Ram Prasad Report on IA2003 Industrial automation

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Seminar on Practical Training at Suratgarh Super Thermal Power Station SUBMITTED BY, NIKHIL SHRIMALI & RAM PRASAD 4 th YEAR, ELECTRICAL.

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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 today’s globally competitive market

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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

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Productivity Quality Labour Cost Plant Total Automation Manufacturing Competitiveness Solution Why Automation required in Industry

History of Automation: 

History of Automation Pneumatic Control Hard wired logic Control Electronic Control using Logic Gates Programmable Logic Controller 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.

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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 Hard wired logic Control The contactor and Relays together with hardware timers and counters were used in achieving the desired level of automation Drawbacks Bulky panels Complex wiring Longer project time Difficult maintenance and troubleshooting 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 Drawbacks Reduced space requirements Energy saving Less maintenance & greater reliability Changes in control logic not possible More project time Programmable Logic Controller 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: 

Advantages of PLCs 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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Industrial Automation Components … Field Instruments Control Hardware Control Software

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Sensors Placed in the field Automation : Typical installation . . . . Junction Box Field Cabling Control Panel Control Hardware SCADA Software Communication Cable Field Cabling

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It works like a supervisor who supervises the entire plant area, it also controls the process as well as it converts the data segments for storing process values i.e. level , pressure , switch positions , density , temperature, messages , etc. From a distant place if we want to run the process i.e. starting , stopping , opening and closing of field instruments as well as logging the various values. SCADA can do for you. SCADA software is to be connected to PLC / DCS systems which in turn are connected to field instruments. Hazardous areas , unhygienic places , hilly areas and sea beds where a person can’t be send regularly but process has to be watched continuously or it should be controlled then it can be done using SCADA. Without going to field area if one wants to reset alarms or wants to log a data for a period of time or wants to know status of various units of his company then SCADA is the best option. S C A D A Features of typical SCADA software include , Dynamic process graphic Real-time and Historical trending Alarms Recipe Management Security Device connectivity Script for logic development Database connectivity Networking

Dynamic Process Graphics: 

Dynamic Process Graphics Using this feature, one can develop graphics which can resemble the plant. The graphics can include Reactors, valves, pumps, agitators, conveyors as well as other equipment and machinery used in the plant. The status of the equipment running / stopped can be shown using different colours / animation. Typically the SCADA software will have many ready to use symbols for proper representation which can be used in any type of industry.

Real-time & Historical Trends: 

Real-time & Historical Trends This facility is used for representing the data in graphical form. Typically the trends plots the value with reference to the time Real-time data will plot the real-time value for fixed period of time while historical data will have historical data stored value which can be viewed on demand.. Depending upon the storing capacity of the hard-disk one can specify the no of days the data can be stored Some SCADA software show real-time and historical trends in single graphics while fewrs use separate tools.

Alarms: 

Alarms Every plant needs proper monitoring and control of the process parameters. Alarms represent warnings of process conditions that could cause problems, and require an operator response Generally alarms are implemented by using the lamps or hooters in field but in SCADA it can be represented using animation. In many SCADA software, four type of alarm limits are used ie HI, HIHI, LOW, LOW LOW

Recipe Management: 

Recipe Management In many cases we use the same plant for manufacturing different product range. For example an oil blending plant can manufacture power oil, transformer oil, automobile oil. The recipe management is facility used for maintain various recipes of different products and implement it on the process. The recipe can be stored in a single server and it can be fetched by any client server from any area to run the process.

Security: 

Security Every SCADA software has various levels of security for securing the application by avoiding unauthorised access. Depending upon the access level given the operator / engineers is allowed to do the task. In most of the cases, operators are allowed only to operate the plant while maintenance engineers can do the application modifications. The security can be given for individual as well as for groups.

Device Connectivity : 

Device Connectivity Every control hardware has its own communication protocol for communicating with different hadrware / software. Some of the leading communication protocol include Modbus, Profibus, Ethernet, Dh +, DH 485, Devicenet, Control net. The SCADA software needs device driver software for communication with PLC or other control hardware. More the driver software available better is the device connectivity. Most of the SCADA software used in the industry have connectivity with most of the leading control system.

Database Connectivity: 

Database Connectivity In many plants, it is important to download the real-time information to the MIS. In this case the database connectivity is must. Many SCADA software don’t have their own database. Hence for storage and reporting they use third party database like MS Access or SQL

Scripts: 

Scripts Script is a way of writing logic in SCADA software. Every SCADA software has its own instructions and way of writing program. Using scripts, one can develop complex applications. You can create your own functions to suit the process requirement. execution. Various types of scripts make project execution simpler for programmer.

Networking: 

Networking In many application, we have to use more than one SCADA software / operator stations. This can be achieved by taking the SCADA node on network. In many cases Ethernet TCP/IP is commonly used for networking. In certain cases the SCADA software use propriety networking protocols for networking.

