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, Switzerland
2012 February, HK
2. 1.5 Control System Architecture
1 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. Principle
The control system is a communication system consisting of controllers and links.
The structure of the control system should reflects that of the plant
Ideally, 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. Example: Power plant control - 1980 (!)
Control systems look similar
Industrial Automation Control System Architecture 1.5 - 4
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 network
processor 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. Example: Newspaper Printing Architecture
Each level has its bus !
Industrial Automation Control System Architecture 1.5 - 6
7. Example: Production management system
production
planning
enterprise network
scheduling maintenance quality control
plant 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
12. Example: ABB Industrial IT (redundant system)
Plant Network / Intranet Workplaces Enterprise
(clients) Optimization
(clients) 3rd party
application
Firewall Mobile
server
Operator
Plant Network (Ethernet)
connectivity aspect application engineering
server server server workplace
Control Network (Ethernet)
Programmable
Serial or Logic Controller
fieldbus AC 800C touch-screen
Redundant
AC 800M
Field Bus Field Bus
3rd party
controllers,
servers etc sensor network
Industrial Automation Control System Architecture 1.5 - 12
13. The internet dimension (example: Alstom)
Industrial Automation Control System Architecture 1.5 - 13
14. The wireless dimension (example: Schneider)
No more wires, but the structure remains
Industrial Automation Control System Architecture 1.5 - 14
15. A real substation project
HP Color Operator's Workstation 1 Engineering Workstation Global Position to Disturbance Recorder
Printer Server 1
Operator's Workstation 2
Laserjet System Central Station Evalution Station
PTUSK Scope
132kV FOX
Alarm and Equipment
Event Printer 1 11kV analog Ether 132kV analog Telephon
LA36W Printer Server 2 Input net Input Modem
Verbindung zu E4
Alarm and
Event Printer 2
o/e
LAN-Interface 11kV Modem 132kV Modem
LA36W 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. Centralized (Hierarchical) Control Architecture
Central Computer
(Mainframe)
Group Group Group
PLCs
Control Control Control
Sensors, Actors plant
Classical, hierarchical, centralized architecture.
The central computer only monitors and forwards commands to the PLCs
Industrial Automation Control System Architecture 1.5 - 16
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: Honeywell's "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. 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
CI871
PB
PI SAN IEDs
PN
PI PI
LANs are
PB
PI PN
PI separate:
PI
there is no
PB
PI Engineering PN
PI IP routing PI PI = Process Interface
between MU = Merging Unit
PB
PI PN
PI MU
PI
Engineering them
PB
PI PN
PI MU
PI
Profibus Profinet RSTP bay bus
Industrial Automation Control System Architecture 1.5 - 18
20. but Distributed Control
Systems reflects a more
complex world....
Industrial Automation Control System Architecture 1.5 - 20
21. Assessment
1. Draw a typical hierarchical control system showing busses and controllers
2. 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
