1.4 Automation Hierarchy EPFL, Spring 2016

Industrial Automation | Introduction 1.1Automation and its importance 1.2Examples of automated processes 1.3Types of plants and controls 1.3.1Open loop and closed loop control 1.3.2Continuous processes 1.3.3Discrete processes 1.3.3Mixed plants 1.4Automation hierarchy 1.5Control system architecture

Industrial Automation | Automation Hierarchy Hierarchy execution supervision device access communication networks field devices, controllers sensors, actors enterprise physical plant Course Jerarquía de la automación Hiérarchie de l'automation Leitsystem-Hierarchie

Industrial Automation | Automation System Structure Applications differ widely, yet same control system architecture Differences stem from domain know-how embedded in the control system. Examples: -Need for *-proof devices (* in {water, weather, explosion}) -Availability (24/7 operation, hot repair) -Regulations (e.g. food and drug administration) -Tradition and customer relationships

Industrial Automation | Automation as a hierarchy of services Group control Unit control Field Sensors & actors AV Supervisory Primary technology Workflow, order tracking, resources SCADA = Supervisory Control And Data Acquisition T Production planning, orders, purchase Planning, Statistics, Finances 5 (manufacturing) execution enterprise administration Hierarchy Overview

Industrial Automation | Details of control system hierarchy AdministrationFinances, human resources, documentation, long-term planning EnterpriseSet production goals, plans enterprise and resources, coordinate different sites, manage orders ManufacturingManages execution, resources, workflow, quality supervision, production scheduling, maintenance. SupervisionSupervise the production and site, optimize, execute operations visualize plants, store process data, log operations, history (open loop) Group (Area)Controls a well-defined part of the plant (closed loop, except for intervention of an operator)Coordinate individual subgroupsAdjust set-points and parametersCommand several units as a whole Unit (Cell)Control (regulation, monitoring and protection) 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 Fielddata acquisition (sensors, actors), data transmission no processing except measurement correction and built-in protection..

Industrial Automation | Field level the field level is in direct interaction with the plant's hardware (primary technology)

Industrial Automation | Group level the group level coordinates the activities of several unit controls the group control is often hierarchical, can be also be peer-to-peer (from group control to group control = distributed control system) Note: "Distributed Control Systems" (DCS) commonly refers to a hardware and software infrastructure to perform Process Automation unit controllers

Industrial Automation | Supervisory level: SCADA - 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 (SCADA = Supervisory Control and Data Acquisition)

Industrial Automation | Plant management -store plant and product data for further processing -track processes and trace products -> Plant Information Management System (PIMS) - make predictions on future behaviour of processes - schedule maintenance of the equipment - track KPIs (key performance indicators) -> Asset Optimisation (AO)

Industrial Automation | ANSI/ISA 95 standard classification Source: ANSI/ISA– –2000 the ANS/ISA 95 standard defines terminology and good practices Enterprise Resource Planning Manufacturing Execution System Control & Command System Business Planning & Logistics Plant Production Scheduling Operational Management, etc. Manufacturing Operations & Control Dispatching Production, Detailed Product Scheduling, Reliability Assurance,... Level 4 Level 3 Levels 2,1,0 Batch Control Continuous Control Discrete Control

Industrial Automation | 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 Control and Data Acquisition) SCADA

Industrial Automation | Data Quantity & Quality and Hierarchical Level Closest to plan most demanding response time. Quantity of raw data very large. Processing is trivial (formerly realized in hardware) Under computer control, except in emergency situations, for maintenance or commissioning. Lower Levels Higher Levels SCADA level Presentation of complex data to operator Help to make decisions (expert system) and maintenance. Require knowledge database in addition to plant database Data reduction Summary information Complex processing and decisions (requires models) Timing requirements are slackened. Historical data are stored

Industrial Automation | Complexity and Hierarchical level MES Supervision Prozessleitung Conduite de processus Group Control Gruppenleitung Conduite de groupe Individual Control Conduite individuelle Field terrain Site usine Command level Führungsebene, étage de conduite ComplexityReaction Speed Sys. d'exécution Ausführungssystem ERP days months minutes seconds 0.1s Einzelleitung, Feld, Anlage,

Industrial Automation | Operation and Process Data base Consideration of human intervention breaches hierarchy. Operator should be at supervisory level, exceptionally, operators (and engineers) access data of lowest levels. The operator sees the plant through a fast data base, refreshed in background. This database reflects current state of plant, key for logging and simulation. logging process data Update operator process data base plant simulation maintenance engineer history knowledge base

Industrial Automation | Assessment Describe the levels of a hierarchical control system. What is the relationship between hierarchical level, the response time, data quantity and complexity? What does SCADA stands for? What is a group control used for ? What is the role of a Manufacturing Execution System ? What are the three functions of the operator interface ? What is Enterprise Resource Planning ? What is the role of the process database ?

