Ai 150 architecture


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Ai 150 architecture

  1. 1. Industrial Automation Automation Industrielle Industrielle Automation Control System Architecture 1.5 Architecture de Contrôle - Commande Leittechnik-Architektur Prof. Dr. H. Kirrmann ABB Research Center, Baden, Switzerland2012 February, HK
  2. 2. 1.5 Control System Architecture1 Introduction 1.1 Automation and its importance 1.2 Applications of automation 1.3 Plants and controls 1.3.1 Open loop and closed loop control 1.3.2 Continuous process 1.3.3 Discrete process 1.3.3 Dual plants 1.4 Automation hierarchy 1.5 Control System Architecture Industrial Automation Control System Architecture 1.5 - 2
  3. 3. PrincipleThe control system is a communication system consisting of controllers and links.The structure of the control system should reflects that of the plantIdeally, each unit of the plant should have its own controller,interacting with the controllers of the other, related units,mirroring their physical interaction.Example: Airbus: a wing is delivered with its own computers. Industrial Automation Control System Architecture 1.5 - 3
  4. 4. Example: Power plant control - 1980 (!)Control systems look similar Industrial Automation Control System Architecture 1.5 - 4
  5. 5. Busses and processors in industrial plants instrument bus (mimic board) open network, WAN Operator panel disk Mimic board Process pictures Process Data Base workstation bus Logging station station plant network (500m .. 3 km) – includes control networkprocessor pool P P P C P P C P PLC nodes node bus (multi-processors) I/O MEM I/O MEM BC fieldbus (30m..2 km) directly coupled control backplane bus input/ stations output sensor bus sensor bus (0,5.. 30 m) transducers M plant (Werk, usine) valve thermo-couple position motor Industrial Automation Control System Architecture 1.5 - 5
  6. 6. Example: Newspaper Printing ArchitectureEach level has its bus ! Industrial Automation Control System Architecture 1.5 - 6
  7. 7. Example: Production management system production planningenterprise network scheduling maintenance quality controlplant network transportation cell manufacturing cell control cell control floor network robot milling controller machine rail-guided vehicle Industrial Automation Control System Architecture 1.5 - 7
  8. 8. Example: Honeywell TotalPlant (2003, today same structure)Industrial Automation Control System Architecture 1.5 - 8
  9. 9. Example: Siemens Distributed Control systemIndustrial Automation Control System Architecture 1.5 - 9
  10. 10. Example: Rockwell (Allen-Bradley) NetLinx Programmable Desktop PC Device with excel Support PC EtherNet / IP Controller and Bridge Servo ControlNet HMI Linking Device Bridge or Linking Device Drive HMI DeviceNet Modular I/O 509 -BOD Micro Sensor 24vdc PLC Block I/OIndustrial Automation Control System Architecture 1.5 - 10
  11. 11. Example: Emersons PlantWeb (Delta V)Industrial Automation Control System Architecture 1.5 - 11
  12. 12. Example: ABB Industrial IT (redundant system) Plant Network / Intranet Workplaces Enterprise (clients) Optimization (clients) 3rd party application Firewall Mobile server OperatorPlant Network (Ethernet) connectivity aspect application engineering server server server workplaceControl Network (Ethernet) Programmable Serial or Logic Controller fieldbus AC 800C touch-screen Redundant AC 800M Field Bus Field Bus3rd partycontrollers,servers etc sensor network Industrial Automation Control System Architecture 1.5 - 12
  13. 13. The internet dimension (example: Alstom)Industrial Automation Control System Architecture 1.5 - 13
  14. 14. The wireless dimension (example: Schneider) No more wires, but the structure remainsIndustrial Automation Control System Architecture 1.5 - 14
