Basics of Automation

Mrs. Meera Ajit Khandekar

Department of Instrumentation & Control
College of Engineering, Pune

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 Industrial Processes

Industrial processes are procedures involving

chemical or mechanical steps to aid in the
manufacture of an item or items, usually carried out
on a very large scale.

Types: Continuous
Batch
Discrete

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 Closed loop

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 Important Definitions
• Process: The physical system we are attempting to control or
measure.

• Process Variable, or PV: The specific quantity we are measuring in

a process.

• Set point, or SP: The value at which we desire the process variable
to be maintained at.

• Primary Sensing Element, or PSE: A device that directly senses the

process variable and translates that sensed quantity into an analog
representation

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 Process description

The process description details the function/ purpose of each item of

equipment in the plant.

e.g. Installation procedure

Operation principles
Specific operating conditions
Performance requirement

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 Process Flow Diagram

The PFD is where we start to define the process by adding equipment

and the piping that joins the various items of equipment together.

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 P & I Diagram and standards

It gives a graphical representation of the process including hardware

(Piping, Equipment) and software (Control systems).

The instrument and equipments in P&I D (Piping and Instrumentation

Drawings) needs standards that will define the format of each
component of the P&ID.

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 P&ID

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 Other documents/ procedures
• Instrument list
• Hook up diagrams
• Cable scheduling
• Loop wiring diagram
• Power distribution diagram
• Load list
• Plant lay out diagram

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 What is automation?

Automation is to use computers to control industrial machinery and

processes replacing human operators

Automation is the self driven process based on suitable logics

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 Need of Automation
• Increasing production volume
• Reducing production cost
• Enhancing production quality
• Improving production flexibility
• Human & plant safety
• Technology changes

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 Historical Overview
• 1940– 1950
⁻ Major boost due to critical production schedules of World
War II
⁻ Pneumatic instrumentation
⁻ Development of PID control algorithm

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 Historical Overview
• 1950– 1970

– Development of “Classical” Control theory

• Responsible for analysis, synthesis and design aspects of linear
control systems
– Further development in pneumatic instruments
• Resulted in remote mounting of controllers in control room, away
from plant area
– Introduction of electronic instruments & multi core cables
• Responsible for the miniaturization, space saving and high speeds
of processing and transmission

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 Instrument & Control system-
generations
• Plant wide control systems –
– Panel based Pneumatic Systems (Mid 40s)
– Panel based Electronic Systems (late 50s)
– Direct Digital Control (DDC) Systems (70s)
– Panel based systems with SLPC s, connected to a supervisory
computer (1980 )
– Programmable Logic Controllers (PLC) with or without supervisory
computer (mid eighties)
– Supervisory Control and Data Acquisition Systems (SCADA)
– Distributed Control Systems (DCS) (mid 80s)

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 Milestones - India
• IL, Bells, Taylor (Pneum) 1960
• Rosemount (Elec Xmitters)

• Bells, Taylor(Micro proc based controllers) 1980

• BlueStar, Taylor, A-B (PLC) 1983

• Siemens, ABB (DCS) Late 1980

• Taylor-ABB, SetPoint, (Adv Control) Late 1980

• Sarla Tech., KLG Systel (SCADA) 1990

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 Automation Strategy Implementation
• List of plant needs
• Operator ideas, suggestions
• Process engineers’ requirements
• Safety and environmental constraints
• Success stories
• Cost Benefit, Price to Performance Analysis
• Scope Definition
• System Specifications

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 Plant wide control systems
• Two main approaches:

– The “DCS” approach

– The “PLC” approach

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 Plant wide control systems
• Other solutions :

– Single/Multiloop Controllers

– “Mixed” PLC + Loop Controllers with HMI

– Customized Solutions

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 Current Issues
• Local or Central control
• PLC or DCS
• Geographical Distribution
• New Technologies –telecom, internet
• Field “buses”
• Integration
• Safety systems

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 Implementation Issues
• Costs Vs benefits

• Criteria for platform selection (PLC/DCS/HMI/SCADA/Other…)

• Control system utilization audit and failure analysis

• Vendor independent professional training

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Thermal Power Generation Process

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Automation functions of system levels
Plant(s) Management Level 4

Production Scheduling & Control Level 3

Plant Supervisory Control Level 2

Direct Process Control Level 1

Process Plant

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 Direct Process Control Level
Level 1
• Acquisition of Process Data
• Plant Monitoring
• Data Check
• Open loop and Closed loop control

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 Plant Supervisory Control
Level 2
• Plant Performance Monitoring
• Plant co-ordination
• Optimal Process Control
• Adaptive Control
• Failure Detection

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 Plant Scheduling & Control
Level 3
• Production Dispatching
• Inventory Control
• Production Supervision
• Production Re-scheduling
• Production Reporting

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 Plant Management Level
Level 4
• Market and Customer Analysis
• Orders and Sales Statistics
• Capacity and Order Balance
• Order Dispatching
• Production Planning
• Production and Delivery Terms Supervision
• Financial Surveys

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 Key Benefits of automation
• Savings in material consumptions and energy
• Superior operator interface – more efficient operation
• Efficient and reliable data storage and retrieval
• Quality improvements due to accurate loop control
• Supervisory control benefits

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 Busses and processors in industrial plants
Operator panel open network:
disk Mimic board TCP/IP, ...
Process pictures

Process Data Base

workstation bus
Logging station statio
instrument bus
n
(mimic board)

process bus (500m .. 3 km)

pool P P P C P P C P
PLC nodes node bus
(multi-processors)
I/O MEM I/O MEM BC
(30m..2 km)
fieldbus
directly coupled control station bus
input/ stations
output
sensor bus (0,5.. 30 m) sensor bus
transducers

M plant (Work, use)

valve thermo-couple position motor
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Example: Rockwell (Allen-Bradley) NetLinx
Programmabl Desktop
e Device PC
Support PC with excel

EtherNet / IP

Controller and Bridge

Servo
ControlNet HMI

Linking Device Bridge or Linking Device

Drive

HM
I
DeviceNet

Modular
I/O
509 -BOD

24vdc

Micro
Sensor
PLC
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Block I/O
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Example: Emerson's PlantWeb (Delta V)

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 Thank you!!

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