Session 1,2 2

8/22/2019 Session 1,2 2

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8/22/2019 Session 1,2 2


Automation Area

8/22/2019 Session 1,2 2


Ø Batch Process Automation

Ø Vehicle Automation

Ø Building AutomationTraffic automation

Heating, air-conditioning

Ø Transportation Automation

Automation Area

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8/22/2019 Session 1,2 2


8/22/2019 Session 1,2 2


ProblemProblemDefinitionDefinition

Business

DomainAutomation

Plant DomainAutomation

EnterpriseResource Planning

Supply ChainManagement

ResultantImprovements

Objectives

Objectives

Control SystemStructure

Industrial NetworkDevelopment

Control Algorithm(APC)

Case StudiesFuture Trends

Conclusion

8/22/2019 Session 1,2 2


CHALENGESCHALENGES ONON INDUSTRIESINDUSTRIES

8/22/2019 Session 1,2 2


8/22/2019 Session 1,2 2


““SMART MANUFACTURING”SMART MANUFACTURING”

Ø Attributes of Smart Manufacturing:

• Wide availability of real time

information on the current status of

manufacturing and productconditions.

• Comparative model-based

performance analysis.

• Decision based on predictive

scenarios of expected future plantand market behavior and analytical

decision models.

8/22/2019 Session 1,2 2


Supply & Demand Planning

Schedule/Plan

Reconciliation

Performance

Monitoring & Analysis

Material Balancing

& Data Reconciliation

Data Gathering

DCS (Real-Time Control)

Process

Monthly Planning

Scheduling

Simulation & Target

Strategy Setting

Process Control &

Local Optimization

ProductionDatabase(Data Model)

PRACTICAL IMPLEMENTATIONPRACTICAL IMPLEMENTATION ININ

PRODUCTION CHAINPRODUCTION CHAIN

8/22/2019 Session 1,2 2


Management objectivesManagement objectives

Product opportunities,sales, pricing, Logistics

Feedstock selection,Pricing,Purchasing, Logistic

Process simulationModel

PerformanceMonitoring

Accruing

Data Reconciliation(DR)

CentralHistorian

On-lineOptimization

Scheduling

Planning

DCS

HistorianInterface

MVC/APC

Physical

Processing Unit

HistorianInterface

MVC/APC

DCS

Physical

Processing Unit

Historian nterface

APC layer

DCS layer

Physical Plant

layer

AUTOMATION AREAAUTOMATION AREA

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The process database is at the centre (example: Wonderware)

8/22/2019 Session 1,2 2


INDUSTRIALINDUSTRIAL PYRAMIDPYRAMID

8/22/2019 Session 1,2 2


INDUSTRIAL PYRAMIDINDUSTRIAL PYRAMID

8/22/2019 Session 1,2 2


8/22/2019 Session 1,2 2


8/22/2019 Session 1,2 2


Large control system hierarchy (1)

Group control

Unit control

Field

Sensors& actors A V

Supervisory

Primary technology

Workflow, order tracking, resources

SCADA =

Supervisory Control

And Data Acquisition

T

Production planning, orders, purchase

1

2

3

4

0

Planning, Statistics, Finances5

(manufacturing) execution

enterprise

administration

8/22/2019 Session 1,2 2


Large control system hierarchy (2)

Administration Finances, human resources, documentation, long-term planning

Enterprise Set production goals, plans enterprise and resources, coordinate different sites,manage orders

Manufacturing Manages execution, resources, workflow, quality supervision,production scheduling, maintenance.

Supervision Supervise the production and site, optimize, execute operationsvisualize 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 interlockingField data acquisition (Sensors & Actors*), data transmission

no processing except measurement correction and built-in protection.

