AUTOMATION

AN INTRODUCTION

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 What is Automation?

Automation is a set of technologies that

results in operation of machines and systems
without significant human intervention and
achieves performance superior to manual
operation.
In effect it is the integration of machines into
a self governing system.

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 What are Control Systems?
Controls is set of technologies that
achieves the desired patterns of variations
of operational parameters and operational
sequence of machines by providing the
input signals necessary.
Automation systems may contain control
systems but the reverse is not true.
Control systems are part of Automation
systems

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 Control Systems vs. Automation
Functional Differences

The main function of control systems is to

ensure that output follows a set point.
Automation includes much more
functionality such as
a. computing set points
b. monitoring system performance,
c. Plant start up and shut down, and
d. equipment scheduling etc

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 Why Automation in ships?

Operation of ships is an economic activity where the

profit depends upon the cost of operation.
The cost of operation can be optimized by Automation
a. By significantly reducing the consumption of
material such as fuel , lubricants etc.
b. By saving energy cost by optimum use of energy.
c. By rationalizing man power by automating where
possible.
d. By suitably designing the infrastructure to reduce
the cost of operation

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 Automation - Architecture

SENSORS AND
ACTUATORS
CONTROL SYSTEMS
SUPERVISORY
SYSTEMS(Alarm &
Monitoring Systems

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 Digital Sensors
Digital sensors interface directly with the process
equipments and machines. They translate Physical
process variables into convenient Electrical signals
or Pneumatic pressure, digital in nature.
The following sensors are digital sensors
1. Pressure switches
2. Temperature switches or Thermostats
3. Flow switches
4. Proximity switches
5. Tacho switches

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 Analogue Sensors
Analog sensors convert continuously varying
signals into corresponding convenient
Electrical signals
1. Pressure transmitters
2. Temperature transmitters
3. Tacho-generators
4. Load cells
5. Flow transmitters
6. Velocity transmitters

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 Actuators

Solenoids/Relay coils
Proportional control valves
Electric motors
Stepper motors
Hydraulic and pneumatic rams,
motors

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 Sensing System

Physical medium refers to the object where the physical phenomenon is

taking place and we are interested in measuring the physical variable
associated with the phenomenon.
Sensing Element is affected by the phenomenon in the physical medium
either through direct contact or indirect interaction.
Signal conditioning element serves the function of altering the nature of the
signal generated in the sensor into another suitable signal form
Signal processing element is used for filtering, linearization, and
diagnostics
Target signal handling element performs various functions such as display,
storage , feedback etc.
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 The Sensing Element

The sensing element is affected by the

phenomenon in the physical medium either
by direct or physical contact or by indirect
interaction of the phenomenon with some
portion of the sensing element.
In case of temperature sensing by RTD the
resistivity of the sensing element is
affected by the change in the temperature
of the medium.

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 Signal Conditioning Elements

Signal Conditioning Elements alter the

nature of signals generated by the sensing
element to suit the requirement of
processing elements.
Example: In temperature measurement the
RTD is connected to a Wheatstone Bridge
which functions as a signal conditioning
element.

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 Signal Processing Element
Signal Processing Element is used to process
the signal generated by the first stage for
variety of functions such as filtering ( to
remove the noise), diagnostics (to know the
health of the sensor), linearization ( to obtain
the output linearly related to the process
variable) etc.

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 Actuator System

The Electronic signal processing unit receives control signal from the
controller, process it to the specific requirement of the Actuator.
Power amplifying unit has either linear power amplifiers called servo
amplifiers or Power Electronic units to drive the Electric Motors.
Variable conversion element and Energy conversion element is either
Electrical or Non- Electrical (Pneumatic of hydraulic) to transform the
actuated variable into desired forms in several stages.
Other miscellaneous elements include filters/lubrication/cooling,
reservoirs, Prime movers, sensors for feedback, display, safety systems
etc.,

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 Control Systems
Controllers are essentially (predominantly
Electronic, sometimes pneumatic /hydraulic) that
accepts command signals from human operators or
Supervisory systems as well as feedback from the
process sensors and produce or compute signals
that are fed to the Actuators.
Control systems are two types
1. Continuous control,
2. Sequence Logic control

The control objective is to have the output follow the

input as closely as possible, in value and over time.

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 Continuous Control System

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 Logic or Sequence Control
In this type of control the control function involves turning on
or off of switches, hydraulic directional valves, starting and
stopping of motors etc in response to operating conditions
and as a function of time.
Such system of control is called Sequence /Logic control .
Before digital era this type controls were executed using
magnetic relay logic.
Now Programmable Logic controllers are used.
The input to the PLCs include push button switches, pressure
switches, Limit switches, proximity switches etc
The out put from the PLCs control contactors, Hydraulic or
pneumatic solenoid operated valves, lamps, relays etc.

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 QUALITY OF CONTROL SYSTEM

The quality and closeness of control depends

upon the selection of the following
The choice of the Control Loop(Normal
feedback, feed forward, cascade feedback,)
Control Algorithm (Proportional, Proportional
Integral or Proportional Integral Differential.)
Choice of feedback signals
Choice of controller gains

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 Response of a closed loop with a
Proportional controller

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 Response of a closed loop with a
Integral control action

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 P-I Controller
The proportional controller action increases
the loop gain and makes the system
less sensitive to variations of system
parameters. The Integral control action
eliminates or reduces the steady state
error.

The Integral control action is adjusted by

varying the integral time. The change in
value of Kp affects both proportional and
Integral parts of control action. The Inverse
of the time Ti is called the reset time.

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 Comparison of Responses of
P, I and P+I control action

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 P-I-D Controller
The process output get smooth
response with quick settling time,
reduce the oscillation and increase
the loop gain.

The proportional controller stabilizes

The gain but produces a steady state
Error. The integral controller reduces
Or eliminates the steady state error.
The derivative controller reduces the
Rate of change of error.

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 P-I-D Controller

The P-I-D controller has universal applicability.

Its response is such that the steady state error
is zero the transient response is faster and the
system is very stable.
For proper use the controller has to be tuned
for a particular application
The selection of the P-I-D parameters is very
important.

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 Selection of Controllers

Proportional (P) controller: It is simple type , tuning is easy. But has

steady state error. Suitable for systems where output is close to
zero value
Integral control: System response is slow. Suitable for very fast
process with high noise level.
Proportional +Integral control: No steady state error, system
response is faster. Used for processes where time constants are
smaller.
Proportional +Derivative control: suitable for systems having large
number of time constants. Not suitable for systems having fast
processes and noisy measurement systems
P-I-D control : has universal application Particularly suitable for
control of slow variables like temperature, Ph etc.

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