Industrial Automation

Automation Industrielle
Industrielle Automation

Control System Architecture

1.5 Architecture de Contrôle - Commande
Leittechnik-Architektur

Prof. Dr. H. Kirrmann

ABB Research Center, Baden, Switzerland
2010 March, HK
 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

Industrial Automation 2 1.5 Control System Architecture

 Principle

The control system is a communication system consisting of controllers and links.

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.

Industrial Automation 3 1.5 Control System Architecture

 Example: Power plant control - 1980 (!)

Control systems look similar

Industrial Automation 4 1.5 Control System Architecture

 Busses and processors in industrial plants
instrument bus
(mimic board)
open network, WAN
Operator panel
disk Mimic board
Process pictures

Process Data Base workstation bus

Logging station station

plant network (500m .. 3 km) – includes control network

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 sensor bus (0,5.. 30 m)

transducers

M plant (Werk, usine)

valve thermo-couple position motor

Industrial Automation 5 1.5 Control System Architecture

 Example: Printing Architecture

Each level has its bus !

Industrial Automation 6 1.5 Control System Architecture

 Example: Production management system

production
planning
enterprise network

scheduling maintenance quality control

plant network

transportation cell manufacturing

cell control cell control

floor network
robot milling
controller machine

rail-guided
vehicle

Industrial Automation 7 1.5 Control System Architecture

 Example: Honeywell TotalPlant (2003 same structure)

Industrial Automation 8 1.5 Control System Architecture

 Example: Siemens

Industrial Automation 9 1.5 Control System Architecture

 Example: Rockwell (Allen-Bradley) NetLinx

Programmable Desktop PC
Device with excel
Support PC

EtherNet / IP

Controller and Bridge

Servo
ControlNet HMI

Linking Device Bridge or Linking Device

Drive

HMI

DeviceNet

Modular
I/O 509 -BOD

Micro
Sensor
24vdc

PLC
Block I/O

Industrial Automation 10 1.5 Control System Architecture

 Example: Emerson's PlantWeb (Delta V)

Industrial Automation 11 1.5 Control System Architecture

 Example: ABB Industrial IT (redundant system)

Plant Network / Intranet Workplaces Enterprise

(clients) Optimization
(clients) 3rd party
application
Firewall Mobile
server
Operator

Plant Network (Ethernet)

connectivity aspect application engineering
server server server workplace

Control Network (Ethernet)

Programmable
Serial or Logic Controller
fieldbus AC 800C touch-screen
Redundant
AC 800M
Field Bus Field Bus
3rd party
controllers,
servers etc sensor network

Industrial Automation 12 1.5 Control System Architecture

 The internet dimension (example: Alstom)

Industrial Automation 13 1.5 Control System Architecture

 The wireless dimension (example: Schneider)

No more wires, but the structure remains

Industrial Automation 14 1.5 Control System Architecture

 A real substation project
HP Color Operator's Workstation 1 Engineering Workstation Global Position to Disturbance Recorder
Printer Server 1
Operato r's Workstatio n 2

Laserjet System Central Station Evalution Station

PTUSK Scope

132kV FOX
Alarm and Equipment
Event Printer 1 11kV analog
Ether132kV analog Telephon
LA36W Printer Server 2 Input net Input Modem

Verbindung zu E4

Alarm and
Event Printer 2
o/e
LAN-Interface 11kV Modem
132kV Modem
LA36W to LV SCMS
Repeater NSK NSK GPS
Master
Redundant Station LAN TCP-IP Repeater

Front-End Station Front-End Station

Computer 1 Computer 2
HP Co lor

Fallback Laserjet
RS232
Switch

Service
Modem Station Alarm Unit Station Alarm Unit
LDCs Interface from Station Computer
IEC870-5-101
2

LDCs Interface from Station Computer

IEC870-5-101
1
Manual
Switch

4 x Star Coupler
RER111 including
redundant
power supply
FO

Fibre optic station bus (LON) in star configuration

Control Protection AVR and tap control

T1 type REGSys Fault Monitoring System
Bay control unit Bay control unit 3Ph and neutral OC Bay control unit Differential protection Bay control unit BBP/BFP Central unit
Analog alarm unit Indactic I650 10 x 132kV
REC316*4 Main 2 REC316*4 SPAJ140C REC316*4 RET316*4 SPAJ110CTertiary REC316*4 REB500
SACO16A3
Earth fault
Prot.

AVR and tap control

T2 type REGSys Analog alarm unit
EF and OC
SACO16A3
Line distance prot. SPAJ110C
REL316*4 500RIO11 , 16DI
SACO16A3 R
SPAJ110C
Stand by
SPAJ110CNeutral
6 x 500RIO11 DI 4 x 11kV
earth fault
overcurrent earth fault
Prot. Prot.
Main 1 10 x BBP/BFP Bay unit
AVR and tap control REB500
SACO64D4
Auxiliary alarm unit
SACO16A3 R SACO16A3 R T3 type REGSys
Phase and
SPAJ140Cneutral Restricted
SPAJ115C
SPAU140C

ystem
overcurrent earth fault
Synchro-
Prot. Protection
SACO64D4
Auxiliary alarm unit
check

Advanced
Automation
o/e

S
AVR and tap control
Siemens 7SD610 für T4 type REGSys
E19 Verbindung SPAJ1 10C Earth fault SPAJ115C SACO64D4
Auxiliary alarm unit
overcurrent Restricted
1 x 500RIO11 DO

SAS570
Prot. earth fault
Protection 1 x spare

ubstation
B69 SACO64D4
Auxiliary alarm unit
Überstrom 132kV Side 11kV Side

Bay control unit

Pilot wire diff. prot. Bay control unit Coaxial cable

(loose delivery) SOLKOR R/Rf. (loose delivery) (loose delivery) (loose delivery) (loose delivery)

S
4 x 132kV Cable Line 1 x 132kV Bus Coupler 4 x 132/11kV Transformer Feeder Trafo Interlocking AVR & Tap Control 132kV BBP / BFP 132kV Common Alarm FMS Fault Monitoring System

Industrial Automation 15 1.5 Control System Architecture

 Centralized (Hierarchical) Control Architecture

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

Industrial Automation 16 1.5 Control System Architecture

 Decentralized Control System (DCS)
hierarchical
(vertical
communication)

engineering operator
data logger
workstation workstation

peer-to-peer (horizontal
communication)
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.

Industrial Automation 17 1.5 Control System Architecture

 Plant with process (e.g. chemical) and electrical (substation) parts
vertical
communication
plant Workplaces
Engineering
network

IEC 61850
CN Connectivity connectivity server
Server (and router)
Aspect Servers

ProcessNetwork substation network

horizontal communication horizontal communication

interfac
controlle
CI871 e
r

PB
PI SAN IEDs
PN
PI PI
LANs are
PB
PI PN
PI separate:
PI
there is no
PB
PI Engineering PN
PI IP routing PI PI = Process Interface
between MU = Merging Unit
PB
PI PN
PI MU
PI
Engineering them
PB
PI PN
PI MU
PI
Profibus Profinet RSTP bay bus

Industrial Automation 18 1.5 Control System Architecture

 Hierarchies are
simple and traditional

Industrial Automation 19 1.5 Control System Architecture

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

Industrial Automation 20 1.5 Control System Architecture

 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 ?)

Industrial Automation 21 1.5 Control System Architecture