Chapter 1 Introduction to Instrumentation systems INC 336 -2010

Process Control System Integrated System System Architecture Agenda Introduction Process Control System Integrated System System Architecture p. 2

Requisite subjects Industrial Process Measurement Feedback Control Systems Process Control Systems Advanced Process Control Systems Instrumentation Drawing p. 3 3

1. Introduction : Discrete versus Continuous discrete system continuous system Source : EPFL / ABB Research Center, Baden, Switzerland Prof. Dr. H. Kirrmann p. 4

1. Introduction : Discrete versus Continuous Automotive Manufacturing Electronics Machinery Textiles Pharmaceuticals Fine Chemical Food & Beverage Metals & Mining Water & Waste Pulp & Paper Vehicles Petrochemicals Oil & Gas Electrical Power discrete continuous Source : EPFL / ABB Research Center, Baden, Switzerland Prof. Dr. H. Kirrmann p. 5

1. Introduction : Types of industrial applications industry distinguishes the following categories of applications: "process control": continuous processes, associated with fluids, for instance sewage water treatment, petrochemical process, cement… "batch control": semi-continuous processes, associated with individual products, for instance chemical, pharmaceutical, brewery… "manufacturing": discrete processes, associated with transformation of parts, e.g. automobile industry, bottle-filling, packaging Source : EPFL / ABB Research Center, Baden, Switzerland Prof. Dr. H. Kirrmann p. 6

1. Introduction : Open-loop versus Closed-loop control output controller + - plant state display control variable (analog) set-point (solicited) measurement plant state sequencer on/off closed-loop control / regulation keywords: feedback, analog variables, continuous processes, "process control" open-loop control / command keywords: sequential / combinatorial, binary variables, discrete processes, "batch control", "manufacturing" error (deviation) binary % process value clock Source : EPFL / ABB Research Center, Baden, Switzerland Prof. Dr. H. Kirrmann p. 7

1. Introduction : Large control system hierarchy PLC nodes (multi-processors) fieldbus Operator panel Mimic board plant (Werk, usine) P disk pool transducers control stations process bus (500m .. 3 km) valve thermo-couple motor Process pictures Process Data Base Logging position station bus (0,5.. 30 m) node bus workstation bus instrument bus (mimic board) sensor bus directly coupled input/ output open network: TCP/IP, ... station C I/O MEM BC M (30m..2 km) p. 8 8

Management Plant Field ERP MES 1. Introduction : Large control system hierarchy ERP Management MES Plant SCADA DCS Large PLC Field Process Control Batch Manufacturing p. 9

1. Introduction : Large control system hierarchy Group control Unit control Field Sensors & actors A V Supervisory Primary technology Workflow, order tracking, resources SCADA = Supervisory Control And Data Acquisition T Production planning, orders, purchase 1 2 3 4 Planning, Statistics, Finances 5 (manufacturing) execution enterprise administration Source : EPFL / ABB Research Center, Baden, Switzerland Prof. Dr. H. Kirrmann p. 10

1. Introduction : Large control system hierarchy Administration Finances, human resources, documentation, long-term planning Enterprise Set production goals, plans enterprise and resources, coordinate different sites, manage orders Manufacturing Manages execution, resources, workflow, quality supervision, production scheduling, maintenance. Supervision Supervise 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 subgroups • Adjust set-points and parameters • Command 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 Field data acquisition (Sensors & Actors*), data transmission no processing except measurement correction and built-in protection. . Source : EPFL / ABB Research Center, Baden, Switzerland Prof. Dr. H. Kirrmann p. 11

1. Introduction : Large control system hierarchy Field level the field level is in direct interaction with the plant's hardware (Primary technology, Primärtechnik) Source : EPFL / ABB Research Center, Baden, Switzerland Prof. Dr. H. Kirrmann p. 12

1. Introduction : Large control system hierarchy Group level unit controllers 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 Source : EPFL / ABB Research Center, Baden, Switzerland Prof. Dr. H. Kirrmann p. 13

1. Introduction : Large control system hierarchy Local human interface at group level sometimes, the group level has its own man-machine interface for local operation control (here: cement packaging) also for maintenance: console / emergency panel Source : EPFL / ABB Research Center, Baden, Switzerland Prof. Dr. H. Kirrmann p. 14

