Role of automation in industries

Presented by

E.Rajesh kumar

Industrial Automation
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

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

History of Automation

Programmable Logic Controller

Electronic Control using Logic Gates

Hard wired logic Control Pneumatic Control

Manual Control

Manual Control
All

the actions related to process control are taken by the operators

Drawbacks Likely human errors and consequently its effect on quality of final product

The production, safety, energy consumption and usage of raw material are all subject to the correctness and accuracy of human action.

Pneumatic Control
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 switches.

Drawbacks
Bulky and Complex System Involves lot of rework to implement control logic Longer project time

Electronic Control using Logic Gates

In 1960s with the advent of electronics, the logic gates started replacing the relays and auxiliary contactors in the control circuits.
The

hardware timers & counters were replaced by electronic timers Advantages Reduced space requirements Energy saving Less maintenance & greater reliability

Drawbacks
Changes in control logic not possible More project time

Programmable Logic Controllers

In

1970s with the coming of microprocessors and associated peripheral chips, the whole process of control and automation underwent a radical change.
Instead

of achieving the desired control or automation through physical wiring of control devices, in PLC it is achieved through a program or say software.
The

programmable controllers have in recent years experienced an unprecedented growth as universal element in Industrial Automation.
It

can be effectively used in applications ranging from simple control like replacing small number of relays to complex automation problems

Advantages of PLCs

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

Languages used in PLCs

Ladder logic Function block diagram (FBD) Structural text language Instruction list Sequential functional chart

Plcs in our plant

a) b) Allenbradely plc Controllogix processor 5561 Compact logix Schneider plc Siemens plc

Allenbradely plc
Controllogix processor 5561

Allenbradely plc
Compactlogix processor L32 E

Schneider plc
Quantum processor 65150

Programmable Logic Controllers

PLC Types

Nano (Small) Micro (Medium) Large

Basic criteria for PLC Types

Memory Capacity I/O Range Packaging and Cost per Point

Programmable Logic Controllers

Components Central Processing Unit (CPU) Input Output Modules a) Analog input module b) Digital input module c) Analog output module d) Digital output module Power Supply Bus system

Programmable Logic Controllers

Central Processing Unit It is a micro-controller based circuitry. The CPU consists of following blocks : Arithmetic Logic Unit (ALU), Program memory Process image memory (Internal memory of CPU) Internal timers and counters Flags CPU performs the task necessary to fulfill the PLC functions. These tasks include Scanning, I/O bus traffic control, Program execution, Peripheral and External device communication, special functions or data handling execution and self diagnostics.

Central Processing Unit The cpu reads input data from connected field devices through the use of its input interfaces, and then executes or performs the control program that has been stored in its memory system. Programs are typically created in ladder logic, a language that closely resembles a relay based wiring schematic. and are entered into the cpus memory prior to the operation. Finally ,based on the program the plc writes or updates output devices via the output interfaces. this process also known as scanning ,continues in the same sequence with out interruption and changes only when a change is made to the control program

Programmable Logic Controllers

Analog Input module These modules act as interface between real-time status of process variable and the CPU. Analog input module :The signal which varies with time is called as Analog signals Typical input to these modules is 4-20 mA, 0-10 V Ex : Pressure, Flow, Level Tx, Analog signals, which are continuous, are converted by the module and used by the controller to mandate field-device results

Programmable Logic Controllers

Digital Input module Digital input module :

The signal which is high or Low i.es either it is 1 or 0 is called a digital signal The signals coming from Mcc feeders or field instruments comes to the terminals of the input module Typical input to these modules is 24 V DC, 115 V AC, Ex. : Switches, Pushbuttons, Relays, pump valve on off status

Programmable Logic Controllers

Analog Output module These modules act as link between the CPU and the output devices in the field. Analog output module :

The set points(seperator rpm,weighfeeder sp,etc) which are given by the operator in scada station

Typical output from these modules is 4-20 mA, 0-10 V Ex : Control Valve, Speed, when an analog output module receives data from the owner-controller and when the output module echoes data. An owner-controller sends data to an analog output module only at the period specified in the RPI

