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ییبسمه تعالبسمه تعال
اتوماسیون صنعتیاتوماسیون صنعتی: : مقدمهمقدمهدکتر سید مجید اسما عیل زادهدکتر سید مجید اسما عیل زاده
گروه کنترل گروه کنترل دانشکده مهندسی برق دانشکده مهندسی برق
دانشگاه علم و صنعت ایراندانشگاه علم و صنعت ایران9090پاییز پاییز
Automation Area
Ø Batch Process Automation
Ø Vehicle Automation
Ø Building AutomationTraffic automationHeating, air-conditioning
Ø Transportation Automation
Automation Area
Problem Problem DefinitionDefinition
Business Domain
Automation
Plant Domain Automation
Enterprise Resource Planning
Supply Chain Management
Resultant Improvements
Objectives
Objectives
Control System Structure
Industrial Network Development
Control Algorithm (APC)
Case StudiesFuture Trends
Conclusion
CHALENGES CHALENGES ON ON INDUSTRIESINDUSTRIES
““SMART MANUFACTURING”SMART MANUFACTURING”
Ø Attributes of Smart Manufacturing:
• Wide availability of real time information on the current status of manufacturing and product conditions.
• Comparative model-based performance analysis.
• Decision based on predictive scenarios of expected future plant and market behavior and analytical decision models.
Supply & Demand Planning
Schedule/PlanReconciliation
PerformanceMonitoring & Analysis
Material Balancing& Data Reconciliation
Data Gathering
DCS (Real-Time Control)
Process
Monthly Planning
Scheduling
Simulation & TargetStrategy Setting
Process Control &Local Optimization
ProductionDatabase(Data Model)
PRACTICAL IMPLEMENTATION PRACTICAL IMPLEMENTATION IN IN PRODUCTION CHAINPRODUCTION CHAIN
Management objectivesManagement objectives
Product opportunities, sales, pricing, Logistics
Feedstock selection,Pricing, Purchasing, Logistic
Process simulationModel
Performance Monitoring
Accruing
Data Reconciliation (DR)
Central Historian
On-line Optimization
Scheduling
Planning
DCS
Historian Interface MVC/APC
Physical Processing Unit
Historian Interface MVC/APC
DCS
Physical Processing Unit
Historian nterfaceAPC layer
DCS layer
Physical Plant layer
AUTOMATION AREAAUTOMATION AREA
The process database is at the centre (example: Wonderware)
INDUSTRIAL INDUSTRIAL PYRAMIDPYRAMID
INDUSTRIAL PYRAMIDINDUSTRIAL PYRAMID
Large control system hierarchy (1)
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
0
Planning, Statistics, Finances5
(manufacturing) execution
enterprise
administration
Large control system hierarchy (2)
Administration Finances, human resources, documentation, long-term planningEnterprise Set production goals, plans enterprise and resources, coordinate different sites,
manage ordersManufacturing 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 transmissionno processing except measurement correction and built-in protection.
Field level
the field level is in direct interaction with the plant's hardware(Primary technology)
Group level the group level coordinates theactivities 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
unit controllers
Group level
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
Mosaic is still in use – with direct wiring
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
(SCADA = Supervisory Control and Data Acquisition)
Today’s 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)
ANSI/ISA 95 standard classification
Source: ANSI/ISA–95.00.01–2000
the ANS/ISA standard 95 defines terminology and good practices
Enterprise Resource Planning
Manufacturing Execution System
Control & Command System
Business Planning & Logistics
Plant Production SchedulingOperational Management, etc.
ManufacturingOperations & Control
Dispatching Production, Detailed ProductScheduling, Reliability Assurance,...
