1. INDUSTRIAL AUTOMATION A General Overview

2. 1-Evolution Of Automation 2-What’s Industrial Automation(IA) ? 3-Why IA ? 4-How To Design IA? 5-Conclusions a-PLC b-DCS c- FCS

3. Evolution of Automation 1. Early Control of Plants 2. Beginnings of Local Control Room Panels 3. More Sophisticated Control Rooms 4. Central Mainframe Computer Control 5. Distributed Process Control 6. Programmable Logic Controllers (PLCs) 7. PC-Based Control 8. Fieldbus Control Systems(FCS) 9. Integrated Automation System

4. Early Control of Plants  Many operators  Locally Mounted Devices  Large Indicating instruments and valves

5. Pneumatic Analogue 4 -20 mA Hybrid (Smart) Fieldbus 1940 196019802000 At First : Evolution Of Signal Transmission technology Vendor Proprietary Communication Protocols Uniform Interoperable Communication Protocols

6. 196019802000 DCS DDCFCS Time PLC Next: Evolution Of control systems

7.  Pneumatic Signal Transmission  3-15 psi signals  Field data gathered in a central control room  Provision of compressed air Pneumatic Control Systems

8. This was the beginning of the concept of bringing the plant to the operator rather than requiring the operator to go out into the plant.

9. Following World War II, electronic controls became more rugged for industrial environments. More measurements becoming possible because the cost of sensors was coming down. More Sophisticated Control Rooms

10. The size of controllers was smaller, so more of them could fit on a panel, in a smaller area. All of this led to a more complex control room.

11. Central Mainframe Computer Control As changes in technology brought down the price of computers, their use became more common in large and more complex facilities. This allowed the single centralized control room to develop further.

12.  Advantages:  Sophisticated Control  Flexible Control  Data Acquisition Alarm  Disadvantages:  Computer reliability  Redundant computer or controllers  Writing complex and extensive  HMI required high-level operators  Expensive

13. Distributed Control The distributed process architecture permits a functional distribution of the tasks among many processors, reducing the of everything failing at once. The central control room view of plant operation give the operator a single window into the process.

14. A DCS system has limited resources. Each transmitter and valve, or each loop that is added to a DCS system consumes some I/Os and processing capacity. So, generally a DCS package is designed with some spare resources for future expansions. However, when these are over, another costly investment would be necessary for an expansion.

15. Programmable Logic Controllers (PLCs) PLCs were designed for use in factory automation functions when the operation required many rapid,repeatable operations as on most assembly lines.

16. Today’s PLSc can be more efficient than ever before in performing sequencing, regulatory and interlocking operations. Real-time control for interlocking motors and related equipment has become very practical within PLCs used in the process control world.

17. PC-based Controllers The next generation of controllers in factory automation was PC-based controllers. Although in the mid-1990’s there was steel the need for “mission-critical” robustness in function- specific hardware, the trend was toward “off-the shell” hardware and a way from proprietary systems. New generation PCs are getting heavily involved in direct control, i.e., the handling of real inputs and the use of control algorisms to provide control outputs directly back to the machine or process.

18. The factors behind success of PC based technology Processing power Windows OS Low cost Modular architecture and easy “application specific configuration” Single network layer Flexibility in connectivity

19. What is Industrial Automation

21. What’s the Automation ? Industrial Automation is the knowledge and technology of industrial process control.

22. Another Definition ” Information is available at proper time, in proper form, in proper size, in proper place for proper user Within the industrial plant.” Siemens

23. Automation Automation Structures

24. Plant Network Local Area Network Fieldbus Network Management  SCM,SSM  ERP,MES Automation & Display System  DCS,PLC,PCs,  SCADA supervisory Systems Instrumentation & Control  Transmitters & Controllers  Valves & Actuators Integrated Information Architecture

25. SSM SCMERP MESP/PE Controls SSM : Sales & Service Management SCM : Supply Chain Management ERP : Enterprises Rec… Planning MES : Manufacturing Execution P/PE : Product & Process Engineering Controls : PLC, FCS, Commercial & PC-Based, DCS

26. Reasons for Automation Development Progress in microprocessor Progress in VLSI Progress in sensors and optical fibers Progress in software and HMI Standardization of information networks Control development

27. Role of Real Time Control  Time Critical Functions  Safety Valve, ESD  Multitasking Keeps Processor Busy  Any Delay Can Result In  Danger to Staff and Equipments  Processor Should Stop All Tasks  Service The Highest Priority Task  All I/O’s Should Be R/W at Fixed Times

