Course detail

Process automation

FEKT-MAUPAcad. year: 2011/2012

Lectures:
Introduction to design automation systems.
Control and visualization system SCADA (InTouch)
Batch Programming of batch-type processes in the Standard S88
MES production management system
Example of a steam heat exchanger station
Mathematical modeling of complex technological units
Selected problems of practical use of regulators
Identification of features of industrial equipments
Case study for power station design
The issue of interference and noise immunity. Examples of typical sensors connected to the PLC and IPC
Safety control systems. Standard 61508 Functional safety of E / E / EP

Laboratory exercises:
Repeat on the fundamentals of programming SIMATIC PLC (hardware configuration, simple programs in STL) programming and the extension of analog signals (temperature)
Creating a PLC control system using PID temperature controller with an action variable voltage as measured by a voltmeter. Creating control and visualization applications for this control loop in WinCC.
Training InTouch application - using the simulated process of filling, heating and emptying the tank
The program to control the temperature in the tank. It will include a PLC program to simulate the process function of the tank and the PLC program control for the filling, heat and emptying the tank. All made in STL language.
Extension of the previous task with control and vizualisation from InTouch system
BATCH programming system on a PC. In this system will be programmed process control functions filling, heating and emptying the tank from the previous task. The simulation function remains in the PLC program. As the BATCH system a module BATCH from the COMES system will be used .
Vizualisation data from the project "filling, heating and emptying the tank" in MES (COMES)
Processing of data from the project "filling, heating and emptying the tank" in MES (COMES)
HW configuration of the control system for a dairy
Offer of the control system for a dairy
MS Project - introduction, schedule of control system project for a dairy in MS Project system

An important part of teaching is also optional excursion to Cement plant Mokrá and Nuclear Power Station Dukovany, where students have the opportunity to see the advanced quality control systems, including the accompanying program.

Language of instruction

Czech

Number of ECTS credits

6

Mode of study

Not applicable.

Guarantor

prof. Ing. František Zezulka, CSc.

Department

Department of Control and Instrumentation (UAMT)

Learning outcomes of the course unit

Knowledge of automation system design with attention to real time (RT) systems. Knowledge in connection of sensors to PLC and DCS. Noisy immunity. IEC 61508 Functional safety standard and assocciate.

Prerequisites

The subject knowledge on the Bachelor´s degree level is requested.

Co-requisites

Not applicable.

Planned learning activities and teaching methods

Teaching methods depend on the type of course unit as specified in the article 7 of BUT Rules for Studies and Examinations.

Assesment methods and criteria linked to learning outcomes

30 points from laboratories
70 points from examination

Course curriculum

Lectures:
Introduction to design automation systems.
Control and visualization system SCADA (InTouch)
Batch Programming of batch-type processes in the Standard S88
MES production management system
Example of a steam heat exchanger station
Mathematical modeling of complex technological units
Selected problems of practical use of regulators
Identification of features of industrial equipments
Case study for power station design
The issue of interference and noise immunity. Examples of typical sensors connected to the PLC and IPC
Safety control systems. Standard 61508 Functional safety of E / E / EP

Laboratory exercises:
Repeat on the fundamentals of programming SIMATIC PLC (hardware configuration, simple programs in STL) programming and the extension of analog signals (temperature)
Creating a PLC control system using PID temperature controller with an action variable voltage as measured by a voltmeter. Creating control and visualization applications for this control loop in WinCC.
Training InTouch application - using the simulated process of filling, heating and emptying the tank
The program to control the temperature in the tank. It will include a PLC program to simulate the process function of the tank and the PLC program control for the filling, heat and emptying the tank. All made in STL language.
Extension of the previous task with control and vizualisation from InTouch system
BATCH programming system on a PC. In this system will be programmed process control functions filling, heating and emptying the tank from the previous task. The simulation function remains in the PLC program. As the BATCH system a module BATCH from the COMES system will be used .
Vizualisation data from the project "filling, heating and emptying the tank" in MES (COMES)
Processing of data from the project "filling, heating and emptying the tank" in MES (COMES)
HW configuration of the control system for a dairy
Offer of the control system for a dairy
MS Project - introduction, schedule of control system project for a dairy in MS Project system

Work placements

Not applicable.

Aims

The aim of the subject is to introduce the students to large process automation problems. Students will be introduced into the automation system design, safe standards, design standards and design procedures by design of control systems. The subject contains also computer aided design of control systems. Special attention will be paid to the real time control system design. One part of the subject is excursions into technological processes. Laboratories deal with PC oriented DCS and noise immunity. The last part of the subject deals with input modules of DCS and PLC and connection of sensors with consideration on noisy immunity.

Specification of controlled education, way of implementation and compensation for absences

lab works, project

Recommended optional programme components

Not applicable.

Prerequisites and corequisites

Not applicable.

Basic literature

Zezulka F.: Automatizační prostředky. Skriptum PC DIR, 2000. (CS)
Zezulka F.: Prostředky průmyslové automatizace, VUTIUM, 2004 (CS)

Recommended reading

Not applicable.

Classification of course in study plans

  • Programme EEKR-M Master's

    branch M-KAM , 2. year of study, winter semester, compulsory

  • Programme EEKR-CZV lifelong learning

    branch ET-CZV , 1. year of study, winter semester, compulsory

Type of course unit

 

Lecture

26 hours, optionally

Teacher / Lecturer

prof. Ing. František Zezulka, CSc.

Syllabus

Introduction into automation system design. System engineering.
Design phases. Design modeling and project documentation.
Design tools, standard automation system design procedures. Case study of heat exchangers.
Introduction into DCS. DCS design procedure. Requirements on DCS's HW/SW design.
SW for real time (RT) systems. RTOS. Methods of synchronization and communication. Failure of application SW.
Hart real time system programming. Case study.
Project phases and realization as an technical-organizing problem.
Mathematics modeling of large scale technological systems. Model creation and verification. Numerical aspects of modeling. Utilization of models.
Case study - control of electric power of the power plant Ledvice. Feasibility study with boundaries.
Requirements on measurement devices (MP) and measurement systems (MZ). CSN EN 61010 standard. Safety of electric devices for control, measurement and laboratory.
Basic elements and components for electronic system design with attention to safety and function.
Part problems of reliability of MP and MZ, passive and active noisy immunity.
Computer aided tools for design of MP and MZ.

Laboratory exercise

39 hours, compulsory

Teacher / Lecturer

Ing. Jan Pásek, CSc.

Syllabus

Laboratories:
1. Refreshment of basic programming of PLC SIMATIC (HW cofiguration, simple programms in STL)
2. Measurement and evaluation of analogue signals in PLS, PID controller
3. WinCC - screen for temperature control in a tank
4. InTouch - introduction
5. InTouch csreen for filling and emptying a tank
6. Program for temperature control in the tank + WinCC
7. HW configuration for PLC control of a dairy plant
8. Offer for PLC control system of a dairy plant
9. MS Project - introduction, time schedule for a dairy project in MS Project
10. Processing of date prom project (Fillinf a tank ..) in MES system
11. Processing of date prom project (Fillinf a tank ..) in MES system
12. Excursion CEMO
13. Spare