c5: Components of Control and Automation Equipments

8/9/2019 c5: Components of Control and Automation Equipments

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Outline: A. Components and types of

control system

Automation hierarchy andArchitecture

Components of control and automationequipments and devices


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Objectives

At the end of the lecture students will be able toIdentify:

The process/system/plant - Process

variable/Measured variable Sensor or sensing element/measuring element System desired value / Set point, error or

deviation

Automatic controller, comparator or comparingelement

Correcting unit actuating unit (Actuator)


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Control system


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1. Control system components


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CourtesyNISTManufacturingEngineeringLab,Intelligent

Systems

- Control System

- Sensors, Switches- Valves, Pumps, Transformers- Resource

Simplified Control System (CS)1234

1

2

3

4

Control System brains of a electronic and/or electro-mechanical system with sensors used to monitor & changelevels or direct: air, water/fluid, electricity, traffic, fuel, etc.


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Simplified Control System (CS)

This is well the interconnected components in a system.

These systems use slower bandwidth, e.g. 9600 bps, tentacles for data collection, real time sampling, firmware types of logic circuits,and electromechanical connections to effect valves, gates, throwswitches, etc.

Control system are often thought as that equipment used solely bylarge utilities, e.g. power, gas, water

In fact these systems exist in every modern building. The larger and newer the building and or building complex, the

greater the likelihood that one of these systems is resident..


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Other frequently used terms for this arena include Distributed ControlSystems or Supervisory Control and Data Acquisition (SCADA)

SOURCE: Vendor Site

Scada system


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Technical necessity of automation

Processing of the information flowEnforcement of safety and availabilityReduction of personal costs


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The Cultures

Focus Safety 100% Availability Electro-mechanical No updating, Aged equipment

The Language RTUs, PLCs, IEDs DNP, Modbus Low Bandwidth Analog & Digital

The Vendors Allen Bradley(AB)/Rockwell,

Honeywell, Siemens, JohnsonControls

Focus Security 99.5% Availability Electronic Continuous Updating, New

The Language Routers, Switches, Servers IP, Ethernet High Bandwidth All Digital

The Vendors IBM, Microsoft, CISCO, Dell

Physical Plant Network Operations


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Expectations of AutomationProcess Optimisation Energy, material and time savings

Quality improvement, reduction of waste, pollution control compliance with laws, product tracking Increase availability, safety Fast response to market Connection to management and accountingAcquisition of large number of Process Variables, data miningPersonal costs reduction Simplify interface Assist decision Require data processing, displays, data base, expert systems Human-Machine Interface (MMC = Man-Machine Communication)

Asset Optimisation Automation of engineering, commissioning and maintenance Software configuration, back-up and versioning Maintenance supportEngineering Tools


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Data Quantity in Different Plants Power Plant (25 years ago)

100 measurement and action variables (called "points") Analog controllers, analog instruments one central "process controller" for data monitoring and

protocol. Thermal power plant (today)

10000 points, comprising: 8000 binary and analog measurement points and 2000 actuation point

1000 micro-controllers and logic controllers Nuclear Power Plant

three times more points than in conventional power plants Electricity distribution network

100000 10000000 points Data reduction and processing is necessary to operate plants


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Sensors devices


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Transmitting devices Telemetering may be defined as signal transmission over a

considerable distance. The device at the measuring point, usually a transducer, is then

often called a transmitter with the receiver located at the recordingor control center.

Flapper-Nozzle Mechanism Pneumatic Converters for Pressure, Flow, and

Temperature Measurements Control Valves Valve Positioners Inductive signal transmitters Capacitive signal transmitters Potentiometric signal transmitters


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Final control elements Final control elements act directly on the controlled body, process or

machine. The controller output signal is fed to the correcting unitwhich then alters the variable to return the system to its desired or set value.

This correcting unit could be a valve, motor, damper or an electriccontactor.

Most marine applications involve the use of valves to regulate fluidflow.

