Beruflich Dokumente
Kultur Dokumente
Automation Overview
2010 January, HK
Page 1
Definition
Automation:
1)
2)
Automation:
1)
2)
automation and automatisation are often confounded, in english, it is the same word.
Automation
Living organism
Industrial system
brain
spinal chord
data networks
ganglions (reflexes)
controllers
axons
field busses
neurons
muscles
organs
skeleton
Page 2
Automation =
the neural system
administration
enterprise
(manufacturing) execution
SCADA =
Supervisory Control
And Data Acquisition
Supervisory
Group control
Unit control
1
Field
Sensors
& actors
0
A V
Primary technology
DB, Historians,
Operator Workplaces
Optimizers, MES
Plant Network
OPC Server
OPC Server
OPC Server
Control Network
IEC 61850 station bus
Controller
Protection &
Control
Fieldbus
HART mux
Instruments
Process
Instrumentation
LV Electrification
Power generation
Page 3
Substation
Automation
Power Management
Automation Applications
Power generation
Transmission
Distribution
electricity, water
Process
Manufacturing
Storage
Building
Transportation
CH-SE
FR
IT
US
US
JP
US
US
FR
UK
DE
JP
Page 4
Fisher
Rosemountl
SACDA
Fisher &
Porter
Control
Techniques
Profimatics
Foxboro
Rockwell
Software
Intellution
Combustion
Engineering
Vickers
P&F Safety
Systems
APV
L&N
PACSIM
Elsag
Bailey
Cellier
Engineering
Tlmcanique
Dodge
Moore
PC&E
CSI
August
Systems
Square D
Wonderware
Measurex
Westinghouse
PCD
Interplant
Consulting
Kenonics
Allied Signal
MDC
Milltronics
Allen-Bradley
Eurotherm
Modicon
Axiva
SimSci-Esscor
Esscor
ORSI
Reliance
Merlin Grin
Baan
Compex
Skyva
Saab Marine
Electronics
GE Fanuc
POMS
ABB
Emerson
GE Industrial
Honeywell
Invensys
Rockwell
Automation
Schneider
Electric
Delta V,
Plantweb
Cimplicity
Experion PKS,
TotalPlant
ArchestA
RSview
Transparent
Factory
umbrella
IndustrialIT
architecture
Turbi-Werke
Triconex
AVANTIS
Alfa-Laval
Automation
Schneider
Walsh
Automation
Siemens
"Totally
Integrated
Automation"
primary technology
(mechanical, electrical)
automation equipment
(control & command)
engineering &
commissioning
Page 5
maintenance
& disposal
Equipment Design
control
air conditioning
brakes
(dveloppement, Entwicklung)
Equipment Production
(production, Herstellung)
Assembler (ensemblier)
Engineering
Commissioning
(mise en service, Inbetriebnahme)
Start on
service
Client, Service
brakes
Maintenance
replacement
(entretien, Unterhalt)
brakes
Out of service
Recycling
(Recyclage, Wiederverwertung)
Page 6
Examples: Cars
Rail vehicles
there are more than 20 interconnected computers on a locomotive
vehicle control unit
radio link
display unit
VCU
VCU
DU
DU
TCU
TCU
SBB 460
brakes
Benefits:
diagnostics
energy
signaling
Page 7
Launch vehicles
GPC 1
CPU 1
GPC 2
CPU 2
IOP 1
IOP 2
GPC 3
CPU 3
IOP 3
GPC 4
CPU 4
GPC 5
CPU 5
IOP 4
IOP 5
Control
Panels
Intercomputer (5)
Mass memory (2)
serial data
buses
( 23 shared,
5 dedicated )
Power plants
Hydro
- river
- dams
- storage dams
Thermo
- coal
- gas
- atom
- solar
- waste
Alternative
- wind
- photo-voltaic
tasks:
fuel supply
primary process control (steam, wind)
personal, plant and neighbourhood safety
monitoring environmental impact
electricity generation (voltage/frequency)
energy distribution (substation)
24 / 365 availability
Page 8
Substations
SS
Substation
(Unterstation , sous-station)
National
Control Center
SS
Regional
Control Center
Regional Control Center
SS
SY
switchyard,
postes HT
Schaltfeld
PP
SS
PP
PP
SS
Substation
PP
Power Plant
Centrale,
Kraftwerk
SY
Page 9
Building Automation
basics: fire, intrusion, climate, energy management
HVAC = Heat, Ventilation and Cooling = air conditioning
2010 February, HK
Page 10
binary
output
sequencer
clock
plant
error
(deviation)
plant
state
plant state
display
on/off
controller
plant
control variable
(analog)
display
measurement
measurement
%
process value
(valeur mesure,
Istwert)
open-loop functions
closed-loop functions
Regulation
Page 11
output
discrete control
continuous control
Textiles
Pharmaceuticals
Fine Chemical
Food & Beverage
Metals & Mining
Water & Waste
Pulp & Paper
continuous
Vehicles
Petrochemicals
Oil & Gas
Electrical Power
source: ARC
Page 12
Enterprise
Manufacturing Execution
Supervision (SCADA)
Group Control
Individual Control
Field
Primary technology
Automation Hierarchy
Page 13
administration
enterprise
(manufacturing) execution
SCADA =
Supervisory Control
And Data Acquisition
Supervisory
Group control
Unit control
1
Field
Sensors
& actors
0
A V
Primary technology
Unit (Cell)
Field
Page 14
Field level
Group level
unit controllers
Page 15
control room
(mimic wall)
1970s...
Page 16
Page 17
beamers replaces the mosaics, there is no more direct wiring to the plant.