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Field level

the field level is in directinteraction with the plant'shardware

(Primary technology)

8/22/2019 Session 1,2 2


Group level

the group level coordinates the

activities of several unit controls

the group control is often hierarchical,

can be also be peer-to-peer (from groupcontrol to group control = distributedcontrol system)

Note: "Distributed Control Systems"

(DCS) commonly refers to a hardwareand software infrastructure to performProcess Automation

unit controllers

Group level

8/22/2019 Session 1,2 2


Local human interface at group level

sometimes,the group level hasits own man-machineinterface for localoperation control(here: cement

packaging)

also for maintenance:console / emergency panel

8/22/2019 Session 1,2 2


Supervisory level: Man-machine interface

control room(mimic wall)

1970s...

formerly, all instruments were directly wired to the control room

8/22/2019 Session 1,2 2


Mosaic is still in use – with direct wiring

8/22/2019 Session 1,2 2


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)

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Today’s control rooms

beamers replaces the mosaics, there is no more direct wiring tothe plant.

8/22/2019 Session 1,2 2


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)

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ANSI/ISA 95 standard classification

Source: ANSI/ISA–95.00.01–2000

the ANS/ISA standard 95 defines terminology and good practices

Enterprise Resource Planning

Manufacturing Execution Syste

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

8/22/2019 Session 1,2 2


Example: Power plant

8/22/2019 Session 1,2 2


Example of generic control siemens: Siemens

WinCC (Generic)

Betr iebs- lei tebene

Product ion

level

Unternehmens

-

lei tebene

Enterpr ise

level

Prozess-

lei tebene

Process level

8/22/2019 Session 1,2 2


planning

scheduling

Online opti

APC

Control

Field

8/22/2019 Session 1,2 2


Response time and hierarchical level

PlanningLevel

ExecutionLevel

ControlLevel

SupervisoryLevel

ms seconds hours days weeks month years

ERP(Enterprise Resource Planning)

DCS

MES(Manufacturing Execution

System)

PLC(Programmable Logic

Controller)

(Distributed ControlSystem)

(Supervisory Control and DataAcquisition)

SCADA

8/22/2019 Session 1,2 2


Complexity and Hierarchical level

MES

Supervision

Group Control

Individual Control

Field

Site

Command level

,

Complexity Reaction Speed

ERP

days

months

minutes

seconds

0.1s

0.1s

8/22/2019 Session 1,2 2


Effects of System Automation

• Dependability

• Plant Efficiency

• Extended Equipment Life

• Improved Operation

• Improved Operator Interface

• Accessibility of Plant Data

• etc

8/22/2019 Session 1,2 2


ProblemDefinition

BusinessBusiness

DomainDomainAutomationAutomation





Objectives

Objectives





Conclusion

8/22/2019 Session 1,2 2


BUSINESS DOMAIN OBJECTIVESBUSINESS DOMAIN OBJECTIVES

8/22/2019 Session 1,2 2


SUPPLY CHAINMANAGEMENT

ENTERPRISERESOURCEPLANNING

8/22/2019 Session 1,2 2


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 termused 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.

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ERP DevelopmentERP Development

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ERP BenefitsERP Benefits

8/22/2019 Session 1,2 2


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

8/22/2019 Session 1,2 2


SCM DefinitionSCM Definition

Supply Chain Management is the process of improving

the distribution from supplier to the final customer tosatisfy customer requirements.

8/22/2019 Session 1,2 2


SCM ArchitectureSCM Architecture

8/22/2019 Session 1,2 2


Impacts of SCMImpacts of SCM

8/22/2019 Session 1,2 2


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

8/22/2019 Session 1,2 2


Integration of ERP & SCMIntegration of ERP & SCM(Simple View)(Simple View)

8/22/2019 Session 1,2 2


Resultant Improvements due to AutomationResultant Improvements due to Automation

In Business DomainIn Business Domain

8/22/2019 Session 1,2 2


ProblemDefinition

Business

DomainAutomation





Objectives

Objectives





Conclusion

8/22/2019 Session 1,2 2


INDUSTRIAL PYRAMIDINDUSTRIAL PYRAMID

8/22/2019 Session 1,2 2


PLANT DOMAIN AUTOMATIONPLANT DOMAIN AUTOMATION

OBJECTIVEOBJECTIVE

8/22/2019 Session 1,2 2


8/22/2019 Session 1,2 2


CONTROL AND OPTIMIZATIONCONTROL AND OPTIMIZATION

ARCHITECTUREARCHITECTURE

8/22/2019 Session 1,2 2


CONTROL HIERARCHY TYPICALCONTROL HIERARCHY TYPICAL

TIMINGTIMING

8/22/2019 Session 1,2 2


Typical Cost/Benefit Relation due to PlantTypical Cost/Benefit Relation due to Plant

