Modern Process Control Systems Research Articles

Опыт внедрения тренажерных комплексов на объектах газовой промышленности территориально-производственного предприятия «Ямалнефтегаз»

Relevance of the development of computer simulator complexes, their advantages, disadvantages, as well as the experience of their implementation at gas industry facilities on the example of computer simulator complexes for checking emergency protection of technological facilities of the territorial production enterprise «Yamalneftegaz» are considered. Complexity of the production technologies and process control, the risks of accidents, the huge industrial and environmental risk in the management of oil and gas facilities, as well as the significant weight of operator control errors in the total number of causes of accidents determine the relevance of efficient personnel training. The use of computer simulators can significantly improve the skills of operational personnel and reduce the risks of accidents at the oil and gas sector enterprises. Simulators give operators and dispatchers the opportunity to learn in practice how to make the right decisions in emergency situations and work with modern process control systems, which in turn can significantly improve fire and industrial safety, the safety of technological equipment and even save human lives. In general, the article emphasizes the importance of using computer simulators in the training of operational personnel at oil and gas enterprises, which can help reduce the risks of accidents and increase the level of industrial safety.

Research of fault-tolerant control system of the formation process of carbon products

The production of carbon products is largely resource- and energy-intensive. That is why increasing the efficiency of this production is an urgent scientific and practical task, especially in modern conditions of constant growth of energy costs. An effective way to solve this problem is to create a modern process control system, taking into account the possible failures of system elements.
 The practice of operating hydraulic presses in carbon graphite production, the control valve of the hydraulic press sometimes fails or works with errors. That is why this paper considers the stage of loading the process of forming carbon products in terms of building a fault-tolerant pressing speed control system.
 The article investigates the fault-tolerant control system of carbon products, which is synthesized on the basis of traditional fault-tolerant systems for non-cyclic processes and control systems with iterative learning, which have demonstrated their effectiveness in control technological processes of cyclical nature. A method using linear matrix inequalities has been developed for optimal adjustment of control system parameters.
 Based on the combination of control with iterative learning and control that takes into account the failures of regulators, built a control system for the formation of carbon products, which takes into account both the cyclical nature of the technological process and possible failures of regulators. The research of the effectiveness of the control system by comparing its work with traditional fault-tolerant systems and control systems with iterative learning in the event of faults and disturbances of various kinds showed that the proposed system improves control quality not only over time during each cycle, but also from cycle to cycle.
 Further research should be aimed at the practical application of the proposed control system for different technological processes in different types of failures of regulatory bodies and the action of disturbances of different nature.

Production process automation of internal combustion engine (ICE) pistons from hypereutectic silumins by injection molding with crystallization under pressure, followed by isothermal forging

A technology for the production of ICE pistons from aluminum alloys with a silicon content of 18 % is proposed. A method for pressing a crystallizing metal by pressure on a horizontal hydraulic press in order to obtain piston blanks for subsequent isothermal forging is developed. The pressing process is controlled by a computer control system embodied through the use of the modern industrial logic controllers and software. An interface for program control is developed. It indicated that the use of modern process control systems makes it possible to control the formation of the final product properties in real time. Keywords automation, computer control system, internal combustion engine pistons, isothermal forging, crystallization, pressure, mechanical properties of metal products

Fault-tolerant control system for the formation of carbon products

The production of carbon products is largely resource- and energy-intensive. That is why increasing the efficiency of this production is an urgent scientific and practical task, especially in modern conditions of constant growth of energy costs. An effective way to solve this problem is to create a modern process control system, taking into account possible failures of system components. A method for the synthesis of a fault-tolerant control system for the cyclic formation of carbon products has been developed, which takes into account control errors that are caused by malfunctions of controllers under conditions of unknown disturbances. According to the cyclic nature of the technological process under consideration, a control method with iterative learning was used in the synthesis of the control system. This method considers cyclic processes based on a two-dimensional model (2D model). The proposed control algorithm ensures the convergence of the control process with the task both in time and in each work cycle in order to promote the required quality of control even in the event of unknown disturbances and errors in the performance of controllers. The synthesis of the control system is based on the solution of a system of linear matrix inequalities. Based on the combination of a control method with iterative learning and a control method that takes into account failures in controllers, a method of constructing a fault-tolerant control system for the cyclic formation of carbon products has been synthesized to ensure acceptable operation of the control object in abnormal conditions. The control system has been synthesized by solving a system of linear matrix inequalities with the MATLAB software. In the future, it is necessary to consider optimal settings of the proposed control system and examine its effectiveness in comparison with conventional fault-tolerant systems for non-cyclic processes.