28. Role of Sotware Technology  Reusability  Maintainability  Expandability  Interoperability  Com,Dcom,OLE,OPC,CORBA  Graphical User Interface(GUI)  Human Machine Interface(HMI)  Alarm Log, History Log

29. Role of Industrial Networks  Geographical Distribution of I/O’s  Analogue Data Transmission(4-20 ma)  Digital Data Transmission(Pulse)  Serial Data Transmission  Intelligent Field Devices  Reduced Cabling  Simple Installation and Maintenance  Less Sensitive to Noise  More Information from Field Devices

30. Why Industrial Automation

31. Objectives of Every Industrial Unit  Reduced Time to Market  Increased Efficiency  Improved ROI  Increased Market Share  Lower Prices  Better Product Quality Industrial Automation

32. Benefits of Automation  Uniform quality of products  Optimization of energy and material utilization  Being Just in Time

33. Lower Cost  Operator Role is Restricted  Rapid Product Redesign  Flexible Manufacturing  Reduced Stock  Compliance with Latest Technology

34. Higher productivity  Reduced Manual Transportation  Reduced No. of Faulty Products  Reduced Assembling Time  Just In Time

35. Better product quality  Less Human Judgment Is Involved  Machine Precision Instead of Human Vision  Less Variations Compared to Human Operator  Better View of Field Level (Shop Floor)  More Uniform Products  Raw Material Quality is Crucial

36. Reduced risk and improved safety  Faster Alarm Handling  Record of Operator Action  Operator Guidance System  Preventive Maintenance  Intelligent Transmitters  Better Hazards (Fire) Detection  Less Dependence On Operator Intelligence

37. Simple operation  Powerful HMI  History Log  Parameter Setting by Mouse Click  Plant Vision at Different Layers  Alarm Handling  Distributed Database  Web-Based-Control  Optimization

38. Reduced shut-down periods  Preventive Maintenance  Maintenance Schedule  Sensor Status Report  Actuator Failure Detection  Data Fusion  Easy Maintenance

39. Increased reliability  Better Components  Intelligent Transmitters  Improved MTBF  Self-Diagnosis  Full-Redundancy at All Levels  Well Proven Standards  Hazardous Areas

40. Shorter time to market  Integrated Automation and Information System  Enterprise Resource Planning  Automated Warehousing  Decision Support System  Management Execution Systems  Supply Chain Management

42. Benefits of the Automation  Equal quality for products  Optimization of energy and substance utilization  being Just in Time

43. AUTOMATION OBJECTIVES Lower Cost Improve time-to- market Higher producti vity Better product quality Reduced risk and improved safety Simple operati on Reduced shut-down periods Increased reliability

44. overall automation cost : installed,,commissioned, and in operation Automation Cost Benefits

45. Automation Costs Benefits “... a five-year projected figure of more than $3 million in savings…” - Phillips “..replacement of failed transmitters with smart transmitters and the use of information generated by these devices could save at least 20% of total maintenance dollars annually.” - Sunoco

46. Automation Costs Benefits “..realized a reduction in steam usage of 200,000 lbs/day, which saves us an average of $90,000 per year” - Abitibi Consolidated “..we realized $210,000 per year in dye and chemical savings after implementing fieldbus based mass flow control of our dye.” - Carriage Industries

47. How to Automate

48. PLC

49.  PLC was introduced in 1960’s and rapidly gained popularity in the area of sequential control application as a “digital electronic device that uses a programming means to store instructions and implement specific functions such as a logic sequence, timing counting and algorithms to control machines and process’.

50.  PLCs perform well sequential tasks such as machine control and are available in different classes and scales, ranging from 30 point input/output and 1 k RAM capacity to large scale versions having input/output capacity of 500 and 64 k RAM.

51. Powerful advantages of PLCs: F Excellent logic-handling capabilities F Very fast, with the ability to detect a malfunction within a few milliseconds F Very cost effective F Can withstand rough environment F Highly reliable F Offer high level of flexibility and expandability F They are usually very compact

52. The main drawback of PLCs: F No ability to predict response time F Limited in its continuous loop control capabilities F Need for host computer or personal computer to interface with process controls F Batch control software is typically not available for the process control F Available user interfaces do not always have the capability of those provided with distributed controls F Requiring the services and costs of an independent integrator

53. TYPICAL PLC SYSTEM CONFIGURATION PLC PC as HMI COMMUNICATION BUS

54. Advantages Of PLC Flexibility Easy to change Low cost High speed Modularity Possibility of local test Easy costume made Noise Protection Several methods for programming Safety

