INDUSTRIAL

AUTOMATION
UNIT V
Prepared by :
Pradnya Sadigale
Types OF Industrial Automation
• Fixed Automation
• Programmable Automation
• Flexible Automation
• Integrated Automation
Fixed Automation:
Features:
High Volume Production
Dedicated Equipment
Fixed efficient operation

For Example blast furnace, steel melting furnace operations, there

equipment will require long life and they handle very much material
that it make sense that they are tuned to fixe efficient operation
Programmable Automation
Where You have to make changes very frequently.
Features:
• Changeable Sequence of operation
• Electronic controls

• Examples:
• NC machines
• Assembly Robots
Flexible Automation
• Features
• Computer Controlled
• Programmable Material Handling
Integrated Automation
• Advanced Optimizing Algorithems
• Computer Communication
• Production/ Management Integration
Distributed Control System (DCS)
• A distributed control system (DCS) is a computerised control system
for a process or plant usually with many control loops, in which
autonomous controllers are distributed throughout the system, but
there is no central operator supervisory control.
• This is in contrast to systems that use centralized controllers; either
discrete controllers located at a central control room or within a
central computer.
• The DCS concept increases reliability and reduces installation costs by
localising control functions near the process plant, with remote
monitoring and supervision.
LEVELS OF DCS
Referring to the diagram;
•Level 0 contains the field devices such as flow and temperature sensors, and final control elements,
such as control valves
•Level 1 contains the industrialised Input/Output (I/O) modules, and their associated distributed
electronic processors.
•Level 2 contains the supervisory computers, which collect information from processor nodes on the
system, and provide the operator control screens.
•Level 3 is the production control level, which does not directly control the process, but is concerned
with monitoring production and monitoring targets
•Level 4 is the production scheduling level.
Levels 1 and 2 are the functional levels of a traditional DCS, in which all equipment are part of an
integrated system from a single manufacturer.
Levels 3 and 4 are not strictly process control in the traditional sense, but where production control
and scheduling takes place.
BASIC ELEMENTS OF
DISTRIBUTED CONTROL SYSTEM
Engineering PC or controller:
• This controller is the supervisory controller over all the distributed
processing controllers. Control algorithms and configuration of
various devices are executed in this controller.
Distributed controller or Local control unit:
• It can be placed near to field devices (sensors and actuators) or
certain location where these field devices are connected via
communication link. It receives the instructions from the engineering
station like set point and other parameters and directly controls field
devices.
Operating station or HMI:
• It is used to monitor entire plant parameters graphically and to log the data in
plant database systems. Trend display of various process parameters provides
the effective display and easy monitoring.
• These operating stations are of different types such as some operating stations
(PC’s) used to monitor only parameters, some for only trend display, some for
data logging and alarming requirements. These can also be configured to have
control capabilities.
Communication media and protocol:
• Communication media consists of transmission cables to transmit the data such
as coaxial cables, copper wires, fiber optic cables and sometimes it might be
wireless. Communication protocols selected depends on the number of devices
to be connected to this network.
• For example, RS232 supports only for 2 devices and Profibus for 126 devices or
nodes. Some of these protocols include Ethernet, DeviceNet, foundation filed
bus, modbus, CAN, etc.
• Advantages of DCS System :-
1.DCS allocate flexibility and simplicity by allowing
central control
2.monitoring and reporting of individual components
and processes
3.DCS are scalable
4.possible to control through dynamic graphic
5.eliminating human error by Logging of data
• Disadvantages of DCS system :-
1.Failure of one controller effects more than one loop
2.DCS required skilled operator because the all
information hidden behind CRT
SCADA SYSTEM
• What is SCADA System?
SCADA stands for Supervisory Control and Data Acquisition; it is an
industrial computer-based control system employed to gather and
analyze the real-time data to keep track, monitor and control industrial
equipments in different types of industries. Consider the application of
SCADA in power systems for operation and control.
SCADA Basics
• Before discussing about the architecture of SCADA and different types
of SCADA systems, primarily we must know a few SCADA basics.
Consider the block diagram of SCADA system shown in the figure
which consists of different blocks, namely Human-machine Interface
(HMI), Supervisory system, Remote terminal units, PLCs,
Communication infrastructure and SCADA Programming.
Introduct
ion
 What is SCADA?

 What is data acquisition?

 Where and why, use of SCADA?

Application area :
 Industrial processes : chemical, power generation and
distribution, metallurgy, …
 Nuclear processes : reactors, nuclear waste, ...
 Experimental physics : HEP laboratories
 Application size:
 20 k I/O to 450 K I/O,
 1 M I/O under development
 ERP Systems

SCADA Expert Systems

? Supervisory Data
And Acquisition
Control
Archiving, Logging,
Graphics and Batch processing Access Control, Alarms

Distributed database
Data Server Data Server PLC’s

Field Bus
Control Programs
Architect
ure
 Hardware

 Software
Hardw
are

Typical Hardware Architecture

Software
Architecture
Software
Architecture
Communication
Internal Communication
Access to Devices
 Interfacing
H/W
 Multiple communication protocols supported in a single system
 Support for major PLCs/DCSs but not VME

S/W
 API
 ODBC, DDE and OLE I/F to PC Products
 OPC Client and OPC Server
 ActiveX Containers
 Scalability

 Database
Configuration DB, alarm DB, Archive DB, log DB and
RTDB resides in the memory of the servers
Functiona
lity
 Generic SCADA functionality
 Access Control,
 MMI,
 Trending,
 Alarm Handling,
 Logging, Archiving,
 Report Generation,
 Automation.
Functionality
Contd..
 Access Control
Users - allocated to groups

group - defined read/write access

 MMI
multiple screens
library of standard graphical symbols
dragged and dropped
zooming, re-sizing, scrolling...
Links - pages to navigate
Functionality
Contd..
 Trending
based on parameters on specific chart
can be predefined or defined on-line
more than 8 trended parameters per chart
both real-time and historical trending
zooming and scrolling
 Alarm Handling
based on limit and status checking
handled centrally

E-mails can be generated

Functionality
Contd..
 Logging, Archiving
 Data stored in compressed and proprietary format
 Logging / Archiving either for a set number of parameters or for
a set period of time
 Logging / Archiving can be frequency or event driven *
 Logging of user actions together with a user ID
 VCR facility for playback of stored data
 Writing logs into RTDB

 Report Generation
 Reports created using SQL type queries to the RTDB or logs
 Automatic generation, printing and archiving of reports Use
 of ‘components’ for report generation
Functionality
Contd..
 Automation
triggered by events
defined in scripting languages
send e-mail ,write into RTDB
recipes
Sequencing
Development
Tools
 Project editor
 Graphics editor
 Configuration through parameter templates
 Scripting language
 Driver Development Tool Kit
 And more…
Data Access
Mechanism's Alarm Server
 Alarm Server typically poll
data from the data server
( -> impact on network Data Server
bandwidth) Polling
More advanced techniques like
publish / subscribe are
available in some cases

o
P
llin
g
 Data from field buses are
mainly polled
Field Bus
SCADA is a control system with

•More frond end functionality

•More interfaces and efficient storage
•More record or device oriented configuration
•but System wide configuration tools are needed
•are less expensive than DCS, but offer different functionality
than DCS
•And finally various applications