Improving the management quality of the process control in the food and agricultural industries

The work focuses on analyzing the modern process control systems in the food and agricultural industries for improving management quality. Computer simulation of the control systems with a network channel for transmitting information was carried out for various volumes of data buffers for system elements. The subject of the investigation is to study the effect of data buffering on the quality of process control for systems with a limited buffer volume for data packets. It is assumed that the transmission of a data packet over a network channel during the quantization period is carried out with a given probability. If the data packet from the digital sensor is not transmitted in one quantization cycle to the controller, then it is placed in the sensor buffer. When data is transmitted over the channel, all packets from the sensor buffer are transferred to the controller buffer. The controller processes the incoming data from the buffer sequentially–one packet per quantization cycle. For simulate such situations, it was proposed to use the corresponding developed random processes. The innovation of the developed simulation models is in the fact that the development of the simulation models is based on modelling the time gap of the information data stream. Modelling the functioning of the network control system was carried out in the Simulink environment of the Matlab system.

About the cybersecurity of automated process control systems

Recently, the number of hacker attacks on industrial production facilities has increased significantly. That growth is associated with the rapid development of information technologies for the control systems. The increase in the number of incidents has led to the emergence of cybersecurity – a new field of scientific and technical research that deals with the industrial companies security issues. Several widely discussed incidents are related to cybersecurity. For example, the STUXNET worm has infected Siemens industrial systems and inflicted heavy losses for the Iranian nuclear program. That worm made use of operating system vulnerabilities and the «human factor». The STUXNET worm has been also served as the basis for a number of modified viruses that have been used to successfully attack on various industrial networks. As Siemens is one of the world’s key manufacturers of industrial equipment, the STUXNET has become widespread. Currently, many publications discuss STUXNET from different points of view. Researchers dealing with this problem often overlook the important fact that the existing standard communication protocols, interaction interfaces and embedded algorithms are in most cases unreliable and are not able to provide the proper level of security, but they focus on the vulnerabilities of intrusion detection and prevention systems. With the increasing number of cyber attacks and their expansion, it is necessary to develop secure communication channels and devices to implement the concept of safe industrial manufacturing. This paper analyzes modern process control systems from the point of view of information security.

Применение модели нечёткой логики для оценки качества передачи данных в сетях индустриального интернета вещей

Fuzzy logic by its main characteristic of simulation of human reasoning, it is classified among the techniques of artificial intelligence. This technique can be used to model and then replace the monitoring and control expertise of the process from the designer or user. Fuzzy logic has contributed to the development of several areas. In industrial maintenance, fuzzy logic is used to solve diagnostic problems by automatically classifying vibration signals corresponding to different modes of operation of machines. In this article, a comparative analysis of the methods of automated control system of technological processes (ACS TP) in modern industrial fields is carried out,  the preferential analysis of applying fuzzy logic methods in modern process control systems, as well as an example of using a fuzzy model in assessing the quality of data transmission in IIoT net-works.&nbsp

Real-time networks and protocols for factory automation and process control systems [scanning the issue

Information is the key element in modern factory automation and process control systems, and one of the most difficult tasks is to provide, distribute, and properly process it. Information transfer and processing in this scenario depend to a large extent on appropriate communication systems, usually referred to as “industrial networks.” Significance, content, and properties of information may, of course, vary within a given application context. For instance, a distributed control system typically handles sensor and actuator information with stringent real-time requirements, whereas production planning needs to cope with huge amounts of data, such as those concerned with customer orders or bills of material, with more relaxed timing. The industrial networks deployed at the various hierarchical levels of automation systems thus have to meet different requirements, to ensure that timely and reliable data flows are maintained among the different components they connect, such as field devices, controllers, human–machine interface (HMI) systems, cloud computers, manufacturing execution systems (MES), and so on [1] , [2] . According to the specific needs of the numerous application fields such as manufacturing, electrical power distribution, motion control, environmental monitoring, and chemical processes, to mention but a few [3] , [4] , industrial networks may have diverse architectures, traffic types, and performance.

