1.1 Automation Overview automación vista general
Automation -vue d'ensemble
Automation - Übersicht
Industrial Automation
Automation Industrielle
Industrielle Automation

Definition
Automation (automation, 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 (automatisation, Automatisierung )
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.
(they are related like electricity and electrification)
Industrial Automation
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5
4
3
2
Automation as a hierarchy of services
Planning, Statistics, Finances
Production planning, orders, purchase administration enterprise
Workflow, order tracking, resources
Supervisory
SCADA =
Supervisory Control
And Data Acquisition
(manufacturing) execution
Group control
Unit control
1
0
Field
Sensors
& actors
Primary technology
Industrial Automation
2013
A V T
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Automation and living beings
Industrial Automation
2013
Society
Enterprise
Trends & History = Brain
Display and react = Cortex
Communication networks = Neurons, spine
Controller = Ganglions
Sensors & Actors = Sensory cells & muscles
Physical plant = Skeleton
Automation = the neural system
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DB, Historians,
Optimizers, MES
Plant Network
Automation as a computer network
Internet
Operator Workplaces
Control Network
Controller
Fieldbus
HART mux
Instruments
OPC Server
Hart
OPC Server
Profinet
OPC Server
IEC 61850 station bus
Protection &
Control
Process
Instrumentation
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LV Electrification
Power generation
Substation
Automation
Power Management
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Technical necessity of automation
• Processing of the information flow
• Enforcement of safety and availability
• Reduction of labor costs
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Expectations
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
Personnel costs reduction
• Simplify interface
•
Assist decision
• Require data processing, displays, data base, expert systems
-> Human-Machine-Interface (HMI)
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
100’000 - 10’000’000 points information flow to the operators: ~ 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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Contents
1 Introduction
1.1
1.2
1.3
1.4
1.5
Automation and its importance
Examples of automated processes
Types of plants and controls
1.3.1
Open loop and closed loop control
1.3.2
Continuous processes
1.3.3
Discrete processes
1.3.3
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
Largest Company Based Major mergers
ABB CH-SE Brown Boveri, ASEA, CE, Alfa-Laval, Elsag-Bailey
Alstom Schneider-Areva FR-GB Alsthom, GEC, CEGELEC, Telemécanique,..
Emerson US Fisher, Rosemount
General Electric
Hitachi - Yokogawa
Honeywell
US
JP
US
Rockwell Automation
Invensys
Siemens
US
UK
DE
Allen Bradley, Rockwell,..
Foxboro, Siebe, BTR, Triconex, Wonderware…
Plessey, Landis & Gyr, Stäfa Controls, Cerberus,..
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Terms plant: the object of automation
F: site, usine, centrale (électricité)
D: Prozess, Werk, Fabrik, Kraftwerk
E: planta, fabrica, instalación 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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2013
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Four distinct businesses primary technology
(mechanical, electrical) automation equipment
(control & command) engineering & commissioning maintenance
& disposal
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2013 offered by different companies
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Manufacturers
Equipment Design
( développement, Entwicklung )
Equipment Production
(production, Herstellung )
Assembler (ensemblier)
Engineering
(bureau d’étude,
Projektierung )
Commissioning
( mise en service, Inbetriebnahme )
Client, Service
Maintenance
(entretien, Unterhalt )
Recycling
(Recyclage, Wiederverwertung )
Industrial Automation
2013
Life-phases of a Plant (Example: Rail Vehicle) control air conditioning brakes
Start on service car body design by assembler brakes brakes
Out of service
Sleeping Wagon XL5000 replacement
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Research and Development
The components and tools are developped
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Design
From the customer’s 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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hard work …
Commissioning on site
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Maintenance…
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