Process Automation Systems

Transcription

1 Dr. Iiro Harjunkoski Adjunct Professor, School of Chemical Technology, Aalto University Corporate Research Fellow, ABB AG, Corporate Research Germany Process Automation Systems October 21, 2016 Slide 1

2 Content My background Process Automation and Production Management Internet of Things Smart Grids Mobility Services Summary Slide 2

3 Acknowledgements I want to thank Prof. Ignacio E. Grossmann (Carnegie Mellon University, Pittsburgh, USA) Dr. Martin Hollender (ABB Corporate Research, Ladenburg, Germany) Mr. Simo Säynevirta (ABB Industry Automation, Finland) for providing part of the background material that was used to prepare these slides Slide 3

4 Iiro Harjunkoski Education Education MSc (Diploma) 1994 at Process Design Laboratory, Dept of Chemical Engineering, Åbo Akademi University (Prof. Tapio Westerlund) DSc (PhD) 1997 at Process Design Laboratory, ÅA (Prof. Westerlund) Application of MINLP Methods to a Scheduling Problem in the Paper-Converting Industry PostDoc at Åbo Akademi University Continued research / collaboration, EU-project, Teaching 1999 (temporary Prof.) Slide 4 Docent in Process Systems Engineering, Åbo Akademi University

5 Iiro Harjunkoski PostDoc at Carnegie Mellon University, Supervisor Prof. Ignacio E. Grossmann (Chem. Eng.) Research topics: Scheduling of a steel-plant, hybrid methods combining MILP and constraint programming Audited optimization-related courses (Ignacio Grossmann, Egon Balas, John Hooker) Pittsburgh, PA Slide 5

6 Iiro Harjunkoski Corporate Research Fellow Global ABB authority and key reference point for technical direction in one domain or across several technology areas. Focus on future scenarios and transform the technology landscape. Identify / Follow-up opportunities Develop new concepts / solutions Competitive intelligence & IP Promote research area / projects Work in the roles of Project manager Project team member Technology expert Customer interaction (internal/external) Publications / conferences / exhibitions Collaborate with universities Slide 6

7 Aalto University Only 55 km from where it all Started Adjunct Professor in Process Systems Engineering Work at Aalto part-time Participate in research projects Contribute with my expertise / industrial views Link to ABB organization Teaching / supervising Slide 7

8 Sadara Process Automation Production Management Slide 8

9 Slide 9 First automation steps from early 1900 Asea, Sweden

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11 Slide s: First PID controllers Taylor Control, USA

12 Slide 12 Automation of a chemical plant, 1970s, Compact single-loop controller Hartmann & Braun

13 Slide Refinery automation system Programmable controllers, vendor-specific devices and software

14 Slide 14 Modern control room open technology, deep integration ABB 800xA automation system

15 Production Restaurant How to Make Automation to Create Value Customer orders, order management Workflow management, resource allocation, scheduling, cost minimization Restaurant Menu: Various appetizers, ERP first plate, main dish, desert, drinks, (mainly supporting business functions, Order (table 11): Appetizer: Onion soup, Caesar's salad, Main dish: Salmon, strategy Pepper Steak, and targets) Desert: Cheese plate, ice-cream, Drinks: Mineral water, red & white wine, coffee Recipes for all dishes have been defined by the chef Production Management Decisions to make (various Who does functions what (assignment)? from asset management, How to time everything? planning, scheduling, In which order quality to control, do what recipe (sequence)? management, What equipment setpoint to use (assignment)? definition, integration, ) Complex scheduling problem, solved by routine and existing workflows Control Equipment: Fridges, stow, oven working according to the set (execution points layer, data collection, short-term decisions) Business strategy, product portfolio Recipe management, procurement to ensure all ingredients are available Process control to ensure good quality October 21, 2016 Slide 15

16 Detailed scheduling Dispatching Tracking Data collection Analyzing (AM) Visualizing Integrating Interacting Maintaining Production Industry Functionalities ERP (mainly supporting business functions, strategy and targets) Production cost Equipment Production health Management & condition (various functions from Product asset quality management, planning, scheduling, quality control, recipe management, setpoint definition, Energy integration, efficiency ) Inventory, safety, Control (execution layer, data collection, short-term decisions) October 21, 2016 Slide 16

17 Production Management Definition in Short Planning, scheduling, tracking and operation of industrial production processes Some examples: Production process Schedule jobs to production units Direct and operate the process Track and analyze production Maintain safe, reliable, secure and economical, efficient system operation Support situation awareness Take into account critical rules, due dates, resource limitations, priorities etc. Collect information necessary for planning and verifying goodness of plan (tracking, monitoring, visualization) October 21, 2016 Slide 17

18 Business Drivers for Automation Today Provide opportunities in all markets Aging installed base and aging population in mature markets Get more of existing assets with optimized control Optimize Asset Management Run process efficiently with fewer experts Greenfield installations and insufficient expertise in emerging markets Use automation technology as knowledge carrier Tight environmental, safety and security requirements Energy efficiency Device and system Security, Integrated safety Economic Process Optimization Increasing global competition Optimize operations holistically Economic Process Optimization Integrated Operations Collaborative Production Management Slide 18

19 Profit Automation: Helps Pushing Performance to the Limits Throughput Design limit Global competition: Operating target Lost opportunity Improve productivity Deliver flexibly, better, more Break Even Plant upset with less: economically, and ecologically Loss Partial shut-down Startup Shut-down Focus capital spending, improve asset utilization Time Slide 19

