industrial automation by rahul gunde (lbrce-mym)
DESCRIPTION
PLC & SCADA PPTTRANSCRIPT
Industrial Automation
PLC & SCADA
By:-Rahul Gunde
What is Automation ?
Making “Automate ”
Automate – To do by itself
What happens if “man” works,
Constantly and Continuously ?
ERRORS !!! ERRORS !!! ERRORS!!!
Why ?
Due to fatigue and over confidence.
In Other Words,
Using Technology in the places
where “humans errors are possible”. And using “manpower” in appropriate way
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 WeConsider, MAN : MACHINE
Then, EYE : Photo Electric Sensors, Vision Systems
EAR :Ultrasonic Sound, Vibratory Sensors SKIN : Temperature, Magnetic, Tactile, Shock, Viscosity, Flow, etc.
NOSE : Chemical Sensors TONGUE : Bio –Sensors
HANDS : Grippers, Motion Controllers LEGS : Motion Controllers, MOUTH : Speakers, Indication, Communication
Devices
BRAIN : Controllers
NERVES : Wires, Communication Devices
INPUTS
OUTPUTS
CONTROLLING SYSTEM
TRANSMITTERS
Automation Components
Sensor for sensing physical conditions Transmitters Control Systems Output Devices
History of Automation ?
Pneumatic Control
Hard wired logic Control
Electronic Control using Logic Gates
Programmable Logic Controller
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 timersAdvantages
•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 PLC
Reduced space Energy saving Ease of maintenance Economical Greater life & reliability Tremendous flexibility Shorter project time Easier storage, archiving and documentation
Industrial Automation Components
Field Instruments Control Hardware Control Software
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
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
Automation Application
Automated video surveillance Automated highway systems Automated manufacturing Home automation Industrial automation
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.
PLC v/s Microcontroller
PLC is an Industrial Microcontroller
Areas of ApplicationsAny application in any industry that requires electrical control
Packaging Bottling & CanningMaterial Handling MachiningPower Generation HVAC/ Building AutomationSecurity Systems Automated AssemblyPaint Lines Water treatment
IndustryCement Automobile ChemicalsPlasticsMetals Paper F&B
Supervisory Control and DataAcquisition (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
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,
DEVICE CONNECTIVITY
Every manufacturer have there one way communication or follow different protocols.
SCADA S/W should have connectivity to different h/w used in automation
Benefits of SCADA
Standard frame for application Rich functionality Limited specific development Technical support and maintenance Once installed reduces the cost and provides more
efficiency.
Roles of Engineers in Industrial Automation
Designing of the Automation system Erection and Commissioning Maintenance and Troubleshooting of existing
system
Job Prospects for Engineer in Industrial Automation
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….
