Presentation on Process-Automation

8/13/2019 Presentation on Process-Automation

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Dr. A. AfzalianDept. of Computer & Control Systems Engineering,

The Power & Water University of Technology (PWUT)

A Short Course, April 2005


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2/27Process Automation

ProcessAutomation

Outline:

Examples of automated processes

Types of plants and controls

Automation hierarchy

Control System Architecture


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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), flexiblefabrication, appliances, automotive, aircrafts

Storage silos, elevator, harbor, deposits, luggage handling

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

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


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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 management

flight recording, black boxesdiagnosticsfly-by-wire


5/275/27Process Automation

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, inaccessibility

explosive environment with gas)

Downstream:(extreme explosive environment)

Distribution:(environmental protection)



Examples of Automated Plants:Power plants

Raw materialssupply

Primary process(steam, wind)

Personal, plant andneighbourhoodsafety

Environmentalimpact

Generationprocess(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 mergersABB CH-SE Brown Boveri, ASEA, CE, Alfa-Laval, Elsag-BaileySiemens DE Plessey, Landis & Gyr, Stfa, Cerberus,..Ansaldo ITEmerson US Fisher RosemountGeneral Electric USHoneywell USRockwell Automation US Allen Bradley, Rockwell,..Alstom FR Alsthom, GEC, CEGELEC, ABB Power,..Schneider Electric FR Tlmcanique, Square-D, ...Invensys UK Foxboro, Siebe, BTR, Triconex,Hitachi JPYokogawa 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

100000 10000000 points

Data reduction and processing is necessary to operate plants


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Little difference in the overallarchitecture of differentapplications 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, DetailedProductScheduling, ReliabilityAssurance,...

Control & Command System: Batch control

Continuous Control

Discrete control

ManufacturingExecution

Supervision (SCADA)

Group Control

Individual

Control

Field

Primary technology

Enterprise

Automation Hierarchy


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Example: Siemens WinCC


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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


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Large control system hierarchyCont 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, Controlroom, 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


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Large control system hierarchyCont 3

Unit (Cell):

Control (regulation, monitoring and protection) of a smallpart 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-inprotection


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Field level

Field level isindirect interactionwith the plant'shardware


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Group levelunit controllers

Group level coordinates

the activities of severalunit controls

Distributed ControlSystems (DCS)

commonly refers to ahardware and softwareinfrastructure to performProcess Automation


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Local human interface at group level

Sometimes, the group level has its ownman-machine interface for local operationcontrol (here: cement packaging)

Maintenance console /emergency panel


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Supervisory level: Man-machine interface

Control room (mimic wall) 1970s...

All instruments were directly wired to the control room

Supervisory level:


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Supervisory level:SCADA = Supervisory Control and Data Acquisition

Displays the current state of

the process (visualization)

Display the alarms andevents (alarm log, logbook)

Display the trends(historians) and analysethem

Display handbooks, datasheets, inventory, expertsystem (documentation)

Allows communication anddata synchronization withother centres

Operator workplace: Three main functions


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Operator workplace:Three main functions

1. Current state

3. Alarms

andevents

2. Trends and history


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Response time and hierarchical level

Planning

Level

Execution

Level

Control

Level

Supervisory

Level

ms seconds hours days weeks month years

ERP(Enterprise Resource

Planning)

DCS

MES(Manufacturing

Execution System)

PLC(Programmable

Logic Controller)

(Distributed

Control System)

(Supervisory Controland Data Acquisition)

SCADA

C l it d R ti S d i Hi hi l l l


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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


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Operation and Process Data

Normally, the operator

is only concerned bythe supervisory level,but exceptionally,operators (andengineers) want toaccess data of the

lowest levels

The operator sees theplant through a fastdata base, refreshed in

background

Presentation on Process-Automation

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