1.5 Control System Architecture EPFL, Spring 2016

Industrial Automation | Control System Architecture 1 Introduction 1.1Automation and its importance 1.2Applications of automation 1.3Plants and controls 1.3.1Open loop and closed loop control 1.3.2Continuous process 1.3.3Discrete process 1.3.3Hybrid plants 1.4Automation hierarchy 1.5Control System Architecture

Industrial Automation | Principles Control system is a communication system of controllers and links. Structure of control system should reflect structure of plant Ideally, each unit of the plant has its own controller, interacting with controllers of related units, mirroring physical interaction. Example: Airbus: a wing is delivered with its own computers.

Industrial Automation | System Architecture Conceptual model presenting Structure Relationships Behavior Including Description of most important elements of system Mapping of functionality onto hardware and software components Description of top-level human interaction with components Goal: support reasoning about elements, structure and behavior guide for implementation

Industrial Automation | Example: Power plant control (!) Control systems still look similar

Industrial Automation | Buses and processors in industrial plants PLC nodes (multi-processors) fieldbus (30m..2 km) Operator panel Mimic board plant (Werk, usine) P disk processor pool transducers control stations plant network (500m.. 3 km) – includes control network valvethermo-couplemotor Process pictures Process Data Base Logging position backplane bus node bus workstation bus instrument bus (mimic board) sensor bus directly coupled input/ output open network, WAN station PPC I/OMEMI/O PPCP MEMBC station M sensor bus (0, m)

Industrial Automation | Example: Production management system transportation cell control manufacturing cell control schedulingmaintenancequality control plant network floor network production planning robot controller enterprise network milling machine rail-guided vehicle cell

Industrial Automation | Plant with process (e.g. chemical) and electrical parts horizontal communication CN Connectivity Server (and router) IEC connectivity server plant network Engineering bay bus substation network process network interface SAN IEDs CI871 Aspect Servers controller PIPB PIPB PIPB PIPB PIPB PI = Process Interface MU = Merging Unit PIPN PIPN PIPN PIPN PIPN PI MU PIMU Profibus Engineering Profinet RSTP LANs are separate: there is no IP routing between them vertical communication Workplaces horizontal communication

Industrial Automation | Example: Newspaper Printing Architecture Each level has its own bus ! MPS = Managed Print Services

Industrial Automation | Example: ABB Industrial IT (redundant system) 3rd party controllers, servers etc Serial or fieldbus engineering workplace Field Bus Firewall Plant Network / Intranet Field Bus Plant Network (Ethernet) 3rd party application server application server aspect server Workplaces (clients) Enterprise Optimization (clients) Mobile Operator connectivity server Control Network (Ethernet) Programmable Logic Controller AC 800C Redundant AC 800M touch-screen sensor network

Industrial Automation | The internet dimension (example: Alstom)

Industrial Automation | The wireless dimension (example: Schneider) No more wires, but the structure remains

Industrial Automation | A real substation project Printer Server 1 Alarm and Event Printer 1 LA36W Fibre optic station bus (LON) in star configuration 4 x Star Coupler RER111 including redundant power supply GPS Master SAS570 Advanced S ubstation Automation S ystem Operator's Workstation 2 Operator's Workstation 1 Global Position System Front-End Station Computer 1 Front-End Station Computer 2 Alarm and Event Printer 2 LA36W Redundant Station LAN TCP-IP Printer Server 2 LAN-Interface to LV SCMS Engineering Workstation Disturbance Recorder Evalution Station to Central Station Manual Switch 132kV analog Input 132kV FOX Equipment 11kV analog Input PTUSK Scope 11kV Modem NSK SACO64D4 Auxiliary alarm unit Main 2 o/e SACO64D4 Auxiliary alarm unit Ether net Verbindung zu E4 FO RS232 Pilot wire diff. prot. SOLKOR R/Rf. B69 Überstrom Main 1 Siemens 7SD610 für E19 Verbindung

Industrial Automation | Centralized (Hierarchical) Control Architecture Sensors, Actors PLCs Group Control Group Control Group Control Central Computer (Mainframe) Classical, hierarchical, centralized architecture. The central computer only monitors and forwards commands to the PLCs plant

Industrial Automation | plant Decentralized Control System engineering workstation operator workstation data logger controller field bus plant bus all controllers can communicate as peers (without going through a central master), restricted only by throughput and modularity considerations. hierarchical (vertical communication) peer-to-peer (horizontal communication)

Industrial Automation | Hierarchies are simple and traditional

Industrial Automation | but Distributed Control Systems reflect a more complex world....

