Industrial Automation Automation Industrielle Industrielle Automation

1.5

Control System Architecture Architecture de Contrle - Commande Leittechnik-Architektur Prof. Dr. H. Kirrmann ABB Research Center, Baden, Switzerland

2011 February, HK

1.5 Control System Architecture

1 Introduction 1.1 1.2 1.3 Automation and its importance Applications of automation Plants and controls 1.3.1 1.3.2 1.3.3 1.3.3 1.4 1.5 Open loop and closed loop control Continuous process Discrete process Dual plants

Automation hierarchy Control System Architecture

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1.5 Control System Architecture

Principle

The control system is a communication system consisting of controllers and links. The structure of the control system should reflects that of the plant Ideally, each unit of the plant should have its own controller, interacting with the controllers of the other, related units, mirroring their physical interaction. Example: Airbus: a wing is delivered with its own computers.

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1.5 Control System Architecture

Example: Power plant control - 1980 (!)

Control systems look similar

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Busses and processors in industrial plants

instrument bus (mimic board) disk Operator panel Mimic board open network, WAN

Process pictures Process Data Base Logging

workstation bus station station

plant network (500m .. 3 km) includes control network

processor pool

I/O MEM I/O directly coupled input/ output

PLC nodes (multi-processors)

P node bus

MEM BC control stations

fieldbus (30m..2 km) backplane bus sensor bus sensor bus (0,5.. 30 m) transducers

valve

thermo-couple

position

plant (Werk, usine) motor

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1.5 Control System Architecture

Example: Printing Architecture

Each level has its bus !

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1.5 Control System Architecture

Example: Production management system

production planning

enterprise network
scheduling maintenance quality control

plant network
transportation cell control

cell floor network

manufacturing cell control

robot controller

milling machine

rail-guided vehicle

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1.5 Control System Architecture

Example: Honeywell TotalPlant (2003 same structure)

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1.5 Control System Architecture

Example: Siemens

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1.5 Control System Architecture

Example: Rockwell (Allen-Bradley) NetLinx

Programmable Device Support PC Desktop PC with excel

EtherNet / IP
Controller and Bridge

Servo

ControlNet

HMI

Linking Device Drive

Bridge or Linking Device

HMI

DeviceNet

Modular I/O

509 -BOD
24vdc

Micro PLC

Sensor Block I/O

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1.5 Control System Architecture

Example: Emerson's PlantWeb (Delta V)

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1.5 Control System Architecture

Example: ABB Industrial IT (redundant system)

Plant Network / Intranet Firewall Workplaces (clients) Enterprise Optimization (clients)

3rd party application server

Mobile Operator

Plant Network (Ethernet) connectivity server Control Network (Ethernet) Serial or fieldbus Field Bus 3rd party controllers, servers etc aspect server application server engineering workplace

Redundant AC 800M

Programmable Logic Controller AC 800C Field Bus

touch-screen

sensor network

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1.5 Control System Architecture

The internet dimension (example: Alstom)

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1.5 Control System Architecture

The wireless dimension (example: Schneider)

No more wires, but the structure remains

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A real substation project

HP Color Laserjet Printer Server 1

Operator's Workstation 1

Operato r's Workstatio n 2

Engineering Workstation
PTUSK Scope

Global Position to Disturbance Recorder System Central Station Evalution Station

Alarm and Event Printer 1 LA36W

132kV FOX Equipment Printer Server 2

11kV analog Ether 132kV analog Input net Input Verbindung zu E4 Telephon Modem

Alarm and Event Printer 2 LA36W Redundant Station LAN TCP-IP

o/e

LAN-Interface to LV SCMS Repeater

11kV Modem 132kV Modem NSK NSK

GPS Master

Repeater

Front-End Station Computer 1

Service Modem

Front-End Station Computer 2

Fallback Switch
Station Alarm Unit LDCs Interface from Station Computer 2 IEC870-5-101

HP Co lor

Laserjet

RS232

Station Alarm Unit

Manual Switch

LDCs Interface from Station Computer 1 IEC870-5-101

FO

4 x Star Coupler RER111 including redundant power supply

Fibre optic station bus (LON) in star configuration

Bay control unit REC316*4

Main 2

Bay control unit REC316*4

3Ph and neutral OC SPAJ140C

Control
Bay control unit REC316*4

Differential protection Tertiary RET316*4 SPAJ110C

Protection

Earth fault Prot.

