Course detail
Process Control
FEKT-MAUPAcad. year: 2017/2018
The course MAUP is designed for students of second year of graduate studies. It is the last year of university studies and course graduates of MAUP after its completion are to join the development and programming teams to be ready for design and implementation of industrial control systems. The basic pillars of this work is the specification of the electrical components of the technological process, specification of input and output signals, control system design, a price quotation for the user, creating a PLC program, the creation of programs for control and visualization (SCADA / HMI), the design of industrial communication networks and the creation of application of MES system. For these activities must be responsible person able to create a timetable. Theoretical underpinnings is the knowledge of mathematical modeling of complex technological systems, model verification, modeling and numerical aspects of functional safety (IEC 61508 standard and related)
Language of instruction
Number of ECTS credits
Mode of study
Guarantor
Learning outcomes of the course unit
- Create demand and quotation for an automation project
- Create a project visualization of technological processes (SCADA)
- Create a mathematical model of technological unit
- Implement appropriate control algorithms
- Create an application with the modules of Manufacturing Execution System (MES)
- Create a program for batch process BATCH
- To assess the degree of risk-driven process in terms of functional safety standard IEC 61508
- Design HW / SW configuration of safe control
Prerequisites
Co-requisites
Planned learning activities and teaching methods
Assesment methods and criteria linked to learning outcomes
- 70 points for examination
- The exam is in the written form
- To pass the written exam a student needs to get 35 points out of 70 possible
Course curriculum
1. Introduction to designing automation systems.
2. Mathematical modeling of complex technological systems
3. Selected problems of practical application controllers.
4. Identification of the characteristics of industrial equipment
5. Batch processes in system COMES Batch a COMES Modeller
6. Batch processes in system COMES Batch a COMES Modeller II
7. Manufacturing Execution Systems I
8. Manufacturing Execution Systems II
9. Industrial intelligence
10. Industry 4.0
11. Product Lifecycle Management Systems
12. Digital Factory
13. Introduction to control systems safety
Laboratory exercies:
1. Revise basic programming SIMATIC PLC (HW configuration, simple programs in STL), Measurement and processing of analog signals in PLC, including visualization
2. STL + LAD modules - mathematical model of a tank, visualisation in WinCC
3. Object model - User Data Types and Data Blocks for Valves and Motors
4. STL functions for control modules
5. Testing of previously development modules and functions, visualisation
6. + 7. Implementation of filling-up, mixing and emptying phases according to ISA-S88
8. Implementation of main module in GRAPH
9. Visualisation in InTouch
10. MES system COMES, module Historian
11. + 12. MES system COMES, module Batch, Batch configuration, scheduling, testing
13. Spare excersise
Work placements
Aims
The course provides students with computer support of design work. On the practical demonstration projects and excursions to selected technological processes students become familiar with a particular form of implementation of automation. Laboratory exercises are geared towards PC-based distributed control systems (DCS) applied to software process models. Another part of the exercise is devoted to software systems to support the engineering works.
In the examples of heat exchangers and power units, students practice the conventions of design and brand management principles and power equipment.
A big part of the lectures provide practice management experts of power plant units from the conventional up to nuclear power plants, mathematical modeling of complex technological systems, selected problems of practical application controllers, identifying the characteristics of industrial equipment, case studies of projecting power station.
Lectures terminates introduction to functional safety standard IEC 61508.
Specification of controlled education, way of implementation and compensation for absences
Recommended optional programme components
Prerequisites and corequisites
Basic literature
Industrial Ethernet. Lorentz K., Lueder A. ed., IAONA Handbook, Magdeburg, 3rd Edition, 2005, ISBN 3-00-016934
Programovatelné automaty v řízení technologických procesů, Jan Pásek, 2007 (CS)
Zezulka F.: Automatizační prostředky. Skriptum PC DIR, 2000. (CS)
Zezulka F.: Prostředky průmyslové automatizace, VUTIUM, 2004 (CS)
2. PowerPoint prezentace autorů jednotlivých přednášek (CS)
Recommended reading
Classification of course in study plans
Type of course unit
Lecture
Teacher / Lecturer
Syllabus
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
Teacher / Lecturer
Syllabus
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