Industrial AutomationIndustrial Automation

AutomationAutomation is a system integration encompassing

Operations & Process controls

with

minimum user defined intervention.

Human body & its functioningHuman body & its functioning

Is the most advanced automated system

Consisting of • Sensors (Eyes, Ears, Skin etc…)• Actuators (Hands, Legs etc…) • Brain as PLC…

Industrial encompasses the

Input, Processing & Output of

Various types of • Material • Energy & • Control

Materials used in a process …• Raw Materials ~ Input materials, available in the

final product in a changed form• Components ~ Input materials, available in the final

product in the original form• Consumables ~ Input materials not available in the

final product but required for processing

Energies used in a process …• Primary energy forms ~ Coal, Oil, Gas…• Secondary energy forms ~ Thermal, Electrical…• Derived energy forms ~ Pneumatic, Hydraulic…• Unconventional energy sources ~ Solar, Wind…

Energies used in a process as …• Power Energy

Conversion of energy from one form to another form.• Control Energy

Energy used to exercise control over operation & process

Control exercised in a process as …• Digital Control

An event dependent control• Analog Control

Actual value dependent control

AutomationAutomation system can be realized by• Identification of Customers needs • Designing • Manufacturing & Testing• Installation & Commissioning of a System• Service support

Customer needs may be identified as…• Input Instructions & references (User & Sensors)• Operational logics• Output commands & references

& other allied requirements, with provisions for• Protection • Safety • Security

Automation can be categorized as • Machine Automation• Process Automation• System Automation

Machine Automation deals with • Individual Machine Operation & Control• Material, Energy & Control Input to M/c (MEC)(MEC)• Operation sequencing & interlocks• Material, Energy & Control Output from M/c• With protection, safety & Security features

Process Automation deals with • Processes• MEC Input to Process & Machines• Operation sequencing & interlocks• MEC Output from Process & Machines• With protection, safety & Security features

System Automation deals with • Integration of various

Machines, Processes & Energy resources• MEC Input to System• Operation sequencing & interlocks• MEC Output from System• With protection, safety & Security features

Industrial Sectors requiring Automation • Electrical generation sector• Chemical & Petrochemical sector• Heavy Engineering like foundries & processing units• Automobile manufacturing units• Textile & allied sector• Pharma & Food Industry• Rubber & Plastic units• AC sector

Automation Automation SystemSystem

Energy Input

Material Input

Energy Output

Material Output

Energy loss Material loss

Machine Machine & &

EquipmentsEquipmentsControl PanelControl Panel

OutputOutputActuatorActuatorSwitchgearSwitchgearControllerControllerCommunicationIn & Out

CommunicationIn & Out

LoadLoad

SensorsSensors

F/B(-)F/B(-)O/C(+)O/C(+)I/C(+)I/C(+)

SystemSystem

Control

Power

Variable Load

Material in

Material O/p

Communication from User to Control Panel• Push buttons• Selector switches / Rockers switches• Emergency switches• Potentiometers• Human Machine Interface (HMI)• SCADA (Supervisory Control & Data Acquisition)

Communication from Control Panel to User• Meters• Gauges• Indication Lamps• Buzzers• Annunciation windows• Human Machine Interface (HMI)• SCADA (Supervisory Control & Data Acquisition)

• Communication from System to Control Panel

• Inductive Sensors • Capacitive Sensors• Photo-electric Sensors (Optical)• Ultrasonic Sensors• Float & Limit switches• Pressure, Flow & Temperature Sensors• Encoders (Incremental & Absolute)

Sensor functions as • Initial condition communication• Operating condition communication• Feed-back communication for process parameter

controls (Closed loop feature)

Basic Controllers…• Relays & Contactors • Solid state relays • Proportional Phase Controllers• Timers & Counters

Process Controllers for• Temperature,• Pressure,• Flow,• Speed &• Displacement

(PID & other versions…)

Advanced Controllers…• Micro-processors• PLC • HMI• SCADA• AC Drives• DC Drives

Switchgears …• Miniature Circuit Breakers – MCB• Molded Case Circuit Breakers – MCCB• Motor Protection Circuit Breakers – MPCB • Earth Leakage Circuit Breakers – ELCB • High Rupturing Capacity Fuse – HRC • Overload Relay - OLR

Actuators…• Electrical Heaters, Motors, Lighting systems• Mechanical, Pneumatic, Hydraulic Systems• AC Systems• Combustion Systems

Output…• Temperature, Pressure, Flow, Speed, Displacement• Proximity, Level• Illumination & Sound levels

Load…• Length, area, volume• Physical mass• Thermal mass

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