Industrial Automation Automation Industrielle Industrielle Automation

Automation Overview 1.1 Automation -vue d'ensemble Automation - bersicht Prof. Dr. H. Kirrmann EPFL / ABB Research Center, Baden, Switzerland
2011 February, HK

Definition

Automation (automation, Automation): 1) 2) set of all measures aiming at replacing human work through machines
(e.g. automation is applied science)

the technology used for this purpose

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

Automation (automatisation, Automatisierung)

1)
2)

replacement of human work through machines

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

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.

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Technical necessity of automation

Processing of the information flow Enforcement of safety and availability Reduction of personal costs

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Expectations of automation Process Optimisation Energy, material and time savings Quality improvement and stabilisation Reduction of waste, pollution control Compliance with regulations and laws, product tracking Increase availability, safety Fast response to market Connection to management and accounting (SAP) -> Acquisition of large number of Process Variables, data mining Personal costs reduction Simplify interface Assist decision Require data processing, displays, data base, expert systems -> Human-Machine Interface (MMC = Man-Machine Communication) Asset Optimisation (gestion des moyens de production) Automation of engineering, commissioning and maintenance Software configuration, back-up and versioning Life-cycle control Maintenance support -> Engineering Tools
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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

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Automation Automation = the neural system

Society

Enterprise Trends & History = Brain

Display and react = Cortex

Communication networks = neural, spine

controller = ganglions

Sensors & Actors = Sense cells & muscles physical plant = skeleton

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Automation as a hierarchy of services 5 4 3 2 Planning, Statistics, Finances Production planning, orders, purchase Workflow, order tracking, resources Supervisory
SCADA = Supervisory Control And Data Acquisition

administration enterprise (manufacturing) execution

Group control Unit control 1 Field Sensors & actors 0 Primary technology
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A V

Automation as a computer network

WWW

DB, Historians, Optimizers, MES Operator Workplaces

Plant Network OPC Server Control Network Controller IEC 61850 station bus OPC Server OPC Server

Fieldbus
HART mux

Protection & Control

Instruments

Process Instrumentation LV Electrification Power generation

Substation Automation

Power Management

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Contents

1 Introduction
1.1 Automation and its importance 1.2 1.3 1.3.1 1.3.2 1.3.3 Examples of automated processes Types of plants and controls Open loop and closed loop control Continuous processes Discrete processes

1.3.3
1.4 1.5

Mixed processes

Automation hierarchy Control System Architecture

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Plant Automation

All automation systems share a common structure They differ in the type of plant controlled, quantity of information, geographical distribution

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Automation Systems - World Players Company Local Major mergers

ABB Alstom-Schneider-Areva Emerson General Electric Hitachi - Yokogawas Honeywell Rockwell Automation Invensys Siemens

CH-SE FR US US JP US US UK DE

Brown Boveri, ASEA, CE, Alfa-Laval, Elsag-Bailey Alsthom, GEC, CEGELEC, Telemcanique,.. Fisher Rosemount

Allen Bradley, Rockwell,.. Foxboro, Siebe, BTR, Triconex, Plessey, Landis & Gyr, Stfa, Cerberus,..

80 Mia / year business (depends on viewpoint), growing 5 % annually

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Terms

plant: the object of automation F: site, usine, centrale (lectricit) D: Prozess, Werk, Fabrik, Kraftwerk E: planta, fabrica, instalacin

general contractor: organizes the suppliers of the different components.

turnkey factory: the client only hires consultants to supervise the contractor increasingly, the general contractor has to pay itself by operating the plant. increasingly, the suppliers are paid on results.

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Four distinct businesses

primary technology (mechanical, electrical)

automation equipment (control & command)

engineering & commissioning

maintenance & disposal

seldom offered by the same company

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

Manufacturers

Equipment Design
(dveloppement, Entwicklung)

control

air conditioning

brakes

Equipment Production
(production, Herstellung) Assembler (ensemblier)
car body design by assembler

Engineering
(bureau dtude, Projektierung)

Sleeping Wagon XL5000 Plus

Commissioning (mise en service, Inbetriebnahme)

Client, Service

Start on service
brakes

Maintenance
(entretien, Unterhalt)
brakes

replacement

Out of service Recycling (Recyclage, Wiederverwertung)

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Research and Development

The components and tools are developped

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Design From the customers requirement specs to the system design

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Programming and engineering

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Factory Acceptance Test The client verifies that the system is ready

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Commissioning on site hard work

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Maintenance

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