Scribd
Upload
95 views

AI 140 Hierarchy

The document describes the hierarchy of industrial automation systems. There are several levels from the enterprise level down to the field level. Higher levels have slower response times but handle more complex functions like planning. Lower levels have faster response times but less complex functions like individual device control. SCADA systems sit between the higher supervision levels and lower control levels, providing data visualization, alarms, and logging. Group controls coordinate multiple individual unit controls. Manufacturing execution systems manage production scheduling and workflow across levels. The process database stores current plant data and feeds interfaces, logging, and simulations.

Uploaded by

Shaukat Ali Shah
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
95 views

AI 140 Hierarchy

The document describes the hierarchy of industrial automation systems. There are several levels from the enterprise level down to the field level. Higher levels have slower response times but handle more complex functions like planning. Lower levels have faster response times but less complex functions like individual device control. SCADA systems sit between the higher supervision levels and lower control levels, providing data visualization, alarms, and logging. Group controls coordinate multiple individual unit controls. Manufacturing execution systems manage production scheduling and workflow across levels. The process database stores current plant data and feeds interfaces, logging, and simulations.

Uploaded by

Shaukat Ali Shah
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
You are on page 1/ 25

Industrial Automation

Automation Industrielle
Industrielle Automation
Enterprise
Manufacturing Execution
Supervision (SCADA)
Group Control
Individual Control
Field
Primary technology

1.4

Automation Hierarchy
Hirarchie de l'automation
Leitsystem-Hierarchie
Prof. Dr. H. Kirrmann

EPFL / ABB Research Center, Baden, Switzerland


2011 February, HK

1.4 Contents

1 Introduction
1.1

Automation and its importance

1.2

Examples of automated processes

1.3

Types of plants and controls


1.3.1

Open loop and closed loop control

1.3.2

Continuous processes

1.3.3

Discrete processes

1.3.3

Mixed plants

1.4

Automation hierarchy

1.5

Control system architecture

Industrial Automation

1.4 Automation hierarchy

Automation System Structure


Although applications differ widely, there is little difference in the
overall architecture of their control systems.
Why the control system of a power plant is not sold also for automating a brewery
depends largely on small differences (e.g. explosion-proof devices), on regulations
(e.g. Food and Drug Administration) and also tradition, customer relationship.
But the biggest difference is the amount of application know-how embedded in the
control system.

Industrial Automation

1.4 Automation hierarchy

Large control system hierarchy (1)


5

Planning, Statistics, Finances

Production planning, orders, purchase

Workflow, order tracking, resources

Supervisory

administration
enterprise
(manufacturing) execution

SCADA =
Supervisory Control
And Data Acquisition

Group control
Unit control
1
Field
Sensors
& actors
0

A V

Primary technology
Industrial Automation

1.4 Automation hierarchy

Administration
Enterprise
Manufacturing
Supervision
Group (Area)

Unit (Cell)

Field

Large control system hierarchy (2)


Finances, human resources, documentation, long-term planning
Set production goals, plans enterprise and resources, coordinate
different sites, manage orders
Manages execution, resources, workflow, quality supervision,
production scheduling, maintenance.
Supervise the production and site, optimize, execute operations
visualize plants, store process data, log operations, history (open loop)
Controls a well-defined part of the plant
(closed loop, except for intervention of an operator)

Coordinate individual subgroups

Adjust set-points and parameters

Command several units as a whole


Control (regulation, monitoring and protection) 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


.
data acquisition (Sensors & Actors*), data transmission
no processing except measurement correction and built-in protection.
(*capteurs et moteurs, Messfhler & Stellglieder)

Industrial Automation

1.4 Automation hierarchy

Field level

the field level is in direct


interaction with the plant's hardware
(Primary technology, Primrtechnik)

Industrial Automation

1.4 Automation hierarchy

Group level
unit controllers

the group level coordinates the


activities of several unit controls

the group control is often hierarchical, can be


also be peer-to-peer (from group control to
group control = distributed control system)
Note: "Distributed Control Systems" (DCS)
commonly refers to a hardware and software
infrastructure to perform Process Automation

Industrial Automation

1.4 Automation hierarchy

Local human interface at group level


sometimes,
the group level has its own
man-machine interface for
local operation control
(here: cement packaging)

also for maintenance:


console / emergency panel

Industrial Automation

1.4 Automation hierarchy

Supervisory level: Man-machine interface

control room
(mimic wall)
1970s...

