Lecture 2 Industrial Network

INDUSTRIAL AUTOMATION • The term industrial automation covers a range of systems used to improve the productivity, safety or product quality  of an industrial concern. • Grouped into the two categories of process industries or  continuous process industries, such as electric power  systems and other utilities, and discrete manufacturing  industries, • There are several models of industrial automation systems in common usage. One of the more well known is the Computer Aided Manufacturing (CIM) 1 pyramid model, in which the system is viewed as a series of layers, ranging  from low-level data acquisition and control functions to high-level functions such as plant and process management  management 

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CIM PYRAMID

Plant and Process Management Process Monitoring

Process Control

Sensors and Actuators

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INDUSTRIAL AUTOMATION •   A conventional automation system used for control of  an industrial plant consists of sensors connected to the plant, data acquisition devices, interface racks, actuators, cables and wires for transmission of  analogue quantities, microprocessor-based controllers and a platform for operator intervention. intervention . • The controllers, which are required to operate online in real time, are usually connected to plant equipment  through relatively short-length cables/wires or optical  fibres, designed with consideration of signal distortion, noise interference and cable reliability. • The network would be very complex, as a huge number  of cables and wires are used for a variety of purposes.

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Automation Applications Power gener generatio ation n hydro hydro,, coal, coal, gas, gas, oil, oil, shale, shale, nucle nuclear, ar, wind, sola solarr

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Transmission

electricity, gas, oil

Distribution

electricity, water

Process

paper, food, pharmaceutical, metal production and processing, glass, cement, chemical, refinery, oil & gas

Man anuf ufac acttur uriing

com ompu pute terr aid ided ed man anuf ufa act ctur urin ing g (C (CIM IM)) flexible fabrication, appliances, automotive, aircrafts

Storage

silos, elevator, harbor, retail houses, deposits, luggage handling

Building

heat, ventilation, air conditioning (HVAC) access control, fire, energy supply, tunnels, parking lots, highways,....

Tran Tr ansp spor orta tati tion on

rollin roll ing g sto stock ck,, str stree eett car cars, s, su subb-ur urba ban n tra train ins, s, busses, trolley busses, cars, ships, airplanes, rockets, satellites satellites,... ,...

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Automation Systems - World Players Compan Com pany y

Locati Loc ation on Maj Major or me merge rgers rs

ABB Bailey Alstom

CH-SE

Brown Boveri, ASEA, CE, Alfa-Laval, Elsag-

FR

Alsthom, GEC, CEGELEC, ABB Power,..

Ansaldo Emerson General Electric Hitachi Honeywell Rockwell Automation Schneider Electric Invensys Siemens Yokogawa

IT US US JP US US FR UK DE JP

Fisher Rosemount

Allen Bradley, Rockwell,.. Télémécanique, Square-D, ... Foxboro, Siebe, BTR, Triconex,… Plessey, Landis & Gyr, Stäfa, Cerberus,..

€ 80 Mia / year business (depends on viewpoint), growing 5 % annually L

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Expectations of automation Process Optimisation • Energy, material and time savings • Quality improvement and stabilisation • Reduction of waste, pollution control • Compliance with regulations and laws, product tracking • Increase availability, safety • Fast response to market • Connection to management and accounting -> Acquisition of large number of “Process Variables”, data mining Personal costs reduction • Simplify interface • Assist decision • Require da data pr processing, di displays, da data ba base, ex expert sy systems -> Human-Machine Interface (MMC = Man-Machine Communication) Asset Optimisation • Automation of engineering, commissioning and maintenance • Software configuration, back-up and versioning • Life-cycle control • Maintenance support -> Engineering Tools L

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Process Industry Application: Water treatment plant Control Room

Japan Remote Maintenance System

source: Kaneka, Japan LA S

Ethernet

SCADA

Malaysia Bus Monitor 

H1 Speed Fieldbus JB

Segment 1

Sub Stati Station on

Segment J3B

AO

AI AI

PI D PI D

AI AI

AI

AO

AI

AI

AI

AI

PLC

AO PID AO

AO

M.C.C.

DI

FB Protocol Converter JB

Segment 2

Segment 4

Digital Input/Output

AI

AI AI

JB

AI

AI

S

P I D A I P ID A I A I A I AO AO

S

S

S

S

AI AI

Numerous analog inputs (AI), low speed (37 kbit/s) segments merged to 1 Mbit/s links. L

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Flexible Automation Conveyor 

ASRS

Robots

CNC Machines

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Large control system hierarchy (1) 5

Planning, Statistics, Finances

4

Production planning, orders, purchase

3

Workflow, order tracking, resources

enterprise (manufacturing) (manufacturing) execution

SCADA = Supervisory Control And Data Acquisition

Supervisory

2

administration

Group control Unit control 1

Field Sensors & actors 0 L

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Large control system hierarchy (2)

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Admi Ad mini nistr strat atio ion n

Fina Fi nanc nces es,, human human reso resour urce ces, s, docu docume ment ntat atio ion, n, long long-te -term rm plan planni ning ng

Ente En terp rprrise

Set pr product ctiion go goals, plans en ente terrpri ris se an and re reso sou urc rce es, co coordinate different sites, manage orders

Manu Ma nufa factu cturin ring g

Manage Mana ges s execu executio tion, n, reso resour urce ces, s, workf workflo low, w, qual quality ity sup super ervi visio sion, n, production scheduling, maintenance.