Operation of Control Valves Control Valve Characteristics Equal Area Percentage Control Valve Characteristics Single Ported Control Valves Double Ported Control Valves Valve Positioner Hydraulic and pneumatic control drives

Dismantle, repair and refit control actuating devices Calibration requirements


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Output Elements Hydraulic Actuators - These actuators can be in the

form of hydraulic motors or hydraulic piston devices,and are available in a wide range of power capacities, torque capacities and speeds.

The figure illustrates a typical double-acting pistonand cylinder actuator. Coulomb friction affects theperformance of these actuators and pressuredifferentials as high as 30% of the supply pressurecan be necessary in order to overcome thisresistance to motion.

The mathematical equations that govern the motionsof these actuators under steady conditions are:

where Q is the flow of oil into the cylinder, LP is theleakage flow coefficient for the piston AP is thepiston area, v is the piston velocity, F is the force thatis generated by the piston and P is the pressuredifferential across the piston.

Q = LPP + APvand

F = APP


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Output Elements Pneumatic Actuators - Pneumatic

actuators can be classified as low-pressure or high-pressure actuators.High-pressure actuators are usuallypiston-type actuators which are similar in operation to hydraulic piston-typeactuators. They are operated usuallyby spool-type control valves.

Low-pressure actuators are frequentlyknown as pneumatic motors and can

be used in order to generatetranslatory or rotary motions.

The figure illustrates a typical motor.In this actuator, low-pressure air causes the large-area diaphragm todeflect which in turn causes thetranslatory motion of an output shaft.This type of actuator is used frequentlyin process industries for operating flowcontrol valves. Translatory movementscan also be generated by capsulesand bellows.


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Exhaust steam pressure control

Exhaust steam for variousauxiliary services may becontrolled at constant pressureby appropriate operation of asurplus steam (dump) valve or a make-up steam valve, A

single controller can be usedto operate one valve or theother in what is known as 'splitrange control.

The control arrangement isshown The steam pressure inthe auxiliary range ismeasured by a pressuretransmitter.

Exhaust steam pressure control

(Source: Introduction to Marine Engineering by D ATaylor)


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Centralized control system


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Steering Control System


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B. Automation hierarchy and archtechture


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Example: Siemens WinCC


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Large control system hierarchy

enterprise

Group Control

Unit Control

Field

Sensors& Actors A V

Supervisory

Primary technology

Workflow, Resources, Interactions

SCADA =Supervisory ControlAnd Data Acquisition

T

administrationPlanning, Statistics, Finances

supervision

1

2

3

4

0

l h h


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Large control system hierarchy Cont 2 Administration:

Production goals, planning

Enterprise : Manages resources, workflow, coordinates activities of

different sitesquality supervision, maintenance, distribution and planning

Supervision : Supervision of the site, optimization, on-line operations,

Control room, Process Data Base, logging (open loop) Group (Area):

Control of a well-defined part of the plant (closed loop,except for intervention of an operator)

Coordinates individual subgroups, Adjusting set-points and parameters

Commands several units as a whole


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Large control system hierarchy Cont 3 Unit (Cell):

Control (regulation, monitoring and protection) of a small partof a group (closed loop except for maintenance)

Measure: Sampling, scaling, processing, calibration Control: regulation, set-points and parameters Command: sequencing, protection and interlocking

Field: Sensors & Actuators, data acquisition, digitalization, data

transmission No processing except measurement correction and built-in

protection


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Fieldlevel

Field level is indirectinteraction withthe plant's

hardware


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Group levelunit controllers

Group levelcoordinates theactivities of severalunit controls

Distributed ControlSystems (DCS)commonly refers toa hardware andsoftware

infrastructure toperform ProcessAutomation


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Local human interface at group level

Sometimes, the group level has its ownman-machine interface for localoperation control

Maintenance console /emergency panel

S i l l M hi


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Supervisory level: Man-machineinterface

Control room (mimic wall) 1970s...