Domain Automation based onDomain Automation based on

Automation LevelAutomation Level

8/22/2019 Session 1,2 2


Plant Automation Requirement

Ø Control System Structure

Ø Data Communication Network

Ø Devices ( sensor & actuator )

Ø Control Algorithm

8/22/2019 Session 1,2 2


ProblemDefinition

Business

DomainAutomation





Objectives

Objectives





Conclusion

8/22/2019 Session 1,2 2


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

8/22/2019 Session 1,2 2



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

control room

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

8/22/2019 Session 1,2 2



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

8/22/2019 Session 1,2 2



Ø (mid-1960s to mid-1970s)Technical turmoil era(birth of PLC)

8/22/2019 Session 1,2 2


Ø(1978)microprocessor era began by birth of integrated circuitchip and therefore use of PID algorithm as built-in software

(appearance of DCS)


8/22/2019 Session 1,2 2


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

control system.


8/22/2019 Session 1,2 2


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

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Digital Controller ProgressDigital Controller Progress

8/22/2019 Session 1,2 2


Digital ControllerDigital Controller

Ø Centralized Control System(DDC):

Disadvantages:

• In large scale system the total number of I/O signals widelyincrease 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.

8/22/2019 Session 1,2 2



Ø DCS (Distributed Control System):

Advantages :

• lower installation costs due to the interconnection

and 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

8/22/2019 Session 1,2 2



DCS :

8/22/2019 Session 1,2 2


8/22/2019 Session 1,2 2


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

8/22/2019 Session 1,2 2


78

ANALOG CONTROL LOOPCONTROLLER

4-20 mA

4-20 mA

CONTROLROOM

FIELD

PROCESSVARIABLE

DT=DEAD TIME

PID

D/AuPA/D

D/A

uP

A/D

SIGNALCONDITIONING

FINALCONTROLELEMENT

TRANSMITTER

1

2

3

1

2

3

DT

8/22/2019 Session 1,2 2


Digital ControllerDigital ControllerØ Smart Distributed Control System (FCS):

Interconnection of low level industrial devices as well as controldevice on a single physical communication link using digitalcommunication.

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

8/22/2019 Session 1,2 2


Digital ControllerDigital ControllerØ Smart Distributed Control System(FCS) :

8/22/2019 Session 1,2 2



ØMoving from DCS toward FCS :

FCS Has a Leaner Hierarchy

8/22/2019 Session 1,2 2


FCS Has a Leaner Hierarchy• DCS • FCS

Power SuppliesControl Cards

Input CardsOutput Cards

Fusing

Marshaling

Termination

Cards

4-20 mA

PID

FieldbusPID

• Hybrid

PID

Fieldbus

PID

Hybrid Control

8/22/2019 Session 1,2 2


Hybrid Control

Control Using Fieldbus

8/22/2019 Session 1,2 2


DCS• Run PID algorithm (now optional)• Send signal to final control element• ALL OTHER DCS DUTIES

Control Using Fieldbus

DevicesTransmitter

• 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

8/22/2019 Session 1,2 2


EXPANDED VIEW

DCS

TRADITIONAL 4-20 MAVIEW STOPS AT I/O SUBSYSTEM

FCS

FIELDBUS

FIELDBUS VIEWEXTENDS INTO INSTRUMENTS

INPUT/OUTPUTSUBSYSTEM

CONTROLLER

8/22/2019 Session 1,2 2


LOCAL AREA NETWORKSUPERVISORY

SYSTEM

FIELDBUS

FIELDDPT101 PT101 FCV101 DPT102 PT102 FCV102

8/22/2019 Session 1,2 2


Field Instrument Interfacing

8/22/2019 Session 1,2 2


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

N d F I f i F D i i M ki

8/22/2019 Session 1,2 2


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

8/22/2019 Session 1,2 2


Conventional x Fieldbus

15,3 mA

DCS

TAG =LIC-012VALUE =70.34UNIT =M3

STATUS=GOODALARM = Y/N

FCS

TRANSMITTERTRANSMITTER

8/22/2019 Session 1,2 2


Increased Process and Instrument

8/22/2019 Session 1,2 2


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

8/22/2019 Session 1,2 2


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.

