History of industrial Automation What is Automation Automation

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History of industrial Automation

History of industrial Automation

What is Automation? Automation is delegation of human control functions to technical equipment for

What is Automation? Automation is delegation of human control functions to technical equipment for increasing productivity, better quality, reduced cost & increase safety in working conditions Sensors for sensing the input parameters (RTD, Thermocouple, Pressure, Flow, Level, etc) Transmitters for transmitting the raw signal in electrical form Control system which includes PLC, DCS, PID & PC based controllers Output devices / actuators like drives, control valves.

ENERGY FLOW MATERIAL FLOW INFOR MATIO N FLOW INDUSTRIAL PROCESS Objective of plant automation

ENERGY FLOW MATERIAL FLOW INFOR MATIO N FLOW INDUSTRIAL PROCESS Objective of plant automation is to identify information flow and control material and energy flow as desired optimum way.

Evolution of Automation • It is not a discovery of recent past but its

Evolution of Automation • It is not a discovery of recent past but its rather as old as industry itself. • Designers has attempted to make industry run as autonomous as possible based on available instrumental tools. • With advances in theoretical and technical innovations, Full Scale Automation is commonplace for industries • Flexible Manufacturing: merging of high technology instruments with most advanced method. • It emerges a concept of CIM (Computer Integrated Manufacturing) • Found several applications in space, surface, air and water transport

Factors contributed to development of automation • • Advances in microprocessor, memory and VLSI

Factors contributed to development of automation • • Advances in microprocessor, memory and VLSI design Development in intelligent semiconductor and fiber optic sensors Implementation of programmable controllers Standardizations of modular hardware and software Advancement in computer technology Emergence of powerful interactive graphics for human interface Standardization of data communication links and networks Development in artificial intelligence and methods of knowledge engineering

AIMS OF PLANT AUTOMATION • • • Production volume enhancement Production cost reduction Productivity

AIMS OF PLANT AUTOMATION • • • Production volume enhancement Production cost reduction Productivity increases Production quality improvement Optimal production flexibility Optimal production scheduling Optimal use of available facilities Market competition Humanization of work place Environmental pollution control Production reliability Plant safety

Process of Automation • What are the Aims of Automations • How they can

Process of Automation • What are the Aims of Automations • How they can be realized in given conditions • Affecting factors: • Investment cost • Cost of possible production disturbances during automation process • Approaches: • Partial plant Automation • Complete plant Automation • Recent trend in automation is Integrated Plant Automation

Plant automation Classical methods Modern methods Manual control PLC , PID control On-off control

Plant automation Classical methods Modern methods Manual control PLC , PID control On-off control SCADA Close loop control DCS

Classical approach to plant Automation • Direct manual process control

Classical approach to plant Automation • Direct manual process control

Development up to 50 s Sensor ( Temperature , pressure , Level , Flow)

Development up to 50 s Sensor ( Temperature , pressure , Level , Flow) Controller ( Electrical , Pneumatic , hydraulic ) PID controller

Modular presentation of a Control loop

Modular presentation of a Control loop

Need of Process Computers Plant size and parameter increase No of operators increase on

Need of Process Computers Plant size and parameter increase No of operators increase on floor Sequential process Self regulation and re-adjusting of set point of controller required , example – chemical plant • Data logging and material balance sheet • Optimal process control • •

Computer based plant automation concept • Digital computer has long been real alternative of

Computer based plant automation concept • Digital computer has long been real alternative of analog control • Initially they were unreliable, slow, bulky and too expensive • First RW-300 computer based plant controlled online polymerization unit in Texas on March 12, 1959 • Centralized computer era : 1965 -1970 • Minicomputer era: 1971 - 1975 • Distributed computer era : Since 1975 • Being unreliable, they had to be used in Operator Guidance Mode and Set-point Control Mode

Operator guidance mode

Operator guidance mode

Set-Point Control mode

Set-Point Control mode

Direct Digital control

Direct Digital control

Advantage of DDC • Easy configuration, reconfiguration and parameterization of process loop • Self

Advantage of DDC • Easy configuration, reconfiguration and parameterization of process loop • Self tuning of controller parameter • Simple introduction of new control loop • Possible to go for few advance control algorithm • Model based calculation • Comprehensive data acquisition and presentation

Disadvantage of DDC • • • Low fail safety : failure of all digital

Disadvantage of DDC • • • Low fail safety : failure of all digital loop Higher investment Higher Maintenance cost High Programming cost Overload of CPU Not possible for High level process control

Dual computer system for DDC

Dual computer system for DDC

Back up concept of DDC

Back up concept of DDC

Distributed control system • Relay based control system can’t control Continuous process • DCS

Distributed control system • Relay based control system can’t control Continuous process • DCS designed for Continuous process control • To fill the gape of Discrete and batch process PLC introduced by General Motor • High speed microcomputer introduced in 1972 using semiconductor technology • In 1975 Honeywell introduced first DCS with PLC and DDC control facilities.

What is PLC? • Hardware interface for input sensors and final output control element

What is PLC? • Hardware interface for input sensors and final output control element of the field. • The field I/p include element like limit switches, sensors, push button and the final control elements like actuator, solenoid/control valves, drives, hooters etc. • PLC Senses the input through I/P modules, Processes the logic through CPU and memory and gives output through output module

Leading PLC providers The leading PLC providers include • Rockwell Automation : Allen Bradley

Leading PLC providers The leading PLC providers include • Rockwell Automation : Allen Bradley (Micrologix, SLC, PLC, Control Logix) • Siemens ( S 7 200, S 7 300 , S 7 400) • Grouppe Schneider : Modicon ( Nano, Micro, Premium, Quantum) • GE Fanuc : Versa, Series 90 -30, 90 -70 • OMRON

DCS • DCS is powerful and flexible integrated control system that supply data acquisition

DCS • DCS is powerful and flexible integrated control system that supply data acquisition , advance process control and monitoring , batch control capacities. • Plant operator monitor and manipulates set point of process from central control room • Operator views the process information on CRT screen and Control through keypad • BASIC function of DCS • • Data collection ( analog and digital ) Generate output signal to actuator Plant GUI Remote location control

Advantages of the DCS • • • The computer can record and store a

Advantages of the DCS • • • The computer can record and store a very large amount of data The data can be displayed in any way the user requires Thousands of sensors over a wide area can be connected to the system The operator can incorporate real data simulations into the system Many types of data can be collected from the RTUs The data can be viewed from anywhere, not just on site

Disadvantages • The system is more complicated than the sensor to panel type •

Disadvantages • The system is more complicated than the sensor to panel type • Different operating skills are required, such as system analysts and programmer • With thousands of sensors there is still a lot of wire to deal with • The operator can see only as far as the PLC

Leading DCS providers The leading DCS providers include • Yokogawa : CS 3000 ,

Leading DCS providers The leading DCS providers include • Yokogawa : CS 3000 , CS 5000 (Earlier Centum Excel, Micro Excel) • Honeywell : TDC 3000 • Fisher - Rosemant - Delta V • ABB - Freelance 2000 • Moore - APACS • Fox boro - I/A series

References • Reference : Distributed computer control for industrial automation by Popovic & Bhatkar.

References • Reference : Distributed computer control for industrial automation by Popovic & Bhatkar.