Data segmentation of effective power signals in the hobbing process

Knowledge about the angular tool position is important for many modern process monitoring or control systems in machining. However, the availability of a high-resolution encoder is not always given, and its access creates further expenditure. Hence, a new method was developed to generate the tool position out of the measurement signal of the effective power. Thus, the signal used for process monitoring also provides further information about the tool position. The method is based on a statistical analysis of the signal in order to find recurring patterns and is validated in a hobbing process.

Design and Implementation of Computer Aided Chemical Laboratory Control System

The computer information technology continues to go deep into the chemical industry, which has brought convenience to the design, transformation and production control of the chemical industry. Thus a simple and effective system is urgently needed to maintain the information management of the chemical industry, so as to improve the efficiency of the experimental equipment and reduce the equipment loss. This paper analyzes the requirement of the computer control system of the chemical industry, undertakes the overall design of the control system with the centrifugal pump in the chemical laboratory of the scientific research institute as an example, and establishes a standardized and modern computer process control system for comprehensive chemical industry, including the storage and modification of centrifugal pump type information and centrifugal pump data information, which significantly improves the experimental efficiency and reduces the experimental loss.

Тенденции развития АСУ ТП на Нововоронежской АЭС

Тенденции развития АСУ ТП на Нововоронежской АЭС

The research of transients of the fourth-order automatic control systems by the quadrature method

Modern transient analysis methods are approximate, which leads to significant control errors. It is shown that improving the accuracy and speed of automatic control systems, and providing optimal operation is possible using the quadrature method for the transient analysis. The fourth-order automatic control system, which is described by a linear differential equation with real and compatible complex roots was investigated. The influence of these roots on the first-quadrature time constants is shown. The methods for determining the first-quadrature time constants and transient analysis accuracy were described. The time constant, which is a multiplier at the first derivative of the first quadrature can be determined by the minimum space between the real RFR of the system and RFR of the first quadrature. The second quadrature can be determined by the difference between the real RFR and RFR, identified by the first quadrature. It is shown that for the fourth-order ACS, transition frequency of the second quadrature RFR is equal to the first quadrature frequency. Since the second quadrature is negligible, it can be neglected in many practical tasks. The main advantage of the quadrature method is the transient analysis using analytical formulas, used for second-order differential equations. Using the quadrature method is especially valuable for the software support of modern computer-integrated process control systems, in which close and complex method of inverse Laplace transform is typically used. Investigating the high-order control systems with delay and using the method for calculating the optimal regulator settings are practically important.

Development of software and hardware device of automated system of the process stabilization of arc dimensional processing

This article discusses the implementation of software and hardware device of automated system of the process stabilization of arc dimensional processing on EDM machines and some results of our research in this area are given. The main aim of research is to develop a functional structure of the program software and hardware devices and then checking its performance. Software and hardware device controller, based on a programmable logic controller, controls the automated electric supply tool electrode for EDM type of AMH-1.It is given the dependences that describe the control law according to which the programmable logic controller stabilizes and supports the arc parameters.The use of modern process control systems of EDM allows processing the materials with higher energy efficiency and less resource consumption.This paper proposes a variant of the problem solution of automated system of the process stabilization of arc dimensional processing.This system allows to automate the process of finding and maintaining the feed rate of the tool-electrode in an area close to the quasi-optimal performance of the process.The investigation results can be used by designers in the field of process automation of tool electrode submission during EDM machining of metals.

Development of and experience using the Del’Tek computerized automation system for furnishing thermal power facilities with automated process control systems

Basic principles of constructing the Russian Del’Tek computerized automation system intended for development of modern process control systems for thermal power engineering facilities are considered. Informational-computation systems and full-scale process control systems built around the Del’Tek computerized automation system, as well as test results and experience gained from their operation, are described.