Level 4
Level 3
Levels2,1,0
BatchControl
ContinuousControl
DiscreteControl
Example: Power plant
Example of generic control siemens: Siemens WinCC (Generic)
Betriebs-leitebene
Production level
Unternehmens-
leitebeneEnterprise
level
Prozess-leitebene
Process level
planning
scheduling
Online opti
APC
Control
Field
Response time and hierarchical level
PlanningLevel
ExecutionLevel
ControlLevel
SupervisoryLevel
ms seconds hours days weeks month years
ERP(Enterprise Resource Planning)
DCS
MES(Manufacturing Execution
System)
PLC(Programmable Logic
Controller)
(Distributed Control System)
(Supervisory Control and Data Acquisition)
SCADA
Complexity and Hierarchical level
MES
Supervision
Group Control
Individual Control
Field
Site
Command level
,
Complexity Reaction Speed
ERP
days
months
minutes
seconds
0.1s
0.1s
Effects of System Automation
• Dependability
• Plant Efficiency
• Extended Equipment Life
• Improved Operation
• Improved Operator Interface
• Accessibility of Plant Data
• etc
Problem Definition
Business Business Domain Domain
AutomationAutomation
Plant Domain Automation
Enterprise Resource Planning
Supply Chain Management
Resultant Improvements
Objectives
Objectives
Control System Structure
Industrial Network Development
Control Algorithm (APC)
Case StudiesFuture Trends
Conclusion
BUSINESS DOMAIN OBJECTIVESBUSINESS DOMAIN OBJECTIVES
SUPPLY CHAIN MANAGEMENT
ENTERPRISE RESOURCE PLANNING
ERP Definition and HistoryERP Definition and History
• 1970’s- Material Requirement Planning (MRP)
• 1980’s- Manufacturing Resource Planning (MRP II)
• early 1990’s- Enterprise Recourse Planning (ERP)
Ø Enterprise resource planning (ERP) is the industry term used to describe a broad set of activities supported by multi-module application software that helps a manufacturer or other business manage the important parts of its business. These parts can include product planning, parts purchasing, maintaining inventories, interacting with suppliers, providing customer service, and tracking orders. ERP can also include application modules for the financeand human resources aspects of a business.
ERP DevelopmentERP Development
ERP BenefitsERP Benefits
ERP Software SuppliersERP Software Suppliers•ABAS Software
•ACCPAC International
•Adonix
•Agilisys
•American Software
•Apps4biz
•Ascomp Technologies
•Bäurer AG
•Caliach
•CeeCom
•Cincom
•command
•Control Group
•Cortis Lentini
•Datasul
•Datatex
•Eastern Software Systems
•Encompix
•Epicor
•Exact Software
•eXegeSys
•Expandable Software
•Friedman
•Fujitsu–Glovia International
•Geac Computer
•Generix
•Gruppo Formula
•IBS
•IFS
•infor business solutions
•Intentia
•Intuitive Manufacturing Systems
•Invensys
•JD Edwards
•K3 Business Technology
•Lilly Software
•Made2Manage
•Manugistics
•MAPICS
•Metasystems
•Microsoft Business Solutions
•OpenMFG
•Oracle
•PeopleSoft
•ProfitKey
•Pronto Software
•PSI
•QAD
•Ramco Systems
•Relevant
•ROI Systems
•Ross Systems
•SAP
•Scala Business Solutions
•Silverprod
•SoftBrands
•SSA GT
•SSI
•Syspro
•Verticent
•Visibility
•XeBusiness
SCM DefinitionSCM DefinitionSupply Chain Management is the process of improvingthe distribution from supplier to the final customer to satisfy customer requirements.
SCM ArchitectureSCM Architecture
Impacts of SCM Impacts of SCM
SCM Software SuppliersSCM Software Suppliers
•ABB
•Adexa
•Applied Materials
•AspenTech
•Brooks Automation
•Descartes
•EXE Technologies
•FWL Technologies
•Honeywell
•i2 Technologies
•Invensys
•Irista
•J.D. Edwards
•Kewill Systems
•Logility
•Manhattan Associates
•Manugistics
•MARC Global Systems
•McHugh Software International
•Optum
•OSIsoft
•Provia
•Retek
•SAP
•Siemens
•Swisslog
•Yantra
•Yokogawa
Integration of ERP & SCMIntegration of ERP & SCM(Simple View)(Simple View)
Resultant Improvements due to Automation Resultant Improvements due to Automation In Business Domain In Business Domain
Problem Definition
Business Domain
Automation
Plant Domain Automation
Enterprise Resource Planning
Supply Chain Management
Resultant Improvements
Objectives
Objectives
Control System Structure
Industrial Network Development
