S01.

Introduction to Integration of Industrial

Processes
Oswaldo Moreno A.
 •Identify
characteristics of
ACHIEVEMENT system
SESSION integration
through CIM
pyramid.
2
 Identify functions of each layer of the
OSI model.
Differentiate different protocols of
industrial networks
Terminal Recognize parts of SCADA, DCS and PLC
capacities systems.
Manage concepts of supervision and
control based on the use of computers.

Configure HMI / SCADA software.

 •Students handle and
apply knowledge of
electronics,
Resultado instrumentation and
control technologies,
using modern tools
and equipment.
4
 Thin Clients for Process Control e-commerce clients Business/ERP-System
e e Remote Client /
Engineering

Intranet or Internet
Infrared
Firewall RMP KM / LIMS Thin
EO / LM Scanning
Router Process Portal Clients Engineer Thin Client Clients
Thin Clients System
Shared Printer

Client/Server Network (TCP/IP)

AC800Connectivity AspectServer DomainServer

KM Knowledge Manager /
LIMS Laboratory /
Information Management /
Server

Expert Optimizer/ RMP

ControlNetwork(Ethernet) /
Server
ProcessPortal Grinding
Autolab
AC800M
X-ray
Infrared
Scanner
Profibus / Foundation Fieldbus / Ethernet/TCPIP
Press
ABB
Profibus
MCC AC800M
MNSiS Laser granulometer
S800I/O ACS / DCS
Field MV Switch Gear
RemoteI/O Drives
Devices Ref 542 Plus Autolab
family

Optional redundancy for any OCS component available

6
7
COMPUTER INTEGRATED MANUFACTURING
(CIM)

8
 WHAT IS CIM?

Basically Computer Integrated

Manufacturing (CIM) is
the manufacturing approach of
using computers to control the
entire production process.
WHAT ARE THE BENEFITS OF CIM?
• CIM allows individual
processes to exchange
information with each other
and initiate actions.
• Through the integration of
computers, manufacturing can
be faster and less error-prone,
although the main advantage
is the ability to create
automated manufacturing
processes.
COMPUTER-INTEGRATED MANUFACTURING
TOPICS:
• Key challenges;
-Integration of components from different.
suppliers.
-Data integrity.
-Process control.
• Subsystems in computer-integrated manufacturing;
-Computer-aided techniques.
-Devices and equipment required.
-Technologies.
Data integrity:
The higher the degree of
automation, the more critical
is the integrity of the data
used to control the
machines.
While the CIM system saves
on labor of operating the
machines, it requires extra
human labor in ensuring that
there are proper safeguards
for the data signals that are
used to control the
machines.
Process control:
• Computers may be used to assist the human operators of the manufacturing facility, but
there must always be a competent engineer on hand to handle circumstances which
could not be foreseen by the designers of the control software.
SUBSYSTEMS IN COMPUTER-INTEGRATED
MANUFACTURING:

A computer-integrated manufacturing system is not the same as a "lights-out"

factory, which would run completely independent of human intervention,
although it is a big step in that direction.
Part of the system involves flexible manufacturing, where the factory can be
quickly modified to produce different products, or where the volume of
products can be changed quickly with the aid of computers.
COMPUTER-AIDED TECHNIQUES:
Some or all of the following subsystems may be found in a CIM operation:

• CAD (computer-aided design)

• CAE (computer-aided engineering)
• CAM (computer-aided manufacturing)
• CAPP (computer-aided process planning)
• CAQ (computer-aided quality assurance)
• PPC (production planning and control)
• ERP (enterprise resource planning)
• A business system integrated by a common
database.
Systems integration

17
18
Fully integrated automation

19
ERP Intregation
 PLC PLC+SCADA DCS

ABB

Honeywell
Invensys

Siemens

Emerson

Yokogawa

Rockwell

Schneider

Factory Hybrid Process

Automation Automation Automation
Market
 Hybrid
Factory Automation Process
Automation Market Automation
PLC PLC+SCADA DCS DCS Architecture

ABB Compact
AC500 Freelance 800F System 800xA Industrial IT
Products 800
Comfort Point Plantscape TPS
Honeywell HC900 PKS
Experion HS Experion PKS

Wonder
Invensys ware
A2 I/A InFusion

Siemens S7 PCS7 PCS7

S7 WinCC TIA/ TIP
Logo PCS7Box T3000

Emerson DeltaV
Bristol Bristol DeltaV PlantWeb
Ovation
Centum Centum Vigilant
Yokogawa FA-M3R Stardom CS1000/VP VP/CS3000 Plant
FlexLogix Control RS Control Logix Control Logix
Rockwell CompactLogix Logix View RSView* RSView* RIA

indirect

direct

Productsnotavailable
* Positionedas DCS
Control System Portfolio
Process

Size
Automation

Hybrid DCS
Automation
Market

Factory
Automation

Complexity
 IndustrialIT

ASPECT OBJECT
Handling Objects Aspects

Graficos de Proceso
SAP, Maximo
Real Object Objects - Aspects Gráficos

Registros de Mantenimiento
Gráficos

Control
MS Word
Control Builder
Control
Data sheet

Modelo
iGES
ElMaster deSimulación
Modelo de Simulación
Diagramas Eléctricos

MS Excel
AutoCad
Diagramas P&I
Especificaciones de Lazo
Diagramas P&I
System
aspects
Boliden Aitik Solution Building
Blocks Maximo® IBM
Asset
Management
Work Orders, Parts Management, Work History, Maintenance Scheduling
Service

ABB
ECS

Industrial IT EnterpriseConnectivity
Asset
Optimization
Asset Optimization Service
Cause, Conditions, Decisions, Actions, KPI s
AO

Rules for Asset Monitoring

800 xA &

Checks
Boolean, limits, alarms, run-time etc.

Equipment Process Environment Infrastructure

 ABB & IBM Predictive Maintenance
Maintenance Productivity Challenge:
IBM Coverage
•Cost of unnecessary maintenance is about the
same size as plant profit
Level4

Timeframe: months, •In many plants, maintenance budget is about

Business Process weeks, days, shifts,
transactions MaximoCMMS hours, minutes 2/3 of annual net profit

Clickfor Runtime Values Fault Re ports W orkorde r Operator

information Status ToDo Lists

ABB & IBM teaming provides :

Production
Manufacturing Operations
Management
Level3
• Integarted Solution of software and services
Timeframe: days, shifts,
Management
Transactions
hours, minutes, seconds • ABB’s 800xA Assetmonitors
• IBM’s Maximo
Real-Time Control & Events
Equipment self-
disgniostics
Asset
Monitors
• ABB’s and IBM’s End toEnd
Integration and implementation Services
Sensors, Actuators and Logical Devices Levels 0, 1, 2

Benefits to the customer :

ABB Coverage
• Return on investment: 10 times
• Reduction in maintenance costs: 25% to 30%
• Elimination of breakdowns: 70%to 75%
• Reduction in downtime: 35% to45%
• Increase in production: 20% to 25%
Real-Time Plant Asset Management
(PAM) system
Asset Asset Condition
Automation Syst
Monitoring Reporting System

Operations Maintenance

Operations Maintenance CMMS and

Calibration
Extended AutomationSystem 800xA Syst ems
Field Devices
 What is an Asset Monitor?
• Asset Monitor is a software component that monitors and
promptly reports one or more conditions of an asset
• Asset Monitors can receive data from Multiple OPC Data
Sources including 3rd party (Allen Bradley, Siemens, etc)
• AO is fully integrated into System 800xA
Next session
• OSI Model