I M C – A E S O P

Use Case 1: Plant Lubrication

IMC-AESOP: ArchitecturE for Service-Oriented Process - Monitoring and Control

Seventh Framework Programme (FP7) Theme ICT - Information and Communication Technologies

Grant agreement no: 258682 | Project Co-ordinator: Armando Walter Colombo | Schneider Electric Automation GmbH

© 2013 The IMC-AESOP consortium. All disclosure and/or reproduction rights reserved

DPWS

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DPWS

Data Model

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Modbus

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AS-I gatewayEdge router

Mediator Configurator

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REST REST

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Edge

router

3 Mulle

nodes

Service

bus

Mediator

Maintenance

station

Service

bus

AS-I 3.0

Master

6LowPAN/

COAP/EXI

Eth/IPv6/COAP

Ethernet/DPWS

using WS-eventing

DCS

Profibus Ethernet/OPC-UA

Ethernet/

Modbus TCP

50+ AS-I slaves

AS-I

The site for Use Case 1: Plant Lubrication was the LKAB

pelletizing plant KK4 in Kiruna, Sweden.

At the pelletizing plant a mixture of ground up iron ore and

additives is rolled into small balls which are then heated to

become pellets.

Use Case 1 consisted of

replacing the traditional control

system of the grate lubrication

system with an IMC-AESOP

architecture.

Several SOA based components

were developed to achieve a

smoother integration.

Old PLC CabinetDistributor

DistributorDistributor

DistributorDistributor DistributorDistributor

DistributorDistributor

ASi 1

ASi 2

End of line A

pressure switchLine A

Line B

PS

Lubrication

DCS

Compressed

air

PS

PS

PL

C

Pro

fib

us

AS

-I

AS

-I

I/O

DP

/DP

Field Devices 50+ Distributors

ZSZS ZS ZS

ZS ZS ZS ZS ZS

End of line B

pressure switch

Change over

valve

Pump

valve

Junction

boxAS

-I

Po

we

r

Mo

du

le

Hard wire

Pipe

Profibus

ZS – Position Switch

PS – Pressure Switch

New SOA Cabinet

AS

-I 3

.0

Ma

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r

Multiplexer

DP

/DP Service bus

Mediator

Mulle

units

Edge

router

Maintenance

station

Supply

Return

Illustrated above is one of the two lubrication circuits

for the Grate. Each lubrication circuit consists of one

air-pressure-controlled pump supplying the lubrication

fluid to distributor valves, alternatingly through Line A

and Line B.

The Mediator

provides a runtime

system for

monitoring and

control of process

facilities by

integrating both

legacy as well as

SOA-based

technologies.

The Distributed Service

Bus provides an

additional integration of

heterogeneous systems

supporting various

communication media,

protocols, and data

models. The integration

is enabled through loose

coupling-based protocol

connectors.

The core components of the Grate

lubrication are the magnetic valves

which control the lubrication pump and

the change over valve.

The distribution valves are operated

through the alternating pressure in the

distribution lines Line A and Line B. As

the pressure is rising in one of the

distribution lines a set amount of

lubrication fluid is distributed to a

number of lubrication points, in this

case on one of the Grate Support

Shafts.

The position of the distribution valve is

detected by an AS-i Pressure Switch,

which is supervised by the control

system.

The LKAB KK4 travelling grate (background) and rotary kiln (foreground), which together

form the warm process of the pelletizing plant.

SOA architecture of the use case.

Basic structure of the Mediator

Core components of the Grate lubrication system.

One of the many distribution valves, with the position switch and AS-i

slave for supervision.

A lubrication point on one of the Grate support shafts.

The Distributed Service Bus

The Mulle hardware

Mulle devices were used as I/O nodes connecting

lubrication pressure switches, air pressure switches,

pump valves, change over valves, and indication lights.