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The Mystery of PACs January 25, 2011 Samuel M. Herb, PE owner ISA—International Society of Automation • The confusion over PAC Monster………. • The Acronym Monster….. • The Configuration Monster……………… • The Network Monster…. • The Fieldbus Monster………………………. What System to Select? PAC? What’s That? Build me a wonderful control room… …all on a tight budget! What are the Issues? ? ! ? No Project is Simple Real Goal for Plant Control System PRODUCTIVITY!!! ! Buying Decision Factors for Process Products 4%-Delivery 11%-Operational Safety 32%-Operational Efficiency 13%-Spares Availability 18%-Price 22%-Ease of Maintenance Control System Issues • Problems of open standards • Impact of fieldbuses • Configuration made easy • Significance to batching functions • Inclusion of safety systems • Challenge of advanced control methods • Wireless capabilities with security • Complexity of cyber security • Confusion of system names • Tie-in with plant business systems • Coordinate with other plants Process vs. Discrete Industries Process Discrete Products Fluids Devices, objects Operations Continuous, Batch Job Shop, Batch, Repetitive Product Design Done in Labs Done with CAD/CAE Equipment Uses Processes Uses Machines Equipment Cost Very High\ Medium to High Labor Cost Low High Sensors Numerous Analog & Discrete Mostly Discrete Control Products DCSs, PLCs, SLCs, PCs PLCs, CNCs, Robotics, PCs Supervisory Process Optimization. Cell Control, Scheduling Control Scheduling Business Mgmt. In-house, MRP II, MES, ERP MRP II, MES, ERP Implementation Bottom up Top Down All Process Control is an ART ! The key in process control is REPEATABILITY! Poor Accuracy; Poor Precision No Repeatability Poor Accuracy; Good Precision Repeatability, but no accuracy Good Accuracy; Good Precision Repeatability with accuracy …But control rooms were nearly all manual! What is going on here? Feedback Control! Evolution: These Were Distributed Touring the plant Pneumatic transmission Electronic miniaturization DDC -- Direct Digital Control Computer Process Analog Computer Back-up Tracking • Advantages: • Disadvantages: – Sophisticated control – Computer reliability – Flexible control – Redundant computer or – Data acquisition & alarm controllers – Wiring complex & extensive – HMI required high level operators – Expensive DDAC -- Supervisory Control Analog Computer Process Panel • Advantages: • Disadvantages: – High reliability – Complex wiring & – Human-machine interface installation adequate – Difficult to make strategy – Data acquisition & alarms changes – Sophisticated control – Expensive – Complete redundancy From Central to Distributed Control • Central CENTRAL CONTROL ROOM – Many wires – Programmed COMPUTER – Vulnerable CONTROLLER DATA CONTROLLER HIWAY CONTROLLER Distributed Data highway Configured CONTROLLER Less risk CENTRAL CONTROL ROOM Functional UNIT CONTROL ROOM Physical Control System Comparisons ANALOG DIGITAL PROCESS PROCESS (Dedicated) (Centralized) • System organization Familiar Unfamiliar • Operator interface Rigid Flexible • Risk of failure Distributed Central • Diagnostics Limited Extensive • Sophisticated control Complicated Program • Record keeping Awkward Built-in • Plant computer interface Difficult Inherent • Ability to change Complex Reprogram Control System Comparisons ANALOG DIGITAL DCS PROCESS PROCESS PROCESS (Dedicated) (Centralized) (Distributed) • System organization Familiar -------- <— same • Operator interface --------- Flexible <— same • Risk of failure Distributed -------- <— same • Diagnostics -------- Extensive <— same • Sophisticated control Objects -------- -------- Config • Record keeping -------- Built-in <— same • Plant computer interface -------- Inherent <— same • Ability to change -------- -------- Modular Traditional DCS - PLC - Computers: & Warning! Generalizations Here! Typical Strengths Typical Weaknesses DCS Distributed Risk Entry Level Cost Real-Time Throughput Proprietary Network Advanced Control Strategy Proprietary Operator Station PID (3-mode control) Complex Interlocks Operator Interface Control Room Environment Low Integration Cost PLC Environmental Human Interface Uptime Integration Cost Sequencing Rapid Repetition of Actions Reporting Complex Interlocks Application Software Logic Steps Easy to Do Recipe Handling Central Data Acquisition Programmed Advanced Control Strategy Environmental Limits Computer Database Storage Costly Redundancy History & Trending Real-Time Throughput Networking Traditional Scan Time Considerations Warning! Generalizations Here! Scan Time Typical Function Likely System 1 Month . Corporate Update of Plant Computer . Operations Summary 1 Day, Shift . Production Report 1 Hour . Off-line Optimization . Batch Management DCS . Batch