Automation Examples 1.2 Exemples de sites automatisés Beispiele Automatisierungssysteme: Prof. Dr. H. Kirrmann EPFL /ABB Research Center, Baden, Switzerland Industrial Automation
Automation Industrielle Industrielle Automation Automation Examples 1.2 Exemples de sites automatisés Beispiele Automatisierungssysteme 2007 March HK
Examples of Automated Plants: Examples of Automated Plants 1 Introduction
1.1 Automation and its importance
1.2 Applications of automation
1.3 Types of Plants and Control
1.3.1 Open Loop and Closed Loop Control
1.3.2 Continuous processes
1.3.2 Discrete processes
1.3.3 Mixed processes
1.4 Automation hierarchy
1.5 Control System Architecture
Cars: Cars traditional: appliances control (windows, seats, radio,..)
motor control (exhaust regulations)
critical new applications: ABS and EPS, brake-by-wire, steer-by-wire (“X-by-wire”)
increased safety ?
extreme price squeezing
2001 US model: 19% of the price is electronics, tendency: +10% per year.
Rail vehicles: Rail vehicles display unit vehicle control unit DU TCU DU TCU VCU radio link there are more than 20 interconnected computers on a locomotive brakes signaling traction control unit diagnostics energy Benefits: reduce operation costs, faster diagnostics, better energy management, automatic train control. VCU SBB 460
Airplanes: Airplanes “avionics”:
flight control (safe flight envelope, autopilot, “engineer”)
flight management
flight recording (black boxes, turbine supervision)
diagnostics
“fly-by-wire” high reliability
Launch vehicles: Launch vehicles serial data buses ( 23 shared, 5 dedicated ) GPC 5 IOP 5 GPC 4 IOP 4 GPC 3 IOP 3 GPC 2 IOP 2 GPC 1 IOP 1 Intercomputer (5) Mass memory (2) Display system (4) Payload operation (2) Launch function (2) Flight instrument (5;1 dedicated per GPC) Flight - critical sensor and control (8) Control Panels CPU 1 CPU 2 CPU 3 CPU 4 CPU 5
Robots: Robots extension limited to 2-3 m (portal robots 10-20m)
frequent reprogramming for new tasks, tooling
simple embedded computer, hierarchical control
Substations: Substations First function: protection of the elements (lines, transformers, generators)
very high speed response
Second Function: control (remote or local) to guarantee power flow
safe operation (interlocking)
Pharmaceutical Industry: Pharmaceutical Industry Inventory
Recipe management
Packaging
Sampling
Tracking & tracing
Comply with government rules: Typical of batch processes.
Manufacturing: Manufacturing
Flexible Automation: Flexible Automation numerous conveyors, robots, CNC machines, paint shops, logistics.
Download from production management, connection to administration
Warehouses: Warehouses extreme dependency on the
availability of the control
system
Connection to
* supply chain management,
* order fulfilment
* customer relationship and
* commercial accounting (SAP)
Printing machines: Printing machines tasks of control system:
motor control (synchronisation of the printing cylinders)
ink and water control
paper web control (reelstands (Rollenwechsler, bobines), web tension, emergency knife)
interface to operator (commands, alarms)
production preparation and statistics - up to the press room
very high requirements on availability: two hours delay and the production is lost.
Oil & Gas, petrochemicals: Oil & Gas, petrochemicals "upstream": from the earth to the refinery
down-sea control
"downstream": from the oil to derived products special requirement: extreme explosive environment distribution special requirement: high pressure, saltwater, inaccessibility
explosive environment with gas. special requirement: environmental protection Switzerland: Colombey, Cressier
Chemical industry: Chemical industry e.g. LONZA logistics,
local control of reactors Characterized by batches of products, reuse of production reactors for different
product types (after cleaning).
Process Industry: Process Industry Metals and Minerals
Glass production
Chemical …. Process Industry = industries de transformation, Verfahrenstechnik
(one of the many meanings of “process”) Cement Continuous flow of materials, often 24 hours a day
Steel mills: Steel mills particularity: synchronization of the motors in the rolling mill
Cement Works: Cement Works Control tasks: Oven rotation and temperature control
fuel supply, silos,
transport belts,
grinding mills,
pollution monitoring,
quality supervision,
filler stations,...
Switzerland is leading
nation in Europe
(Holcim, Jura, …) The rotating oven is the
heart of the cement
process: the grinded kiln
is burnt and comes
out as chunks later reduced to powder.
Mining: Mining
Building Automation: Building Automation basics: fire, intrusion, climate, energy management
HVAC = Heat, Ventilation and Cooling = air conditioning visitors, meeting rooms, catering,….
low price tag
Automation of Building Groups: Automation of Building Groups EPFL
Airports: Airports large building automation system: fire, security access, energy, lighting, air conditioning, communications, traffic control luggage control in
Zurich-Airport
Traffic control: Traffic control fire
intrusion
energy
water
ventilation
pollution monitoring
cameras
light control
traffic jams prevention,.... (Tunnel Letten near Zurich)
Harbours: Harbours from ship planning
to crane manipulation
and stock control
Water treatment: Water treatment (fresh and waste water)
manage pumps, tanks, chemical composition, filters, movers, quality...
auxiliaries: methane electricity generation
Power plants: Power plants tasks: fuel supply
primary process control (steam, wind)
personal, plant and neighbourhood safety
monitoring environmental impact
electricity generation (voltage/frequency)
energy distribution (substation) 24 / 365 availability Hydro - river
- dams
- storage dams
Thermo
- coal
- gas
- atom - solar - waste
Alternative
- wind
- photo-voltaic
Waste treatment, incinerators: Waste treatment, incinerators raw material supply
burning process
smoke cleaning
environmental control
co-generation process (steam, heat)
ash analysis
ash disposal
Power transmission network: Power transmission network Power Plant Centrale,
Kraftwerk switchyard, postes HT
Schaltfeld SS Regional
Control Center Regional Control Center PP Substation
( Unterstation , sous-station) SS SS PP SS PP SY SY PP Huge number of "points" (power plants, transformers, breakers, substations)
lying 2km to 2000 km apart.
All time-critical operations executed locally in the substations and power generation units.
International Control Center National
Control Center SS Substation
Swiss electricity interconnection network: Swiss electricity interconnection network
Pipelines: Pipelines particularities: long-range communication system, safety, explosive environment
Assessment: Assessment Name the applications you remember and indicate at least one task for the
control system
What could be the order behind the plant types that were presented ?