Control Systems Training - Session 01

Introduction to Industrial Automation

 Agenda
• Self Introduction.
• What does control system, industrial automation mean?
• What is your expectation from this course?

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• What can be inferred about of different industries.
• Size( Geographical Extent).
• Complexity of Operation.
• Type of Industry
• Assembling to Product
• Raw material to Product/Products
• How is the process done?
• Consequences of Failure.

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 Introduction to Control Systems Training
• What is the expectation from these industries.
• Quality and Quantity
• Efficiency and Proficiency
• Fail safe conditions
• Shutdown and consequences
• Value of industry and products

• The answer to these expectations leads to a general question of how? and

what?
• This leads to the topics which we would be seeing in the forthcoming classes.

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• Project : Small scale preliminary study, programming and designing in order

to understand and improve upon the knowledge of actual industries and
their functioning. This requires the involvement and interest of the students.

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Petrochemical Plant Power Plant

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Food processing industry Assembling industry

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 Introduction to Control Systems Training
• From the above pictures we saw there were two kinds of manufacturing
happening
• The first one being a process manufacturing.
• The second being a discrete manufacturing.
• Discrete manufacturing
• Discrete manufacturing is an industry term for the manufacturing of
finished products that are distinct items capable of being easily
counted, touched or seen. In theory, a discrete product can be broken
down at the end of its lifecycle so its basic components can be recycled.
An automobile is a product of discrete manufacturing.
• Process manufacturing
• In process manufacturing, the product is created by using a formula or
recipe to refine raw ingredients and the final product cannot be broken
down to its basic components. Process manufacturing industries include
chemicals, food and beverage, gasoline, paint and pharmaceutical.

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• Discrete manufacturing is all about assembling things, and making things that
are exact.
• The products are typically manufactured in individually defined lots.
• The sequence of work centers through production varying for each one of
these.
• Thus in discrete manufacturing, the product is made by sequential steps
made in the same process or by the same craftsman.
• Discrete manufacturing based on the production orders and products change
frequently from order to order.
• Discrete manufacturers are making a finished good that may have screws,
nuts, handles, etc. that can be taken apart and used on something else if
need be.
• In discrete manufacturing, the manufacturing floor works on shop orders to
build something. The individual products are easily identifiable.

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• Process Manufacturing is when you have a product that requires a set of
processes to be finished, each process in turn has certain needs.
• Thus each process is separated from the other while planning and setting the
Manufacturing requirements to ensure that the individual processes are
better controlled and maintained if they are dealt separately.
• Process manufacturers build something that cannot be taken apart,
technically you can take the mix out of the container and reuse the container,
but you can’t take the ingredients out of the finished goods produced.
• This makes process manufacturers ‘process’ or formula based.
• In process manufacturing, you can’t tell the difference between one product
and another.

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Discrete Manufacturing- Car Assembling Process

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Process Manufacturing- Oil and Gas Refinery

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 INDUSTRIAL AUTOMATION
• When we look at both the above industries it becomes clear that lot of
complex processes have to be done with accuracy and precision.
• Thus it is going to be a labour intensive task if it’s a manually operated
industry.
• Also the risk for manual labors also rises in case of process industries due to
the usage of chemicals and the condition of parameters(temperature,
pressure, flow, etc..) which are controlled.
• Due to some of the above mentioned factors and other such factors,
industries have long been looking for alternative techniques where in the
process can be done accurately resulting in better quality of products as well
as providing safe work environment.
• This requirement led to the replacement of humans with various control
equipments to control the process. This is called as industrial automation.

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 INDUSTRIAL AUTOMATION
• Industrial Automation: The topic has two word namely Industry and
Automation.
• Industry: An industry is a group of manufacturers or businesses that
produce a particular kind of goods or services.

• Automation: The word Automation is derived from the Greek words

‘Auto’ and ‘Matos’ where auto means self while Matos means moving
which gives the meaning ‘self dictating’ or ‘a mechanism moved by itself’.

• Industrial automation can be defined as the use of set technologies and

automatic control devices that results the automatic operation and control
of industrial processes without significant human intervention and
achieving superior performance than manual control.

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 INDUSTRIAL AUTOMATION
• To understand the above definition better let us look into an example of a
process .
• In most of the industries there is a requirement of hot water for various
purposes , in our case we will look to the supply of water to a number of
cleaning stations, where the water temperature needs to be kept constant in
spite of the demand.

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 INDUSTRIAL AUTOMATION
• Process: Steam and cold water are fed into a heat exchanger, where heat
from the steam is used to bring the cold water to the required working
temperature. A thermometer is used to measure the temperature of the
water from the process or exchanger.
• How would you maintain the water at the defined temperature irrespective
of the changes in the demand of water at outlet.
• If the temperature has to be maintained there should be a constant
monitoring of the thermometer and adjustment of the steam flow.
• This can be done by two ways : the earlier manual control and the automated
control.