Control Algorithm (APC)
Case StudiesFuture Trends
Conclusion
INDUSTRIAL PYRAMIDINDUSTRIAL PYRAMID
PLANT DOMAIN AUTOMATIONPLANT DOMAIN AUTOMATIONOBJECTIVEOBJECTIVE
CONTROL AND OPTIMIZATION CONTROL AND OPTIMIZATION ARCHITECTUREARCHITECTURE
CONTROL HIERARCHY TYPICAL CONTROL HIERARCHY TYPICAL TIMINGTIMING
Typical Cost/Benefit Relation due to Plant Typical Cost/Benefit Relation due to Plant Domain Automation based on Domain Automation based on
Automation LevelAutomation Level
Plant Automation Requirement
Ø Control System Structure
Ø Data Communication Network
Ø Devices ( sensor & actuator )
Ø Control Algorithm
Problem Definition
Business Domain
Automation
Plant Domain Automation
Enterprise Resource Planning
Supply Chain Management
Resultant Improvements
Objectives
Objectives
Control System Structure
Industrial Network Development
Control Algorithm (APC)
Case StudiesFuture Trends
Conclusion
History of Automation in Industries
ØRefining industry has been a pioneer in automating its processing operation because of:
• Mass production of automobile in early 1900s
• petroleum product requirement in World War I
• increasing of demands for fuel in World War II (30000barrels/day in 1940 to 580000 b/d in 1945)
ØThus increasing:
• plant size
• production quantity MORE AUTOMATION
• quality
History of Automation in Industries
Ø (1943) invention of CRT:use of panel board graphic display in a control room
Ø(1948) miniature pneumatic instrument (birth of PID controller).
History of Automation in Industries
Ø(1956 post-war )Birth of DDC by invention of solid-state and transistor
Ø(1960s)Appearance of low-cost digital mini-computer and data logging was introduced into the control room
History of Automation in Industries
Ø (mid-1960s to mid-1970s)Technical turmoil era(birth of PLC)
Ø(1978)microprocessor era began by birth of integrated circuit chip and therefore use of PID algorithm as built-in software(appearance of DCS)
History of Automation in Industries
Ø(1980s & 1990s )birth and development of smart distributed control system.
History of Automation in Industries
1. Analog Controller
• Pneumatic PID controller
• Hydraulic PID controller
2. Digital Controller
• Centralized Control System(DDC)
• Distributed Control System(DCS)
• Smart Distributed Control System(FCS)
Control Systems StructureControl Systems Structure
Why toward digital signal ?• High interference immunity• Easy data storage• Flexible processing• Various transmission option
Digital Controller ProgressDigital Controller Progress
Digital ControllerDigital Controller
Ø Centralized Control System(DDC):Disadvantages:
• In large scale system the total number of I/O signals widely increase that is beyond the capacity of computer hardware.
• not flexible
• unable to take best use of on-line technique
• slow to take advantage of improved technology
• high installation cost
• Failing of central control unit stop working of all the system.
Digital ControllerDigital Controller
Ø DCS (Distributed Control System):
Advantages :
• lower installation costs due to the interconnectionand grouping of control modules ·• lower maintenance cost• better system reliability and flexibility• ease of configuring the process• concept and ease of expandability• More real-time capability
Digital ControllerDigital ControllerDCS :
DCS•Convert analog signal to digital
•Run PID algorithm•Convert digital signal to analog
•Send signal to final control element•ALL OTHER DCS DUTIES
Transmitter•Measure ONE parameter
•Convert digital signal to analog•Transmit to control System
•Using 1 pair of wires
Final Control Element•Receive analog signal
•Position valve•Using 1 pair of wires
Conventional Control
78
ANALOG CONTROL LOOPCONTROLLER
4-20 mA4-20 mA
CONTROLROOM
FIELD
PROCESSVARIABLE
DT=DEAD TIME
PID
D/AuPA/D
D/A
uP
A/D
SIGNALCONDITIONING
FINALCONTROLELEMENT
TRANSMITTER
1
23
1
2
3
DT
Digital ControllerDigital ControllerØ Smart Distributed Control System (FCS):
Interconnection of low level industrial devices as well as control device on a single physical communication link using digital communication.
