Industrial AutomationAutomation IndustrielleIndustrielle Automation

Control System Architecture1.5 Architecture de Contrôle - Commande

Leittechnik-Architektur

Prof. Dr. H. KirrmannABB Research Center, Baden, Switzerland

2008 June, HK

1.5 Control System Architecture2Industrial Automation

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

1.5 Control System Architecture3Industrial Automation

Principle

The control system has to suit the plant, not the reverse

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.

1.5 Control System Architecture4Industrial Automation

Busses and processors in industrial plants

PLC nodes(multi-processors)

fieldbus (30m..2 km)

Operator panelMimic board

plant (Werk, usine)

P

disk

processor pool

transducers

controlstations

plant bus (500m .. 3 km)

valve thermo-couple motor

Process pictures

Process Data Base

Logging

position

backplane bus

node bus

workstation bus

instrument bus(mimic board)

sensor bus

directly coupled input/output

open network, WAN

station

P P C

I/O MEM I/O

P P C P

MEM BC

station

M

sensor bus (0,5.. 30 m)

1.5 Control System Architecture5Industrial Automation

Example: Printing Architecture

1.5 Control System Architecture6Industrial Automation

Example: Production management system

transportationcell control

manufacturingcell control

scheduling maintenance quality control

plant network

floor network

productionplanning

robotcontroller

enterprise network

millingmachine

rail-guided vehicle

cell

1.5 Control System Architecture7Industrial Automation

Example: Power plant control - 1980 (!)

Control systems look similar

1.5 Control System Architecture8Industrial Automation

Example: Honeywell TotalPlant (2003 same structure)

1.5 Control System Architecture9Industrial Automation

Example: Rockwell (Allen-Bradley) NetLinx

Modular I/O

HMI

24vdc

509 -BOD

Bridge or Linking Device

Programmable Device Support PC

Block I/O

MicroPLC

Drive

Servo

Controller and Bridge

HMI

Desktop PCwith excel

Linking Device

Sensor

EtherNet / IP

ControlNet

DeviceNet

1.5 Control System Architecture10Industrial Automation

Example: Emerson's PlantWeb (Delta V)

1.5 Control System Architecture11Industrial Automation

Example: ABB Industrial IT (redundant system)

3rd partycontrollers,servers etc

Serial, OPCor fieldbus

engineeringworkplace

Field Bus

Firewall

Plant Network / Intranet

Field Bus

Client/server Network

3rd party application server

applicationserver

aspectserver

Workplaces(clients)

Enterprise Optimization

(clients)

MobileOperator

connectivityserver

Control Network

ProgrammableLogic ControllerAC 800C

RedundantAC 800M

touch-screen

1.5 Control System Architecture12Industrial Automation

The internet dimension (example: Alstom)

1.5 Control System Architecture13Industrial Automation

The wireless dimension (example: Schneider)

No more wires, but the structure remains

1.5 Control System Architecture14Industrial Automation

A real substation projectPrinter Server 1

Alarm andEvent Printer 1LA36W

Fibre optic station bus (LON) in star configuration

4 x Star CouplerRER111 includingredundantpower supply

GPSMaster

SAS5

70 A

dvan

ced

Sub

stat

ion

Auto

mat

ion S

yste

m

Operator's Workstation 2Operator's Workstation 1

Global PositionSystem

Front-End StationComputer 1

Front-End StationComputer 2

Alarm andEvent Printer 2LA36W

Redundant Station LAN TCP-IP

Printer Server 2

LAN-Interfaceto LV SCMS

Engineering Workstation

Disturbance RecorderEvalution Station

toCentral Station

ManualSwitch

Bay control unitREC316*4

Bay control unitREC316*4

4 x 132kV Cable Line 1 x 132kV Bus Coupler Trafo Interlocking 132kV Common Alarm

Differential protectionRET316*4

6 x 500RIO11 DI

SACO64D4 Auxiliary alarm unit

3Ph and neutral OCSPAJ140C

Bay control unit(loose delivery)

4 x 132/11kV Transformer Feeder

SPAJ110CStand byearth faultovercurrentProt.

SPAJ115CRestrictedearth faultProtection

Neutralearth faultProt.

SPAJ110C

SPAJ115C Restrictedearth faultProtection

132kV Side 11kV Side

132kV BBP / BFP

BBP/BFP Central unit

REB500

10 x BBP/BFP Bay unit REB500

Bay control unitREC316*4

Bay control unitREC316*4

AVR & Tap Control

AVR and tap controlT1 type REGSys Fault Monitoring System

Indactic I650

Coaxial cable

TelephonModem

SACO64D4 Auxiliary alarm unit

AVR and tap controlT2 type REGSys

Repeater

(loose delivery)

1 x 500RIO11 DO

ServiceModem

132kV ModemNSK

FallbackSwitch

LDCs Interface from Station Computer 2 IEC870-5-101

LDCs Interface from Station Computer 1 IEC870-5-101

AVR and tap controlT3 type REGSys

Line distance prot.REL316*4

AVR and tap controlT4 type REGSys

(loose delivery)(loose delivery)Bay control unit(loose delivery)

HP ColorLaserjet

HP Color

Laserjet

EF and OCSPAJ110C

500RIO11 , 16DI

Analog alarm unitSACO16A3

Station Alarm Unit Station Alarm Unit

SPAJ110C

SPAJ110C

Earth faultovercurrentProt.

TertiaryEarth faultProt.

Repeater

Control ProtectionAnalog alarm unitSACO16A3

FMS Fault Monitoring System

10 x 132kV

4 x 11kV

1 x spare

SACO16A3 R

SPAU140CSynchro-

check

SPAJ140CPhase andneutralovercurrentProt.

SACO16A3 R

SACO16A3 R

132kV analogInput

132kV FOXEquipment

11kV analogInput

PTUSK Scope

11kV ModemNSK

SACO64D4 Auxiliary alarm unit

Main 2

o/e

o/e

SACO64D4 Auxiliary alarm unit

Ethernet

Verbindung zu E4

FO

RS232

Pilot wire diff. prot. SOLKOR R/Rf.

B69Überstrom

Main 1

Siemens 7SD610 fürE19 Verbindung

1.5 Control System Architecture15Industrial Automation

Centralized Control Architecture (classical)

Sensors, Actors

PLCsGroup

Control

Group

Control

Group

Control

Central Computer

(Mainframe)

Classical, hierarchical, centralized architecture.

The central computer only monitors and forwards commands to the PLCs

plant

1.5 Control System Architecture16Industrial Automation

plant

Decentralized Control System (DCS)

engineeringworkstation

operatorworkstation

data logger

controller controller controller controller

field bus

plant bus

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.

peer-to-peer (horizontal communication)hierarchical(vertical communication)

1.5 Control System Architecture17Industrial Automation

Hierarchies are simple and traditional

1.5 Control System Architecture18Industrial Automation

but Distributed Control Systems reflects a more

complex world....

1.5 Control System Architecture19Industrial Automation

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 ?)