Industrial Automation1

Reference: Prof. Dr. H. Kirrmann

EPFL-ABB

Automation Overview

2010 January, HK

Page 1

Definition
Automation:
1)

set of all measures aiming at replacing human work through machines

(e.g. automation is applied science)

2)

the technology used for this purpose

(e.g. this company has an automation department)

Automation:
1)

replacement of human work through machines

(e.g. the automatisation of the textile factory caused uproar of the workers)

2)

replacement of conscious activity by reflexes

(e.g. drill of the sailors allows the automatisation of ship handling)

automation and automatisation are often confounded, in english, it is the same word.

Automation
Living organism

Industrial system

brain

historian, expert optimizers,

manufacturing execution system

spinal chord

data networks

ganglions (reflexes)

controllers

axons

field busses

neurons

sensors and actors

muscles

motors, pneumatic movers

organs

primary equipment (vessels, turbines)

skeleton

buildings and sites

Page 2

Automation =
the neural system

Automation as a hierarchy of services

5

Planning, Statistics, Finances

Production planning, orders, purchase

Workflow, order tracking, resources

administration
enterprise
(manufacturing) execution

SCADA =
Supervisory Control
And Data Acquisition

Supervisory

Group control
Unit control
1
Field
Sensors
& actors
0

A V

Primary technology

Automation as a computer network

WWW

DB, Historians,
Operator Workplaces

Optimizers, MES

Plant Network
OPC Server

OPC Server

OPC Server

Control Network
IEC 61850 station bus

Controller

Protection &
Control

Fieldbus
HART mux

Instruments

Process
Instrumentation
LV Electrification

Power generation

Page 3

Substation
Automation

Power Management

Automation Applications
Power generation

hydro, coal, gas, oil, shale, nuclear, wind, solar

Transmission

electricity, gas, oil

Distribution

electricity, water

Process

paper, food, pharmaceutical,

metal production and processing, glass, cement,
chemical, refinery, oil & gas

Manufacturing

computer aided manufacturing (CIM)

flexible fabrication, appliances, automotive, aircrafts

Storage

silos, elevator, harbor, retail houses,

deposits, luggage handling

Building

heat, ventilation, air conditioning (HVAC)

access control, fire, energy supply, tunnels,
parking lots, highways,....

Transportation

rolling stock, street cars, sub-urban trains,

busses, trolley busses, cars,
ships, airplanes, rockets, satellites,...

Automation Systems - World Players

Company (alpha. order) Location Major mergers
ABB
Alstom
Ansaldo
Emerson
General Electric
Hitachi
Honeywell
Rockwell Automation
Schneider Electric
Invensys
Siemens
Yokogawa

CH-SE
FR
IT
US
US
JP
US
US
FR
UK
DE
JP

Brown Boveri, ASEA, CE, Alfa-Laval, Elsag-Bailey

Alsthom, GEC, CEGELEC, ABB Power,..
Fisher Rosemount

Allen Bradley, Rockwell,..

Tlmcanique, Square-D, ...
Foxboro, Siebe, BTR, Triconex,
Plessey, Landis & Gyr, Stfa, Cerberus,..

80 Mia / year business

(depends on viewpoint),
growing 5 % annually

Page 4

Worldwide Consolidation Process: the Big Eight

Hartmann &
Braun

Fisher
Rosemountl

SACDA

Fisher &
Porter

Control
Techniques

Profimatics

Foxboro

Rockwell
Software

Intellution

Combustion
Engineering

Vickers

P&F Safety
Systems

APV

L&N

PACSIM

Elsag
Bailey
Cellier
Engineering

Tlmcanique

Dodge
Moore

PC&E

CSI
August
Systems

Square D
Wonderware

Measurex
Westinghouse
PCD
Interplant
Consulting

Kenonics

Allied Signal

MDC

Milltronics

Allen-Bradley
Eurotherm
Modicon

Axiva

SimSci-Esscor
Esscor

ORSI
Reliance
Merlin Grin

Baan

Compex

Skyva

Saab Marine
Electronics

GE Fanuc

POMS

ABB

Emerson

GE Industrial

Honeywell

Invensys

Rockwell
Automation

Schneider
Electric

Delta V,
Plantweb

Cimplicity

Experion PKS,
TotalPlant

ArchestA

RSview

Transparent
Factory

umbrella
IndustrialIT
architecture

Turbi-Werke

Triconex
AVANTIS

Alfa-Laval
Automation

Schneider

Walsh
Automation
Siemens
"Totally
Integrated
Automation"

