Introduction to Process
Control & Automation
University of Nottingham – Andrew Mieleniewski
Industrial Food
Manufacture –
Process Control &
Automation
- Agenda
1. Introductions
2. Introduction to batch
process control
3. Control system hardware
(overview only)
4. System software
terminology and concepts
Why Automate?
University of Nottingham – Andrew Mieleniewski
Introduction
Automation is complex, expensive, and can be full
of jargon and acronyms!
So why do we do it?
Three key points:
Improvements in quality (improved repeatability
and increased precision)
Reduction in human intervention (redeploy
personnel or allow more to be done for similar
manual input).
Because the underlying technology requires it
(speed of response or complexity difficult for a
human to provide).
Example – Storage Tank Farm Valve Matrix
Example – Storage Tank Farm Valve Matrix
Matrix Valve Actuator
Control Top
Digital control signals
Open feedback signal Actuator
Closed feedback signal
Air-to-open
Energise signal Spring-to-close
Solenoid Valve
(small electrically
operated valve)
Compressed Air
Open Closed
Position Position
System Hardware
► PLC (Programmable Logic Controllers)
► HMI (Human Machine Interface)
University of Nottingham – Andrew Mieleniewski
PLC Based Control System
HMI
SCADA Terminal Food & Drink Automation
Program
Panel Mainly batch sequence processing
Terminal
Other PLCs Using Programmable Logic Controllers (PLC)
Modular Rack/chassis
ERP Power Supply Unit (PSU)
MES System
Central Processing Unit (CPU)
System
Networks Network Modules (Ethernet)
Terminals and other systems
Fieldbus (smart instruments)
PLC Digital Input/Output (I/O)
Analogue I/O
PSU CPU Net Net I/O I/O I/O I/O I/O I/O 4-20mA loops
Control Remote I/O HART (Highway Addressable Remote
Digital I/O Analogue I/O
Panel Transducers) Instruments – additional digital
A/C information
3-phase Air
Motor
Remote I/O
4-20mA
Starter
Pneumatic valve Field Item Interface
Valve actuators
HART Signal Motor Starters
Control Panels
Plant Flow
Fieldbus Auto Control Analogue
Pump/Motor
Sensors Valve Valve Sensor
PLC Hardware
PLC are industrialised PLCs are proprietary closed architecture systems
Rugged & reliable Parts and software from one manufacturer cannot
be used with parts of another
Handle high temperatures, humidity,
& electrical noise Once you have made your initial choice you will be
locked into your suppliers range for future
mean-times-between-failures are two upgrades and expansions
orders of magnitude higher than that
of a PC The two big vendors are Siemens and Rockwell
Siemens – S7 PLC Rockwell Allen Bradley – Controllogix PLC
Cable Management
Control Panels
Valves & Instrumentation
HMI - Glen Ord Distillery Control Room
HMI (Human Machine Interface)
1 2 3 4
System Software
► Ladder Logic
► System Size
► Control Loops
► Software Development
► State of the Art Systems
University of Nottingham – Andrew Mieleniewski
Software – Ladder Logic I:2/2 O:3/11 Ladder
Logic
|⎯][⎯⎯⎯( )⎯|
(Program)
I:2/2 O:3/11 Processor
Input Output Memory
Image Image
PLC Software – Ladder logic Table Table
Ladder logic
PLC
Replicates relay logic
Logic conditions on left
Outputs on right Illuminated
Push
Rungs processed sequentially PSU CPU 1 2 3 4 Button
Scanned many times per
second
0 0
8 8
1 1
9 9
2 2
Off On 10 10
3 3
11 11
Switch 4 4
12 12
5 5
13 13 Lamp
6 6
14 14
7 7
15 15
Input Card Output Card
System Size
Hardware Setup
Proportional to I/O points (# Racks → # Chassis)
Each valve could have 3 I/O points
Large systems can have 1000’s of I/O points
Software
Proportional to I/O
Process complexity is a factor
Chiller with 12 I/O points Brewhouse Vessels with 126 I/O points
Control Loops – PID Controllers
Feedback control loops are often used and have three elements:
Process Variable (PV) – measurement of the parameter to be
controlled
Set Point (SP) – required or target value of the process variable
Output (OP) – output from the control loop
PID Algorithm
PLC Common feedback loop controller is a PID controller.
Proportional (P) – the output value is changed in proportion to the
size of the error
Integral (I) – the output value is changed in proportion to the
CPU I/O I/O duration of the error
Set point (SP)
Process
Derivative (D) – the output value is changed in proportion to the
Output (OP) rate of change of the error.
Variable (PV)
The ratio of each of the three terms can be varied thereby tuning the
Plant loop to give good control.
Flow
PID controllers used to be separate electronic units but now usually
Control Flow
Valve Meter
algorithms built into the PLC software.
Software Development
Design Software
User Notes
Engineer Developer
Defines automation requirements from
URS (User Requirement Specification)
users point of view Getting the
specification
Detailed definition of how the right
FDS (Functional Design Specification)
automation system works
Software Development structured by in-house
Development and/or customer coding standards
Writing Code
In-house testing of software code and
Internal Testing / software simulation function – most bugs removed at this
point
Testing
Functional demonstration of system
Customer Acceptance Testing (CAT) &
requirements
Verification
Parameter setting, fine tuning, and
Field Testing / Commissioning hopefully only minor changes to support
process commissioning
State Of The Art Systems
1
Process Control Supervision, Control, & Data Management Information & In one
Acquisition (SCADA) Execution (MES/MIS) system
2
3
For example –
brewmaxx by
Configurable recipe management Parameterised software development
(more easily changed) ProLeit
- No ladder logic coding
4
Mobile data monitoring
5
Run on multiple PLC hardware platforms
Questions?
T: +44 1283 566661
E: sales@briggsplc.co.uk
W: www.briggsplc.com
Briggs of Burton PLC, Briggs House, Derby Street, Burton on Trent, Staffordshire, DE14 2LH, United Kingdom
