What is Industrial Automation? Industrial automation is the use of control systems, such as computers or robots, and information technologies for handling different processes and machineries in an industry to replace a human being. It is the second step beyond mechanization in the scope of industrialization.
Advantages of Industrial Automation
1. Low operating cost
2. High Productivity
3. High Quality
4. High Flexibility
5. High Information Accuracy
6. High Safety
Conclusion:
Industrial automation has recently found more and more acceptance from various industries because of its huge benefits, such as, increased productivity, quality and safety at low costs.
Industrial Control System (ICS)
A term used to encompass the many applications and uses of industrial and facility control and automation systems. ISA-99/IEC 62443 is using Industrial Automation and Control Systems (ISA- 62443.01.01) with one proposed definition being “a collection of personnel, hardware, and software that can affect or influence the safe, secure, and reliable operation of an industrial process.”
ICS Applications
Types of Industrial/Facility
Automation & Control
Uses & Applications Examples
SCADA & EMS – Supervisory
Control & Data Acquisition &
Energy Management
System
Control and data acquisition
over large geographic areas
Gas Pipeline SCADA
Water Distribution
Network SCADA
Power Distribution &
Monitoring System
DCS - Distributed Control
System
Systems which control, monitor, and manage industrial processes that are disbursed but operated as a coupled System
DCS for Petrochemical
Plant
DCS for Pharmaceutical
Plant
DCS for Sewage
Treatment Plant
PCS – Process Control System Systems which control, monitor, and manage an industrial processes
PCS for car paint shop
PCS for car chassis
welding
ICS Applications
Types of Industrial/Facility
Automation & Control
Uses & Applications Examples
Building Automation, BMS –
Building Management System
Control systems used to
manage security, safety, fire,
water, air handling in a building
or facility
BMS for hotels
BMS for malls
I&C - Instrumentation &
Control
Electronic devices or assemblies used to monitor, measure, manage or operate equipment in many applications
Pressure Transmitters
Level Transmitters
Flow Transmitter
Temp. Transmitter
Energy Meter
Solenoid Valves
Control Valves
VFD
ICS Applications
Types of Industrial/Facility
Automation & Control
Uses & Applications Examples
SIS - Safety Instrumented
System, safety systems,
protection systems
System with the sole function to monitor specific conditions and act to maintain safety of the process
ESD – Emergency
Shutdown System
HIPPS – High Integrity
Pressure Protection
System
BMS – Burner
Management System
Railway Signaling
Safety System
SCADA Supervisory Control & Data Acquisition
DATA ACQUISITIONS
DATA COMMUNICATION
INFORMATION/DATA PRESENTATION
MONITORING/CONTROL
DCS Distributed Control System
A Distributed Control System (DCS) is a computerised control system for a process or plant, in which autonomous controllers are distributed throughout the system, but there is central operator supervisory control
DCS Distributed Control System
Typical applications: Distributed control systems (DCS) are dedicated systems used in manufacturing processes that are continuous or batch-oriented Processes where a DCS might be used include: *Chemical Plants *Food and food processing *Petrochemical (oil) and refineries *Agro chemical and fertilizer *Pulp and Paper Mills *Metal and mines *Boiler controls and power plant systems *Automobile manufacturing *Nuclear power plants *Metallurgical process plants *Environmental control systems *Pharmaceutical manufacturing *Water management systems *Sugar refining plants *Water treatment plants *Agriculture Applications *Sewage treatment plants
PLC Programmable Logic Controller
A programmable logic controller (PLC), or programmable controller is an industrial digital computer which has been ruggedized and adapted for the control of manufacturing processes, such as assembly lines, or robotic devices, or any activity that requires high reliability control and ease of programming and process fault diagnosis.
PLC Programmable Logic Controller
PROGRAMMING LANGUAGES
The majority of PLC systems today adhere to the IEC 61131/3 control systems programming standard that defines 5 languages:
1. Ladder Diagram (LD)
PLC Programmable Logic Controller
PROGRAMMING LANGUAGES
3. Function Block Diagram (FBD)
5 5
0
0
7
0 7
7
1 0 7
PLC Programmable Logic Controller
PROGRAMMING LANGUAGES
4. Instruction List (IL)
LD TRUE (*load TRUE in the accumulator*) ANDN BOOL1 (*execute AND with the negated value of the BOOL1 variable*) JMPC label (*if the result was TRUE, then jump to the label "label"*) LDN BOOL2 (*save the negated value of *) ST ERG (*BOOL2 in ERG*) label: LD BOOL2 (*save the value of *) ST ERG (*BOOL2 in ERG*)
PLC Programmable Logic Controller
Simplex Configuration
TYPES OF CONFIGURATION
Redundant Configuration
SAMPLE MOTOR CONTROL (HMI+PLC+VFD)
AO: 0-10V AI: 0-10V
FREQ: 0-60Hz
WRITE VALUE TO PLC
READ VALUE FROM PLC
(MODBUS/PROFIBUS/MODBUS TCP)
PLC in Various Applications (RTU)
A remote terminal unit (RTU) is
a microprocessor-controlled
electronic device that interfaces
objects in the physical world to
a DCS or SCADA (supervisory
control and data acquisition)
system by
transmitting telemetry data to a
master system, and by using
messages from the master
supervisory system to control
connected objects. Other terms
that may be used for RTU
is remote telemetry unit or remote telecontrol unit.
PLC in Various Applications (RTU)
Some Unique RTU Features
1. Low power
2. DNP3 protocol
3. Sleep Mode
4. Robust and High Temp
Capacity
5. Small IO capacity
PLC in Various Applications (Safety PLC)
Pros of using a safety PLC: Major savings on field wiring (Safety Circuit Category 3-4) Flexible Scalable Remote I/O capability with safety Safety control and standard control in one unit Good diagnostic capability Perfect for multiple e-stop zone applications Cons of using a safety PLC: Upfront cost is higher Requires programming Possibly too complex for certain applications Requires educated maintenance people
Pros of using a normal PLC: Simple to wire and troubleshoot Cost effective for simple systems Cons of using a normal PLC: Many different relay types Problems increase with an increase in relays and can quickly get complicated Poor diagnostics and poor status indicators Very difficult to do multiple e-stop zones
SAFETY INTEGRITY LEVEL
PFD (probability of failure on demand) and RRF (risk reduction factor) of
low demand operation for different SILs as defined in IEC EN 61508 are as follows:
SAFETY INTEGRITY LEVEL
For continuous operation, these change to the following. (Probability of failure per hour)
DCS & PLC BRANDS
DCS • ABB (800 xA) • SIEMENS (PCS 7) • YOKOGAWA (Centum
3000) • HONEYWELL (Experion) • AZBIL (DEO 500) • EMERSON (Delta V)
PLC • Allen Bradley (Contrologix) • SIEMENS (Step 7) • Mitsubishi (Melsec) • Schneider (M340, Quantum) • Omron (CS Series)
Stages to Automation Control System Specification, Design and Installation
Step 1 ------------ Consider Safety First
Step 2 ------------ Identifying Processes for Automation
Step 3 ------------ Specify Devices
Step 4 ------------ Design
Step 5 ------------ Build
Step 6 ------------ Install and Start-up
Step 7 ------------ Maintain
“ The engineer’s first problem
in any design situation is to
discover what the problem really is.”