1. Chapter 1
Introduction to Instrumentation systems
INC

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

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

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

5. 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

6. 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

7. 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

8. 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, 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

9. 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

10. 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

11. 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

12. 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

13. 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

14. 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

15. 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

16. 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

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

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

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

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

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

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. 22 22

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. 23 23

24. 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

25. 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

26. 2. Process Control Systems26

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

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

29. 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– –2000
p. 29

30. 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

31. 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

32. 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

33. 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

34. 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
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

35. 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

36. 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

37. 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

38. 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

39. 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

40. 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

41. 4. Integrated system : MES & ERP

42. 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

43. 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

44. 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

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

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

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

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

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

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

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

52. 4. System Architecture : Examples of integrated system

53. 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

54. 4. System Architecture : Examples of integrated system

55. SUMMARY AND QUESTIONS
p. 55 55