BY- LAKHAN RATHI GUIDED BY- PROF. G.K.

MAHAJAN

Automation is encompassing virtually every walk of life. Automation solutions are required right from agricultural to space technology. Plant Automation is the necessity for the manufacturing industry to survive in todays globally competitive market

Automation is basically the delegation of human Control function to technical equipment for Increasing Productivity Increasing Quality Reducing Cost Increasing Safety in working conditions

ProgrammableLogic Controller

Electronic Control using Logic Gate Hard wired logic Control

Pneumatic Control Manual Control

All the actions related to process

control are taken by the operators Drawba cks Likely human errors and consequently its effect on quality The production, safety, energy of final product consumption and usage of raw material are all subject to the correctness and accuracy of human

Industrial automation, with its machine

and process control, had its origin in the 1920s with the advent of "Pneumatic Controllers". Actions were controlled by a simple manipulation of pneumatic valves, which in turn were controlled by relays and Drawbacks switches. Bulky and Complex System Involves lot of rework to implement control logic Longer project time

The contactor and Relays together with hardware timers and counters were used in achieving the desired level of automation Drawbacks
Bulky panels Complex wiring Longer project time Difficult maintenance and troubleshooting

In 1960s with the advent of electronics, the logic gates started replacing the relays and auxiliary The hardware timers & counters were contactors in electronic timers replaced by control circuits.

Advantage Reduced space requirements s

Energy saving Less maintenance & greater reliability

Drawback Changes in control logic not possible s More project time

xField Instruments xControl Hardware xControl Software

RTD : Output in Ohms (Temperature) Thermocouples : Output in mV (Temperature) Pressure Transmitters : 4-20mA, 0-10 V .. Flow Transmitter : 4-20mA, 0-10 V .. Level Transmitter : 4-20mA, 0-10 V .. Conductivity meter : 4-20mA, 0-10 V .. Density meter : 4-20mA, 0-10 V .. And Many more

 PC Based Controllers Programmable logic

controllers Distributed Control System

The PLC is programmed interface between the field I/p element like limit switches, sensors, push button and the final control elements like actuator, solenoid,control valves, drives, hooters etc

PLC consist of
CPU Input Module Output module Bus System Power Supply

CPU I/O Modules External Power Supply

 Reduced space Energy saving Ease of maintenance Economical Greater life & reliability Tremendous flexibility Shorter project time Easier storage and documentation

 What is SCADAand where is it used

Supervisory Controls And Data Acquisition Application area : Industrial processes: chemical, power generation and

distribution, metallurgy, Nuclear processes: reactors, nuclear waste, ... Experimental physics: Tokamaks, HEP laboratories Application size: 20 K I/O to 450 K I/O, two examples of 1 M I/O under development

Alarm Handling
Based

on limit and status checking * More complicated expressions developed by creating derived parameters * Alarms are time stamped and logically centralised * Notifications (audible, visual, Email, GSM) Multiple alarm priority levels Grouping of alarms and handling of groups is possible Suppression and masking of alarms either individually or as a complete group Filtering of alarms is possible

Trending
Multiple

trending charts Charts are pre-defined or configured on-line Charts contain multiple pens, Zooming, scrolling, panning, Hairline Real-time and historical trending Write data to RDB

Access Control
Users

organised in groups with a set of allocated privileges Large number of groups possible Privileges limit write access to process parameters Some allow access to graphics and functionality to be limited

Automation
Actions can be initiated automatically triggered by an event *
Recipes Sequencing

and scripting possibilities

Logging, Archiving
Data

stored in compressed and proprietary format Logging / Archiving either for a set number of parameters or for a set period of time Logging / Archiving can be frequency or event driven * Logging of user actions together with a user ID VCR facility for playback of stored data Writing logs into RDB

Report

Generation
created using SQL type queries to the RTDB or

Reports

logs Automatic generation, printing and archiving of reports Use of components for report generation

 Designing of Automation

system Erection and Commissioning Maintenance and Troubleshooting

of existing system

Automation is the only solution for industries

to cope up with the advancing industrial revolution. Engineers play an eminent role in automation. Automation doesnt just means automatic control but it means maintaining security and avoiding hazardous conditions on field and thus ensuring safety to the field workers and engineers. Moreover Automation has added a new scope for employment to engineers.

Torsten cegrell,power systems control technology . ii. S. Rao, Switchgear Protection and Power Systems iii. A.K. Sawhney, Electrical Measurements & Measuring Instruments iv. WWW.SCRIBD.COM v. WWW.WIKIPEDIA.ORG vi. PROLIFIC TECHNOLOGIES, PUNE
i.