Industrial AutomationAutomation IndustrielleIndustrielle Automation
Control System Architecture1.5 Architecture de Contrôle - Commande
Leittechnik-Architektur
Prof. Dr. H. KirrmannABB Research Center, Baden, Switzerland
2012 February, 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 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.
1.5 Control System Architecture4Industrial Automation
Example: Power plant control - 1980 (!)
Control systems look similar
1.5 Control System Architecture5Industrial 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 network (500m .. 3 km) – includes control network
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 Architecture6Industrial Automation
Example: Newspaper Printing Architecture
Each level has its bus !
1.5 Control System Architecture7Industrial 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 Architecture8Industrial Automation
Example: Honeywell TotalPlant (2003, today same structure)
1.5 Control System Architecture9Industrial Automation
Example: Siemens Distributed Control system
1.5 Control System Architecture10Industrial 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 Architecture11Industrial Automation
Example: Emerson's PlantWeb (Delta V)
1.5 Control System Architecture12Industrial Automation
Example: ABB Industrial IT (redundant system)
3rd partycontrollers,servers etc
Serial or fieldbus
engineeringworkplace
Field Bus
Firewall
Plant Network / Intranet
Field Bus
Plant Network (Ethernet)
3rd party application server
applicationserver
aspectserver
Workplaces(clients)
Enterprise Optimization
(clients)
MobileOperator
connectivityserver
Control Network (Ethernet)ProgrammableLogic ControllerAC 800CRedundant
AC 800M
touch-screen
sensor network
1.5 Control System Architecture13Industrial Automation
The internet dimension (example: Alstom)
1.5 Control System Architecture14Industrial Automation
The wireless dimension (example: Schneider)
No more wires, but the structure remains
1.5 Control System Architecture15Industrial 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 Ad
vanc
ed S
ubst
atio
n Au
tom
atio
n Sys
tem
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 Architecture16Industrial Automation
Centralized (Hierarchical) Control Architecture
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 Architecture17Industrial 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.
hierarchical(vertical
communication)
peer-to-peer (horizontal communication)
1.5 Control System Architecture18Industrial Automation
Plant with process (e.g. chemical) and electrical (substation) parts
horizontal communication
CN Connectivity Server (and router)
IEC 61850 connectivity server
plant network
Engineering
bay bus
substation networkProcessNetwork
interface
SAN IEDs
CI871
Aspect Servers
controller
PIPB
PIPB
PIPB
PIPB
PIPB
PI = Process Interface MU = Merging Unit
PIPN
PIPN
PIPN
PIPN
PIPN
PIPI
PIPI
PIPI
PIMU
PIMUProfibus
Engineering
Engineering
Profinet RSTP
LANs are separate: there is no IP routing between
them
vertical communication
Workplaces
horizontal communication
1.5 Control System Architecture19Industrial Automation
Hierarchies are simple and traditional
1.5 Control System Architecture20Industrial Automation
but Distributed Control Systems reflects a more
complex world....
1.5 Control System Architecture21Industrial 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 ?)