Course detail

Process automation

FEKT-MAUPAcad. year: 2013/2014

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

Czech

Number of ECTS credits

6

Mode of study

Not applicable.

Learning outcomes of the course unit

The student is able to
- 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

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

Co-requisites

Not applicable.

Planned learning activities and teaching methods

Teachning methods include lectures, case studies, practical laboratories and excursions in technological processes. Course is taking advantage of e-learning (Moodle) system. Students work with the system COMES, one system of an operative production control. Students have to write three project/assignment and in another three acts as a co-author during the course.

Assesment methods and criteria linked to learning outcomes

30 points for practice exercise (student is due to work out 5 reports)
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

Lectures:
1. Introduction to designing automation systems.
2. Control and visualization SCADA (InTouch)
3. Mathematical modeling of complex technological systems
4. Selected problems of practical application controllers.
5. Identification of the characteristics of industrial equipment
6. Case study of projecting a power plant
7. The Manufacturing Execution System MES
8. Programming batch processes in the Batch and Modeller modules of COMES system
9. Example of a steam heat exchanger station

Laboratory exercies:
1. Revise basic programming SIMATIC PLC (HW configuration, simple programs in STL)
2. Measurement and processing of analog signals in PLC, including visualization
3. Visualization in InTouch
4. STL program for filling and emptying the tank
5. Functions in STL for control module (motor, valve, ..)
6. The program for controlling the temperature in the tank
7. Visualization of tanks processing in InTouch
8. Buffer exercise / visualization in WinCC
9. Processing of data from tanks processing program in the MES (COMESA)
10. BATCH program Filling a tank heating system (COMESA)
11. BATCH program Filling a tank heating system (COMESA)
12. Excursions CEMO
13. Spare exercise

Work placements

Not applicable.

Aims

Aim of the MAUP course is to acquaint students with the complex issues of process automation.
The course is to prepare the student for entry into the design and programming teams to address the design and implementation of industrial control systems. The basic pillars of this course is to specify the electrical components of the technological process, specification of input and output signals, control system design, establish quotations for users to create programs for PLC, creating programs for control and visualization (SCADA / HMI), the creation of industrial communication networks and the creation of a MES system application. For these activities a responsible person must be able to create a schedule, to know the work flows of designing a process control system and its commissioning.
This course is teaching computer support the engineering work as well. A methodology of mathematical models is rolled out. The example of the practice is presented one possible method for creating models of complex systems. Here the students are being made familiar with the technical resources currently usable for modeling systems, including access to selected numerical solutions to problems that are often encountered in practice. Included is design of own dedicated simulator for a given technological functional unit. A practical approach is focused on selected issues of practical application controllers, identification of the characteristics of industrial equipment and case study design power.
Lectures terminates introduction to functional safety standard IEC 61508.
A huge part of the course provides practice automation experts from various technological processes.

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

Laboratory exercises are compulsory, properly excused missed laboratory exercise is to be replaced after agreement with the teacher

Recommended optional programme components

Not applicable.

Prerequisites and corequisites

Not applicable.

Basic literature

Automatizace procesů, el. učební texty, Zezulka a kolektiv (CS)
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

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-M Master's

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

  • Programme EEKR-CZV lifelong learning

    branch EE-FLE , 1 year of study, winter semester, compulsory

Type of course unit

 

Lecture

26 hod., optionally

Teacher / Lecturer

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 hod., compulsory

Teacher / Lecturer

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