Industrial Automation by Rahul Gunde (LBRCE-MYM)

Industrial Automation

PLC & SCADA

By:-Rahul Gunde

What is Automation ?

Making “Automate ”

Automate – To do by itself

What happens if “man” works,

Constantly and Continuously ?

ERRORS !!! ERRORS !!! ERRORS!!!

Why ?

Due to fatigue and over confidence.

In Other Words,

Using Technology in the places

where “humans errors are possible”. And using “manpower” in appropriate way

What is Automation ?

Automation is a step beyond mechanization.

Automation is the use of control systems and information technologies to reduce the need for human work in the production of goods and services.

What is Industrial Automation ?

Making products under the control of computers and programmable controller is known as Industrial Automation.

Automation is a delegation of human control functions of technical equipment for increasing productivity, better quality, increasing safety in working conditions reducing manpower and cost.

How do you do ? Simplification through applying ideas of appropriate branch of engineering

ELECTRICAL ELECTRONICS MECHANICAL INSTRUMENTATION MECHATRONICS OPTICAL COMPUTERS,

Almost You apply Al l branches of SCIENCE & ENGINEERING

If WeConsider, MAN : MACHINE

Then, EYE : Photo Electric Sensors, Vision Systems

EAR :Ultrasonic Sound, Vibratory Sensors SKIN : Temperature, Magnetic, Tactile, Shock, Viscosity, Flow, etc.

NOSE : Chemical Sensors TONGUE : Bio –Sensors

HANDS : Grippers, Motion Controllers LEGS : Motion Controllers, MOUTH : Speakers, Indication, Communication

Devices

BRAIN : Controllers

NERVES : Wires, Communication Devices

INPUTS

OUTPUTS

CONTROLLING SYSTEM

TRANSMITTERS

Automation Components

Sensor for sensing physical conditions Transmitters Control Systems Output Devices

History of Automation ?

Pneumatic Control

Hard wired logic Control

Electronic Control using Logic Gates

Programmable Logic Controller

Manual Control

Manual Control

All the actions related to process control are taken by the operators Drawbacks

Likely human errors and consequently its effect on quality of final product

The production, safety, energy consumption and usage of raw material are all subject to the correctness and accuracy of human action.

Pneumatic Control Industrial automation, with its machine and process control, had its origin in the 1920s with the advent of "Pneumatic Controllers".

Actions were controlled by a simple manipulation of pneumatic valves, which in turn were controlled by relays and switches.

Drawbacks

• Bulky and Complex System• Involves lot of rework to implement control logic• Longer project time

Electronic Control using logic Gates

In 1960s with the advent of electronics, the logic gates started replacing the relays and auxiliary contactors in the control circuits.

The hardware timers & counters were replaced by electronic timersAdvantages

•Reduced space requirements•Energy saving•Less maintenance & greater reliability

Drawbacks

•Changes in control logic not possible•More project time

Programmable Logic Controllers

In 1970s with the coming of microprocessors and associated peripheral chips, the whole process of control and automation underwent a radical change.

Instead of achieving the desired control or automation through physical wiring of control devices, in PLC it is achieved through a program or say software.

The programmable controllers have in recent years experienced an unprecedented growth as universal element in Industrial Automation.

It can be effectively used in applications ranging from simple control like replacing small number of relays to complex automation problems

Advantages of PLC

Reduced space Energy saving Ease of maintenance Economical Greater life & reliability Tremendous flexibility Shorter project time Easier storage, archiving and documentation

Industrial Automation Components

Field Instruments Control Hardware Control Software

Automation Advantages

Replacing human operators in tasks that involve hard physical or monotonous work.

Replacing humans in tasks done in dangerous environments (i.e. fire, space, volcanoes, nuclear facilities, underwater, etc.)

Performing tasks that are beyond human capabilities of size, weight, speed, endurance, etc.

Economy improvement

Automation Disadvantages

Unemployment rate increases due to machines replacing humans and putting those humans out of their jobs.

Technical Limitation Security Threats/Vulnerability Unpredictable development costs High initial cost

Automation Application

Automated video surveillance Automated highway systems Automated manufacturing Home automation Industrial automation

Introduction to Programmable Logic Controller (PLC)

A PLC is a solid state / industrial computer that performs discrete or sequential logic in a factory environment.

It was originally developed to replace mechanical relays, timers, counters.

A sequence of instructions is programmed by the user to the PLC memory. Its purpose is to monitor crucial process parameters and adjust process operations accordingly.

PLC v/s Microcontroller

PLC is an Industrial Microcontroller

Areas of ApplicationsAny application in any industry that requires electrical control

Packaging Bottling & CanningMaterial Handling MachiningPower Generation HVAC/ Building AutomationSecurity Systems Automated AssemblyPaint Lines Water treatment

IndustryCement Automobile ChemicalsPlasticsMetals Paper F&B

Supervisory Control and DataAcquisition (SCADA) Systems

SCADA systems used to monitor and control a plant or equipment

in industries

such as: telecommunications, water and waste control,

energy, oil and gas refining and transportation

Purpose

A SCADA SYSTEM Gathers information from Remote Terminal Units

(RTUs) and/or (PLCs), and the central host and the operator terminals(such as where a leak on a pipeline has occurred).

Transfers the information back to a central site, then alerts the home station that a leak has occurred

carries out necessary analysis and control,

DEVICE CONNECTIVITY

Every manufacturer have there one way communication or follow different protocols.

SCADA S/W should have connectivity to different h/w used in automation

Benefits of SCADA

Standard frame for application Rich functionality Limited specific development Technical support and maintenance Once installed reduces the cost and provides more

efficiency.

Roles of Engineers in Industrial Automation

Designing of the Automation system Erection and Commissioning Maintenance and Troubleshooting of existing

system

Job Prospects for Engineer in Industrial Automation

Manufacturing Industries like Reliance, Ceat, Godrej,

Colgate …. Automation Solution Products

manufacturer/developer like Rockwell, Siemens, Schneider, Yokogawa, ABB, Honeywell.

System Integrators for Schneider, Rockwell, Siemens, etc

Consultants for Automation And many more….

Sree Vahini Institute of Science & Technology

E-Mail:- Rahul252592@gmail.comPh No:- +91 901 412 7090