1. Introduction : Large control system hierarchy Supervisory level: Man-machine interface control room (mimic wall) 1970s... formerly, all instruments were directly wired to the control room Source : EPFL / ABB Research Center, Baden, Switzerland Prof. Dr. H. Kirrmann p. 15

1. Introduction : Large control system hierarchy 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 Source : EPFL / ABB Research Center, Baden, Switzerland Prof. Dr. H. Kirrmann p. 16

2. Process Control Systems Example of process control p. 17 17

2. Process Control Systems Manipulated variable Fs(t) Process Ti(t) T(t) Disturbance Process variable p. 18 18

2. Process Control Systems Temperature Resistance RTD Transmitter Standard signal p. 19 19

2. Process Control Systems Standard signal Flow Control Valve p. 20 20

2. Process Control Systems SP: Standard signal Controller CO: Standard signal TO: Standard signal p. 21 21

2. Process Control Systems Components in Control Loop Process Sensor/Transmitter Controller Final Control Element Ti(t) Fs(t) Controller Control Valve Process Tsp(t) T(t) Transmitter p. 22 22

2. Process Control Systems Components in Control Loop Process Sensor/Transmitter Controller Final Control Element Ti(t) Fs(t) Controller Control Valve Process Tsp(t) T(t) Transmitter p. 23 23

2. Process Control Systems Components in Control Loop Process Sensor/Transmitter Controller Final Control Element Ti(t) Fs(t) Controller Control Valve Process Tsp(t) T(t) Transmitter p. 24 24

Example From the process given in a figure below, draw the block diagram of process control system, and also explain the functions of this process. p. 25

2. Process Control Systems 26

3. Sequence Control Systems Examples of sequence control and Programmable Logic Controller p. 27 27

3. Sequence Control Systems An example of PLC control panel p. 28 28

Business Planning & Logistics 4. Integrated system the ANS/ISA standard 95 defines terminology and good practices Level 4 Business Planning & Logistics Plant Production Scheduling Operational Management, etc. Enterprise Resource Planning Level 3 Manufacturing Operations & Control Dispatching Production, Detailed Product Scheduling, Reliability Assurance,... Manufacturing Execution System Levels 2,1,0 Control & Command System Batch Control Continuous Control Discrete Control Source: ANSI/ISA–95.00.01–2000 p. 29

Operational Monitoring 4. Integrated system : MES & ERP ERP Enterprise Resource Planning Corporate Level Decision support System MES Manufacturing Execution System Plant Level Operational Planning and Decision Making RESULTS OBJECTIVES Unit Process Level Operational Monitoring and Control System OCS Open Control System p. 30

Make a batch of QR6 Execution The Schedule The Report The Equipment 4. Integrated system : MES & ERP Make a batch of QR6 Execution The Schedule The Report The Equipment QR6 The Recipe The Batch p. 31

MES Information Domain Control Domain Automation System Controllers 3. Integrated system : MES & ERP Enterprise – Site – Area Information Domain Recipe Management Production Planning and Scheduling Production Information Management MES Instructions (make a batch) Process Management Unit Supervision Process Control Data (Batch Record) Controllers Automation System Control Domain Safety Protection p. 32

Significance of Integrating ERP with OCSin the Real World 3. Integrated system : MES & ERP Significance of Integrating ERP with OCSin the Real World Plant Wide MIS/MES/ERP Network Remote Access UNIX® Operator’s Stations Batch Supervisor Workstation Workstation X-Terminal PC PC Windows Operator’s Stations Controllers Fieldbus Remote I/O p. 33

Fieldbus Fieldbus (or field bus) is the name of a family of industrial computer network protocols used for real-time distributed control, now standardized as IEC 61158. A complex automated industrial system — such as a manufacturing assembly line — usually needs an organized hierarchy of controller systems to function. In this hierarchy there is usually a Human Machine Interface (HMI) at the top, where an operator can monitor or operate the system. This is typically linked to a middle layer of programmable logic controllers (PLC) via a non time critical communications system (e.g. Ethernet). At the bottom of the control chain is the fieldbus which links the PLCs to the components which actually do the work such as sensors, actuators, electric motors, console lights, switches, valves and contactors. Fieldbus is an industrial network system for real-time distributed control. It is a way to connect instruments in a manufacturing plant. Previously computers were connected using RS-232 (serial connections) by which only two devices could communicate. This would be the equivalent of the currently used 4-20 mA communication scheme which requires that each device has its own communication point at the controller level, while the fieldbus is the equivalent of the current LAN-type connections, which require only one communication point at the controller level and allow multiple (100's) of analog and digital points to be connected at the same time. This reduces both the length of the cable required and the number of cables required. Furthermore, since devices that communicate through fieldbus require a Microprocessor, multiple points are typically provided by the same device. Some fieldbus devices now support control schemes such as PID control on the device side instead of forcing the controller to do the processing. p. 34