Plant management
- store the plant and product data for further processing in a secure way
(historian), allowing to track processes and trace products
-> Plant Information Management System (PIMS)
Page 18
Engineering workplace
The engineering workplace manages the control system, not the plant.
The engineer can configure the networks and devices, load the software, assign
authorizations, troubleshoot the control system,...
Level 3
Manufacturing
Operations & Control
Dispatching Production, Detailed Product
Scheduling, Reliability Assurance,...
Levels
2,1,0
Batch
Control
Continuous
Control
Discrete
Control
Source: ANSI/ISA95.00.012000
Page 19
Unternehmensleitebene
Enterprise level
Betriebsleitebene
Production level
Prozessleitebene
Process level
Page 20
Planning
Level
(Enterprise Resource
Planning)
MES
Execution
Level
(Manufacturing
Execution System)
SCADA
(Supervisory Control
and Data Acquisition)
Supervisory
Level
DCS
(Distributed
Control System)
Control
Level
PLC
(Programmable
Logic Controller)
ms
seconds
hours
days
weeks
month
years
Page 21
Complexity
Reaction Speed
months
ERP
MES
Command level
Sys. d'excution
Ausfhrungssystem
Fhrungsebene,
days
Supervision
minutes
Prozessleitung
tage de conduite
Conduite de processus
Group Control
seconds
Gruppenleitung
Conduite de groupe
Individual Control
Einzelleitung,
0.1s
Conduite individuelle
Field
Feld,
0.1s
terrain
Site
Anlage,
usine
man-machine
communication
operator
history
logging
process
data base
simulation
instructor
maintenance
engineer
actualization
process data
plant
Page 22
Page 23
disk
instrument bus
(mimic board)
open network, WAN
Operator panel
Mimic board
workstation bus
statio
n
Logging station
PLC nodes P P C P
(multi-processors)
I/OMEMI/O
MEMBC
directly coupled
input/
output
node bus
fieldbus (30m..2 km)
control
backplane bus
stations
sensor bus sensor bus (0,5.. 30 m)
transducers
M
valvethermo-couple position
motor
Page 24
Example: Siemens
Page 25
Desktop PC
with excel
EtherNet / IP
Controller and Bridge
Servo
ControlNet
Linking Device
HMI
HMI
DeviceNet
Modular
I/O
Micro
PLC
509 -BOD
24vdc
Sensor
Block I/O
Page 26
Enterprise
Optimization
(clients)
Workplaces
(clients)
3rd party
application
server
Firewall
Mobile
Operator
aspect
server
application
server
engineering
workplace
Programmable
Logic Controller
AC 800C
Redundant
AC 800M
touch-screen
Field Bus
sensor network
Page 27
Printer Server 1
Alarm and
Event Printer 1
LA36W
Printer Server 2
Operator's Workstation 1
Global Position
System
Engineering Workstation
PTUSK Scope
to
Central Station
Disturbance Recorder
Evalution Station
132kV FOX
Equipment
11kV analog
Input
Telephon
Modem
Verbindung zu E4
Alarm and
Event Printer 2
LA36W
o/e
LAN-Interface
to LV SCMS
Repeater
GPS
Master
Repeater
Front-End Station
Computer 1
Service
Modem
Front-End Station
Computer 2
HP Col or
Fallback
Switch
RS232
Laser j et
Manual
Switch
4 x Star Coupler
RER111 including
redundant
power supply
FO
Main 2
SPAJ110C
Tertiary
Earth fault
Prot.
SPAJ110C
Neutral
earth fault
Prot.
REB500
EF and OC
SPAJ110C
SACO16A3 R
500RIO11 , 16DI
SPAJ110C
Main 1
SACO16A3 R
Protection
Differential protection
RET316*4
Stand by
earth fault
overcurrent
Prot.
SPAJ140C
Synchr o-
Phase and
neutral
overcurrent
Prot.
4 x 11kV
E19 Verbindung
Restricted
earth fault
Protection
check
B69
berstrom
10 x 132kV
6 x 500RIO11 DI
SACO16A3 R
SPAU140C
SPAJ110C
Earth fault
overcurrent
Prot.
SPAJ115C
Restricted
earth fault
Protection
132kV Side
1 x 500RIO11 DO
1 x spare
SACO64D4 Auxiliary alarm unit
11kV Si de
Coaxial cable
(loose delivery)
(loose delivery)
4 x 132/11kV Transformer Feeder
Trafo Interlocking
Page 28
SAS570Advanced
SubstationAutomation System
Control
Bay control unit
REC316*4
Group
Group
Group
Control
Control
Control
Sensors, Actors
PLCs
plant
operator
workstation
data logger
controller
controller
controller
field bus
plant
all controllers can communicate as peers (without going through a central master),
restricted only by throughput and modularity considerations.
Note: Honeywell's "DCS" stands for "Distributed Control System", it is not a decentralized control system, but
a control system for the process industry.
Page 29
vertical
communication
Engineering
Workplaces
IEC 61850
connectivity server
CN Connectivity
Server (and router)
Aspect Servers
ProcessNetwork
substation network
horizontal communication
controller
CI871
PB
PI
PN
PI
PB
PI
PN
PI
PB
PI
PB
PI
PB
PI
Profibus
Engineering
horizontal communication
interface
PN
PI
PN
PI
PN
PI
Profinet
RSTP
Engineering
LANs
are
separa
te:
there
is no
IP
routing
betwee
n them
Page 30
SAN IEDs
PI
PI
PI
PI = Process Interface
MU = Merging Unit
MU
PI
MU
PI
bay bus