Industrial Automation | Assessment 1.Give a high-level description of the architecture of a washing machine 2.What is a bus and why do we have more than one kind of them in a plant? 3.Name the parts of a typical hierarchical control system its busses and controllers 4.How does the network hierarchy relate to the plant control hierarchy? 5.What is the difference between a centralized and a decentralized control system ? What are the (dis)advantages of the two approaches?

2 Programmable Logic Controllers EPFL, Spring 2016

Industrial Automation | PLC = Programmable Logic Controller: Definition Definition:“small computers, dedicated to automation tasks in an industrial environment" cabled relay control (hence 'logic'), analog (pneumatic, hydraulic) “governors” real-time (embedded) computer with extensive input/output Function:Measure, Control, Protect AP = Automates Programmables industriels SPS = Speicherprogrammierbare Steuerungen Formerly: Today: DistinguishInstrumentation flow meter, temperature, position,…. but also actors (pump, …) Control programmable logic controllers with digital peripherals & field bus Visualization Human Machine Interface (HMI) in PLCs (when it exists) is limited to service help and control of operator displays

Industrial Automation | Simple PLC network digital inputs digital outputs analog inputs / outputs

Industrial Automation | PLC in a cabinet CPU1 redundant field bus connection CPU2 inputs/outputs serial connections

Industrial Automation | example: turbine control (in the test lab)

Industrial Automation | PLC: functions Measure Control (Command and Regulation) Event Logging Communication Human interface Protection (Messen, Schützen, Regeln = MSR) PLC = PMC: Protection, Measurement and Control

Industrial Automation | PLC: Characteristics large number of peripherals: I/O per CPU, high density of wiring, easy assembly. digital and analog Input/Output with standard levels operate under harsh conditions, require robust construction, protection against dirt, water and mechanical threats, electro-magnetic noise, vibration, extreme temperature range (-30C..85C), sometimes directly located in the field. programming: either very primitive with hand-held terminals on the target machine itself, or with a laptop network connection for programming on workstations and connection to SCADA primitive Human-Machine-Interface for maintenance, either through LCD-display or connection of a laptop over serial lines (RS232) or wireless. economical - € €15'000.- for a full crate. the value is in the application software (licenses € 20'000.. € 50'000) field bus connection for remote I/Os

Industrial Automation | PLC: Location in the control architecture Enterprise Network directly connected I/O Control Bus (e.g. Ethernet) Engineer station I/O CPU Sensor Bus (e.g. ASI) Field Bus gateway Field Stations Control Station with Field Bus direct I/O I/O Field Devices FB gateway I/O CPU COM I/O COM CPU COM I/O Field Bus CPU COM 2 I/O CPU COM1 COM 2 I/O CPU Operator station large PLCs small PLC PLC COM1 Supervisor Station data concentrators, not programmable, but configurable

Industrial Automation | Why 24V / 48 V supply ? … After the plant lost electric power, operators could read instruments only by plugging in temporary batteries … [ IEEE Spectrum Nov 2011 about Fukushima ] Photo TEPCO

Industrial Automation | Global players Total sales in 2004: 7’000 Mio € Source: ARC Research,

Industrial Automation | Kinds of PLC Monolithic construction Monoprocessor Fieldbus connection (1) Modular construction (backplane) One- or multiprocessor system Fieldbus and LAN connection Small Micro Memory Card (MMC) function possible (2) Compact Modular PLC (3) Soft-PLC Linux or Windows NT or CE-based automation products Direct use of CPU or co-processors

Industrial Automation | Compact PLC Monolithic (one-piece) construction Fixed casing Fixed number of I/O (most of them binary) No additional processing capabilities (no MMC) Can be extended and networked by an extension (field) bus Sometimes LAN connection (Ethernet, Arcnet) Monoprocessor Typical product: Mitsubishi MELSEC F, ABB AC31, SIMATIC S7 costs: € 2000 courtesy ABB