Four distinct businesses

primary technology
(mechanical, electrical)

automation equipment
(control & command)

engineering &
commissioning

seldom offered by the same company

Page 5

maintenance
& disposal

Life-phases of a Plant (Example: Rail Vehicle)

Manufacturers

Equipment Design

control

air conditioning

brakes

(dveloppement, Entwicklung)

Equipment Production
(production, Herstellung)

car body design by assembler

Assembler (ensemblier)

Engineering

Sleeping Wagon XL5000

Plus

(bureau dtude, Projektierung)

Commissioning
(mise en service, Inbetriebnahme)

Start on
service

Client, Service

brakes

Maintenance

replacement

(entretien, Unterhalt)

brakes

Out of service
Recycling
(Recyclage, Wiederverwertung)

Data quantity in plants

Power Plant 30 years ago
100 measurement and action variables (called "points")
Analog controllers, analog instruments
one central "process controller" for data monitoring and protocol.
Coal-fired power plant today
10'000 points, comprising
8'000 binary and analog measurement points and
2'000 actuation point
1'000 micro-controllers and logic controllers
Nuclear Power Plant
three times more points than in conventional power plants
Electricity distribution network
100000 - 10000000 points
information flow to the personal: > 5 kbit/s.
human processing capacity: about 25 bit/s
without computers, 200 engineers (today: 3)
Data reduction and processing is necessary to operate plants

Page 6

Examples: Cars

today: 50..100 ECU (electronic control units)

critical new applications:

brake-by-wire, steer-by-wire (X-by-wire) increased safety ?
extreme price squeezing
of the cost is electronics, tendency increasing
http://spectrum.ieee.org/green-tech/advanced-cars/this-car-runs-on-code

Rail vehicles
there are more than 20 interconnected computers on a locomotive
vehicle control unit

radio link

display unit

VCU

VCU
DU

DU
TCU

TCU

SBB 460
brakes
Benefits:

diagnostics

traction control unit

energy

signaling

reduce operation costs, faster diagnostics, better energy management,

automatic train control.

Page 7

Launch vehicles

GPC 1
CPU 1

GPC 2
CPU 2

IOP 1

IOP 2

GPC 3
CPU 3
IOP 3

GPC 4
CPU 4

GPC 5
CPU 5

IOP 4

IOP 5

Control
Panels

Intercomputer (5)
Mass memory (2)

serial data
buses
( 23 shared,
5 dedicated )

Display system (4)

Payload operation (2)
Launch function (2)
Flight instrument (5;1 dedicated per GPC)
Flight - critical sensor and control (8)

Power plants
Hydro
- river
- dams
- storage dams
Thermo
- coal
- gas
- atom
- solar
- waste
Alternative
- wind
- photo-voltaic

tasks:
fuel supply
primary process control (steam, wind)
personal, plant and neighbourhood safety
monitoring environmental impact
electricity generation (voltage/frequency)
energy distribution (substation)
24 / 365 availability

Page 8

Substations

protection (Lines, transformers, generators) very high speed response

control (remote or local) to guarantee power flow, safe operation (interlocking)
measurement (local and remote), electricity bill, power flow in grid

Power transmission network

International
Control Center

SS

Substation
(Unterstation , sous-station)

National
Control Center

SS
Regional
Control Center
Regional Control Center

SS

SY

switchyard,
postes HT
Schaltfeld

PP
SS

PP

PP

SS
Substation

PP

Power Plant
Centrale,
Kraftwerk

SY

Huge number of "points" (power plants, transformers, breakers, substations)

lying 2km to 2000 km apart.
All time-critical operations executed locally in the substations and power generation units.

