1. Industrial AutomationAutomation IndustrielleIndustrielle Automation Control System Architecture 1.5 Architecture de Contrôle - Commande Leittechnik-Architektur Prof. Dr. H. Kirrmann ABB Research Center, Baden, Switzerland 2008 June, HK

2. 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

3. Principle The control system has to suit the plant, not the reverse 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.

4. disk Busses and processors in industrial plants instrument bus (mimic board) open network, WAN Operator panel Mimic board Process pictures Process Data Base workstation bus station station Logging plant bus (500m .. 3 km) processor pool P P P C P P C P PLC nodes node bus (multi-processors) I/O MEM I/O MEM BC fieldbus(30m..2 km) directly coupled control backplane bus input/ stations output sensor bus (0,5.. 30 m) sensor bus transducers plant (Werk, usine) M valve thermo-couple position motor

5. Example: Printing Architecture

6. Example: Production management system productionplanning enterprise network scheduling maintenance quality control plant network cell transportationcell control manufacturingcell control floor network robotcontroller millingmachine rail-guided vehicle

7. Example: Power plant control - 1980 (!) Control systems look similar

8. Example: Honeywell TotalPlant (2003 same structure)

9. Desktop PC with excel 509 -BOD 24vdc Block I/O Example: Rockwell (Allen-Bradley) NetLinx Programmable Device Support PC EtherNet / IP Controller and Bridge Servo ControlNet HMI Linking Device Bridge or Linking Device Drive HMI DeviceNet Modular I/O Micro PLC Sensor

10. Example: Emerson's PlantWeb (Delta V)

11. MobileOperator connectivity server Example: ABB Industrial IT (redundant system) Plant Network / Intranet Enterprise Optimization (clients) Workplaces (clients) 3rd party application server Firewall Client/server Network aspect server application server engineering workplace Control Network Programmable Logic Controller AC 800C Serial, OPC or fieldbus touch-screen Redundant AC 800M Field Bus Field Bus 3rd party controllers, servers etc

12. The internet dimension (example: Alstom)

13. The wireless dimension (example: Schneider) No more wires, but the structure remains

14. HP Color Laserjet Telephon Modem 132kV Modem NSK Repeater Repeater HP Color Fallback Laserjet Switch Service Modem Station Alarm Unit Station Alarm Unit LDCs Interface from Station Computer 2 IEC870-5-101 LDCs Interface from Station Computer 1 IEC870-5-101 AVR and tap control Control Protection Fault Monitoring System T1 type REGSys 10 x 132kV 3Ph and neutral OC Differential protection Bay control unit Bay control unit Bay control unit Bay control unit Analog alarm unit Indactic I650 BBP/BFP Central unit SPAJ140C RET316*4 Tertiary SPAJ110C REC316*4 REC316*4 REC316*4 REC316*4 SACO16A3 REB500 Earth fault Prot. AVR and tap control Analog alarm unit T2 type REGSys EF and OC SACO16A3 SPAJ110C Line distance prot. 4 x 11kV SACO16A3 R Stand by 6 x 500RIO11 DI 500RIO11 , 16DI REL316*4 SPAJ110C SPAJ110C Neutral earth fault earth fault overcurrent Prot. Prot. 10 x BBP/BFP Bay unit REB500 AVR and tap control SACO64D4 Auxiliary alarm unit SACO16A3 R SACO16A3 R T3 type REGSys Phase and SPAJ140C Restricted SPAJ115C neutral SPAU140C earth fault overcurrent Protection Prot. Synchro- SACO64D4 Auxiliary alarm unit check AVR and tap control T4 type REGSys SPAJ115C Earth fault SPAJ110C Restricted overcurrent 1 x 500RIO11 DO earth fault Prot. Protection 1 x spare 132kV Side 11kV Side Bay control unit Bay control unit Coaxial cable (loose delivery) (loose delivery) (loose delivery) (loose delivery) (loose delivery) 4 x 132kV Cable Line 1 x 132kV Bus Coupler Trafo Interlocking AVR & Tap Control 132kV BBP / BFP 132kV Common Alarm FMS Fault Monitoring System 4 x 132/11kV Transformer Feeder A real substation project Global Position to Disturbance Recorder Operator's Workstation 1 Engineering Workstation Printer Server 1 Operator's Workstation 2 System Central Station Evalution Station PTUSK Scope 132kV FOX Equipment Alarm and Event Printer 1 11kV analog Ether 132kV analog LA36W Input net Input Printer Server 2 Verbindung zu E4 Alarm and o/e Event Printer 2 11kV Modem LAN-Interface LA36W to LV SCMS NSK GPS Master Redundant Station LAN TCP-IP Front-End Station Front-End Station Computer 1 Computer 2 RS232 Manual Switch 4 x Star Coupler RER111 including redundant power supply FO Fibre optic station bus (LON) in star configuration Main 2 Main 1 ystem S o/e Siemens 7SD610 für Advanced E19 Verbindung SACO64D4 Auxiliary alarm unit Automation SAS570 B69 SACO64D4 Auxiliary alarm unit ubstation Überstrom Pilot wire diff. prot. SOLKOR R/Rf. S

15. Centralized Control Architecture (classical) Central Computer (Mainframe) Group Group Group PLCs Control Control Control Sensors, Actors plant Classical, hierarchical, centralized architecture. The central computer only monitors and forwards commands to the PLCs

16. Decentralized Control System (DCS) peer-to-peer (horizontal communication) hierarchical (vertical communication) engineering workstation operator workstation data logger plant bus controller controller controller controller field bus plant 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.

17. Hierarchies are simple and traditional

18. but Distributed Control Systems reflects a more complex world....

19. 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 ?)