formerly, all instruments were directly wired to the control room

Industrial Automation

1.4 Automation hierarchy

Mosaic is still in use with direct wiring

Industrial Automation

10

1.4 Automation hierarchy

Supervisory level: SCADA


(SCADA = Supervisory Control and Data Acquisition)

- displays the current state of the process (visualization)


- display the alarms and events (alarm log, logbook)
- display the trends (historians) and analyse them
- display handbooks, data sheets, inventory, expert system (documentation)
- allows communication and data synchronization with other centres
Industrial Automation

11

1.4 Automation hierarchy

Todays control rooms

beamers replaces the mosaics, there is no more direct wiring to the plant.

Industrial Automation

12

1.4 Automation hierarchy

Plant management

- store the plant and product data for further processing in a secure way
(historian), allowing to track processes and trace products
-> Plant Information Management System (PIMS)

- make predictions on the future behaviour of the processes and in particular


about the maintenance of the equipment, track KPI (key performance indicators)
-> Asset Optimisation (AO)

Industrial Automation

13

1.4 Automation hierarchy

Engineering workplace

The engineering workplace manages the control system, not the plant.
The engineer can configure the networks and devices, load the software, assign
authorizations, troubleshoot the control system,...

Industrial Automation

14

1.4 Automation hierarchy

ANSI/ISA 95 standard classification


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, Reliability Assurance,...

Levels
2,1,0

Batch
Control

Continuous
Control

Discrete
Control

Enterprise Resource Planning

Manufacturing Execution System

Control & Command System

Source: ANSI/ISA95.00.012000

Industrial Automation

15

1.4 Automation hierarchy

Example: Power plant

Industrial Automation

16

1.4 Automation hierarchy

Example of generic control siemens: Siemens WinCC (Generic)

Unternehmensleitebene
Enterprise level

Betriebsleitebene
Production level

Prozessleitebene
Process level

Industrial Automation

17

1.4 Automation hierarchy

Response time and hierarchical level


ERP

Planning
Level

(Enterprise Resource
Planning)

MES

Execution
Level

(Manufacturing
Execution System)

SCADA

(Supervisory Control
and Data Acquisition)

Supervisory
Level

DCS

(Distributed
Control System)

Control
Level

PLC
(Programmable
Logic Controller)

ms

seconds

Industrial Automation

hours

days
18

weeks

month

years

1.4 Automation hierarchy

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.
Industrial Automation

19

1.4 Automation hierarchy

Complexity and Hierarchical level

Complexity

Reaction Speed
months

ERP

Command level
Fhrungsebene,

MES

Sys. d'excution
Ausfhrungssystem

Supervision
tage de conduite

Prozessleitung
Conduite de processus

Group Control

Gruppenleitung
Conduite de groupe

Individual Control
Einzelleitung,

days

minutes

seconds

0.1s

Conduite individuelle

Field
Feld,

0.1s

terrain

Site
Anlage,

Industrial Automation

usine

20

1.4 Automation hierarchy

Operation and Process Data base


Consideration of human intervention breaches this hierarchy.
Normally, the operator is only concerned by the supervisory level,
but exceptionally, operators (and engineers) want to access data of the lowest levels.
The operator sees the plant through a fast data base, refreshed in background.
This database is the pivot for logging and simulation.
knowledge base

man-machine
communication
operator

history

logging

process
data base

simulation
instructor

maintenance
engineer

actualization
process data
plant

Industrial Automation

21

1.4 Automation hierarchy

The process database is at the centre (example: Wonderware)

Industrial Automation

22

1.4 Automation hierarchy

Process Data Base and Historical Data Base

The Process Data Base reflects the latest known state of the plant
The Historical Data Base registers the events that happened in the plant
(and is therefore a subset of the Process Data Base snapshot)

Industrial Automation

23

1.4 Automation hierarchy

Assessment
Describe the levels of a hierarchical control system
What is the relationship between hierarchical level, the response time, data quantity and complexity ?
What does SCADA stands for ?
What is a group control used for ?
What is the role of a Manufacturing Execution System ?
What are the three functions of the operator interface ?
What is Enterprise Resource Planning ?
What is the role of the process database ?

Industrial Automation

24

1.4 Automation hierarchy

You might also like