Advantages :• Increasing process safety through Abnormal Situation Management(ASM)($20 billion/year is losses in petrochemical industry in US)• Increasing product quality• Increasing occupational health• Decreasing environmental hazards
Digital ControllerDigital ControllerØ Smart Distributed Control System(FCS) :
Digital ControllerDigital Controller
ØMoving from DCS toward FCS :
FCS Has a Leaner Hierarchy• DCS • FCS
Power SuppliesControl CardsInput CardsOutput CardsFusingMarshalingTerminationCards
4-20 mA
PID
FieldbusPID
• Hybrid
PID
Fieldbus
PID
Hybrid Control
DCS• Run PID algorithm (now optional)• Send signal to final control element• ALL OTHER DCS DUTIES
Control Using FieldbusDevices
Transmitter• Measure MULTIPLE parameters• Pure digital signal transmitted• PID algorithms on board• Network style communication
Final Control Element• Receive digital signal• Position valve• PID algorithms on board• Network style communication
Up to 1900 Meters in length
EXPANDED VIEW
DCS
TRADITIONAL 4-20 MAVIEW STOPS AT I/O SUBSYSTEM
FCS
FIELDBUS
FIELDBUS VIEWEXTENDS INTO INSTRUMENTS
INPUT/OUTPUTSUBSYSTEM
CONTROLLER
LOCAL AREA NETWORKSUPERVISORY
SYSTEM
FIELDBUS
FIELDDPT101 PT101 FCV101 DPT102 PT102 FCV102
Field Instrument Interfacing• DCS
– Input/output cards 8-16 channels• Rarely redundant
– One fault = 8 loops lost• Redundant mainly in
petrochemical industry (which coincidentially uses galvanic isolators)
– One fault = no problem
– One device per wire– One fault = 1 loop lost
– No master– = no problem
• FCS– No I/O cards
– = no problem
– Many devices per wire• 12-16 devices per wire
– One fault = 8 loops lost• 2-4 devices per barrier/repeater
– One fault = 1 loop lost
– Requires communication master• Backup master
– Fault = no problem
Need For Information For Decision Making
• 4-20 mA is an information bottle-neck
• With Fieldbus system:– Access to all device information:
• instrument identification, location• status of PVs and MVs etc.• ambient conditions• diagnostics• configuration• instrument characteristics• calibration information
– date– who– method– location
Conventional x Fieldbus
15,3 mA
DCS
TAG =LIC-012VALUE =70.34UNIT =M3
STATUS=GOODALARM = Y/N
FCS
TRANSMITTERTRANSMITTER
Increased Process and Instrument Information
• DCS:Sufficient control information. Insufficient management information.
• FCS:Slight increase in control information. Vast increase in management information
MANAGEMENTINFORMATION
CONTROLINFORMATION
Need reduced process variability & down-time
• Though DCS perform a good job of process control, they do not cater for management of the field instruments.
• With Fieldbus system:– Being able to see the field instruments bring important benefits:
• On-line status and diagnostics information enables predictive maintenance.
• Access to identification and calibration data in the device enables better calibration management.
• I.e. Instrument Management may be used to ensure that devices are in good condition increasing availability and that the process is at its optimum values, resulting in higher quality and long term savings.
Predictive Maintenance
• Schedule maintenance based on device diagnostics• Schedule calibration based on device calibration
data storage• Perform maintenance and calibration of several
devices at the same time with fewer shut-downs• Perform maintenance and calibration at scheduled
shut-downs, not at emergency shut-downs.• Increase plant availability• Don’t waste time on maintenance of equipment
which does not need it (preventive maintenance).
95
TWO WAY COMMUNICATION
DPT + PID FCV TT PT
OPERATIONSTATION
MAINTENANCETOOL
96
Status• The engineering software may be used for detail
investigation of non-good status.– Good Normal– Bad E.g. sensor failure– Uncertain E.g. out of calibrated range
• Provides automatic failsafe action in output devices when failures in sensors or communication etc. occurr.
• Assures cascade initialization (bumplesstransfer) and anti-reset-windup and many other functions.
Need For Lower Maintenance Costs
• Cost of maintenance, upgrade and expansion of proprietary DCS is skyrocketing.
• With a Fieldbus system:– Interoperability ensures:
• Buy spares from third parties to keep price down.• Buy spares from those that stock, i.e. user need not keep stock.• The best of its kind device may be used independent of
manufacturer. – Open technology means:
• Knowledge to maintain, expand and modify the system yourself.
106
Need for easier documentation
• DCS and PLC card system and point-to-point wiring requires a lot of documentation.
• With a Fieldbus system:– Drawings are simplified as wiring is drastically reduced and devices
are connected in parallel.– Panel and cabinet drawings reduced.– Automatic generation of configuration documentation as
configuration is done. Export/import of files to spreadsheets.– Comments and notes may be included in the configuration.– Complete field device data in Fieldbus devices.