Industrial Automation | Specific Controller (example: Turbine) Thermocouple inputs binary I/Os, CAN field bus RS232 to HMI Relays and fuses Programming port cost: € tailored for a specific application, produced in large series courtesy Turbec

Industrial Automation | courtesy ABB Modular PLC RS232 CPU Analog I/OBinary I/O backplane parallel bus housed in a 19" (42 cm) rack (height 6U ( = 233 mm) or 3U (=100mm) concentration of a large number of I/O Power Supply high processing power (several CPUs) primitive or no HMI cost effective if the rack can be filled can be tailored to needs of application supply V, 24V or 48V (redundant) fieldbus LAN large choice of I/O boards interface boards to field busses requires marshalling of signals fieldbus development environment cost ~ €10’000 for a filled crate Typical products: SIMATIC S5-115, Hitachi H-Serie, ABB AC110

Industrial Automation | Small modular PLC mounted on DIN-rail, 24V supply cheaper (€5000) not water-proof, no ventilator extensible by a parallel bus (flat cable or rail) courtesy ABB courtesy Backmann

Industrial Automation | Compact or modular ? € # I/O modules Limit of local I/O compact PLC (fixed number of I/Os) modular PLC (variable number of I/Os field bus extension

Industrial Automation | Industry- PC Wintel architecture (but also: Motorola, PowerPC), HMI (LCD..) Limited modularity through mezzanine boards (PC104, PC-Cards, IndustryPack) Backplane-mounted versions with PCI or Compact-PCI Competes with modular PLC no local I/O, fieldbus connection instead, courtesy INOVAcourtesy MPI costs: €

Industrial Automation | Soft-PLC (PC as PLC) PC as engineering workstation PC as human interface (Visual Basic, Intellution, Wonderware) PC as real-time processor PC assisted by a Co-Processor (ISA- or PC104 board) PC as field bus gateway to a distributed I/O system I/O modules

Industrial Automation | Protection devices Protection devices are highly specialized PLCs that measure the current and voltages in an electrical substation, along with other statuses (position of the switches,…) to detect situations that could endanger the equipment (over-current, short circuit, overheat) and trigger the circuit breaker (“trip”) to protect the substation. In addition, they record disturbances and send the reports to the substation’s SCADA. Sampling: 4.8 kHz, reaction time: < 5 ms. Human interface for status and settings measurement transformers IrIr IsIs ItIt UrUr UsUs UTUT Programming interface trip relay communication to operator costs: € 5000 substation

Industrial Automation | Comparison Criteria – what matters Siemens Number of Points Memory Programming Language Programming Tools Download Real estate per 250 I/O Label surface Network Hitachi KB Ladder Diagrams Instruction List Logic symbols Basic Hand-terminal Graphical (on PC) yes 1000 cm2 6 characters 6 mm kbit/s 1024 Ladder Diagrams Instruction List Logic symbols Hand-terminal Graphical (on PC) no 2678 cm2 5.3 mm2 7 charactersper line/point 10 Mbit/s 10 KB MountingcabinetDIN rail Brand

Industrial Automation | Implementation PLC operates periodically Samples signals from sensors and converts them to digital form with A/D converter Computes control signal and converts it to analog form for the actuators. 1. Wait for clock interrupt 2. Read input from sensor 3. Compute control signal 4. Send output to the actuator 5. Update controller variables 7. Communication 6. Repeat Waiwera Organic Winery, Distillation Plant

Industrial Automation | The signal chain within a PLC analog variable (e.g mA) filtering & scaling analog- digital converter processing digital- analog converter analog variable e.g. -10V..10V time y y(i) sampling binary variable (e.g V) filteringsampling time y transistor or relay binary variable amplifier counter 1 non-volatile memory time y(i)

Industrial Automation | General PLC architecture CPU Real-Time Clock flash EPROM ROM buffers signal conditioning power amplifiers relays signal conditioning serial port controller Ethernet parallel bus ethernet controller RS 232 analog- digital converters digital- analog converters Digital Output Digital Input fieldbus controller external I/Os extension bus field bus direct Inputs and Outputs

Industrial Automation | Assessment What characterizes a PLC, which kinds exist and what is their application field? List selection criteria for PLCs Describe the chain of signal from the sensor to the actors in a PLC

Industrial Automation | Next week … we’ll talk about how PLCs control plant See you then!