Dr. A. Afzalian Dept. of Computer & Control Systems Engineering, The Power & Water University of Technology (PWUT) A Short Course, April 2005.

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

Field

Primary technology

Enterprise

Automation Hierarchy


Example: Siemens WinCC


Large control system hierarchy

enterprise

Group Control

Unit Control

Field

Sensors& Actors A V

Supervisory

Primary technology

Workflow, Resources, Interactions

SCADA =Supervisory ControlAnd Data Acquisition

T

administrationPlanning, Statistics, Finances

supervision

1

2

3

4

0


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)

DCS

MES(Manufacturing

Execution System)

PLC(Programmable Logic Controller)

(Distributed Control System)

(Supervisory Control and Data Acquisition)

SCADA


Complexity and Reaction Speed in Hierarchical levels

MES

Supervision

Group Control

Individual Control

Field

SiteComplexity Reaction Speed

ERP

days

months

minutes

seconds

0.1s

0.01s


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 Technology (PWUT) A Short Course, April 2005.

Documents

process automation outline

wire slide

primary process steam

hitachijp yokogawajp

access control

power plants raw materials

energy supply

water treatment