Industrial Automation: PLC & Scada

Innovians
Technologies
Industrial Automation
PLC & SCADA
By:Prateek Gupta
www.innovianstechnologies.com
Innovians
Technologies
What is Automation ?
Making Automate
Automate To do by
itself
Innovians
Technologies
What happens if man

works,
Constantly and Continuously
?
ERRORS !!! ERRORS !!! ERRORS!!
Why ?
Due to fatigue and over confidence.
Innovians
Technologies
In Other Words,
Using Technology
in the places
where humans errors
are possible.
And using manpower in
appropriate way
Innovians
Technologies
What is Automation ?
Automation is a step beyond mechanization.
Automation is the use of control systems and

information technologies to reduce the need
for human work in the production of goods and
services.
What is Industrial
Automation ?
Making products under the control of

computers and programmable controller is
known as Industrial Automation.
Automation is a delegation of human control

functions of technical equipment for increasing
productivity, better quality, increasing safety
in working conditions reducing manpower and
cost.
How do you do ?
Simplification
through applying ideas of
appropriate branch of engineering
ELECTRICAL
ELECTRONICS
MECHANICAL
INSTRUMENTATION
MECHATRONICS
OPTICAL
COMPUTERS,
Almost You apply Al l branches of SCIENCE &
ENGINEERING
If We
Consider, MAN
Then,
EYE
Systems
EAR
SKIN
NOSE
TONGUE
: MACHINE
: Photo Electric Sensors, Vision
:Ultrasonic Sound, Vibratory Sensors
INPUTS
: Temperature, Magnetic, Tactile,
Shock, Viscosity, Flow, etc.
: Chemical Sensors
: Bio Sensors
OUTPUTS
HANDS
LEGS
MOUTH
: Grippers, Motion Controllers

: Motion Controllers,
: Speakers, Indication, Communication
CONTROLLING SYSTEM
BRAIN
: Controllers
Devices
TRANSMITTERS
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Technologies
Automation
Components
Sensor for sensing physical conditions

Transmitters
Control Systems
Output Devices
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Technologies
History of Automation ?
Programmable Logic Controller

Electronic Control using Logic Gates
Hard wired logic Control
Pneumatic Control
Manual Control
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Technologies
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.
Innovians
Technologies
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
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Technologies
Hard wired logic control
The contactor and Relays together with hardware timers and

ounters were used in achieving the desired level of automation
Drawbacks
Bulky panels
Complex wiring
Longer project time
Difficult maintenance and troubleshooting
Innovians
Technologies
Electronic Control using logic

Gates
In 1960s with the advent of electronics, the logic gates started

eplacing 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
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Technologies
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
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Technologies
Advantages of PLC
Reduced space
Energy saving
Ease of maintenance
Economical
Greater life & reliability
Tremendous flexibility
Shorter project time
Easier storage, archiving and documentation
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Technologies
Components
Field Instruments
Control Hardware
Control Software
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Automation: Typical Installation

SCADA Software
Communication
Cable
Control Hardware
Control Panel
Field Cabling
Junction Box
Field Cabling
Sensors Placed in the field
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Technologies
Automation Advantages
Replacing human operators in tasks that involve

hard physical or monotonous work.
Replacing humans in tasks done in dangerous
environments (i.e. fire, space, volcanoes, nuclear
facilities, underwater, etc.)
Performing tasks that are beyond human
capabilities of size, weight, speed, endurance, etc.
Economy improvement
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Technologies
Automation
Disadvantages
Unemployment rate increases due to machines

replacing humans and putting those humans out of
their jobs.
Technical Limitation
Security Threats/Vulnerability
Unpredictable development costs
High initial cost
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Automation Application
Automated video surveillance

Automated highway systems
Automated manufacturing
Home automation
Industrial automation
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Introduction to Programmable
Logic Controller (PLC)
A PLC is a solid state / industrial computer that

performs discrete or sequential logic in a factory
environment.
It was originally developed to replace
mechanical relays, timers, counters.
A sequence of instructions is programmed by the
user to the PLC memory. Its purpose is to monitor
crucial process parameters and adjust process
operations accordingly.
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Technologies
PLC v/s Microcontroller
PLC is an Industrial Microcontroller
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Technologies
Areas of Applications
Any application in any
industry that requires
electrical control
Packaging
Bottling & Canning
Material Handling Machining
Power Generation HVAC/ Building
Automation
Security Systems
Automated Assembly
Paint Lines
Water treatment
Industry
Cement Automobile Chemicals
Plastics
Metals Paper
F&B
PLC: Location in the control architecture