All instruments were directly wired to the control room


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Supervisory level:

SCADA = Supervisory Control and Data Acquisition Displays the current state

of the process(visualization )

Display the alarms andevents ( alarm log, logbook )

Display the trends

(historians ) and analysethem

Display handbooks, datasheets, inventory, expertsystem ( documentation )

Allows communication anddata synchronization withother centres


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Operator workplace: Three main functions

1. Current state

3. Alarmsand

events

2. Trends and history


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Response time and hierarchicallevelPlanning

Level

ExecutionLevel

ControlLevel

SupervisoryLevel

ms seconds hours days weeks month

years

ERP

(Enterprise ResourcePlanning)

DCS

MES(Manufacturing

Execution System)

PLC(ProgrammableLogic Controller)

(DistributedControlSystem)

(Supervisory Controland Data

Acquisition)

SCADA


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Operation and process data Normally, the operator

is only concerned bythe supervisory level,but exceptionally,operators (andengineers) want to

access data of thelowest levels

The operator sees theplant through a fastdata base, refreshed in

background


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Automation applicationsPower generation hydro, coal, gas, oil, shale, nuclear, wind, solar

Transmission electricity, gas, oil Distribution electricity, water Process paper, food, pharmaceutical, metal,processing,

glass, cement, chemical, refinery, oil & gas Manufacturing computer aided manufacturing (CIM), flexible

fabrication, appliances, automotive, aircrafts Storage silos, elevator, harbor, deposits, luggage

handling Building heat, ventilation, air conditioning

(HVAC), process control, fire, energysupply, tunnels, highways,....

Transportation rolling stock, street cars, sub-urban trains,busses, cars, ships, airplanes, satellites,...

What is a CS?


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Local Infrastructure possibly using CSs

Electrical distribution, &UPS

Natural gas distribution

Fuel Oil storage & flow Water storage & flow Lighting

Heating, cooling,ventilation

Fire alarms &suppression

Elevators & escalators

Gates & doors, alarms Video security cameras Traffic signals

Process Line Control

What is a CS?

Modern engineering applications of control


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Modern engineering applications of control

Flight Control Systems Modern commercial and

military aircraft are fly by wire systems, unmanned aerialvehicles (UAVs) are already inplace

Robotics High accuracy positioning for

flexible manufacturing Remote environments: space,

sea, non-invasive surgery, etc.

Chemical Process Control Regulation of flow rates,

temperature, concentrations, etc.

Long time scales, but only crudemodels of process

Communications and Networks Amplifiers and repeaters Congestion control of the Internet Power management for wireless

communications Automotive

Engine control, transmissioncontrol, cruise control, climatecontrol, etc

Luxury sedans: 12 control devicesin 1976, 42 in 1988, 67 in 1991

AND MANY MORE...

Automation systems manufacturers


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Automation systems manufacturers

80 B / year business, growing 5 % annually

Company Location Major mergers

ABB CH-SE Brown Boveri, ASEA, CE, Alfa-Laval, Elsag-Bailey

Siemens DE Plessey, Landis & Gyr, Stfa, Cerberus,..

Ansaldo IT

Emerson US Fisher Rosemount

General Electric US

Honeywell US

Rockwell Automation US Allen Bradley, Rockwell,..

Alstom FR Alsthom, GEC, CEGELEC, ABB Power,..

Schneider Electric FR Tlmcanique, Square-D, ...

Invensys UK Foxboro, Siebe, BTR, Triconex,Hitachi JP

Yokogawa JP


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Examples of automated plants

CarsAppliances control (windows, seats,radio,..)

Motor control (exhaust regulations)ABS and EPS, brake-by-wire, steer-by-wire

19% of the price is electronics, (+10% peryear)

Airplanes Avionicsflight control, autopilot

flight managementflight recording, black boxesdiagnosticsfly-by-wire



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Flexible automation, Manufacturing

Numerous conveyors,robots, CNCmachines, paintshops, logistics.


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Examples of automated plants:Oil, Gas and Petrochemicals

Upstream:from the earth to the refinery(High pressure, saltwater,inaccessibilityexplosive environment with gas)

Downstream: (extreme explosive environment )

Distribution:(environmental protection)

E l f A d l


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Examples of Automated plants:power plants

Raw materials

supply Primary

process (steam,wind)

Personal, plantandneighbourhoodsafety

Environmentalimpact

Generation

process(voltage/frequency)

Energydistribution(substation)

Examples of automated


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Examples of automatedplants:

Waste treatment, incinerators Raw material supply Burning process Smoke cleaning Environmental control Co-generation process

(steam, heat)

Ash analysis Ash disposal


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Examples of automated plants:water treatment

Managing pumps, tanks, chemical composition, filters, movers,..