Improving the Real-Time Behavior of Ethernet Networks Using Traffic Smoothing

In modern process control systems, Ethernet is achieving a leading position, proposing itself as a network capable of supporting all communication needs at all levels in the Computer Integrated Manufacturing hierarchy. The main obstacle to using Ethernet at the Field level is the nondeterminism of the Ethernet MAC protocol, which cannot provide real-time traffic with bounded channel access times. This paper focuses on industrial applications featuring soft real-time constraints, such as periodic control or industrial multimedia, which do not require deterministic guarantees on deadline meeting. To cope with this class of applications, Ethernet should be able to guarantee the timely delivery of real-time packets in statistical terms. The paper presents fuzzy traffic smoothing, a technique to perform adaptive traffic smoothing over Ethernet networks at the Field level thus enabling them to provide a statistical bound on packet delivery time. Previous work showed that the fuzzy smoother outperforms other adaptive smoothers proposed in the literature. This paper addresses fuzzy smoother optimization through genetic algorithms. The proposed optimization is applied to tune the inference engine membership functions. The results obtained show the effectiveness of the approach.

Using an object-oriented database as a repository for process configuration data

This paper describes the use of object-oriented database (ODBMS) technology to store process configuration data in a modern process control system. To demonstrate the improved utility and performance of an ODBMS, a comparison is made with relational databases (RDBMS). An example of how an ODBMS can be used to store Fieldbus™ configuration information is given.

Man-Machine Interface Oriented and Dynamic Simulation Based Configuration of a Low-Cost Process Control System

Abstract By means of an industrial application, it is shown that the use of dynamic simulation during software development, and a proper man-machine interface design, are no longer restricted to large systems like nuclear power plants, aircraft or petrochemical processing plants. If modern low-cost process control systems, designed for medium-size processing plants, are used to their full extent and in an intelligent manner, it is possible to achieve high quality, and at the same time to reduce the project costs.

Distributed simulation using distributed control systems

Modern process automation and control systems must be able to control discrete as well as continuous events. These events are sensed and controlled by distributed devices. Simulation is a necessity in order to design and tune the automatic control system. This paper addresses the advantages and disadvantages of using the discrete and continuous functions available in the control system to perform simulations. The simulation should run in real time for the purpose of operator training. The simulation should be transparent to the operator or user. Simulation should use generic building blocks to gain a wide variety of applications. As an example, the same simulator could be used to train both a nuclear reactor operator and a textile process operator. While this usually does not happen, it could become a necessity in an academic environment where fundamental concepts need to be taught to a variety of students with a minimal amount of duplication of effort.

A Target-Independent Functional Programming Language

This paper presents a new type of programming system, offering a new approach to programming modern process control systems. The kernel of the programming system is a graphical, basically functional programming language which is very easy to learn and understand. The language concept is based on modern theories of computer science. Its appearance (the syntactical form) is adapted to standards for graphical representations which are widely used in control technique; thus the new language is readily accepted by the users. Also, a complete set of software engieering tools has been developed for the language, dedicated to the requirements of process control software. This programming system is independent of the type of target processor and may thus be used to support a wide range of process control systems. Such programming systems (implementing a subset of the functionality presented here) have already been used successfully in a number of Brown Boveri's control systems.

Omega - A RISC Architecture for Real-Time Applications

Abstract Although the recently developed reduced instruction set computer (RISC) architecture has proven to offer impressive performance in general applications, it has its drawbacks in the field of multitasking real-time environments. The difficulties are mainly related to the large number of processor registers which must be saved and restored on every context switch. On the other hand, since this large number of registers accounts for most of the performance benefits, a concept had to be developed which preserves the advantages of the RISC architecture and provides for the necessary real-time capabilities. This paper describes a solution in which additional hardware performs a part of the save/restore task associated with every context switch. This approach yields a RISC architecture suited for the requirements of a modern process control system. Subject area. 4.1 Digital Computer Control Systems