WIRING & HARDWARE SAVINGS
DCS
4-20 MA
I.S I.S. I.S.
I/OSUBSYSTEM
CONTROLLER
FCS
I.S.
FIELDBUS
Need For Scalable Systems
• The cost of expanding a DCS with one or a few loops is too high.
• With a Fieldbus system:– A few devices can be added without adding interfaces or even
wires.– Even major expansion requires a minimum of hardware since
input, output and control cards are virtually eliminated.– Systems with a number of loops ranging from 1 to more than
1000 (32,000 points) are possible.
• I.e. you need not buy a system which is larger than you need or can afford, being assured it can be expanded as the plant grows and changed as your requirements change.
Fieldbus Makes FCS Extremely Scalable
- Safety Without Redundancy?
• FCS also has redundant operator consoles• FCS also has redundant power supplies• FCS has no controller card, hence
redundancy not applicable, no problem.
• The Difference between DCS and FCS lies in the interfacing of the field devices...
From DCS to FCS fault tolerance
• DCS (Redundancy)– An input or output card fault affects
8 loops– 1 loop with redundant I/O cards
• FCS (Fault isolation)– A wire fault affects 8 loops
– 1 loop with barrier/repeater
1... 81... 8
1...8 1...8
Control
OI II O O
1...4 1...2
OI II O O
Control
OI II O O
118
FAULT TOLERANT• Redundant Fieldbus power supplies• Redundant operator stations• Additional backup LAS(Link Active Scheduler ) in the field
devices• Independent interface CPU for LAS, bridge and blocks.• Devices distributed over several buses with few loops.• Critical loops may have individual buses• Operator station power is backed up by UPS• Output devices handle failsafe conditions on their own.
Last value or predetermained safety position.• Sensor, device or communication failure invokes failsafe
action in output devices.• Number of modules and components (CPU, input or output
cards) is minimized reducing failure probability.
119
FAILURE EFFECTS• Failure of one operator station does not affect
another. In case of station failure system may be operated from another.
• Failure, connection or removal of a field device does not affect another.
• Control may continue in the absence of any host.• Power supply switchover is automatic and does
not affect the system.• Failure in any Fieldbus does not result in loss of
control or the operators view except with respect to the loops or I/O on a single Fieldbus.
• LAS switchover is automatic and does not affect the system.
120
DRIVERA / B
DRIVERA / C ?
STANDARDFIELDBUS
INTERFACE
MANUFACTURERB
MANUFACTURERC
MANUFACTURERD
MANUFACTURERD
MANUFACTURERB
MANUFACTURERC
FIELDBUS = OPEN SYSTEM
TransmittersTransmittersBenefits
•Multiple measurements from single transmitter
•Lower total installed & maintenance costs
•Pure digital signal output •No D/A errors, greater accuracy-repeatability
•PID algorithms on board • Less burden on the DCS true distributed control
•Network communication•Communication can occur directlyfrom transmitter to valve
Evolutions in Smart Transmitters
Features
Features Benefits
•More data available•More variables for better control and history of process events & changes
•Pure digital signal input•No A/D errors, greater accuracy-repeatability less I/O hardware
••PID algorithmsPID algorithms in field devicesin field devices ••Less burdenLess burden on the DCS true on the DCS true distributed controldistributed control
D C SD C S
Evolutions in Smart DCS
Features Benefits
•Multiple mission device •Lower total installed & maintenance costs
•Pure digital signal input •No A/D errors, greater accuracy-repeatability
•PID algorithms on board •Less burden on the DCS true distributed control
•Network communication•Communication can occur directlyfrom transmitter to valve
ValveValve
Evolutions in Smart Valve
DCS• Run PID algorithm (now optional)• Send signal to final control element• ALL OTHER DCS DUTIES
Transmitter• Measure MULTIPLE parameters• Pure digital signal transmitted• PID algorithms on board• Network style communication