3. Integrated system : MES (Production capability) People Materials Equipment Product Time Capabilities Segments What is available Current Future Per resource, usually a limited resource Per segment p. 35

3. Integrated system : MES (Production schedule) People Materials Equipment Segments Product Definitions Production Schedule Per location (Site, Area, …) Per week, day, shift, order, … What to make Priority and/or dates What materials to use What equipment to use What personnel to use Production parameters (e.g. Color, Options,…) Per Segment p. 36

3. Integrated system : MES (Production performance) What was made What material was actually produced What materials were actually consumed Equipment used Personnel used Production data (e.g. Purity, density,…) Per Segment People Materials Equipment Segments Production Schedule Performance Per location (Site, Area, …) Per shift, hour, end of batch, … p. 37

3. Integrated system : Response time and hierarchical level 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 Source : EPFL / ABB Research Center, Baden, Switzerland Prof. Dr. H. Kirrmann p. 38

3. Integrated system : Data Quantity & Quality Higher Levels When ascending the control hierarchy, data are reduced: higher level data are created (e.g. summary information) Processing and decisions becomes more complicated (requires using models). Timing requirements are slackened. Historical data are stored SCADA level Presentation of complex data to the human operator, aid to decisions (expert system) and maintenance. Requires a knowledge database in addition to the plant's database Lower Levels Lowest levels (closest to the plant) are most demanding in response time. Quantity of raw data is very large. Processing is trivial (was formerly realized in hardware). These levels are today under computer control, except in emergency situations, for maintenance or commissioning. Source : EPFL / ABB Research Center, Baden, Switzerland Prof. Dr. H. Kirrmann p. 39

3. Integrated system : Complexity and Hierarchical level Reaction Speed months ERP Command level MES days Supervision minutes Group Control seconds Individual Control 0.1s Field 0.1s Site Source : EPFL / ABB Research Center, Baden, Switzerland Prof. Dr. H. Kirrmann p. 40

4. Integrated system : MES & ERP

4. System Architecture Centralized Control Architecture (classical) Sensors, Actors PLCs Group Control Central Computer (Mainframe) plant Classical, hierarchical, centralized architecture. The central computer only monitors and forwards commands to the PLCs. Sometimes it may be called as “Direct Digital Control” (DDC). Source : EPFL / ABB Research Center, Baden, Switzerland Prof. Dr. H. Kirrmann p. 42

plant 4. System Architecture Decentralized Control Architecture plant engineering workstation operator data logger controller field bus control bus all controllers can communicate as peers (without going through a central master), restricted only by throughput and modularity considerations. Source : EPFL / ABB Research Center, Baden, Switzerland Prof. Dr. H. Kirrmann p. 43

plant 4. System Architecture Field Control Architecture engineering workstation operator data logger field bus control bus fieldbus Interface Mostly controller functions are run in field level instruments, the field information can be communicated via the fieldbus interface module. Source : EPFL / ABB Research Center, Baden, Switzerland Prof. Dr. H. Kirrmann p. 44

4. System Architecture : DDC, DCS and FCS p. 45

4. System Architecture : DDC, DCS and FCS p. 46

4. System Architecture : Distribution Control Systems Task Distribution p. 47

4. System Architecture : Examples of integrated system ABB System 800xA p. 48

4. System Architecture : Examples of integrated system ABB System 800xA p. 49

4. System Architecture : Examples of integrated system ABB System 800xA p. 50

4. System Architecture : Examples of integrated system ABB System 800xA p. 51

4. System Architecture : Examples of integrated system

4. System Architecture : Examples of integrated system Desktop PC with excel Programmable Device Support PC EtherNet / IP Controller and Bridge Servo ControlNet HMI Linking Device Bridge or Linking Device Drive HMI DeviceNet Block I/O Modular I/O 24vdc 509 -BOD Micro PLC Sensor p. 53

4. System Architecture : Examples of integrated system

SUMMARY AND QUESTIONS p. 55 55