Industrial Automation

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

• 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), 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,...

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Examples of Automated Plants

• Cars
• Appliances 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 Avionics
• flight control, autopilot
• flight management
• flight recording, black boxes
• diagnostics
• fly-by-wire

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Examples of Automated PlantsFlexible Automation,
Manufacturing
Numerous conveyors, robots, CNC machines, paint
shops, logistics.
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Examples of Automated Plants Oil, Gas and
Petrochemicals
Distribution (environmental protection)
Upstream from the earth to the refinery (High
pressure, saltwater, inaccessibility explosive
environment with gas)
Downstream (extreme explosive environment)
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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)

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Examples of Automated PlantsWaste treatment,
incinerators

• Raw material supply
• Burning process
• Smoke cleaning
• Environmental control
• Co-generation process (steam, heat)
• Ash analysis
• Ash disposal

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Examples of Automated Plants Water treatment

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

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Automation Systems Manufacturers
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
80 B / year business, growing 5 annually
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Technical Necessity of Automation

• Processing of the information flow
• Enforcement of safety and availability
• Reduction of personal costs

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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

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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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Automation Hierarchy

• 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
• ManufacturingOperations Control
• Dispatching Production, Detailed
  ProductScheduling, Reliability Assurance,...
• Control Command System
• Batch control
• Continuous Control
• Discrete control

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Example Siemens WinCC
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Large control system hierarchy
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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

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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

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Field level

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

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Group level

• 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

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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
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Supervisory level Man-machine interface

• Control room (mimic wall) 1970s...
• All instruments were directly wired to the
  control room

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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

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Operator workplace Three main functions
2. Trends and history
1. Current state
3. Alarms and events
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Response time and hierarchical level
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Complexity and Reaction Speed in Hierarchical
levels
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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