8/22/2019 Session 1,2 2


Predictive Maintenance

• Schedule maintenance based on device diagnostics

• Schedule calibration based on device calibration

data storage

• Perform maintenance and calibration of severaldevices 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).

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95

TWO WAYCOMMUNICATION

DPT + PID FCV TT PT

OPERATIONSTATION MAINTENANCETOOL

8/22/2019 Session 1,2 2


96

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 outputdevices when failures in sensors or communication etc. occurr.

• Assures cascade initialization (bumplesstransfer) and anti-reset-windup and many other functions.

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Need For Lower Maintenance Costs

8/22/2019 Session 1,2 2


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.

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106

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.

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8/22/2019 Session 1,2 2


WIRING & HARDWARE SAVINGS

DCS

4-20 MA

I.S I.S. I.S.

I/OSUBSYSTEM

CONTROLLER

FCS

I.S.

FIELDBUS

8/22/2019 Session 1,2 2


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Need For Scalable Systems

8/22/2019 Session 1,2 2


Need For Scalable Systems

• The cost of expanding a DCS with one or a few loops istoo 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.

8/22/2019 Session 1,2 2


Fieldbus Makes FCS Extremely

Scalable

8/22/2019 Session 1,2 2


- 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 liesin the interfacing of the field devices...

From DCS to FCS fault tolerance

8/22/2019 Session 1,2 2


• 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

8/22/2019 Session 1,2 2


118

FAULT TOLERANT

• Redundant Fieldbus power supplies

• Redundant operator stations

• Additional backup LAS(Link Active Scheduler ) in the fielddevices

• 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 failsafeaction in output devices.

• Number of modules and components (CPU, input or outputcards) is minimized reducing failure probability.

FAILURE EFFECTS

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119

FAILURE EFFECTS• Failure of one operator station does not affect

another. In case of station failure system may beoperated from another.

• Failure, connection or removal of a field devicedoes 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 respectto the loops or I/O on a single Fieldbus.

• LAS switchover is automatic and does not affectthe system.

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120

DRIVERA / B

DRIVERA / C ?

STANDARDFIELDBUS

INTERFACE

MANUFACTURERB

MANUFACTURERC

MANUFACTURERD

MANUFACTURERD

MANUFACTURERB

MANUFACTURERC

FIELDBUS = OPEN SYSTEM

Evolutions in Smart Transmitters

8/22/2019 Session 1,2 2


TransmittersTransmitters Benefits

•Multiple measurements fromsingle 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 truedistributed control

•Network communication•Communication can occur directlyfrom transmitter to valve

Evolutions in Smart Transmitters

Features

Evolutions in Smart DCS

8/22/2019 Session 1,2 2


Features Benefits

•More data available•More variables for better control andhistory 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 trueon the DCS truedistributed controldistributed control

D C SD C S

Evolutions in Smart DCS

Evolutions in Smart Valve

8/22/2019 Session 1,2 2


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 truedistributed control

•Network communication•Communication can occur directlyfrom transmitter to valve

ValveValve

Evolutions in Smart Valve

Digital Control System Elements

( i f i )

8/22/2019 Session 1,2 2


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

(more details after Evolution)

FIELDBUS CONTROL LOOP

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125

FIELDBUS CONTROL LOOP

DT=DEAD TIMETR=PROCESS TIME RESPONSE

uP

D/A

SIGNALCONDITIONING

+PID

FINALCONTROLELEMENT

1

23

1

2

3

DT

uP

A/D

CONTROLLABILITY = DT /TR

BETTER = SMALLER

FIELD

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Smart DCS(Fieldbus) Applications

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( ) pp

Ø Manufacturing AutomationCar manufacturing

Bottling systems

Storage systems

Ø Building Automation

Traffic automation

Heating, air-conditioning

Ø Process AutomationPurification plants

Chemical and petrochemical industry

Paper and textile industry

Ø Power industry and power distributionPower plants

Switching 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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Theimagepart with relationship ID rId3wasnot found in thefile.

