Discover the Building Blocks for Modular Plant Projects

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The solution may come from an unexpected source. Automation suppliers are devoting more attention to integration of package units. In recommendation NE 148, Namur expresses its support for autonomous, decentralized controllers which have the capability to independently monitor internal flows. DIMA (Distributed Intelligence in Modular Systems) unveiled by Wago in 2014 is one of the first implementations of this recommendation. The module is based on a standardized, open, non-proprietary systems communication and interface architecture which supports integration of process flows in decentralized automation and package unit environments. Intelligent modules with on-board automation capability have the versatility needed for integration into, or disconnection from, a higher-level system.

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Customized or off the shelf?

Package units are currently a hot topic, and the industry is hoping that off-the-shelf plug-and-play systems will soon be available. Unfortunately, it is not yet possible to order package units out of a catalogue. The requirements are still too diverse in the different industries and engineering disciplines. Skids are normally built at the supplier’s factory to customer specification. If you think that nothing could go wrong with this approach, think again. Highly complex system modules require a greater degree of on-board intelligence and connectivity, so that a puzzle consisting of many individual parts can be pieced together. If the industry fails to define standards and conventions at an early stage, plug-and-play will forever remain a pipe dream.

Integration is Crucial

Once the integration issue is resolved, it will be possible to exploit the full potential of package units: short lead times, integrated designs and lower overall investment costs. Pre-assembly minimizes the time to install and connect the equipment on-site and also reduces downtime particularly when enhancements and extensions are made to the production line. The modules are produced at the supplier’s manufacturing plant, so conditions on site are generally not a major consideration. Regardless of whether the destination is a chemical plant or a windy off-shore drilling platform, the modules are assembled in a safe, clean, reliable production environment. Functional testing and a completeness check are performed prior to shipment. One-stop shopping also reduces the number of organizational interfaces, if not the number of process control system interfaces.

Gallery

Package units come in all sizes: From smaller modules...

Chemical Injection Packages such as the one shown here made by the pump manufacturer Lewa have been widely used in the oil & gas industry for many years. The intention now is to transfer the concept to chemical production and other process industries.

Stand-alone solutions are not the answer if the future objective is large-scale rollout of package units at chemical parks. The systems will have to operate as part of the network in a complex production environment. It may well be that automation solutions such as DIMA are the piece that is missing in the modular system toolkit. At any rate, there is still a big need for plug-and-play products.

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Skids and Package Units

Discover the Building Blocks for Modular Plant Projects

Integration is Crucial

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