Page 9

Building Automation
basics: fire, intrusion, climate, energy management
HVAC = Heat, Ventilation and Cooling = air conditioning

visitors, meeting rooms, catering,.

low price tag

Types of Plants and Control

2010 February, HK

Page 10

Open loop and closed loop

open-loop control / command

(commande / pilotage, steuern, )
keywords: sequential / combinatorial,
binary variables, discrete processes,
"batch control", "manufacturing"

closed-loop control / regulation

(rgulation, Regelung)
keywords: feedback, analog variables,
continuous processes, "process control"
set-point (solicited)
valeur de consigne
Sollwert,

binary
output

sequencer

clock

plant

error
(deviation)

plant
state

plant state

display
on/off

controller

plant

control variable
(analog)

display
measurement

measurement

%
process value
(valeur mesure,
Istwert)

Function of computers in control systems

open-loop functions

closed-loop functions

Data acquisition and pre-processing

Protection and interlocking*

Data transfer between plant and operator

Regulation

Display the plant state

Process-driven sequential control

Logging and history recording

Simulation and training
Process optimization algorithms
the control system acts directly
and autonomously on the plant

Interlocking*: prevent dangerous actions,

such as all lights on green at a crossing

Page 11

output

Discrete and continuous plants

discrete control

continuous control

Accent depends on industrial process

Automotive Manufacturing
Electronics
Machinery
discrete

Textiles
Pharmaceuticals
Fine Chemical
Food & Beverage
Metals & Mining
Water & Waste
Pulp & Paper

continuous

Vehicles
Petrochemicals
Oil & Gas
Electrical Power
source: ARC

Page 12

The main categories in industry

industry distinguishes the following categories of applications:
"process control": continuous processes, associated with fluxes,
e.g. sewage water treatment, petrochemical process, cement
"batch control":

semi-continuous processes, associated with individual products,

e.g. fine chemicals, pharmaceutical, brewery

"manufacturing": also called factory automation

discrete processes, associated with transformation of parts,
e.g. automobile industry, bottle-filling, packaging

Enterprise
Manufacturing Execution

Supervision (SCADA)
Group Control
Individual Control
Field
Primary technology

Automation Hierarchy

Page 13

Large control system hierarchy (1)

5

Planning, Statistics, Finances

Production planning, orders, purchase

Workflow, order tracking, resources

administration
enterprise
(manufacturing) execution

SCADA =
Supervisory Control
And Data Acquisition

Supervisory

Group control
Unit control
1
Field
Sensors
& actors
0

A V

Primary technology

Large control system hierarchy (2)

Administration
Enterprise
Manufacturing
Supervision
Group (Area)

Unit (Cell)

Field

Finances, human resources, documentation, long-term planning

Set production goals, plans enterprise and resources, coordinate
different sites, manage orders
Manages execution, resources, workflow, quality supervision,
production scheduling, maintenance.
Supervise the production and site, optimize, execute operations
visualize plants, store process data, log operations, history (open loop)
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

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

data acquisition (Sensors & Actors*), data transmission
.
no processing except measurement correction and built-in protection.
(*capteurs et moteurs, Messfhler & Stellglieder)

Page 14

Field level

the field level is in direct

interaction with the plant's hardware
(Primary technology, Primrtechnik)

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

Page 15

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

Supervisory level: Man-machine interface

control room
(mimic wall)
1970s...

formerly, all instruments were directly wired to the control room

Page 16

Mosaic is still in use with direct wiring

Supervisory level: SCADA

(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

Page 17

Todays control rooms

beamers replaces the mosaics, there is no more direct wiring to the plant.

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)

Page 18

Engineering workplace

The engineering workplace manages the control system, not the plant.
The engineer can configure the networks and devices, load the software, assign
authorizations, troubleshoot the control system,...

ANSI/ISA 95 standard classification

the ANS/ISA standard 95 defines terminology and good practices
Level 4

Business Planning & Logistics

Enterprise Resource Planning

Plant Production Scheduling

Operational Management, etc.