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Basic System Configuration

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y g

Controller

Operation / Engineering

Control Bus

4 - 20mA Digital

Fieldbus Fieldbus

Scalable System Architecture

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ODS

< Exaquantum >

y

Ethernet

Small TypeController

HMIEngineering

Large TypeController

Control Bus

4 - 20mA Digital

Safety Control System< Pro-Safe >

ERP

Fieldbus

OPC Server

Fieldbus

Router

Wide Area Communication Gateway

Console Type HMI DeviceManagement

Process Automation System< CENTUM >

Remote i/o

ProblemDefinition

Enterprise

Objectives

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BusinessDomain

Automation

Plant Domain

Automation


Supply Chain

Management


Objectives

Control System

Structure




Conclusion

Evolution in Industrial Data CommunicationEvolution in Industrial Data Communication

N t k(B )N t k(B )

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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

SMART

HART

DE

FOXCOMBRAIN

80’s

FIELDBUS

Protocol Unification

Interoperability

90’s

Electro-Mechanical

10-50 mA

60’s

Local Adjustments

Pneumatic ElectronicAnalog Hybrid Digital

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• جن

Instrument Society of America (ISA),

International Electrotechnical Commission (IEC),

IEC/ISA SP50 Fieldbus committee

Profibus(German national standard) and

FIP (French national standard)

•

ين

گ

.پ

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• 1992

گ

گ

گ

Interoperable Systems Project (ISP)

Factory Instrumentation Protocol (WorldFIP)

• جت من جتISA SP50من .

رب• پ 1994WorldFIPISP Fieldbus Foundation

من من گ .پ

مب• – BPمن حت يت . ني

گ – جيEssoپ پ ني ژ

.جنWorldFIPISP پ

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Desirable Network(Fieldbus)Desirable Network(Fieldbus)

CharacteristicsCharacteristicsØO

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CharacteristicsCharacteristicsØOpen

ØStandardØAdvanced Functionality, Services

ØReliable, High Performance

ØInteroperableØPlug & Play

ØVendors’ Support

ØEconomicalØSimple, Easy

FieldbusesFieldbuses

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FieldbusesFieldbuses

Ø Field device protocol that process use

mostly:

• Foundation Fieldbus

• HART

• Profibus

What is Foundation Fieldbus?What is Foundation Fieldbus?

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ØFOUNDA T I ON f i e l d b u s ( F F) i s a n a l l - d i g i t a l ,

s e r i a l , t w o - w a y c om m u n i ca t i o n s s y s t e m t h a t s e r v e s a s a Lo c a l A r e a N e t w o r k ( L A N ) f o r

f a c t o r y / p l a n t i n s t r u m e n t a t i o n a n d co n t r o l

d e v i c e s

Control &monitoring

DCS

Fieldbus

Process

F

T

P

• I ntell igent f ield devices and systems

• Digital, two way, mul ti-drop

• Communication system for i nstruments and other automation equipment

• Self-Diagnostics

• Local controllabil ity

Benefits of Foundation FieldbusBenefits of Foundation Fieldbus

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• 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?

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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 the

same pair of wires

HART SpecificationHART Specification

ØDi it l C bilit

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• 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

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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?

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• 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 busstandard for a wide range of applications in manufacturingand process automation

يت

خم

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F:

B:

V:

D:

S:

P:

F:

B:

V:

D:

S:

P:


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ProblemDefinition


Objectives

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BusinessDomain

Automation

Plant Domain

Automation

Resource Planning

Supply Chain

Management


Objectives

Control System

Structure




Conclusion

Advanced Process ControlAdvanced Process Control

(APC)(APC)

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(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 anThis makes the control of an plantplant form a very challenging andform a very challenging anddaunting task for even the best tuned PID controller .daunting task for even the best tuned PID controller .