55. Distinctive features of PLCs Intelligent I/O number of counters & timers be coming network Type of I/O number of I/O Amount of memory Level of voltages & currents Program- ming languages Mathem- tical operation HMI

56. DCS

57. 4 - 20 mA Proprietary Bus 4 -20 mA Plant Network Business App Maintenance App DCS Structure

58. TYPICAL DCS SYSTEM CONFIGURATION CLR1CLR2CLR3 PC as HMI COMMUNICATION BUS WORKSTATION as HMI

59. DCS has since dominated the industry where continuous control has been the main concern. There is now variety of choices to fit particular applications. These cover :

60.  PLC based DCSs which consist of network of PLCs used to perform similar functions as a conventional DCS, and reapplied when there is a need for more programmable functionality such as material handling and packaging.  Hybrid DCSs, being combinations of above, used in order to perform process and sequential control  The conventional DSCs that the pure “process only” control systems and come in small, medium and large-scale versions in terms of their input/output handling and control capacity.

61. Important product of DCS until 1990 : TDC 3000 Honeywell Teleperm M Teleperm XP Simense Centum Yokogawa

62. Distributed Digital Control System History 1975(JUN)YOKOGAWA - CENTUM 1975(NOV)HONEYWELL - TDC2000 1976TAYLOR - MOD III 1976HOKUSHIN - 900/TX 1979EMC - EMCON-D 1979FOXBORO - SPECTRUM/MICROSPEC 1979B.B.KENT - P4000 1979FISHER & PORTER - DCI4000 1979BECKMAN - MV8000 1980FISHER CONTROL - PROVOX 1980MOORE - MYCRO 1980BAILEY - NETWORK 90 1980LEEDS & NORTHRUP - MAX 1 - CENTUM FIRST - CENTUM is the FIRST Distributed Control System in the world. Centum3000

63. Today : New DCS For Integrated Production Control System : CENTUM CS 3000

64. DCS Order Trend For Yokogawa Co. SYSTEMS FY Over 15,000 CS1000 As of March 31, 2000 MICRO YEWPACK CS3000 CENTUM XL CS

65. FCS

66. Fieldbus is a digital, serial, multidrop, two-way communication path among industrial field equipment such as sensors, actuators, controllers, and even control room devices. Definition of FIELDBUS Fieldbus P T L F Process CONTROL SYSTEM Control & Monitoring

67. Kinds Of FIELDBUS ? FOUNDATION FIELDBUS PROFIBUS DEVICE Net CONTROL Net CAN ASI LONWORKS

68. PD Meters Analytical Instrs -Process -Envrmtl Mass Flow Smart I/O and Field Controllers Intelligent Field Devices Smart Device and System Interfaces Wireless Configuration and Maintenance Tools Measurement -Pressure -Temp -Flow -Level Other Devices - Pumps - Cond Mntrs - Drives - Motors OperationsMaintenance ManagementEngineering Valves H1 Fieldbus System Architecture Linking Device HSE PLC

69. Analyzer Linking Device FCS Control System H1 FIELDBUS AND HSE (H2) FIELDBUS ooo High Speed Ethernet(HSE) 100 Mbps or higher Redundancy H1... Low Speed 31.25 kbps 2 - 32 Devices Two-wired I.S. capability 1900 m (max)

70. Communication Function System Management Kernel Function Block Transducer Block Fieldbus Fieldbus Instrument Resource Block Measurement Circuit Execution environment for function block  Devices tag and address setting  Time synchronization  Execution control of function block  Hardware information  Setting of measurement and control  Communication connection Hardware Management Standardized function for measurement and control Devices characteristic Actual measurement Communication resource Architecture of a Field Device Sending and receiving circuit Network Management Agent

71. Control Self- Diagnostics Predictive Diagnostics Process Diagnostics Plant Ethernet Business Fieldbus H1 OperationsEngineering Maintenance Open Control Network (HSE) Fieldbus Enables a New Architecture

72. EXAMPLE OF CONTROL LOOP Symbolic Representation PID LIC AIAO PID FIC Main Steam Flow CALC Feed ForwardThree-Element Control Level Flow AI PVI FWD Feed Water

73. IMPLEMENTATION OF CONTROL LOOP Configuration of Function Blocks in Controller PID LIC PID LIC AIAO AI PID FIC PVI CALC DUAL PVI CALC AI Interlock Logic Sequential Control Parameter Change Calculation Other Segment Main Steam Flow Temp. SW CALC Feed Forward PVICALC Three-Element Control Single-Element Control Redundant Density Level Press. Flow Density FWD Feed Water PVI AI

