Same
51.9 %
Increase
5.8 %
Never
0
5
10
15
20
25
30
Training Trends
Maintenance TRAINING for
Support Currently Required?
What level of TRAINING for Autom ation Support is typically required? - Maintenance
None
OJT
ISA Certificate
Associates Degree
BS Engineering
1.9 %
BS Engineering
19.2 %
Associates Degree
13.5 %
ISA Certificate
61.5 %
OJT
3.8 %
None
0
5 10 15 20 25 30 35 40 45
Technician TRAINING for Support
Currently Required?
What level of TRAINING for Automation Support is typically required? - Technician
None
OJT
ISA Certificate
Associates Degree
BS Engineering
2.0 %
BS Engineering
37.3 %
Associates Degree
13.7 %
ISA Certificate
45.1 %
OJT
2.0 %
None
0
5
10 15
20
25
30
Control Engineer TRAINING for
Support Currently Required?
What level of TRAINING for Autom ation Support is typically required? - Control Engineer
73.1 %
BS Engineering
Associates Degree
ISA Certificate
OJT
None
11.5 %
1.9 %
9.6 %
3.8 %
0 5 10 15 20 25 30 35 40 45 50 55
None
OJT
ISA Certificate
Associates Degree
BS Engineering
Control Engineer TRAINING for
Support Required In 5 years?
What level of TRAINING for Autom ation Support do you feel w ill be required in 5 years? - Contro
80.8 %
BS Engineering
Associates Degree
ISA Certificate
9.6 %
0.0 %
OJT
5.8 %
None
3.8 %
0 5 10 15 20 25 30 35 40 45 50 55 60
None
OJT
ISA Certificate
Associates Degree
BS Engineering
Summing it all Up
Comments/Queries….?

You can contact me at:

tech@idc-online.com

http://www.idc-online.com
Good Luck !
And now for something
completely different !



A quick Instrumentation and Control
Quiz
Prizes are not mickey mouse…but practical, highly
regarded and excellent books:
Two of the famous “Industrial Control Handbook”….
R2500 each
Four of the practical “EMC For Product Designers” at
R800 each
De Beer da Rules...
First person to put his hand up gets to
give his answer to the panel - ie to YOU !
 Your peers will decide.
 Geoff Cragg’s decision will be final.
 You only get one chance !

Quiz Question No. 1
What are the main differences between the
data communications standards: RS-232 and
RS-485 ?
Quiz Question No. 2
Where would you use an OTDR as opposed to
a power meter in faultfinding of fibre optic
cable ?
Quiz Question No. 3
What is the difference in the functions of TCP
and IP in the TCP/IP protocol ?
Quiz Question No. 4
Why and where would you use the D or
derivative term in control (with the PID form
of control) ?
Quiz Question No. 5
Is Feedforward an Open or Closed Loop form
of control ?
Quiz Question No. 6
How many tries has Jonah
Lomu scored against South
Africa and where ?