Local Control Stations (OI and HMI) : 

Local Control Stations (OI and HMI)

Evolution of SCADA: 

Evolution of SCADA To start with the SCADA software were used for monitor and controlling the parameters locally. Subsequently the modems were used the monitor the data over a distance

Advanced Network Arrangement: 

Advanced Network Arrangement The latest advancement in the SCADA technology includes the data monitoring on wide area network using modems, Ethernet tcp/ip as well as GPS system

Wireless Industrial Applications: 

Wireless Industrial Applications Wireless Ethernet, Self-Powered Wireless Sensors RFID Wireless and RFID technologies are finding extensive usage in a field of industrial automation

Typical Industry Application : 

Typical Industry Application Apart from manufacturing process, SCADA software are being used very effectively in water supply and management. The functionality includes. Control of Substations Control of auto-reclosers Load shedding Metering Downtime analysis Despatch and assessment Electricity In electricity, the functionality includes. Chemical Plants Reservoir Management

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Some of the Leading SCADA Software Wonderware : InTouch Intellution : iFix (Earlier Fix DMACS) Allen Bradley : RS View (Earlier Control View) Siemens : WinCC (Earlier Coros LS /B ) GE Fanuc : Cimplicity Indusoft : I W S Movicon : Progea

Programmable Logic Controllers: 

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

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PROGRAMMABLE LOGIC CONTROLLERS Now a days PLCs are the most widely used control hardware in control applications. The applications ranges from standalone system for CNC machines to Hot swappable Redundant System for Critical Process Control

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What Constitutes A PLC ? The PLC is programmed interface between the field I/p element like limit switches, sensors, push button and the final control elements like actuator, solenoid/control valves, drives, hooters etc PLC consist of Input Module CPU with Processor and Program memory Output module Bus System Power Supply

Input Devices: 

Input Devices Pushbuttons Selector Switches Limit Switches Level Switches Photoelectric Sensors Proximity Sensors Motor Starter Contacts Relay Contacts Thumbwheel Switches Output Devices Valves Motor Starters Solenoids Control Relays Alarms Lights Fans Horns Relays 120 VAC/VDC 240 VAC 24 VAC/VDC Triac 120/230 VAC Transistor MOSFET 24 VDC

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PSU CPU DI 16 CH DI 8 CH DO 16 CH PSU DI 32 CH AI 4 CH AO 4 CH AI/AO 4 CH Slot 0 Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 Slot 6 Slot 7

Addressing Scheme in AB PLC: 

Addressing Scheme in AB PLC File type : slot add . word add /bit add CPU generally is in Slot 0 Slot 1 - I :1.0/0 to I:1.0/15 Slot 2 - I:2.0/0 to I:2.0/7 Slot 3 - O:3.0/0 to O:3.0/15 Slot 4 - I:4.0/0 to I:4.0/31 Slot 5 - I:5.0 to I:5.3 Slot 6 - O:6.0 to O:6.3 Slot 7 - I:7.0 to I:7.1 O:7.0 to O:7.1

Various Brands of PLCs: 

Various Brands of PLCs Allen Bradley USA Siemens Germany Modicon France Mitshubishi Japan GE Fanuc USA Omron Japan

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

CONFIGURATION OF PLC :: 

8 ANALOG INPUTS 1 ANALOG OUTPUT UP/DOWN FAST COUNTER UP COUNTER PROGRAMMING TERMINAL PC CONNECTION UNITELWAY PORT FOR CONNECTION OF UP TO 5 SLAVES Memory expansion port Communications port tsx37-22 BUILT IN DISPLAY FOR I/O (IN-RACK, AS-I) I/O MODULES CONFIGURATION OF PLC : MODICON SIEMENS CPU External Power Supply I/O Modules ALLEN BRADLEY CPU Power Supply I/O Modules

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DISTRIBUTED I/O MODULES Distributed I/O modules PLC Distributed I/O scanner Data Communication Bus

HOT REDUNDANT SYSTEM CONFIGURATION: 

Remote I/O Network SPLITTER FIBER OPTIC LINK TAPS Remote I/O HOT REDUNDANT SYSTEM CONFIGURATION

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NETWORKING OF PLCS Supervisory HMI Modicon : Modbus +, Uniteleway, Ethernet Allen Bradley : DH+, DH485, Ethernet, Control Net, Devicenet Siemens : Sinec L1/L2/H1, Profibus

Operation of Mixer: 

Operation of Mixer IF sensor 2 is high when low level THEN MOTOR 1 ON and MOTOR 3 and 2 OFF. IF sensor 1 is High when high level then enable timer (10 seconds) for MOTOR 2 ON and MOTOR1 OFF. After 10 sec drain MOTOR 3 ON until sensor 2 is not high. Motor 2 Motor 1 Motor 3 Sensor 1 Sensor 2 Ingredient A Cement Manufacturing

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PROGRAMMING LANGUAGES IN PLCS Ladder Logic ( LAD/LD ) Structured Text ( ST) Instruction List ( IL ) Sequential Function Chart ( SFC ) Function Block Diagram ( FBD )

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| | |/| Read / Conditional Instructions Write / Control Instructions | | |/| | | |/| | | | | |/| ( ) | | ( ) ( ) ( ) ( ) | | Start (Rung #1) End (Rung #5) Ladder Logic Concepts Read / Conditional Instructions Write / Control Instructions No Logical Continuity |/| | | True False False |/| |/| ( ) ( ) True True True Logical Continuity Ladder Logic Concepts

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ROLE OF ENGINEERS IN INDUSTRIAL AUTOMATION Designing of the Automation system Erection and Commissioning Application Engineering Maintenance and Troubleshooting of existing system