ﯽﺘﻌﻨﺻ نﻮﯿﺳﺎﻣﻮﺗا...

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

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

Historian Interface MVC/APC

Physical Processing Unit

Historian Interface MVC/APC

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

Sensors& actors A V

Supervisory

Primary technology

Workflow, order tracking, resources

SCADA =

Supervisory Control

And Data Acquisition

Production planning, orders, purchase

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

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

Prozess-leitebene

Process level

planning

scheduling

Online opti

Control

Response time and hierarchical level

PlanningLevel

ExecutionLevel

ControlLevel

SupervisoryLevel

ms seconds hours days weeks month years

ERP(Enterprise Resource Planning)

MES(Manufacturing Execution

System)

PLC(Programmable Logic

Controller)

(Distributed Control System)

(Supervisory Control and Data Acquisition)

Complexity and Hierarchical level

Supervision

Group Control

Individual Control

Command level

Complexity Reaction Speed

months

minutes

seconds

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

Objectives

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

Objectives

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

Objectives

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

Ø (1943) invention of CRT:use of panel board graphic display in a control room

Ø(1948) miniature pneumatic instrument (birth of PID controller).

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

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)

Ø(1980s & 1990s )birth and development of smart distributed control system.

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.

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

ANALOG CONTROL LOOPCONTROLLER

4-20 mA4-20 mA

CONTROLROOM

PROCESSVARIABLE

DT=DEAD TIME

D/AuPA/D

SIGNALCONDITIONING

FINALCONTROLELEMENT

TRANSMITTER

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) :

ØMoving from DCS toward FCS :

FCS Has a Leaner Hierarchy• DCS • FCS

Power SuppliesControl CardsInput CardsOutput CardsFusingMarshalingTerminationCards

4-20 mA

FieldbusPID

• Hybrid

Fieldbus

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

TRADITIONAL 4-20 MAVIEW STOPS AT I/O SUBSYSTEM

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

TAG =LIC-012VALUE =70.34UNIT =M3

STATUS=GOODALARM = Y/N

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).

TWO WAY COMMUNICATION

DPT + PID FCV TT PT

OPERATIONSTATION

MAINTENANCETOOL

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.

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

4-20 MA

I.S I.S. I.S.

I/OSUBSYSTEM

CONTROLLER

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

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.

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.

DRIVERA / B

DRIVERA / C ?

STANDARDFIELDBUS

INTERFACE

MANUFACTURERB

MANUFACTURERC

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)

FIELDBUS CONTROL LOOP

DT=DEAD TIMETR=PROCESS TIME RESPONSE

SIGNALCONDITIONING

FINALCONTROLELEMENT

CONTROLLABILITY = DT /TR

BETTER = SMALLER

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 >

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

Objectives

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

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

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

Fieldbus

Process

• 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?

• 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

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

Problem Definition

Business Domain

Automation

Objectives

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

APC ControllerAPC ControllerThe image part with relationship ID rId3 was not found in the file.

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

Objectives

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

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

II. APC & Fieldbus solution

ü Process optimization

ü Report generation

ü Improve Manufacturing throughput

ü Trend Analysis

Benefits

• 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

Problem Definition

Business Domain

Automation

Objectives

Conclusion

Hybrid Digital NetworkHybrid Digital NetworkNew

Generation

Overall Business System Landscape Overall Business System Landscape in Process Manufacturing in Process Manufacturing

Enterprise

e-business e-businessSCM

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

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