1. History of industrial Automation

2. What is Automation?
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.
Automation is delegation of human control functions to technical equipment for increasing productivity, better quality, reduced cost & increase safety in working conditions

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

4. 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

5. 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

6. 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

7. 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

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

9. Classical approach to plant Automation
Direct manual process control

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

11. Modular presentation of a Control loop

12. 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

13. 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 :
Minicomputer era:
Distributed computer era :- Since 1975
Being unreliable, they had to be used in Operator Guidance Mode and Set-point Control Mode

14. Operator guidance mode

15. Set-Point Control mode

16. Direct Digital control

17. 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

18. 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

19. Dual computer system for DDC

20. Back up concept of DDC

21. 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.

22. 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

23. Leading PLC providers The leading PLC providers include
Rockwell Automation : Allen Bradley (Micrologix, SLC, PLC, Control Logix)
Siemens ( S7 200, S7 300 , S7 400)
Grouppe Schneider : Modicon ( Nano, Micro, Premium, Quantum)
GE Fanuc : Versa, Series 90-30, 90-70
OMRON

24. 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

26. 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

27. 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

28. 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

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