Programmable Logic Controllers

Digital Output module
As per our programming logic if our output is healthy. this output signal is send to the required output module through the controller or Plc processor Typical output from these modules is 24 V DC, 115 V AC, 230 V AC Ex. : Solenoid Valves, lamps, Actuators, dampers, Pump valve on off control

Programmable Logic Controllers

Power Supply The power supply gives the voltage required for electronics module (I/O Logic signals, CPU, memory unit and peripheral devices) of the PLC from the line supply. The power supply provides isolation necessary to protect the solid state devices from most high voltage line spikes. As I/O is expanded, some PLC may require additional power supplies in order to maintain proper power levels.

Programmable Logic Controllers

Bus System It is path for the transmission of the signal . Bu system is responsible for the signal exchange between processor and I/O modules The bus system comprise of several single line ie wires / tracks

PLC Cycle
Sense the Input Process the Logic Give Output
Programmable controller

Inputs Machine or Process

Outputs

PLC Signal Flow

Input Module Processor Memory Data Output Input Image Table Image Table I:0/6 I:0/6 I:1/4 O:1/5 Output Devices O:0/7 O:0/7 Output Modules

Input Devices
Ladder Program I:0/6 O:0/7 O:1/5 O:1/5

I:1/4

I:1/4

Programming Terminal

Output modules

Input modules

These are the output terminals, from this output terminals signal goes to field actuators, motors ,solenoid valves

signals coming from field comes to this terminal ies from Mcc feeders, and from field Instruments

Definition of SCADA
Supervisory Control and Data Acquisition
a computer system for gathering and analyzing real time data.

Used to monitor and control a plant or equipment in industries such as cements, water and waste control, energy, oil and gas refining and transportation.

Source: http://www.webopedia.com/TERM/S/SCADA.html

SCADA
A SCADA system gathers information, such as where a leak on a pipeline has occurred, transfers the information back to a central site, alerting the home station that the leak has occurred, carrying out necessary analysis and control, such as determining if the leak is critical, and displaying the information in a logical and organized fashion. Can be relatively simple
such as one that monitors environmental conditions of a small office building

or complex
such as a system that monitors all the activity in a nuclear power plant or the activity of a municipal water system.

 Supervisory Control And Data Acquisition

Supervisory control
Data acquisition
In real-time

SCADA

Network

Scada screen shots

Configurations required to start a motor from scada

Creating a new tag database Creating a new motor page popup Configuring page properties Configuring button properties Configuring touch action to the motor

Creating a new tag database

Creating a tag

The plc tag or address which is used in the program, that tag had to be addressed in tag database of the scada software ( EX: RsView32) To create a new tag database Go to Rs view 32 works Go to edit menu Click on System folder And now double click on tag database

Select the node name ( i.e. plc processor of the Corresponding section)

Click on new button to create a new tag database

Give a new tag name so that this tag name is used for the correspo nding plc address

Enter the address which we had used in the plc programming

Creating a motor popup page

To create motor popup page just click on display option which is in graphics folder of the Edit menu in Rsview works

Now there appears a blank page and make all the possible things in the page (ex: motor ,buttons) From the library which is in graphic folder In this library we will be having inbuilt mimics of motors , pipes, Etc

Creating a motor popup page

Select the required fields from the library Arrange the size of the page by right clicking the mouse on the page ,Adjust its properties on clicking on page properties Save the file by any name or its drive number

Generally we have start and stop are used as buttons in the software so we have to configure the button properties by Double clicking mouse on the button

Select the required Action for the button wether it is set,reset,toggle,momentory off or momentary on Now our requirement is momentary on so click on momentary on and browse the required tag from tag database and click on ok

Configuring touch action to the motor

In Rsview works menu select the motor to which the touch action to be provided Right click the mouse by placing the pointer on the motor Select on touch, there will appear a popup and give the required command click next button And in the next page select the motor page and click on finish button