Industrial Automation

Automation Overview 1.1 Automation

 UTS

: 15% UAS : 15% TUGAS BESAR : 70%

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PEMANASAN 1
Apa manfaat calon Industrial Engineer mengetahui

Otomasi? Hal apa saja yang ingin kalian capai setelah mengikuti kuliah Otomasi?

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Definition
Automation (automation, Automation):

1)
2)

set of all measures aiming at replacing human work through machines

(e.g. automation is applied science)

the technology used for this purpose

(e.g. this company has an automation department)

Automation (automatisation, Automatisierung) 1) 2) replacement of human work through machines

(e.g. the automatisation of the textile factory caused uproar of the workers)

replacement of conscious activity by reflexes

(e.g. drill of the sailors allows the automatisation of ship handling)

automation and automatisation are often confounded, in english, it is the same word.

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Automation
Living organism brain Industrial system historian, expert optimizers, manufacturing execution system data networks controllers field busses sensors and actors motors, pneumatic movers primary equipment (vessels, turbines) buildings and sites

spinal chord ganglions (reflexes) axons neurons muscles organs skeleton

Automation = the neural system

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Automation as a hierarchy of services

5 4 3 2 Planning, Statistics, Finances Production planning, orders, purchase Workflow, order tracking, resources Supervisory
SCADA = Supervisory Control And Data Acquisition

administration enterprise (manufacturing) execution

Group control Unit control 1 Field Sensors & actors 0 Primary technology
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A V

Automation as a computer network

WWW DB, Historians, Optimizers, MES Operator Workplaces

Plant Network OPC Server Control Network Controller IEC 61850 station bus OPC Server OPC Server

Fieldbus
HART mux

Protection & Control

Instruments

Process Instrumentation LV Electrification Power generation

Substation Automation

Power Management

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Contents
1 Introduction 1.1 Automation and its importance

1.2
1.3

Examples of automated processes

Types of plants and controls 1.3.1 1.3.2 1.3.3 1.3.3 Open loop and closed loop control Continuous processes Discrete processes Mixed processes

1.4

Automation hierarchy

1.5

Control System Architecture

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Automation Applications
Power generation
Transmission Distribution Process

hydro, coal, gas, oil, shale, nuclear, wind, solar

electricity, gas, oil electricity, water paper, food, pharmaceutical, metal production and processing, glass, cement, chemical, refinery, oil & gas computer aided manufacturing (CIM) flexible fabrication, appliances, automotive, aircrafts silos, elevator, harbor, retail houses, deposits, luggage handling heat, ventilation, air conditioning (HVAC) access control, fire, energy supply, tunnels, parking lots, highways,.... rolling stock, street cars, sub-urban trains, busses, trolley busses, cars, ships, airplanes, rockets, satellites,...

Manufacturing Storage Building

Transportation

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Company (alpha. order) Location Major mergers ABB Alstom Ansaldo Emerson General Electric Hitachi Honeywell Rockwell Automation Schneider Electric Invensys Siemens Yokogawa CH-SE FR IT US US JP US US FR UK DE JP

Automation Systems - World Players

Brown Boveri, ASEA, CE, Alfa-Laval, Elsag-Bailey Alsthom, GEC, CEGELEC, ABB Power,.. Fisher Rosemount

Allen Bradley, Rockwell,.. Tlmcanique, Square-D, ... Foxboro, Siebe, BTR, Triconex, Plessey, Landis & Gyr, Stfa, Cerberus,..

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

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Terms
plant: the object of automation F: site, usine, centrale (lectricit) D: Prozess, Werk, Fabrik, Kraftwerk E: planta, fabrica, instalacin

general contractor: organizes the suppliers of the different components. turnkey factory: the client only hires consultants to supervise the contractor increasingly, the general contractor has to pay itself by operating the plant. increasingly, the suppliers are paid on results.

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Four distinct businesses

primary technology (mechanical, electrical)

automation equipment (control & command)

engineering & commissioning

maintenance & disposal

seldom offered by the same company

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Life-phases of a Plant (Example: Rail Vehicle)

Manufacturers

Equipment Design
(dveloppement, Entwicklung)

control

air conditioning

brakes

Equipment Production
(production, Herstellung) Assembler (ensemblier)
car body design by assembler

Engineering
(bureau dtude, Projektierung)

Sleeping Wagon XL5000 Plus

Commissioning (mise en service, Inbetriebnahme)

Client, Service

Start on service
brakes

Maintenance
(entretien, Unterhalt)
brakes

replacement

Out of service Recycling (Recyclage, Wiederverwertung)

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Technical necessity of automation

Processing of the information flow Enforcement of safety and availability Reduction of personal costs

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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 (SAP) -> Acquisition of large number of Process Variables, data mining Personal costs reduction Simplify interface Assist decision Require data processing, displays, data base, expert systems -> Human-Machine Interface (MMC = Man-Machine Communication)

Asset Optimisation (gestion des moyens de production) Automation of engineering, commissioning and maintenance Software configuration, back-up and versioning Life-cycle control Maintenance support -> Engineering Tools
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Power Plant 30 years ago 100 measurement and action variables (called "points") Analog controllers, analog instruments one central "process controller" for data monitoring and protocol. Coal-fired power plant today 10'000 points, comprising 8'000 binary and analog measurement points and 2'000 actuation point 1'000 micro-controllers and logic controllers Nuclear Power Plant three times more points than in conventional power plants Electricity distribution network 100000 - 10000000 points information flow to the personal: > 5 kbit/s. human processing capacity: about 25 bit/s without computers, 200 engineers (today: 3) Data reduction and processing is necessary to operate plants

Data quantity in plants

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Worldwide Consolidation Process: the Big Eight

Hartmann & Braun Fisher & Porter Combustion Engineering Alfa-Laval Automation August Systems Elsag Bailey Cellier Engineering PC&E L&N CSI Measurex Westinghouse PCD Kenonics Interplant Consulting Eurotherm Modicon PACSIM Square D Wonderware Allen-Bradley Axiva Milltronics Fisher Rosemountl Control Techniques Intellution SACDA Foxboro Triconex Profimatics AVANTIS P&F Safety Systems APV Dodge
Tlmcanique

Rockwell Software

Schneider

Turbi-Werke

Vickers

Moore

SimSci-Esscor
Esscor Baan ORSI Reliance Merlin Grin Compex Walsh Automation Invensys
ArchestA

MDC Saab Marine Electronics Emerson

Delta V, Plantweb

Allied Signal

Skyva

GE Fanuc

POMS

ABB umbrella IndustrialIT architecture

GE Industrial
Cimplicity

Honeywell
Experion PKS, TotalPlant

Rockwell Automation
RSview

Schneider Electric
Transparent Factory

Siemens
"Totally Integrated Automation"

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