Basic of Industrial Automation

What one will Learn?

 What are the basic elements of Industrial Automation?
History
Concept
 Why is automation relevant to industry?
 What are the different technologies available?
Automation  Where can automation be applied purposefully?
Pyramid  What are the different kinds of controllers?
 What is meant by visualization (HMI & SCADA)?
Controller

Visulization
Basic of Automation
What is Automation
 The dictionary defines automation as “ The technique of
History
making an apparatus.a process, or a system operate
Concept
automatically.”

Automation
 Automation Federation define automation as “The creation
Pyramid
& application of technology to monitor & control the
production and delivery of products and services.”
Controller

Visulization  Automation Means use of available technologies to

reduce the need of human work.

 Automation greatly decreases the needforhuan sensory

and mental requirements as well.
Basic of Automation
Concept of Automation

History
Concept

Automation
Pyramid

Controller

Visulization
Basic of Automation
The Automation Pyramid

History
Concept

Automation
Pyramid

Controller

Visulization
Basic of Automation
The Automation Pyramid
 Sensors and Actuators Layer
History • Closest to the process and machines & field Signal
Concept  Automation Control Layer
• Consists of automatic control & monitoring systems
Automation  Supervisory Control Level
Pyramid • The automatic control system by setting target /goal to the controller
 Production Control Layer
Controller • The decision problems like production targets, resource allocation, task
allocation to machines, maintenance management
Visulization  Enterprise control layer
• This deals less technical and more commercial activities
• like supply, demand, cash flow, product marketing
Basic of Automation
Types of Controller

History
Manual Control
Concept

Option - 1

Option - 2
Programmable

Automation

Hard Wired /
Option-4
Controller

Relay Logic
Pyramid Machine / Process

Control
(PLC)

Control &
Controller
Automation
Visulization Option-3

Dedicated Electronic
Control
Basic of Automation
Characteristics Manual Relay/Wired Dedicated PLC
Control
Price per function Lowest Low High Medium
History
Physical Size Depend Compact/ Bulky Fairly Compact Very Compact
Concept Operating Speed Low Good Fairly Fast Fast
Electrical Noise Low Excellent/Low Quit Good Good
Immunity
Automation
Installation Time Time Consuming Programming is Simple to Program
Pyramid Consumming design & Time Consuming and Install
Installation
Capability of No No Yes Yes
Controller Complex operation
Ease of Changing Difficult Difficult Quite Simple Very Simple
Functions
Visulization Ease of Poor ,New Poor- large Poor- several Good- few
Maintenance Power Man number of custom boards standard cards
contacts/Poor for
Wiring Breakage
Additional No Difficult Not too much Simple to add
Functionality
Basic of Automation
Acid mixing Process using PLC

History
Concept V1 V2
M
L2
Automation
L1
Pyramid

Controller L0
V3
Visulization
VI OPEN SENSE LEVEL L1 V1 CLOSE
V2 CLOSE SENSE LEVEL L2 V2 OPEN
MOTOR ON MEASURE TIME MOTOR OFF
V3 CLOSE SENSE LEVEL L0 V3 OPEN
Basic of Automation
Benefits of PLC

History PLC CAPABILITIES

Concept
Logic Control
Automation
Pyramid
Timer Communication
Controller
Counter

Visulization
Analog Signal Signalling & Listing

PID Control Real Time Function

Basic of Automation
Advantages of PLC
Advantages of Using PLC
History
Concept Reduced Space

Energy Saving
Automation
Pyramid Ease of Maintenance

Economical
Controller
Greater Life & Reliability
Visulization Tremendous Flexibility
Shorter Project Time

Archiving & Documentation

Basic of Automation
Evaluation of Visulization
 Lamp/Indicators :
History
• A control might consist of hundreds of pushbuttons and LEDs
Concept
performing different operations.
 Alarm Annuciators :
Automation
• An Annunciator panel is a system to alert operators of alarm
Pyramid conditions in the plant
 Text Display :
Controller
• An electronic alphanumeric display that is mainly or only capable
of showing text or extremely limited graphic characteristics
Visulization
 Graphics:
• Schematic representation of process with variety of additional
functionality like Alram,Trend,Report,Script,User Admin,Recipes
etc.
Basic of Automation

History
Concept

Automation
Lamp
Pyramid
Graphics

Controller

Visulization

Alarm Annuciators Indicators Display

Programming Logic Controller
Introduction
PLC  The PLC processor, or controller
Introduction  Memory
 I/O (Input /Output) modules
Range of  Chassis or backplane
PLCs  Power supply
 Programming software that runs in a PC
Architecture
of PLCs