74. PID LIC PID LIC AIAO AI PID FIC PVI CALC DUAL PVI CALC AI Interlock Logic Sequential Control Calculation SW CALC Feed Forward PVICALC Three-Element Control Single-Element Control Redundant Density Level Press. Flow Density FWD Feed Water Parameter Change Other Segment Main Steam Flow PVI IMPLEMENTATION OF CONTROL LOOP Configuration of Function Blocks in Field Devices Temp. AI Complex Communication Complicated Engineering

75. Example Of FIELDBUS Control Solution oooooo oooooo oooooo oooooo ooo Control LAN 4-20mA/ Smart Intranet AIAO PID Remote IO Enterprise Management MIS Field Contents on Web Fieldbus Browser WEB OPC Fiber Optic oooooo oooooo Subsystems Ethernet Client Safety System Remote Location APC/ AOA

76. Questions to think about it before developing a Fiedlbus product : “Which kind of End-Product are you looking for?” “How am I looking to develop this product?” “How much time and resources am I able to provide?“ “Which parts could I develop in-house? If so, how can I develop it?”

77. If you look to a typical Foundation Fieldbus installation, your main parts are Power Supplies, Power Supplies Impedance, Bus Terminators, Devices and cable. All of them are simple equipment, connected in parallel.

78.  Cycling control loop  Sticking measurement  Sticking valve  Open cascade  Control wound down  Control wound up  Questionable measurement changes  Questionable control changes List of possible loop problems that can be diagnosed :

79. As many as 16 loop drawings Do you know? 1 fieldbus segment drawing

80. Fieldbus Cost Benefits “We used to estimate installation costs at two times the cost of hardware. With fieldbus, our installation costs were less than one quarter of the cost of hardware. As a result, we did not have to capitalize our installation costs; we were able to pay for them on our maintenance budget.…” Major Pharmaceutical Company

81. “To add a traditional well with hard wiring takes about 6 weeks…a month to 6 weeks, by the time you go through all of the drawings and all of the updates. To do a fieldbus, it would take a pretty green person…I’d give him a day, but I could do it in 2-3 hours.” Jim Cameron, Alaska Anvil Fieldbus Cost Benefits

82. Sira Test and Certification Ltd. Continued

83. CableInst.RoomOverall Saving Results 805452.72 $ 144000 $ 591897.22 $ 76%75%24.3%

84. BENEFITS OF FIELDBUS TECHNOLOGY Reduction of Installation Cost for Yokogawa

85. Cost Compensation Data : Fieldbus Vs. Conventional

86.  Combination of material and labor costs for installing wire, cable tray, conduit, marshalling cabinets, junction boxes, terminal blocks, and IS barriers Wiring costs savings Wiring With F OUNDATION Fieldbus Wiring With Traditional Architectures

87. Commissioning Costs Without fieldbus: Project Cost Benefits 2 hours / device for 2 technicians  Individually ring out wiring  Attach device  Verify communications  Verify link to control strategy

88. Commissioning Costs With fieldbus: Project Cost Benefits 25 minutes / device for 1 technician  Check segment wiring  Attach device  Drag-and-drop commissioning

89. Control room  Less I/O, Less Space Required  Uses one I/O module for up to 32 devices Project Costs Benefits 350 device control room with traditional architecture 350 device control room with field based architecture using FF Accommodates 64 blocks, compared to 8 channels for a typical DCS I/O card

90. Foundation Fieldbus the Only Choice Interoperability via design True control in the field using function Integrated information Ease of use Truly global

91. Two issues are important : Interchangeability Devices from different suppliers can be functionally interchanged by Providing the same functionality for the same type of devices. Interoperability Devices from different suppliers can communicate with each other and perform their functionality In multi-vendor environments.

92. Benefits of Field Based Architectures With FF  FF helps address demands by providing  Status/Quality Information  Predictive information  Information flow between functions  Diagnostics at all levels  Plug and Play  Customer benefits  project costs benefits  operational benefits  Interoperability via design  Device descriptions and function blocks  Accommodates new devices, new functions  Non profit organization for conformance testing  All functionality of a device available to all other devices

93.  Integrated information  More and better information from intelligent devices  True control in the field using function blocks  Robust time synchronization  Direct device-to-device communication for single-loop integrity  Ease of use  Consistent use of Device Description Language and function blocks by all vendors  No reprogramming the host for new devices  Automatic address assignment capability  Truly global  Board members from AP, NA, EMA  Global end users on board  End user groups active in NA, LA, EMA, AP