Enterprise Network
Engineer Operator
station
station
Supervisor
Station
gateway
direct I/O
data concentrators,
not programmable,
but configurable
COM 2
CPU
I/O
COM1
I/O
I/O
PLC
gateway
COM
COM
CPU
I/O
Field Bus
I/O
COM
I/O
CPU
COM
I/O
I/O
I/O
I/O
CPU
Field Stations
small PLC
Control Station
with Field Bus
Field Bus
COM
directly connected
I/O
I/O
I/O
PLC
COM 2
CPU
COM1
I/O
I/O
I/O
I/O
I/O
COM1
large
PLCs
CPU
Control Bus
(e.g. Ethernet)
FB
gateway
Field Devices
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Technologies
Human Machine
Interface
In the
industrial design field of humanmachine interaction,
the user interface is the space where interaction between
humans and machines occurs.
The user interface includes hardware (physical) and
software (logical) components.
It provides a means of :
Input, allowing the users to manipulate a
system, and/or
Output, allowing the system to indicate
the effects of the users' manipulation
HMI of a machine for the

sugar industry with
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Technologies
Supervisory Control and Data

Acquisition (SCADA) Systems
SCADA systems
used to monitor and control a plant or equipment
in industries
such as:
telecommunications, water and waste control,
energy, oil and gas refining and transportation
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Technologies
Purpose
A SCADA SYSTEM
Gathers information from Remote Terminal Units
(RTUs) and/or (PLCs), and the central host and the
operator terminals(such as where a leak on a
pipeline has occurred).
Transfers the information back to a central site,
then alerts the home station that a leak has
occurred
carries out necessary analysis and control,
Innovians
Technologies
What do SCADA
Provide?
Dynamic
Process Graphics
Basic SCADA functionality
Real time &historical trend
Alarms
Recipe Management
Security
Report Generation
Logging, Archiving
Device connectivity
Data base connectivity
Interfaces
to H/W and S/W

Interfaces to ERP- and Expert-Systems
Development Tools
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Technologies
DEVICE CONNECTIVITY
Every
manufacturer
have
there
one
communication or follow different protocols.
way
SCADA S/W should have connectivity to different h/w

used in automation
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Technologies
Benefits of SCADA
Standard frame for application

Rich functionality
Reliability and Robustness (very large installed
base, mission critical processes)
Limited specific development
Technical support and maintenance
Once installed reduces the cost and provides more
efficiency.
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Configuration of SCADA
Systems
Data Server
Data Server
PLCs
Field Bus
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Configuration of SCADA
Systems
PLC
Program
s
Communicatio
n
Processor
Analog-Input
Value-AI-0
Value-AI-1
Analog-Output
Value-AO-0
Value-AO-1
SCADA
Mapping
Field Bus
Analog-Input
Vacuum_VALUE
Pressure_VALUE
Analog-Output
Valve_1_OUT
Heater_1_OUT
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Technologies
Roles of Engineers in
Designing of the Automation system

Erection and Commissioning
Maintenance and Troubleshooting of existing
system
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Technologies
Job Prospects for Engineer in

Manufacturing Industries like Reliance, Ceat,

Godrej,
Colgate .
Automation Solution Products
manufacturer/developer like Rockwell, Siemens,
Schneider, Yokogawa, ABB, Honeywell.
System Integrators for Schneider, Rockwell,
Siemens, etc
Consultants for Automation
And many more.

Industrial Automation: PLC & Scada

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Innovians

What happens if man

Automation is a step beyond mechanization.

Automation is the use of control systems and

Making products under the control of

Automation is a delegation of human control

: Grippers, Motion Controllers

Sensor for sensing physical conditions

Programmable Logic Controller

the actions related to process control are taken by the

The production, safety, energy consumption and usage

automation, with its machine and process control,

were controlled by a simple manipulation of

Hard wired logic control

The contactor and Relays together with hardware timers and

Electronic Control using logic

In 1960s with the advent of electronics, the logic gates started

hardware timers & counters were replaced by

1970s with the coming of microprocessors and associated

of achieving the desired control or automation through

programmable controllers have in recent years experienced

can be effectively used in applications ranging from simple

Automation: Typical Installation

Sensors Placed in the field

Replacing human operators in tasks that involve

Unemployment rate increases due to machines

Automated video surveillance

A PLC is a solid state / industrial computer that

PLC v/s Microcontroller

PLC is an Industrial Microcontroller

PLC: Location in the control architecture

HMI of a machine for the

Supervisory Control and Data

to H/W and S/W

SCADA S/W should have connectivity to different h/w

Standard frame for application

Designing of the Automation system

Job Prospects for Engineer in

Manufacturing Industries like Reliance, Ceat,

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