what is industrial automation? - iiee abu...

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

Disadvantage of Industrial Automation

1. High Initial Cost

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




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




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

EMS Energy Monitoring System

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

Process Automation

PLC


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.


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)



2. Structured Text (ST)



3. Function Block Diagram (FBD)

5 5

0

0

7

0 7

7

1 0 7



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*)



5. Sequencial Flow Chart (SFC)


Simplex Configuration

TYPES OF CONFIGURATION

Redundant Configuration

BASIC CONCEPT OF CONTROL SYSTEM

SAMPLE MOTOR CONTROL (HMI+PLC+VFD)

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)

Normal PLC Safety PLC

SIL2 or SIL3

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.”

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what is industrial automation? - iiee abu...

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