IIoT for

manufacturing
industry
 Key concept :
Situational Awareness
This is our mantra
number 2
Examples:
• on-shift information directly to the
assigned specialist for each event

• problem solving and decision making

in real time: connection with vendors,
client data, 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
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