Automation Examples 1.2Exemples de sites automatis

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Automation Examples1.2 Exemples de sites
automatisés Beispiele Automatisierungssysteme
Industrial Automation Automation
IndustrielleIndustrielle Automation
Prof. Dr. H. Kirrmann
EPFL / ABB Research Center, Baden, Switzerland
2008 March HK
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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
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Cars
traditional appliances control (windows, seats,
radio,..) motor control (exhaust
regulations) critical new applications ABS
(anti-skip) and EPS (stability), 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.
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Rail vehicles
there are more than 20 interconnected computers
on a locomotive
vehicle control unit
radio link
display unit
VCU
VCU
DU
DU
TCU
TCU
SBB 460
brakes
signaling
traction control unit
diagnostics
energy
Benefits reduce operation costs, faster
diagnostics, better energy management, automatic
train control.
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Airplanes
avionics flight control (safe flight envelope,
autopilot, engineer) flight management flight
recording (black boxes, turbine
supervision) diagnostics fly-by-wire
high reliability
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Launch vehicles
Control
Panels
GPC 5
GPC 4
GPC 3
GPC 2
GPC 1
CPU 1
CPU 2
CPU 3
CPU 4
CPU 5
IOP 3
IOP 5
IOP 4
IOP 2
IOP 1
Intercomputer (5)
Mass memory (2)
serial data
Display system (4)
buses
Payload operation (2)
( 23 shared,
Launch function (2)
5 dedicated )
Flight instrument (51 dedicated per GPC)
Flight - critical sensor and control (8)
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Robots
extension limited to 2-3 m (portal robots
10-20m) frequent reprogramming for new tasks,
tooling simple embedded computer, hierarchical
control
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Substations
protection (Lines, transformers, generators) very
high speed response control (remote or local) to
guarantee power flow, safe operation
(interlocking) measurement (local and remote),
electricity bill, power flow in grid
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Pharmaceutical Industry
Inventory Recipe management Packaging Sampling Tra
cking tracing Comply with government rules
Typical of batch processes.
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Manufacturing
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Flexible Automation
numerous conveyors, robots,
CNC machines, paint shops,
logistics. Download from production management,
connection to administration
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Warehouses
extreme dependency on the availability of the
control system Connection to supply chain
management, order fulfilment customer
relationship and commercial accounting (SAP)
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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.
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Oil Gas, petrochemicals
"upstream" from the earth to the
refinery down-sea control
special requirement high pressure, saltwater,
inaccessibility explosive environment with gas.
distribution
special requirement environmental protection
"downstream" from the oil to derived products
special requirement extreme explosive environment
Switzerland Colombey, Cressier
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Chemical industry
logistics, local control of reactors
e.g. LONZA
Characterized by batches of products, reuse of
production reactors for different product types
(after cleaning).
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Process Industry
Process Industry industries de transformation,
Verfahrenstechnik (one of the many meanings of
process)
Cement
Metals and Minerals Glass production Chemical .
Continuous flow of materials, often 24 hours a day
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Steel mills
particularity synchronization of the motors in
the rolling mill
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Cement Works
The rotating oven is the heart of the
cement process the grinded kiln is burnt and
comes out as chunks later reduced to powder.
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, )
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Mining
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Building Automation
basics fire, intrusion, climate, energy
management HVAC Heat, Ventilation and Cooling
air conditioning
visitors, meeting rooms, catering,. low price tag
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Automation of Building Groups
EPFL
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Airports
large building automation system fire, security
access, energy, lighting, air
conditioning, communications, traffic control
luggage control in Zurich-Airport
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Traffic control
fire intrusion energy water ventilation pollution
monitoring cameras light control traffic jams
prevention,....
(Tunnel Letten near Zurich)
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Harbours
from ship planning to crane manipulation and
stock control
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Water treatment
(fresh and waste water) manage pumps, tanks,
chemical composition, filters, movers,
quality... auxiliaries methane electricity
generation
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Power plants
Hydro - river - dams - storage dams Thermo -
coal - gas - atom - solar -
waste Alternative - wind - photo-voltaic
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
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Waste treatment, incinerators
raw material supply burning process smoke
cleaning environmental control co-generation
process (steam, heat) ash analysis ash disposal
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Power transmission network
InternationalControl Center
Substation
SS
(
Unterstation
, sous-station)
National
Control Center
SS
Regional
Control Center
Regional Control Center
SS
PP
SS
Power PlantCentrale, Kraftwerk
PP
switchyard,postes HT Schaltfeld
PP
SY
SS
PP
SY
Substation
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.

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Swiss electricity interconnection network
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Pipelines
particularities long-range communication system,
safety, explosive environment
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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 ?
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