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APC ControllerAPC Controller

( l i )( l i )

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(general view)(general view)

ØTh b kb f ll APC t ll M lti i bl M d l B d

APC Controller DutiesAPC Controller Duties

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ØThe backbone of all APC controllers are Multivariable Model-BasedPredictive Controller(MMBPC).

ØDifferent formulations of MPC differ in :• robustness

• fault-tolerance

Ø R i t

APC Controller ElenentsAPC Controller Elenents

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• 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 ControllerAPC ControllerTheimagepart with relationship ID rId3wasnot found in thefile.

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Application area of Dynamic SimulationApplication area of Dynamic SimulationApplication area of Dynamic SimulationApplication area of Dynamic Simulation

Ø Benefits:

APC Controller BenefitsAPC Controller Benefits

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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 PerformanceAPC Performance

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Ø APC Performance: APC push process set point close to its limits or

constrains .

APC Application AreaAPC Application Area

Ø APC benefit example:

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Ø 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 totalproduction value through quality control to gain 1.7 year’spayback time

•Generally accurate control means less safety margin and thistogether with the feed-pushing control gives 1 to 5 percentincrease in throughput.

APC RealAPC Real--Time ApplicationTime Application

Ø APC benefit example:(Universal Adaptive Control)

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Ø APC benefit example:(Universal Adaptive Control)

Management Objectives

Process Improvement (general view)

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ProblemDefinition

Business


Objectives

8/22/2019 Session 1,2 2


BusinessDomain

Automation

Plant Domain

Automation

Supply Chain

Management


Objectives

Control System

Structure




Conclusion

Case Study 1Case Study 1

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Background. ARCO Alaska, Inc. is responsible for exploring, developingand producing ARCO’s oil and gas interests in Alaska and surroundingoffshore waters.

I. Design criteria

v Reduced wiring and terminations

v Modular system design

v Reduced maintenance costs

v Useful diagnostic tools

Case StudyCase Study 11

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II. Fieldbus solution

ü Simplified wiring

ü Easier installation

ü Reduced operator time

ü Reduced engineering time

Benefits



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• 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

yy

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Background. DETEN Chemical S.A. Located in petrochemical zone of camacari , bahia Brazil ,produces linear alkyl benzene , basic raw materialused in detergents by 146000 tpy production capacity.

I. Challenge

v More reliability

v Flexibility

v long/short term economic benefits


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II. APC & Fieldbus solution

ü Process optimization

ü Report generation

ü Improve Manufacturing throughput

ü Trend Analysis

Benefits


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• 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


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ProblemDefinition

BusinessDomain


Supply Chain

Objectives

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Automation

Plant Domain

Automation



Objectives





Conclusion

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Hybrid Digital Network Hybrid Digital Network

New

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Generat ion

Overall Business System LandscapeOverall Business System Landscape

in Process Manufacturingin Process Manufacturing

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Enterprise

Plant

e-business e-businessSCM

Supply Chain Management

ERPEnterprise Resource Planning

CRM

Customer

Relationship

Management

SRM

Supplier

Relationship

Management

DCS

Distributed Control System

Design Engineering

Plant Simulators

MESManufacturing Execution

System

APS Advanced Planning

& Scheduling

FCSFinite Capacity

Scheduling

EE--Commerce based on ITCommerce based on IT

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Typical Improvement due to Automation,Typical Improvement due to Automation,

Control and Integrated OperationControl and Integrated Operation

ProjectsProjects

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ProjectsProjects

Typical Performance due to Automation,Typical Performance due to Automation,

Control and Integrated OperationControl and Integrated Operation

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ProjectsProjects

Typical Incremental Payback Intervals dueTypical Incremental Payback Intervals due

to Applying Automation and Advancedto Applying Automation and Advanced

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ControlControl

Eight Practices Necessary to make an IntegratedEight Practices Necessary to make an Integrated

Operation or an AutomationOperation or an Automation

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Project a SuccessProject a Success

Documents

Session 1,2 2