Level 3

Manufacturing
Operations & Control
Dispatching Production, Detailed Product
Scheduling, Reliability Assurance,...

Levels
2,1,0
Batch
Control

Continuous
Control

Discrete
Control

Manufacturing Execution System

Control & Command System

Source: ANSI/ISA95.00.012000

Page 19

Example: Power plant

Example of generic control siemens: Siemens WinCC (Generic)

Unternehmensleitebene
Enterprise level

Betriebsleitebene
Production level

Prozessleitebene
Process level

Page 20

Response time and hierarchical level

ERP

Planning
Level

(Enterprise Resource
Planning)

MES
Execution
Level

(Manufacturing
Execution System)

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

Data Quantity & Quality and Hierarchical Level

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.

Page 21

Complexity and Hierarchical level

Complexity

Reaction Speed
months

ERP
MES

Command level

Sys. d'excution
Ausfhrungssystem

Fhrungsebene,

days

Supervision

minutes

Prozessleitung

tage de conduite

Conduite de processus

Group Control

seconds

Gruppenleitung
Conduite de groupe

Individual Control
Einzelleitung,

0.1s

Conduite individuelle

Field
Feld,

0.1s

terrain

Site
Anlage,

usine

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 the pivot for logging and simulation.
knowledge base

man-machine
communication
operator

history

logging

process
data base

simulation

instructor
maintenance
engineer

actualization
process data
plant

Page 22

The process database is at the centre (example: Wonderware)

Control System Architecture

Page 23

Example: Power plant control - 1980 (!)

Control systems look similar

Busses and processors in industrial plants

Process pictures

disk

instrument bus
(mimic board)
open network, WAN
Operator panel
Mimic board

Process Data Base

workstation bus
statio
n

Logging station

plant network (500m .. 3 km) includes control network

processor pool
P P P C

PLC nodes P P C P
(multi-processors)
I/OMEMI/O
MEMBC

directly coupled
input/
output

node bus
fieldbus (30m..2 km)

control
backplane bus
stations
sensor bus sensor bus (0,5.. 30 m)
transducers

M
valvethermo-couple position
motor

Page 24

plant (Werk, usine)

Example: Honeywell TotalPlant (2003 same structure)

Example: Siemens

Page 25

Example: Rockwell (Allen-Bradley) NetLinx

Programmable
Device
Support PC

Desktop PC
with excel

EtherNet / IP
Controller and Bridge

Servo

ControlNet

Linking Device

HMI

Bridge or Linking Device

Drive

HMI

DeviceNet

Modular
I/O

Micro
PLC

509 -BOD
24vdc

Sensor
Block I/O

Example: Emerson's PlantWeb (Delta V)

Page 26

Example: ABB Industrial IT (redundant system)

Plant Network / Intranet

Enterprise
Optimization
(clients)

Workplaces
(clients)

3rd party
application
server

Firewall

Mobile
Operator

Plant Network (Ethernet)

connectivity
server

aspect
server

application
server

engineering
workplace

Control Network (Ethernet)

Serial or
fieldbus
Field Bus
3rd party
controllers,
servers etc

Programmable
Logic Controller
AC 800C

Redundant
AC 800M

touch-screen

Field Bus

sensor network

The internet dimension (example: Alstom)

Page 27

The wireless dimension (example: Schneider)

No more wires, but the structure remains

A real substation project

HP Color
Laserjet

Printer Server 1

Alarm and
Event Printer 1
LA36W

Printer Server 2

Operator's Workstation 1

Global Position
System

Engineering Workstation

O per at or 's Wor kst at i on 2

PTUSK Scope

to
Central Station

Disturbance Recorder
Evalution Station

132kV FOX
Equipment
11kV analog
Input

Ether 132kV analog

net
Input

Telephon
Modem
Verbindung zu E4

Alarm and
Event Printer 2
LA36W

o/e
LAN-Interface
to LV SCMS
Repeater

Redundant Station LAN TCP-IP

GPS
Master

Repeater

Front-End Station
Computer 1
Service
Modem

11kV Modem 132kV Modem

NSK
NSK

Front-End Station
Computer 2

HP Col or

Fallback
Switch

Station Alarm Unit

RS232

Laser j et

Station Alarm Unit

LDCs Interface from Station Computer 2 IEC870-5-101
LDCs Interface from Station Computer 1 IEC870-5-101

Manual
Switch

4 x Star Coupler
RER111 including
redundant
power supply

FO

Fibre optic station bus (LON) in star configuration

Main 2

Line distance prot.

