Dr. A. Afzalian Dept. of Computer & Control Systems Engineering,

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

2. Process Automation Outline: • Examples of automated processes • Types of plants and controls • Automation hierarchy • Control System Architecture

3. 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 • Manufacturingcomputer aided manufacturing (CIM), flexible fabrication, appliances, automotive, aircrafts • Storage silos, elevator, harbor, deposits, luggage handling • Buildingheat, ventilation, air conditioning (HVAC), access control, fire, energy supply, tunnels, highways,.... • Transportation rolling stock, street cars, sub-urban trains, busses, cars,ships, airplanes, satellites,...

4. 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”

5. Examples of Automated PlantsFlexible Automation, Manufacturing Numerous conveyors, robots, CNC machines, paint shops, logistics.

6. Distribution: (environmental protection) 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)

7. 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)

8. 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

9. Examples of Automated Plants:Water treatment Managing pumps, tanks, chemical composition, filters, movers,..

10. Automation Systems Manufacturers € 80 B / year business, growing 5 % annually

11. Technical Necessity of Automation • Processing of the information flow • Enforcement of safety and availability • Reduction of personal costs

12. 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

13. 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

14. Enterprise Manufacturing Execution Supervision (SCADA) Group Control Individual Control Field Primary technology 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

15. Example: Siemens WinCC

16. 4 administration Planning, Statistics, Finances 3 Workflow, Resources, Interactions enterprise supervision SCADA = Supervisory 2 Supervisory Control And Data Acquisition Group Control Unit Control 1 Field Sensors T A V & Actors 0 Primary technology Large control system hierarchy

17. 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

18. 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

19. Field level • Field level isin direct interaction with the plant's hardware

20. unit controllers 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

21. 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

22. Supervisory level: Man-machine interface • Control room (mimic wall) 1970s... • All instruments were directly wired to the control room

23. 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

24. Operator workplace: Three main functions 2. Trends and history 1. Current state 3. Alarms and events

25. ERP(Enterprise Resource Planning) Planning Level MES (Manufacturing Execution System) Execution Level 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 Response time and hierarchical level

26. months ERP days MES minutes Supervision seconds Group Control 0.1s Individual Control 0.01s Field Site Complexity Reaction Speed Complexity and Reaction Speed in Hierarchical levels

27. 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