Course detail

Process automation

FEKT-NAUPAcad. year: 2014/2015

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

English

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

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:
•Introduction to design automation systems.
•Batch Programming of batch-type processes in the Standard S88. MES production management system
•Design of temperature systems. 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

Laboratory exercises:
Repeat on the fundamentals of programming SIMATIC PLC (hardware configuration, the extension of analog signals (temperature)
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. 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)

Work placements

Not applicable.

Aims

The aim of the course is to introduce students to the total issues of process automation. Students will learn the basics of design and construction work on projects of automation machinery, production lines and processes. Become familiar with the safety norms, project symbols applied for measurement and control and development procedures for the implementation of systems of measurement, control and automation.
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

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)
Efficient DDS System Implementation, Boed V., ChiltonBook Company, Pennsylvania1996, ISBN 0-8019-8722-9 (EN)

Recommended reading

Not applicable.

Classification of course in study plans

  • Programme EECC-MN Master's

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

Type of course unit

 

Lecture

26 hod., 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 hod., compulsory

Teacher / Lecturer

prof. Ing. František Zezulka, CSc.

Syllabus

Introduction.
Introduction into PC oriented DCS. Basic functions.
Extension functions of PC oriented DCS.
Finishing of PC oriented DCS system education. Tasks for individual students work.
Individual students work.
Testing of individual students work.
Individual work presentation.
Design methodology. Project documentation.
Process simulation. CAD of MP and MZ.
Realization and testing of MP and MZ design.
Realization and testing of MP and MZ design.
Individual students work.
Evaluation of laboratories.