Slide 1:PLC & AUTOMATION By SUMANTA KUMAR OJHA REGD.NO::0721219007


Slide 2:PROCESS CONTROL & AUTOMATION


PROCESS CONTROL & AUTOMATION :PROCESS CONTROL & AUTOMATION CONTENTS What is Process Control What is Automation History of Process Control and Automation Advantages of PLC Building Blocks of PLC Application Conclusion


Slide 4:PROCESS CONTROL & AUTOMATION PROCESS CONTROL The process of recognizing the state of the process at all times, analyse the information according to the set rules & guidelinens & accordingly actuate the control elements is referred to as process control. Recognising the Status Process the Information Actuate the Control elements Rules & Guidelines In the control of process all these actions can be taken manually with human involvement or in a semiautomatic or fully automatic manner.


:PROCESS CONTROL & AUTOMATION AUTOMATION Automation is basically the delegation of human control functions to technical equipment aimed towards achieving. Higher productivity Superior quality of end product Efficietn usage of energy & raw materials Improved safety in working conditions ………..Etc.


Slide 6:PROCESS CONTROL & AUTOMATION HISTORY OF PROCESS CONTROL & AUTOMATION MANUAL CONTROL HARD WIRED CONTROL ELECTRONIC CONTROL PLC CONTROL


Slide 7:PROCESS CONTROL & AUTOMATION HISTORY OF PROCESS CONTROL & AUTOMATION MANUAL CONTROL In this all actions related to process control & automation are taken care by the operators. One of the major drawback of this method is the likely human errors & consequently its effect on quality of the final product. The manual control has its own limitations with regard to mass production techniques & hence this method cannot provide the consumer with quality goods at an affordable price. The safety or efficient use of raw material & energy are all subject to the correctness & accuracy of human action.


Slide 8:PROCESS CONTROL & AUTOMATION HISTORY OF PROCESS CONTROL & AUTOMATION HARD WIRED LOGIC CONTROL This was considered to be first step towards automation. Here the contactor & relays together with timers & counters were used in achieving the desired level of automation. Although this method served the purpose for many years, it had certain limitations as listed below : Bulky & Complex Wiring Involves lot of rework to implement changes in control logic The work can be started only when the task is fully defined & this leads to longer project time.


Slide 9:PROCESS CONTROL & AUTOMATION HISTORY OF PROCESS CONTROL & AUTOMATION ELECTRONICS CONTROL With the advent of electronics, the logic gates started replacing the relays & auxiliary contactors in the control circuits. The bimetalic & motorized timers were replaced by electronic timers…..etc. With incorporation of these changes, we got the benefits of : Reduced space requirements Energy saving Less maintenance & hence greater reliability ………….etc.


Slide 10:PROCESS CONTROL & AUTOMATION HISTORY OF PROCESS CONTROL & AUTOMATION ELECTRONICS CONTROL However even with electronics, the implementation of changes in the control logic as well as reducing the project lead time was not possible. This method of control & automation was also popular for quite some time.


Slide 11:PROCESS CONTROL & AUTOMATION HISTORY OF PROCESS CONTROL & AUTOMATION PROGRAMMABLE LOGIC CONTROLLER As the desired Logic control is achieved through a ‘program’, these controllers are referred to as 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. With the coming of microprocessor & associated peripheral chips, the whole process of control & automation underwent a radical change.


Slide 12:PROCESS CONTROL & AUTOMATION HISTORY OF PROCESS CONTROL & AUTOMATION PROGRAMMABLE LOGIC CONTROLLER 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.


Slide 13:PROCESS CONTROL & AUTOMATION ADVANTAGES OF PLC REDUCED SPACE PLC are fully solid state & hence extremely compact as compared to hard – wired controller where in electro – mechanical devices are used. Average power consumption is just 1/10th of power consumed by an equivalent relay logic control. ENERGY SAVING EASE OF MAINTENANCE # Modular replacement. # Easy Trouble Shooting. # Error diagnostics with programming unit.


Slide 14:PROCESS CONTROL & AUTOMATION ADVANTAGES OF PLC # Considering one time investment ; PLC is most economical system. ECONOMICAL # Cost of PLC recovers within a short period (Low pay back period). GREATER LIFE & RELIABILITY # Static devices hence lesser number of moving parts, reduces wear & tear.


Slide 15:PROCESS CONTROL & AUTOMATION ADVANTAGES OF PLC GREATER LIFE & RELIABILITY # In the case of hard wired logic, the control hardware is either electromechanical or pneumatic & therefore it is more prone to faults due to wear & tear of moving parts resulting in lesser ON TIME of the system.


Slide 16:PROCESS CONTROL & AUTOMATION ADVANTAGES OF PLC # To implement changes in control logic no rewiring is required so considerable time is saved. TREMENDOUS FLEXIBILITY # PLC can carry out complex function such as generation of time delays, counting, comparing , arithmetic operations etc. # “ On line ” (I.e. without disturbing the process ) as well as “ Off line ” programming is possible. # High processing speed & great flexibility in the processing of both analog & digital signals. # Suitability for closed loop tasks with several loops & high sampling frequencies.


PROCESS CONTROL & AUTOMATION FLEXIBILITY & FASTER RESPONSE TIME :PROCESS CONTROL & AUTOMATION FLEXIBILITY & FASTER RESPONSE TIME


Slide 18:PROCESS CONTROL & AUTOMATION BUILDING BLOCKS OF PLC SYSTEM Do these counters, timers, etc. really exist? No, They don't "physically" exist but rather they are simulated and can be considered software counters, timers, etc. These internal relays are simulated through bit locations in registers. (more on that later)


Slide 19:PROCESS CONTROL & AUTOMATION BUILDING BLOCKS OF PLC SYSTEM


PROCESS CONTROL & AUTOMATION :PROCESS CONTROL & AUTOMATION


PROCESS CONTROL & AUTOMATIONAPPLICATION OF PLC IN INDAUSTRY :PROCESS CONTROL & AUTOMATIONAPPLICATION OF PLC IN INDAUSTRY


Problem :Problem Q. design a ladder logic for interlocking of 3 conveyor belts. When we switch on immidiately 1st conveyor will on .Then 2nd conveyor will on after 5 min of former by switching off the 1st .Then 3rd will on after switching of the 2nd.If there are 3 errors in 3rd conveyor then whole conveyor system will off. PROCESS CONTROL & AUTOMATION


Slide 23:PROCESS CONTROL & AUTOMATION


PROCESS CONTROL & AUTOMATION :PROCESS CONTROL & AUTOMATION


PROCESS CONTROL & AUTOMATION :PROCESS CONTROL & AUTOMATION


PROCESS CONTROL & AUTOMATION :PROCESS CONTROL & AUTOMATION


PROCESS CONTROL & AUTOMATION :PROCESS CONTROL & AUTOMATION


PROCESS CONTROL & AUTOMATION :PROCESS CONTROL & AUTOMATION Normally, the operator is only concerned by the supervisory level, but exceptionally, operators (and engineers) want to access data of the lowest levels The operator sees the plant through a fast data base, refreshed in background


PROCESS CONTROL & AUTOMATION :PROCESS CONTROL & AUTOMATION Now a days PLC is being applied in our day to day life. Whenever there is a requirement of automation, we are using PLC. It is not even used in industrial application but used in home appliances . CONCLUSION


THNAK YOU :THNAK YOU