Industrial Automation

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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

2013

Overview 1.1 - 2

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

Overview 1.1 - 3

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

Overview 1.1 - 4

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

Overview 1.1 - 5

Technical necessity of automation

• Processing of the information flow

• Enforcement of safety and availability

• Reduction of labor costs

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Overview 1.1 - 6

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

Industrial Automation

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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,..

€ 80 Mia / year business

(depends on viewpoint), growing 5 % annually

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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….

Industrial Automation

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Four distinct businesses primary technology

(mechanical, electrical) automation equipment

(control & command) engineering & commissioning maintenance

& disposal

Industrial Automation

2013 offered by different companies

Overview 1.1 - 13

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

Overview 1.1 - 14

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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