Scheduling 1 Minute . Unit Process Optimization DCS 1 Second . Display Update . Analog Control . Process Calculations . Batch Sequencing 100 mSec . Flow Control 20 mSec . High Speed Sequencing PLC . Interlocks 1 mSec . Sequence of Events DCS vs. PLCs with PCs as a System Typical PLC System Configuration: Some Proprietary Network that passes as de facto Physical & PC Communication Standard as HMI PLC PLC PLC PLC Each Individually Configured Must configure to communicate with each PLC, to link views, etc. Typical DCS System Configuration: PC as ―Add-on‖ Proprietary Network, often based upon a HMI configured Workstation Physical Standard separately as HMI Controller Controller Controller Controller Single database configured for all stations Traditional PLC Vendor Supply Model End User Buys from: …AND …Indirectly From Suppliers: Component Implementer Provider Manufacturer(s) OEM Distributors Software System Value Added Drive Integrator Resellers PLC Engineering Manufacturers Motion Contractor Representatives Sensor HMI Manufacturer Traditional DCS Vendor Supply Model End User Buys from: …OR …Directly From Supplier: Capabilities DCS Manufacturer System System design Integrator IT integration Services Process Project Management Engineering optimization Engineering Contractor Performance Field services guarantees Technical call Platform in Consulting Software Single Source Control Supply I/O Global support DCS - PLC - PC/PLC Report Card Warning! Generalizations Here! DCS PLC PC/PLC Control Capabilities: Process I/O A A A Multivariable Regulatory Control A C C Complex Interlocking C A A Sequencing B D C Recipe Handling A D B Batch Process Control B D C User Interface: Ease of Configuration (links & displays) A C D Ease of Operator Use A D B Ease of Creating Custom Displays A C B Cost: Hardware C A B Installation A C D Application Programming A B C Additional Considerations: Ease of Expansion (interactive functions) A D D Flexibility A D C Redundancy A C C Reliability B A C Hardware Maintainability B A B Software Maintainability B C D Then What is Hybrid? Depends upon who you ask… • Defined by Industry (ARC Research) • Defined by Input & Output Capability – Analog + Discrete I/O • Defined by Function (Batch Capability) • Defined by Architecture – Advantages of both PLCs & DCSs – Few disadvantages of either Automation Architecture Migration Process Hybrid Discrete Industries Industries Industries ABB Emerson Mitsubishi Omron Honeywell Petrochemical Pharmaceutical Automotive Invensys Refining Fine Chemical Aerospace Rockwell Power Food & Beverage Machining Schneider Siemens Pulp & Paper Consumer Yokogawa Packaged Goods Siemens Rockwell GE?? GE?? From ARC Advisory Group Strategies – June, 2001 Hybrid Architecture Emerging System Configuration: Choice of Open Network Flexibility Workstation or Proprietary Network Security as HMI Control Control Control Control User Choice; Single distributed control strategy: Uploads control • Single configuration database for: • Created on any PC away from system • Screen Views • Use any PC as a simulator • Trends • History BUT… Suppliers bundle THEIR PC now… • etc. soooo… ARC Group calls this “PAC” – Process Automation Control PC-based vendors call it Programmable Automation Control Now PLC vendors use this definition too! Emergence of PC as a Controller • Robustness still a serious concern – “Industrial strength” for processes is far more severe than factory floor where some replace PLCs – Corrosive atmosphere & vibration significant • Potential to “liberate” end user from being proprietary hostage • All serious vendors already growing into selling software rather than hardware • Not likely to make control “shrink-wrapped” • Standards still an obstacle System Size Considerations Warning! Generalizations Here! Over Large DCS Large DCS 150 Large with with DCS Medium PLCs Large PLCs Loops of 30 Small DCS Small DCS Modulating to Small with with Control 150 DCS Medium PLCs Large PLCs Small PLC Medium PLC Large PLCs Under w/PC with PC with 30 or or Integrated PC & SLCs with SLCs Workstation LoopPAC Under 200 200 to 600 Over 600 Strategies? Systems Channels of Discrete I/O Hybrid = PAC – Process Automation Control? ARC Advisory Group’s definition says • PAC consists of multi-domain functionality, including logic, motion, drives, and process on a single platform. Attributes: • Single, multi-discipline development platform incorporating common tagging and a single database • Software tools that allow the design by process to flow across several machines or process units • Open, modular architectures that mirror industry applications from machine layouts in factories to unit operations in process plants • De facto standards for network interfaces, languages, and the like, allowing data exchange as part of