Supe Su perv rvis isio ion n

Superv Supe rvis ise e the the pr pro odu duct ctio ion n and and si site te,, opti optimi mize ze,, exec execut ute e ope opera rati tio ons visualize plants, store process data, log operations, history (open loop)

Gro Gr oup (A (Are rea a)

Contr Con trol ols s a we wellll-d defi fin ned pa part rt of th the e pl pla ant (closed loop, except for intervention of an operator) Coordinate individual subgroups, Adjust set-points and parameters, Command several units units as a whole whole

Uniit (C Un (Ce ell)

Contr tro ol (r (re egulati tio on, monitoring and protecti tio on) part of a group (closed loop except for maintenance) Measure: Sampling, scaling, processing, calibration. Control: regulation, set-points and parameters Command: sequencing, protection and interlocking

Field

data acquisition (Sensors & Actors*), d. ata transmission no processing except measurement correction and built-in protection.

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ANSI/ISA 95 standard the ANS/ISA standard 95 defines terminology and good practices Level 4

Business Planning & Logistics Plant Production Scheduling Operational Management, etc.

Level 3

Manufacturing Operations & Control Dispatching Production, Detailed Product Scheduling, Schedulin g, Reliability Assurance,...

Levels 2,1,0

Continuous Batch Control Control

Discrete Control

Enterprise Resource Planning

Manufacturing Execution System

Control & Command System

Source: ANSI/ISA–95.00.01–2000

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Example: Power plant

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Example: Siemens WinCC (Generic)

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Data Quantity & Quality and Hierarchical Level Higher Levels When ascending the control hierarchy, data are reduced: higher level data are created (e.g. summary information) Processing and decisions becomes more complicated (requires using models). Timing requirements are slackened. Historical data are stored SCADA level Presentation of complex data to the human operator, aid to decisions (expert system) and maintenance. Requires a knowledge database in addition to the plant's database Lower Levels Lowest levels (closest to the plant) are most demanding in response time. Quantity of raw data is very large. Processing is trivial (was formerly realized in hardware). These levels are today under computer control, except in emergency situations, for maintenance or commissioning. L

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Complexity and Hierarchical level Complexity

Reaction Speed ERP

months

MES

days

Supervision

minutes

Group Control

seconds

Individual Control

0.1s

Command level

Field

0.1s

Site

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INDUSTRIAL NETWORK • The main difference between an office grade network  and an industrial network is the robustness or the hardness of the component it use. • Office networks are usually in an environmentally  controlled space with little variation in temperature or  humidity. But in the industrial arena things are different. • For a factory environment the bus topology is popular.

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Busses and processors in industrial plants

disk

Process pictures

open network: TCP/IP, ...

Operator panel Mimic board

Process Data Base Logging

workstation bus statio n

station

instrument bus (mimic board)

process bus (500m .. 3 km) pool

P P P C I/O MEM I/O

PLC nodes (multi-processors)

P P C P MEM BC

directly coupled input/ output

node bus (30m..2 km) fieldbus station bus

control stations sensor bus (0,5.. 30 m)

sensor bus

transducers

valve thermo-couple L

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position

M

motor  

plant 17

Example: Printing Architecture

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Example: Production management system production planning

enterprise network scheduling

maintenance

quality con control

plant network transportation cell cell control

manufacturing cell control

floor network robot controlle r 

milling machine

rail-guided vehicle

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Example: Honeywell TotalPlant (2003)

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Example: Rockwell (Allen-Bradley) NetLinx Programmabl e Device Support PC

Desktop PC with excel

EtherNet / IP

Controller and Bridge

Servo

ControlNet

Linking Device

HMI

Bridge or Linking Device Drive

HM I

DeviceNet

Modular  I/O

509-BOD 24vdc

Micro PLC

Sensor  Block I/O

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Example: Emerson's PlantWeb (Delta V)

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Example: ABB Industrial IT (redundant system) Plant Network / Intranet

Workplaces (clients)

Enterprise Optimization (clients)

3rd party applicatio n server 

Firewall

Mobile Operator 

lient/server Network connectivity server 

aspect server 

application server 

engineering workplace

Control Network Serial, OPC or fieldbus Field Bus

Redundant AC 800M

Programmable Logic Controller  Controller  AC 800C

touch-screen

Field Bus

3rd party controllers, servers etc

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The internet dimension (example: Alstom)

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The wireless dimension (example: Schneider)

No more wires, but the structure remains L

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Centralized Control Architecture (classical) Central Computer (Mainframe)

Group

Group

Group

Control

Control

Control

Sensors, Actors

PLCs

plant

Classical, hierarchical, centralized architecture. The central computer only monitors and forwards commands to the PLCs

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Decentralized Control System (DCS) engineering workstation

operator workstation

data logger

control bus controller

controller

controller

controller

field bus

plant all controllers can communicate communicate as peers 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. L

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Example of Industrial Network  – Modbus  –  AS-I   – HART   – DeviceNet   – ControlNet   – Profibus PA/DP/FMS   – Foundation Fielbus  – Controller Link   – Industrial Ethernet 

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Location of the field bus in the plant hierarchy File Edit

SCADA level

Operator

23 4 2 33

12 2

Network Management

Process bus Programmable Logic Controller

Process Level

Field bus Field level

Sensor/  Actor Bus direct I/O L

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Field busses classes Office network

Example of Fieldbus  –

TCP IP Ethernet

Modbus

 –  AS-I   – HART 

Plant Network Ethernet, ControlNet

 –

DeviceNet 

 –

ControlNet 

 –

Profibus PA/DP/FMS 

 –

Foundation Fielbus

 –

Controller Link 

 –

Industrial Ethernet 

Fieldbus intelligent field devices FF, PROFIBUS PA, LON

Sensor Busses simple switches etc. CAN, DeviceNet, SDS, ASI-bus, ASI-bus, Interbus-S

The field bus depends on: its function in the hierarchy the distance it should cover the data density it should gather L

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Conventional Industrial Communication

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Simplified System Architecture

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