REL316*4

Bay control unit

REC316*4

3Ph and neutral OC

SPAJ140C

SPAJ110C

Tertiary
Earth fault
Prot.

SPAJ110C

Neutral
earth fault
Prot.

Bay control unit

REC316*4

Analog alarm unit

SACO16A3

BBP/ BFP Cent r al uni t

REB500

AVR and tap control

T2 type REGSys

EF and OC
SPAJ110C

SACO16A3 R

500RIO11 , 16DI

SPAJ110C

Main 1
SACO16A3 R

AVR and tap control

T1 type REGSys

Protection
Differential protection
RET316*4

Bay control unit

REC316*4

Stand by
earth fault
overcurrent
Prot.

SPAJ140C
Synchr o-

Phase and
neutral
overcurrent
Prot.

4 x 11kV

AVR and tap control

T3 type REGSys
SPAJ115C

10 x BBP/BFP Bay unit

REB500

SACO64D4 Auxiliary alarm unit

o/e Siemens 7SD610 fr

AVR and tap control

T4 type REGSys

E19 Verbindung

Bay control unit

Pilot wire diff. prot.
(loose delivery)
SOLKOR R/Rf.
4 x 132kV Cable Line

SACO64D4 Auxiliary alarm unit

Restricted
earth fault
Protection

check

B69
berstrom

10 x 132kV

Analog alarm unit

SACO16A3

6 x 500RIO11 DI

SACO16A3 R
SPAU140C

Fault Monitoring System

Indactic I650

SPAJ110C

Bay control unit

(loose delivery)
(loose delivery)
1 x 132kV Bus Coupler

Earth fault
overcurrent
Prot.

SPAJ115C

SACO64D4 Auxiliary alarm unit

Restricted
earth fault
Protection

132kV Side

1 x 500RIO11 DO

1 x spare
SACO64D4 Auxiliary alarm unit

11kV Si de

Coaxial cable

(loose delivery)
(loose delivery)
4 x 132/11kV Transformer Feeder

Trafo Interlocking

Page 28

AVR & Tap Control

132kV BBP / BFP

132kV Common Alarm

FMS Fault Monitoring System

SAS570Advanced
SubstationAutomation System

Control
Bay control unit
REC316*4

Centralized (Hierarchical) Control Architecture

Central Computer
(Mainframe)

Group

Group

Group

Control

Control

Control

Sensors, Actors

PLCs

plant

Classical, hierarchical, centralized architecture.

The central computer only monitors and forwards commands to the PLCs

Decentralized Control System (DCS)

hierarchical
(vertical communication)
engineering
workstation

operator
workstation

data logger

peer-to-peer (horizontal communication)

plant bus
controller

controller

controller

controller

field bus

plant
all controllers can communicate as peers (without going through a central master),
restricted only by throughput and modularity considerations.
Note: Honeywell's "DCS" stands for "Distributed Control System", it is not a decentralized control system, but
a control system for the process industry.

Page 29

Plant with process (e.g. chemical) and electrical (substation) parts

plant network

vertical
communication

Engineering

Workplaces

IEC 61850
connectivity server

CN Connectivity
Server (and router)
Aspect Servers

ProcessNetwork

substation network

horizontal communication

controller
CI871

PB
PI

PN
PI

PB
PI

PN
PI

PB
PI
PB
PI
PB
PI

Profibus

Engineering

horizontal communication

interface

PN
PI
PN
PI
PN
PI

Profinet
RSTP

Engineering

LANs
are
separa
te:
there
is no
IP
routing
betwee
n them

Page 30

SAN IEDs

PI
PI
PI

PI = Process Interface
MU = Merging Unit

MU
PI
MU
PI

bay bus