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 INDUSTRIAL AUTOMATION
• In manual control the temperature is observed by an operator who adjusts
the flow of steam into the heat exchanger to keep the water flowing from the
heat exchanger at the constant set temperature.

• In automatic control the output variable is sensed and the amplitude of the
output parameter is compared to the desired or set level and an error signal
is sent to controller and the corrective signal is sent to control the process at
desired condition.

• In our case steam a temperature sensor is attached to the outlet pipe, it

senses the temperature of the water flowing. As the demand for hot water
increases or decreases, a change in the water temperature is sensed and
converted to an electrical signal, amplified, and sent to a controller that
evaluates the signal and sends a correction signal to an actuator. The
actuator adjusts the flow of steam to the heat exchanger to keep the
temperature of the water at its predetermined value.

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 INDUSTRIAL AUTOMATION

This is how the manual control to automated control changes occur in the
industries.
The thermometer is replaced by a sensor which produces electrical signal.

• The human response is provided by a controller.

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 INDUSTRIAL AUTOMATION
ADVANTAGES OF INDUSTRIAL AUTOMATION: The following are seen as the
advantages when industry is automated.

• High productivity: Automation of factory or manufacturing or process

plant improves production rate through a better control of production.
With manual control of the production line there is always a requirement
to have some down time to ensure effective working of work force.
Where as the automated control systems will be able to work for long
hours without compromising on accuracy. Hence increased productivity
and efficiency per hour of labor input.

• High Quality: The automation system performs operations with greater

conformity and uniformity to the quality specifications once it is designed
and programmed. Thus by using the automation systems, industrial
processes are controlled and monitored at all stages in order to produce a
qualitative end product.

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 INDUSTRIAL AUTOMATION
• High flexibility: When making changes or upgrading task is done humans
require training but, robots can be programmed to do any task. This
makes the manufacturing process more flexible.

• High Information Accuracy: The automated systems are enabled with

easy data collection techniques, which allows us to collect key production
information, improve data accuracy, and reduce data collection costs.
This provides with the facts to make the right decisions enabling in
reducing waste and improving processes.

• High safety: Work environment is made safer by transferring the workers

from an on location role in the process to the supervising role. The
automated machines designed to work in the hazardous environments
and other extreme environments. Industrial automation makes the
production line safe for the employees by deploying robots to handle
hazardous conditions.

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LAYERS OF AUTOMATION
Industrial automation can be complex in nature, they have large number of
devices working in synchronization with automation technologies. The figure
below describes the hierarchical arrangement of an automation system.

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FIELD LEVEL

This is the lowest level of the automation hierarchy, which includes the field
devices like sensors and actuators. The main task of these field devices is to
transfer the data of processes and machines to the next higher level for
monitoring and analysis.
Sensors convert the real time parameters like temperature, pressure, flow,
level, etc into electrical signals. The sensor data is transferred to the
controller to monitor and analyze the real time parameters. Sensors include
thermocouple, proximity sensors, RTDs, flow meters, etc.

Actuators converts the electrical signals from the controllers into

mechanical means to control the processes. Flow control valves, solenoid
valves, pneumatic actuators, relays, DC motors and servo motors are the
examples of actuators.

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CONTROL LEVEL

• The control level consists of various automation devices like CNC machines,
PLCs, DCSs, etc., which acquires the process parameters from various sensors.
The automatic controllers drive the actuators based on the processed sensor
signals and program or control technique.
• Programmable Logic Controllers (PLCs) are the most widely used robust
industrial controllers which are capable of delivering automatic control
functions based on inputs from sensors and the programs downloaded into
the PLC.
• DCS is the advanced or more integrated controller used for large process
industries.

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SUPERVISING AND PRODUCTION CONTROL LEVEL

• In this level, automatic devices and monitoring system facilitates, the

continuous viewing (supervising) of the process and also provides for
controlling and intervening functions like Human Machine Interface (HMI).
• These systems enable supervising various parameters, setting production
targets, historical archiving, setting machine start and shutdown, etc.
• Mostly, either Distribution Control System (DCS) or Supervisory Control and
Data Acquisition (SCADA) and HMIs are popularly used in this level.

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INFORMATION OR ENTERPRISE LEVEL

• This is the top most level of the industrial automation which manages the
whole automation system. The tasks of this level include production planning,
customer and market analysis, orders and sales, etc. So it deals more with
commercial activities and less with technical aspects.

• Industrial communication networks are most prominent in industrial

automation systems, they transfer the information from one level to the
other. So these are present in all the levels of automation system to provide
continuous flow of information. The communication network can vary from
one level to the other. Example of some of these networks include RS485,
CAN, DeviceNet, Foundation Field bus, Profibus, Ethernet etc.

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In this hierarchy there is continuous information flow from high level to low
level and vice-versa. This can be represented in graphical way, like a pyramid
in which as we go up, the information gets aggregated and while going down,
we get detailed information about the process.

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 Thank You!

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