Final Control Element• Receive digital signal• Position valve• PID algorithms on board• Network style communication
Up to 1900 Meters in length
Digital Control System Elements(more details after Evolution)
125
FIELDBUS CONTROL LOOP
DT=DEAD TIMETR=PROCESS TIME RESPONSE
uP
D/A
SIGNALCONDITIONING
+PID
FINALCONTROLELEMENT
1
23
1
2
3
DT
uP
A/D
CONTROLLABILITY = DT /TR
BETTER = SMALLER
FIELD
Smart DCS(Fieldbus) Applications
Ø Manufacturing AutomationCar manufacturing Bottling systems Storage systems
Ø Building AutomationTraffic automationHeating, air-conditioning
Ø Process AutomationPurification plantsChemical and petrochemical industryPaper and textile industry
Ø Power industry and power distributionPower plantsSwitching gears
e.g. BMW manufacturing,Regensburg, Germany
e.g. Bibliothèque Nationalede France, Paris, France
e.g. Darboven Coffee,Hamburg, Germany
e.g.. Warsaw Subway,Warsaw, Poland
e.g. Oil refinery, Esmeralda, Ecuador
e.g. Polymer storage tank,Scarborough, Canada
e.g. bottling plantTaunton, UK
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Basic System Configuration
Controller
Operation / Engineering
Control Bus
4 - 20mA Digital
FieldbusFieldbus
ODS< Exaquantum >
Scalable System Architecture
Ethernet
Small TypeController
HMIEngineering
Large TypeController
Control Bus
4 - 20mA Digital
Safety Control System< Pro-Safe >
ERP
Fieldbus
OPC Server
Fieldbus
Router
Wide Area Communication Gateway
Console Type HMI DeviceManagement
Process Automation System< CENTUM >
Remote i/o
Problem Definition
Business Domain
Automation
Plant Domain Automation
Enterprise Resource Planning
Supply Chain Management
Resultant Improvements
Objectives
Objectives
Control System Structure
Industrial Network Development
Control Algorithm (APC)
Case StudiesFuture Trends
Conclusion
Evolution in Industrial Data Communication Evolution in Industrial Data Communication Network(Bus) Network(Bus)
Protocol
Features& Benefits
Pneumatic
3-15 PSI
50’s
Intrinsic Safety
4-20 mA
70’s
Remote-Re-ranging
Protocol Dependence
SMART
HARTDEFOXCOMBRAIN
80’s
FIELDBUS
Protocol Unification
Interoperability
90’s
Electro-Mechanical
10-50 mA
60’s
Local Adjustments
Pneumatic ElectronicAnalog Hybrid Digital
موسسات و اجنمنهاي تشكيل دهنده اوليه كميته فيلد باس •
Instrument Society of America (ISA), International Electrotechnical Commission (IEC),
IEC/ISA SP50 Fieldbus committee
Profibus (German national standard) and FIP (French national standard)
پس از گذشت مدت زمان طوالين راه حل مشخص و استاندارد واحدي بوجود •.نيامد
دو گروه بزرگ متشكل از تعداد بسياري از توليد كنندگان 1992در سال •Interoperable Systems Project (ISP) Factory Instrumentation Protocol (WorldFIP)
شروع به توليد جتهيزات فيلد باس منودند و قرار بر اين بود كه جتهيزاتشان را بر اساس •.دتوليد مناين ISA SP50استاندارد
Fieldbusبطور مشترك ISPوWorldFIP، 1994در سپتامرب • Foundation را.پايه گذاري منودند تا با سرعت بيشتري آنرا استاندارد منايند
،تست فيلدباسمبنظور •– BP و. اولني سايت حتقيقايت بود كه با موفقيت آنرا تست منوددر نروژ دومني تست موفق را براي پياده سازي كنترل دجييتال Essoپااليشگاه –
.اجنام داد ISPوWorldFIPبا استفاده از پروتكل
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Desirable Network(Fieldbus) Desirable Network(Fieldbus) CharacteristicsCharacteristicsØOpen
ØStandardØAdvanced Functionality, ServicesØReliable, High PerformanceØInteroperableØPlug & PlayØVendors’ SupportØEconomicalØSimple, Easy
FieldbusesFieldbuses
Ø Field device protocol that process use mostly:
• Foundation Fieldbus
• HART
• Profibus
ØFOUNDATION fieldbus(FF) is an all-digital, serial, two-way communications system that serves as a Local Area Network (LAN) for factory/plant instrumentation and control devices
Control & monitoring
DCS
Fieldbus
Process
F
T
P
• Intelligent field devices and systems• Digital, two way, multi-drop• Communication system for instruments and
other automation equipment• Self-Diagnostics• Local controllability
What is Foundation Fieldbus?What is Foundation Fieldbus?
