Industrial Automation Automation Industrielle Industrielle Automation Manufacturing Execution Supervision (SCADA) Group Control Individual Control Field Primary technology Enterprise 1.4Automation Hierarchy Jerarquía de la automación Hiérarchie de l'automation Leitsystem-Hierarchie

Automation hierarchy Industrial Automation 1.4 Contents 1 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

Automation hierarchy Industrial Automation Automation System Structure Applications differ widely, yet there is little difference in the overall architecture of their control systems. The small differences stem from domain know-how embedded in the control system. Examples: -Need for *-proof devices (* in {water, weather, explosion}) -Availability (24hours operation and hot repair) -Regulations (e.g. Food and Drug Administration) -Tradition and customer relationships

Automation hierarchy Industrial Automation Large control system hierarchy (1) 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

Automation hierarchy Industrial Automation Large control system hierarchy (2) 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. (*capteurs et moteurs, Messfühler & Stellglieder).

Automation hierarchy Industrial Automation Field level the field level is in direct interaction with the plant's hardware (Primary technology, Primärtechnik)

Automation hierarchy 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

Automation hierarchy 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)

Automation hierarchy Industrial Automation 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) - make predictions on the future behaviour of the processes and in particular about the maintenance of the equipment, track KPI (key performance indicators) -> Asset Optimisation (AO)

Automation hierarchy Industrial Automation ANSI/ISA 95 standard classification Source: ANSI/ISA– –2000 the ANS/ISA standard 95 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

Automation hierarchy 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

Automation hierarchy Industrial Automation Data Quantity & Quality and Hierarchical Level 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. Lower Levels Higher Levels SCADA level Presentation of complex data to the human operator, help to make decisions (expert system) and maintenance. Requires a knowledge database in addition to the plant's database 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

Automation hierarchy 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,

Automation hierarchy Industrial Automation Operation and Process Data base Consideration of human intervention breaches this hierarchy. 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. This database is key for logging and simulation. man-machine communication instructor logging process data Update operator process data base plant simulation maintenance engineer history knowledge base

Automation hierarchy 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 ?