Dr. A. Afzalian Dept. of Computer & Control Systems Engineering, The Power & Water University of...

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Dr. A. AfzalianDept. of Computer & Control Systems Engineering,The Power & Water University of Technology (PWUT)

A Short Course, April 2005

2/27Process Automation

Process Automation

Outline:• Examples of automated processes

• Types of plants and controls

• Automation hierarchy

• Control System Architecture

Automation Applications Power generation hydro, coal, gas, oil, shale, nuclear, wind, solar

Transmission electricity, gas, oil

Distribution electricity, water

Process paper, food, pharmaceutical, metal, processing, glass, cement, chemical, refinery, oil & gas

Manufacturing computer aided manufacturing (CIM), flexible fabrication, appliances, automotive, aircrafts

Storage silos, elevator, harbor, deposits, luggage handling

Building heat, ventilation, air conditioning (HVAC), access control, fire, energy supply, tunnels, highways,....

Transportation rolling stock, street cars, sub-urban trains, busses, cars, ships, airplanes, satellites,...

Examples of Automated Plants

CarsAppliances control (windows, seats, radio,..)Motor control (exhaust regulations)ABS and EPS, brake-by-wire, steer-by-wire

19% of the price is electronics, (+10% per year)

Airplanes Avionicsflight control, autopilotflight managementflight recording, black boxesdiagnostics“fly-by-wire”

Examples of Automated PlantsFlexible Automation, Manufacturing

Numerous conveyors, robots, CNC machines, paint shops, logistics.

Examples of Automated Plants: Oil, Gas and Petrochemicals

Upstream:from the earth to the refinery(High pressure, saltwater, inaccessibilityexplosive environment with gas)

Downstream: (extreme explosive environment)

Distribution: (environmental protection)

Examples of Automated Plants: Power plants

• Raw materials supply

• Primary process (steam, wind)

• Personal, plant and neighbourhood safety

• Environmental impact

• Generation process (voltage/frequency)

• Energy distribution (substation)

Examples of Automated Plants:Waste treatment, incinerators

• Raw material supply

• Burning process

• Smoke cleaning

• Environmental control

• Co-generation process (steam, heat)

• Ash analysis

• Ash disposal

Examples of Automated Plants: Water treatment

Managing pumps, tanks, chemical composition, filters, movers,..

Automation Systems Manufacturers

€ 80 B / year business, growing 5 % annually

Company Location Major mergers

ABB CH-SE Brown Boveri, ASEA, CE, Alfa-Laval, Elsag-Bailey

Siemens DE Plessey, Landis & Gyr, Stäfa, Cerberus,..

Ansaldo IT

Emerson US Fisher Rosemount

General Electric US

Honeywell US

Rockwell Automation US Allen Bradley, Rockwell,..

Alstom FR Alsthom, GEC, CEGELEC, ABB Power,..

Schneider Electric FR Télémécanique, Square-D, ...

Invensys UK Foxboro, Siebe, BTR, Triconex,…

Hitachi JP

Yokogawa JP

Technical Necessity of Automation

Processing of the information flow

Enforcement of safety and availability

Reduction of personal costs

Expectations of Automation Process Optimisation

– Energy, material and time savings– Quality improvement, reduction of waste, pollution control – compliance with laws, product tracking– Increase availability, safety– Fast response to market– Connection to management and accounting

Acquisition of large number of “Process Variables”, data mining

Personal costs reduction– Simplify interface– Assist decision– Require data processing, displays, data base, expert systems

Human-Machine Interface (MMC = Man-Machine Communication)

Asset Optimisation– Automation of engineering, commissioning and maintenance– Software configuration, back-up and versioning– Maintenance support

Engineering Tools

Data Quantity in Different Plants• Power Plant (25 years ago)

– 100 measurement and action variables (called "points")

– Analog controllers, analog instruments

– one central "process controller" for data monitoring and protocol.

• Thermal power plant (today)

– 10000 points, comprising:

» 8000 binary and analog measurement points and

» 2000 actuation point

– 1000 micro-controllers and logic controllers

• Nuclear Power Plant

– three times more points than in conventional power plants

• Electricity distribution network

– 100’000 – 10’000’000 points

• Data reduction and processing is necessary to operate plants

• Little difference in the overall architecture of different applications control systems.

• ANS/ISA standard

• Enterprise Resource Planning:– Business Planning & Logistics– Plant Production Scheduling– Operational Management, etc.

• Manufacturing Execution System:– Manufacturing

Operations & Control– Dispatching Production, Detailed

ProductScheduling, Reliability Assurance,...

• Control & Command System:– Batch control– Continuous Control– Discrete control

Manufacturing Execution

Supervision (SCADA)

Group Control

Individual Control

Primary technology

Enterprise

Automation Hierarchy

Example: Siemens WinCC

Large control system hierarchy

enterprise

Group Control

Unit Control

Sensors& Actors A V

Supervisory

Primary technology

Workflow, Resources, Interactions

SCADA =Supervisory ControlAnd Data Acquisition

administrationPlanning, Statistics, Finances

supervision

Large control system hierarchy – Cont… 2• Administration:

– Production goals, planning

• Enterprise:

– Manages resources, workflow, coordinates activities of different sitesquality supervision, maintenance, distribution and planning

• Supervision:

– Supervision of the site, optimization, on-line operations, Control room, Process Data Base, logging (open loop)

• Group (Area):

– Control of a well-defined part of the plant (closed loop, except for intervention of an operator)

» Coordinates individual subgroups, Adjusting set-points and parameters

» Commands several units as a whole

Large control system hierarchy – Cont… 3• Unit (Cell):

– Control (regulation, monitoring and protection) of a small part of a group (closed loop except for maintenance)

» Measure: Sampling, scaling, processing, calibration

» Control: regulation, set-points and parameters

» Command: sequencing, protection and interlocking

• Field:

– Sensors & Actuators, data acquisition, digitalization, data transmission

– No processing except measurement correction and built-in protection

Field level

• Field level is in direct interaction with the plant's hardware

Group level unit controllers

• Group level coordinates the activities of several unit controls

• Distributed Control Systems (DCS) commonly refers to a hardware and software infrastructure to perform Process Automation

Local human interface at group level

Sometimes, the group level has its own man-machine interface for local operation control (here: cement packaging)

Maintenance console / emergency panel

Supervisory level: Man-machine interface

• Control room (mimic wall) 1970s...

• All instruments were directly wired to the control room

Supervisory level: SCADA = Supervisory Control and Data Acquisition • Displays the current state of

the process (visualization)

• Display the alarms and events (alarm log, logbook)

• Display the trends (historians) and analyse them

• Display handbooks, data sheets, inventory, expert system (documentation)

• Allows communication and data synchronization with other centres

Operator workplace: Three main functions

1. Current state

3. Alarms and

events

2. Trends and history

Response time and hierarchical level

PlanningLevel

ExecutionLevel

ControlLevel

SupervisoryLevel

ms seconds hours days weeks month years

ERP(Enterprise Resource

Planning)

MES(Manufacturing

Execution System)

PLC(Programmable Logic Controller)

(Distributed Control System)

(Supervisory Control and Data Acquisition)

Complexity and Reaction Speed in Hierarchical levels

Supervision

Group Control

Individual Control

SiteComplexity Reaction Speed

months

minutes

seconds

Operation and Process Data

• Normally, the operator is only concerned by the supervisory level, but exceptionally, operators (and engineers) want to access data of the lowest levels

• The operator sees the plant through a fast data base, refreshed in background

Dr. A. Afzalian Dept. of Computer & Control Systems Engineering, The Power & Water University of...

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