  15. 15. A real substation projectHP Color Operators Workstation 1 Engineering Workstation Global Position to Disturbance Recorder Printer Server 1 Operators Workstation 2Laserjet System Central Station Evalution Station PTUSK Scope 132kV FOXAlarm and EquipmentEvent Printer 1 11kV analog Ether 132kV analog TelephonLA36W Printer Server 2 Input net Input Modem Verbindung zu E4Alarm andEvent Printer 2 o/e LAN-Interface 11kV Modem 132kV ModemLA36W to LV SCMS Repeater NSK NSK GPS Master Redundant Station LAN TCP-IP Repeater Front-End Station Front-End Station Computer 1 Computer 2 HP Color Fallback Laserjet RS232 Switch Service Modem Station Alarm Unit Station Alarm Unit LDCs Interface from Station Computer 2 IEC870-5-101 LDCs Interface from Station Computer 1 IEC870-5-101 Manual Switch 4 x Star Coupler RER111 including redundant power supply FO Fibre optic station bus (LON) in star configuration Control Protection AVR and tap control T1 type REGSys Fault Monitoring System Bay control unit Bay control unit 3Ph and neutral OC Bay control unit Differential protection Bay control unit BBP/BFP Centra l unit Analog alarm unit Indactic I650 10 x 132kV REC316*4 Main 2 REC316*4 SPAJ140C REC316*4 RET316*4 SPAJ110C Tertiary REC316*4 REB500 SACO16A3 Earth fault Prot. AVR and tap control T2 type REGSys Analog alarm unit EF and OC SACO16A3 Line distance prot. SPAJ110C REL316*4 500RIO11 , 16DI SACO16A3 R SPAJ110C Stand by SPAJ110C Neutral 6 x 500RIO11 DI 4 x 11kV earth fault overcurrent earth fault Prot. Prot. Main 1 10 x BBP/BFP Bay unit AVR and tap control REB500 SACO64D4 Auxiliary alarm unit SACO16A3 R SACO16A3 R T3 type REGSys Phase and SPAJ140C neutral SPAJ115C Restricted SPAU140C overcurrent earth fault Substation Automation System Synchro- Prot. Protection SACO64D4 Auxiliary alarm unit check o/e SAS570 Advanced AVR and tap control Siemens 7SD610 für T4 type REGSys E19 Verbindung SPAJ110C Earth fault SPAJ115C SACO64D4 Auxiliary alarm unit overcurrent Restricted Prot. earth fault 1 x 500RIO11 DO Protection 1 x spare B69 Überstrom 132kV Side 11kV Side SACO64D4 Auxiliary alarm unit Bay control unit Pilot wire diff. prot. Bay control unit Coaxial cable (loose delivery) SOLKOR R/Rf. (loose delivery) (loose delivery) (loose delivery) (loose delivery) 4 x 132kV Cable Line 1 x 132kV Bus Coupler 4 x 132/11kV Transformer Feeder Trafo Interlocking AVR & Tap Control 132kV BBP / BFP 132kV Common Alarm FMS Fault Monitoring System Industrial Automation Control System Architecture 1.5 - 15
  16. 16. Centralized (Hierarchical) Control Architecture Central Computer (Mainframe) Group Group Group PLCs Control Control Control Sensors, Actors plantClassical, hierarchical, centralized architecture.The central computer only monitors and forwards commands to the PLCs Industrial Automation Control System Architecture 1.5 - 16
  17. 17. Decentralized Control System (DCS) hierarchical(vertical communication) engineering operator data logger workstation workstation peer-to-peer (horizontal communication) plant bus controller controller controller controller field bus plant all controllers can communicate as peers (without going through a central master), restricted only by throughput and modularity considerations. Note: Honeywells "DCS™" stands for "Distributed Control System", it is not a decentralized control system, but a control system for the process industry. Industrial Automation Control System Architecture 1.5 - 17
  18. 18. Plant with process (e.g. chemical) and electrical (substation) parts vertical Engineering communication plant network Workplaces IEC 61850 CN Connectivity connectivity server Server (and router) Aspect Servers ProcessNetwork substation network horizontal communication horizontal communication interface controller CI871PBPI SAN IEDs PN PI PI LANs arePBPI PN PI separate: PI there is noPBPI Engineering PN PI IP routing PI PI = Process Interface between MU = Merging UnitPBPI PN PI MU PI Engineering themPBPI PN PI MU PIProfibus Profinet RSTP bay bus Industrial Automation Control System Architecture 1.5 - 18
  19. 19. Hierarchies aresimple and traditional Industrial Automation Control System Architecture 1.5 - 19
  20. 20. but Distributed ControlSystems reflects a more complex world.... Industrial Automation Control System Architecture 1.5 - 20
  21. 21. Assessment1. Draw a typical hierarchical control system showing busses and controllers2. How does the network hierarchy relate to the plant control hierarchy ?3. What is the difference between a centralized and a decentralized control system ? (can this difference be seen from the outside ?) Industrial Automation Control System Architecture 1.5 - 21