20 Automation System Architecture Complex Hierarchy of Multiple Systems ERP (Level 4) MES / CPM (Level 3) Supervisory control (Level 2) Regulatory control (Level 1) Process (Level 0) October 21, 2016 Slide 20

21 Today s Production System Workflow Several Hierarchical Decision Layers Top Down Demands, costs Planning Production targets Produced amounts Scheduling Batch sizes, assignments, start times Progress, equipment availability Recipe execution Set-points, constraints End times, yields, quality parameters Continuous optimization Targets Measured and estimated variables Advanced control References Controls variables, measured data Low-level control Manipulated variables Raw materials Utilities Process Measurements, binary feedback Products Waste October 21, 2016 Slide 21

22 Today s Production System Workflow Several Optimization Layers Bottom Up Planning Scheduling Recipe execution Continuous optimization Advanced control Regulatory control level: Flow controller Focus only on one control loop Set point given from above Main target: Stability Real-time optimization (RTO) or Advanced Process Control (APC) Coordination of many control loops Decisions based on multiple measurements Set point defined as a recipe (from schedule) Main target: Productivity (local) Scheduling and production management functions What to produce when, how much etc. Decisions based on orders, stock, etc. Set point from ERP (e.g. weekly orders) Main target: Productivity & Profitability (global) Low-level control Process October 21, 2016 Slide 22

23 More Complex Cases Important to Separate Levels of Details Planning Scheduling Recipe execution Continuous optimization Advanced control Low-level control Process October 21, 2016 Slide 23

24 Today s Production System Workflow Several Optimization Layers Potential of Conflicting Actions Demands, costs Production targets Batch sizes, assignments, start times Planning Scheduling Optimization! Produced amounts Optimization! Progress, equipment availability Recipe execution Set-points, constraints End times, yields, quality parameters Continuous optimization Optimization! Targets Measured and estimated variables Advanced control Optimization! References Controls variables, measured data Low-level control Optimization! Manipulated variables Raw materials Utilities Process Measurements, binary feedback Products Waste October 21, 2016 Slide 24

25 Automation System Requirements are Stringent Technologies Must Satisfy these before Acceptance Reliability 24 x 365 x (7-10) operations. Shutdowns can cost hundreds of thousand of dollars per hour Real-time performance - down to millisecond level, i e. nothing may disturb the process Predictability - the system will behave in expected ways irrespective of what happens Safety Personnel and equipment safety. With personnel safety being the overriding criteria Data security - Security against intrusion and sabotage becomes increasingly important October 21, 2016 Slide 25 Source: ABB CTO Bazmi Husain in 2009

26 Automation System Requirements are Stringent Technologies Must Satisfy these before Acceptance Reliability 24 x 365 x (7-10) operations. Shutdowns can cost hundreds of thousand of dollars per hour Real-time performance - down to millisecond level, i e. nothing may disturb the process Predictability - the system will behave in expected ways irrespective of what happens Safety Personnel and equipment safety. With personnel safety being the overriding criteria Data security - Security against intrusion and sabotage becomes increasingly important October 21, 2016 Slide 26 Source: ABB CTO Bazmi Husain in 2009

27 Relevant Hypes / Trends / Enablers Affecting Production Management and Automation Internet of Things Automation Cloud Big Data Mobility Service Renewable energy Unmanned sites Remote operations Smart Grids Slide 27

28 Internet of Things Slide 28

29 Paradigm Change: We Face a Tremendous Transition Automation Network and Hierarchy ERP (Level 4) MES / CPM (Level 3) Supervisory control (Level 2) Regulatory control (Level 1) Process (Level 0) October 21, 2016 Slide 29

30 Paradigm Change: We Face a Tremendous Transition Automation Network and Hierarchy ERP (Level 4) MES / CPM (Level 3) Supervisory control (Level 2) Regulatory control (Level 1) October 21, 2016 Slide 30 Process (Level 0)

31 Industrial Internet of Things Global trend 4 th industrial revolution Different national programs Germany: Industrie 4.0 USA: Smart Manufacturing China: Smart Automation 2.0 Industry First practical steam engine Industry First elevated conveyor belts Industry Electronics / software based control Industry 4.0 today and tomorrow Internet of People Services Things Japan: Future of Manufacturing We lead proactively with new connected offerings South Korea: Creative Economy UK: Future of Manufacturing October 21, 2016 Slide 31

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34 Dissolution of the Automation Pyramid Opportunity and Challenge ERP (Level 4) MES / CPM (Level 3) Supervisory control (Level 2) Regulatory control (Level 1) Process (Level 0)? Production systems lose their old stiff hierarchy enabler of cross-benefits In principle, anyone can communicate with anyone Different question: What actually makes sense? By full connectivity basically anything is possible! Countless innovation opportunities how to create added value to customers? How to integrate and aggregate data from a large number and wide range of data sources? Information security and privacy is key! How to deal with dirty and incomplete / incompatible data? How to build-in the flexibility and agility necessary to deal with future changes and unexpected questions? October 21, 2016 Slide 34

35 Summary What is relevant? Future challenges? Slide 35

36 Challenges Cross-disciplinary questions many for Chemical Engineers! Automation Systems Design flexible & adaptable Process Operations 100% availability Synergies Modeling and Optimization collaborative Simplicity and Usability Operator effectiveness October 21, 2016 Slide 36

37 Discussion Questions? October 21, 2016 Slide 37