Benefits of Foundation FieldbusBenefits of Foundation Fieldbus
• Device Interoperability
• Enhanced Process Data
• Expanded View of the Process
• Improved Plant Safety
• Easier Predictive Maintenance
• Reduced Wiring and Maintenance Costs
What is HART?What is HART?
Ø HART ® Field Communications Protocol is digitallyenhanced 4-20 mA smart instrument communication.
Digital master/slave communicationsimultaneous with the 4-20 mA analogsignal
The HART protocol has the capabilityto connect multiple field devices on thesame pair of wires
HART SpecificationHART Specification
• Access to all instrument parameters & diagnostics
• Supports multivariable instruments
• On-line device status
ØDigital Capability
ØAnalog Compatibility
ØInteroperability
ØAvailability
• Simultaneous analog & digital communication
• Compatible with existing 4-20 mA equipment & wiring
• Fully open de facto standard
• Common Command and data structure
• Field proven technology with more than 1,400,000 installations
• Large and growing selection of products
• Used by more smart instruments than any other in the industry
BENEFITS OF HART COMMUNICATIONBENEFITS OF HART COMMUNICATION
Ø Improved Plant Operations
- Cost Savings in Commissioning
- Cost Savings in Installation
Ø Improve Measurement Quality
Ø Cost Saving in Maintenance
Ø Operational Flexibility
Ø Instrumentation Investment Protection
Ø Using benefits of digital instrument
What is Profibus?What is Profibus?
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• Profibus is a substitute for the analog
4 to 20 mA technology.
• Profibus connects automation systems
and process control systems with field
devices
• Profibus achieves cost savings of over
40% in planning, cabling, commissioning
and maintenance
ØPROFIBUS is a vendor-independent, open field bus standard for a wide range of applications in manufacturing and process automation
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مقايسه اي از شبكه هاي خمتلف صنعيت
:F اتوماسيون كارخانه ها :Bاتوماسيون ساختمان ها
:V اتوماسيون وسايل نقليه :D انتقال داده :S اابزار دقيق
:Pصنعت فرآيند
:F اتوماسيون كارخانه ها :Bاتوماسيون ساختمان ها
:V اتوماسيون وسايل نقليه :D انتقال داده :S اابزار دقيق
:Pصنعت فرآيند
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Problem Definition
Business Domain
Automation
Plant Domain Automation
Enterprise Resource Planning
Supply Chain Management
Resultant Improvements
Objectives
Objectives
Control System Structure
Industrial Network Development
Control Algorithm (APC)
Case StudiesFuture Trends
Conclusion
Advanced Process Control Advanced Process Control (APC)(APC)
• Long time delay
• Frequent and severe disturbance
• Multivariable interaction
• Physical and environmental constraints
• Dynamic market supply and demand factor effect on product(higher product quality & narrowing economic margins)
• Highly interactive and variable dynamics of the process andsystem parameters
ØProcess industry Properties:
This makes the control of an This makes the control of an plant plant form a very challenging and form a very challenging and daunting task for even the best tuned PID controller .daunting task for even the best tuned PID controller .
APC ControllerAPC Controller(general view)(general view)
ØThe backbone of all APC controllers are Multivariable Model-Based Predictive Controller(MMBPC).
ØDifferent formulations of MPC differ in :
APC Controller DutiesAPC Controller Duties
• robustness
• fault-tolerance
• Process Model: provide reliable estimate for important processquantities which are either immeasurable or difficult to measure thatused for controller adaptation.
• Real-Time Model-Based Multivariable Optimization algorithm
• Real-Time Model-Based Multivariable Prediction algorithm
• Supervisory control for fault tolerant
• Intelligent performance monitoring of process equipment
• Process Simulator(Dynamic Simulation): understand the underlyingprocess and how it can be operate at
Ø Requirement:
APC Controller ElenentsAPC Controller Elenents
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Application area of Dynamic SimulationApplication area of Dynamic SimulationApplication area of Dynamic SimulationApplication area of Dynamic Simulation
Ø Benefits:
• Provide robust control
• Disturbance rejection
• Better constrain handling
• fault detection and monitoring capability that reduce the number of plant shutdown
• provide valuable data for scheduling
• increase production rate and quality
• safety
• reliability
• reduction raw material
• reduction energy consumption
• environmental pollution control
APC Controller BenefitsAPC Controller Benefits
Ø APC Performance: APC push process set point close to its limits or constrains .