Bay control unit REC316*4

AVR and tap control T1 type REGSys

BBP/BFP Central unit

REB500

Analog alarm unit SACO16A3

Fault Monitoring System 10 Indactic I650

x 132kV

Line distance prot. REL316*4

500RIO11 , 16DI

EF and OC SPAJ110C

AVR and tap control T2 type REGSys SACO16A3 R

Stand by SPAJ110C earth fault overcurrent Prot. Neutral SPAJ110C 6 x 500RIO11 DI earth fault Prot.

Analog alarm unit SACO16A3

4 x 11kV

Main 1
SACO16A3 R SACO16A3 R SPAU140C
Synchrocheck

overcurrent Prot.

earth fault Protection

SACO64D4 Auxiliary alarm unit AVR and tap control T4 type REGSys
1 x 500RIO11 DO

o/e Siemens 7SD610 fr

E19 Verbindung
SPAJ1 10C

Earth fault overcurrent Prot.

SPAJ115C

Restricted earth fault Protection

SACO64D4 Auxiliary alarm unit

1 x spare
11kV Side

Bay control unit wire diff. prot. Pilot (loose delivery) SOLKOR R/Rf. 4 x 132kV Cable Line

B69 berstrom

Bay control unit (loose delivery) (loose delivery) 1 x 132kV Bus Coupler

132kV Side (loose delivery)

SACO64D4 Auxiliary alarm unit Coaxial cable

(loose delivery) Trafo Interlocking AVR & Tap Control 132kV BBP / BFP 132kV Common Alarm FMS Fault Monitoring System

4 x 132/11kV Transformer Feeder

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1.5 Control System Architecture

SAS570 Advanced ubstation S Automation S ystem

SPAJ140C neutral

Phase and

AVR and tap control T3 type REGSys

Restricted SPAJ115C

10 x BBP/BFP Bay unit REB500

SACO64D4 Auxiliary alarm unit

Centralized (Hierarchical) Control Architecture

Central Computer (Mainframe)

Group Control

Group Control

Group Control PLCs

Sensors, Actors

plant

Classical, hierarchical, centralized architecture. The central computer only monitors and forwards commands to the PLCs

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1.5 Control System Architecture

Decentralized Control System (DCS)

hierarchical (vertical communication)

engineering workstation

operator workstation

data logger
peer-to-peer (horizontal communication)

plant bus
controller 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.

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1.5 Control System Architecture

Plant with process (e.g. chemical) and electrical (substation) parts

plant network
Workplaces Engineering
vertical communication

Aspect Servers

CN Connectivity Server (and router)

IEC 61850 connectivity server

ProcessNetwork

substation network
horizontal communication

horizontal communication

controlle CI871 r

interfac e

PB PI PB PI PB PI PB PI PB PI
Profibus
Engineering

PN PI PN PI PN PI PN PI PN PI
Profinet RSTP
Engineering

LANs are separate: there is no IP routing between them

PI PI PI MU PI MU PI
bay bus

SAN IEDs

PI = Process Interface MU = Merging Unit

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1.5 Control System Architecture

Hierarchies are simple and traditional

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1.5 Control System Architecture

but Distributed Control Systems reflects a more complex world....

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1.5 Control System Architecture

Assessment
1. Draw a typical hierarchical control system showing busses and controllers 2. How does the network hierarchy relate to the plant control hierarchy ? 3. What is the difference between a centralized and a decentralized control system ? (can this difference be seen from the outside ?)

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1.5 Control System Architecture