Chemical Engineering June 2018 - 21

Modular based automation
engineering
Modullibrary
Modular
NE150
Bulk
engineering
engineering
Management of
change
Autodocumentation
Flexible
binding
Yokogawa
HIS
ENG
FCS
FCS
OPC
UA
Module A
Module B
3rd party PLC
Field IOs
Stardom
Communication IOs
Module C
3rd party PLC
Package units
Stardom
FIGURE 2. Chemical and pharmaceutical-related industrial associations are discussing a technology
concept, called a Modular Type Package (MTP), to support easy integration of any type of controller.
MTPs are based on Automation Markup Language (AML) technology in which the significant information
of the process module automation application can be exported for easy integration with any upper
automation system
modular environment, " says Turner.
Safety can be another issue in
modular plants. " In the environment
of the chemical industry, safety is
very important. There are emergency
shutdown systems and safety instrumented
systems (SIS) and modules
have to be consistent with those systems, "
notes Craig Correia, director of
process industries for North America
with Festo (Islandia, N.Y.; www.festo.
com). " If there is an emergency shutdown,
the module can't go rogue.
It must cooperate with the safety
system. You can't have a module
with a safety protocol or shutdown
system that isn't consistent with the
equipment in other areas. In addition,
it's important that the interfaces
look the same from skid to skid. In
layman's terms: you can't have one
emergency stop that's a round, red
button that you physically push and
another that's on a touchscreen because
this could confuse operators.
Consistency in safety is crucial. "
A modern module approach
While a remedy is necessary, integration
of modular components is
still a work in progress. However,
component providers, module builders
and automation suppliers are all
working toward the common goal
of simplifying integration between
module automation and higher-level
control systems.
On the component level, manufacturers
like Festo are embedding controllers
on instruments and devices
so they can be tested when used in a
modular process skid and are making
sure that the control is neutral so
their controller can " handshake on
the supervisory level with the 'big
boys' in the marketplace, " says Correia.
" It is our responsibility that our
controller can pass all the relevant
information and handle all the safety
protocols being exchanged between
the skid and the automation system.
We are continually evolving and getting
better at this. "
On the module side, builders are
simplifying the physical connection,
says Ted Faiella, senior director of
Honeywell UOP's (Des Plaines, Ill.;
www.uop.com) Applied Process Excellence
Center. Traditionally, modular
units were automated by installing
junction boxes within the modules.
" All the instrumentation on the module
was connected to junction boxes
at the module-fabrication shop so
continuity checks could occur before
shipment. At the plant, this junction
box connected to a marshalling
rack, which connected to the actual
I/O cards, " Faiella explains. " But,
within the last five years, this has
changed. We now provide universal
process-control cabinets (UPCs)
that contain I/O cards. This eliminates
the traditional wiring method, "
he says. " Instead, the I/O cards are
in the field and you only need to run
fiber optic cabling from the UPC box
to the control room. "
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Chemical Engineering June 2018

Table of Contents for the Digital Edition of Chemical Engineering June 2018