APC PerformanceAPC Performance
APC Application AreaAPC Application AreaØ APC benefit example:
• Ethylene plant: production increase by 2 to 3 percent
• polymer plant: production 2% & throughput 3%
• refinery with two atmospheric crude units: increase total production value through quality control to gain 1.7 year’s payback time
•Generally accurate control means less safety margin and this together with the feed-pushing control gives 1 to 5 percent increase in throughput.
APC RealAPC Real--Time Application Time Application Ø APC benefit example:(Universal Adaptive Control)
Management ObjectivesProcess Improvement (general view)
Problem Definition
Business Domain
Automation
Plant Domain Automation
Enterprise Resource Planning
Supply Chain Management
Resultant Improvements
Objectives
Objectives
Control System Structure
Industrial Network Development
Control Algorithm (APC)
Case StudiesFuture Trends
Conclusion
Case Study 1Case Study 1
Background. ARCO Alaska, Inc. is responsible for exploring, developingand producing ARCO’s oil and gas interests in Alaska and surroundingoffshore waters.
I. Design criteriav Reduced wiring and terminations
v Modular system design
v Reduced maintenance costs
v Useful diagnostic tools
II. Fieldbus solution
ü Simplified wiring
ü Easier installation
ü Reduced operator time
ü Reduced engineering time
Benefits
Case Study Case Study 11
• 69% reduction in comparable wiring costs
• 98% reduction in home run wiring
• 90% reduction in configuration time to add an expansion well
• 92% reduction in engineering drawings to add or expand a well
• 83% reduction in instrument QA / QC
III. Results: The company have a total cost savings of $621k per drill site. This includes savings of approximately $206k in materials, $324k in labor, and $91k in engineering
Specific savings attributed to the following
Case Study 1Case Study 1
Case Study Case Study 22
Case Study Case Study 22
Case Study Case Study 22
Case Study 2Case Study 2
Case Study Case Study 22
Case Study Case Study 22
Background. DETEN Chemical S.A. Located in petrochemical zone ofcamacari , bahia Brazil ,produces linear alkyl benzene , basic raw materialused in detergents by 146000 tpy production capacity.
I. Challengev More reliability
v Flexibility
v long/short term economic benefits
Case Study Case Study 33
II. APC & Fieldbus solution
ü Process optimization
ü Report generation
ü Improve Manufacturing throughput
ü Trend Analysis
Benefits
Case Study Case Study 33
• 97% reduction in wiring costs
• Reduce installation time up to 23 day
III. Results: The company have a total Project savings approximately %32 to %45
Specific savings attributed to the following
Case Study Case Study 33
Case Study Case Study 44
Case Study Case Study 44
Case Study 4Case Study 4
Problem Definition
Business Domain
Automation
Plant Domain Automation
Enterprise Resource Planning
Supply Chain Management
Resultant Improvements
Objectives
Objectives
Control System Structure
Industrial Network Development
Control Algorithm (APC)
Case StudiesFuture Trends
Conclusion
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Hybrid Digital NetworkHybrid Digital NetworkNew
Generation
Overall Business System Landscape Overall Business System Landscape in Process Manufacturing in Process Manufacturing
Enterprise
Plant
e-business e-businessSCM
Supply Chain Management
ERPEnterprise Resource Planning
CRM Customer
Relationship Management
SRM Supplier
Relationship Management
DCSDistributed Control System
Design EngineeringPlant Simulators
MESManufacturing Execution
System
APSAdvanced Planning
& Scheduling
FCSFinite Capacity
Scheduling
EE--Commerce based on ITCommerce based on IT
Typical Improvement due to Automation, Typical Improvement due to Automation, Control and Integrated Operation Control and Integrated Operation
ProjectsProjects
Typical Performance due to Automation, Typical Performance due to Automation, Control and Integrated Operation Control and Integrated Operation
ProjectsProjects
Typical Incremental Payback Intervals due Typical Incremental Payback Intervals due to Applying Automation and Advanced to Applying Automation and Advanced
ControlControl
Eight Practices Necessary to make an Integrated Eight Practices Necessary to make an Integrated Operation or an Automation Operation or an Automation
Project a SuccessProject a Success