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Other examples of feedback

Biological Systems Physiological regulation

(homeostasis) Bio-molecular regulatory networks

Environmental Systems Microbial ecosystems Global carbon cycle

Financial Systems Markets and exchanges Supply and service chains

ESE


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Cruise control

engine hill

engine des( )

mv bv u u

u k v v

= + +

=

&

Control System++-

disturbance

reference

Stability/performance Steady state velocity approaches

desired velocity as k Smooth response; no overshoot or

oscillations Disturbance rejection

Effect of disturbances (hills)approaches zero as k

Robustness Results dont depend on the

specific values of b, m, or k for k sufficiently large

ss des hill

1k

v v ub k b k = ++ +

time

velocity

v des

1 ask

0 ask


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Local Infrastructure possibly using CSs

Electrical distribution, &UPS

Natural gas distribution

Fuel Oil storage & flow Water storage & flow Lighting

Heating, cooling,ventilation

Fire alarms &suppression

Elevators & escalators

Gates & doors, alarms Video security cameras Traffic signals

Process Line Control


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Insect flight

More information: M. D. Dickinson, Solving the

mystery of insect flight, Scientific American, June 2001.

ACTUATION

two wings(di-ptera)

specializedpowermuscles

SENSING

neural

superpositioneyes

hind winggyroscopes(halteres)

COMPUTATION

~500,000 neurons

S Th


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Segway: Thehuman Transporter

Automated manufacturing


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Automated manufacturingbenchmarks

3) Injection Molding Station1) Flexible Manufacturing

2) CNC Machining


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Automation of processes


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Integrating part quality into themanufacturing system

Automated and Semi-AutomatedQuality Assessments

On-Line Part Characterizationand Statistical Quality Control


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Controller design

PID Processr e u

y

Traditional Form:

Adaptive Form:

Process

ProcessModel

StateCalculation

StateController

y

u

r

e


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The Changing landscape1. Remote connectivity/control of CS devices

2. Standardization of CS Protocols3. Connection of CS & Business LANs4. Windowing of CS & SCADA Control

IPIP

1.

3.

2.

4.

What are the concerns?


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Access sirport lighting controlsFrom your PDA

SOURCE: Vendors web site



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Facility Electrical Grid Accessvia your cell phone

SOURCE: Vendors web site


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WAYNE, Pa., Oct. 24, 2002 -- Energy information systems and wind-powered generation will emerge as the two most critical energy technologies in the nextfive years, according to a majority of energy entrepreneurs and investors surveyed at the EnerTech Forum in Phoenix last week. Scott Ungerer, ManagingDirector of EnerTech Capital, said respondents believed energy information systems, which allow companies to better manage their energy use, would continueto grow, particularly given the current economic climate. "With corporate America's increased focus on the bottom line, monitoring and managing energy use isreceiving more attention than ever by corporate users." On the telecommunications front, respondents predicted the following communications technologieswould be in widespread use in the next five years: broadband wireless (named by 68 percent) and optical networks (named by 51 percent). When asked whyutilities have been so slow to adopt energy management solutions like sophisticated monitoring, data collection, and equipment control and dispatch, 49percent said the economics of the technology is not yet compelling enough for utilities. The same percentage predicted that the energy management marketsector would remain fragmented for many years, with no clear and pronounced trend.

Cost Justification



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Operational Security


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Raise AwarenessImprove Understanding & Connections between Computer/IT & Building Engineers

IT Security Worker Electronic

Equipment settings Switch settings Access Control

Computer Programming & Data

Creation

Execution Storage

Building/CampusEngineer Supply & Discharge

Electricity Water Fuel

Circuit Settings Valve Settings Electro-Mechanical

Equipment Physical Plant Safety

Educate


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Conclusion

The following has been discussed: The process/system/plant - Process

variable/Measured variable

Elements of control system and components Correcting unit actuating unit (Actuator) Example of control system and components


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Documents

c5: Components of Control and Automation Equipments