Programming
Techniques
Programming Logic Controller
Range of PLCs
PLC 1) Micro PLCs - It covers units with up to 128 I/O’s and
Introduction memories up to 2 Kbytes.
(Small PLC) - these PLC’s are capable of providing simple to
Range of advance levels or machine controls.
PLCs 2) Mid Range PLCs- This PLC have up to 2048 I/O’s and
memories
Architecture up to 32 Kbytes.
of PLCs 3) Large PLCs-
• The most sophisticated units of the PLC family.
Programming • They have up to 8192 I/O’s and memories up to 750 Kbytes.
Techniques • It can control individual production processes or entire plant.
4) Soft PLCs- PC based Automation(PLC and HMI is integrated in
one platform)
Programming Logic Controller
Architecture of PLCs
PLC
Introduction

Range of
PLCs

Architecture
of PLCs

Programming
Techniques  PROCESSOR :
• Provides intelligence to command and govern the activities of
the entire PLC systems.
Programming Logic Controller
Memory :
PLC All PLC contain both RAM and ROM memory
Introduction  Executive Memory: ROM memory .The operating system is a
special machine language program that runs the PLC
Range of  System Memory: ROM memory. This area is allotted for use
PLCs of the operating system only and is not available to the
user for programming
Architecture  IO Status Memory: RAM memory. This portion of RAM is
of PLCs allocated for the storage of current I/O status
 DATA Memory: RAM memory. This portion of RAM is allocated
timers, counters, mathematics and process parameters are
Programming required, an area of memory must be set aside for data
Techniques storage
 User Memory: RAM/EPROM/EEPROM memory. The final area
of memory in a PLC is allocated to the storage of the user
program
Programming Logic Controller
 I/O MODULES :
PLC • Provides signal conversion and isolation between the internal
Introduction logic level signals inside the PLC and the field’s high level signal

Range of  SCANNING: Input Scan + Program Scan+ Output Scan

PLCs
 POWER SUPPLY :
Architecture • Provides the voltage needed to run the primary PLC
of PLCs components

Programming  PROGRAMMING DEVICE :

Techniques • Used to enter the desired program that will determine the
sequence of operation and control of process equipment or
driven machine.
Programming Logic Controller
1) Standalone PLCs
PLC
Introduction

Range of
PLCs

Architecture
of PLCs

Programming
Techniques
Programming Logic Controller
2) Distributed PLCs
PLC
Introduction

Range of
PLCs

Architecture
of PLCs

Programming
Techniques
Programming Logic Controller
3) Redundant PLCs
PLC  Hardware Redundancy
Introduction  Software Redundancy

Range of
PLCs

Architecture
of PLCs

Programming
Techniques
Programming Logic Controller
Pogramming Techniques
PLC A) Basic Types of Programming
Introduction 1) Linear Programming
 Main Blocks for whole program
Range of  Simple Program
PLCs  Simple Operation

Architecture
of PLCs

Programmin
g Techniques
Programming Logic Controller
2) Structured Programming
PLC  Complex Programming ,Simple and clear programming, even for
Introduction large programs
 Program parts can be standardized, Easy alterations
Range of  Simple program test,Simple start-ups
PLCs  Subroutine techniques (block call from different locations)
 Debugging is simplified since
Architecture  Separate sections can be tested.
of PLCs

Programmin
g Techniques
Programming Logic Controller
Programming Langauges
PLC 1) Ladder Langauge
Introduction  Scanning of the each rung
 Easy and simple for programming
Range of  Easy for diagnosis
PLCs

Architecture
of PLCs

Programmin
g Techniques
Programming Logic Controller
2) Functional Block diagram (FBD)
PLC  Graphical Blocks for Programming
Introduction  Simple for Programming
 Many Input but Single output
Range of 3) Statement List Programming
PLCs  Statement List Operations
* Load (LD) instruction.
Architecture * And (A) instruction.
of PLCs * Or (O) instruction.
* Output (=) instruction.

Programmin
g Techniques
Programming Logic Controller
2) Functional Block diagram (FBD)
PLC  Graphical Blocks for Programming
Introduction  Simple for Programming
 Many Input but Single output
Range of 3) Statement List Programming
PLCs  Statement List Operations
* Load (LD) instruction.
Architecture * And (A) instruction.
of PLCs * Or (O) instruction.
* Output (=) instruction.

Programmin
g Techniques
SCADA/HMI
Evaluation
History • Frequent new versions
Concept • From “tag/ channel-based” to “device oriented”
• Multi-team development
Automation • Web technology, Active X, Java, etc.
Pyramid • OPC for internal communication
• Different third party PLC driver
Controller • Modbus Communication

Visulization
SCADA/HMI
Architecture
 Various process busses (Profinet,Modbus,Profibus,Ethernet,…)
SCADA/HMI  Non-proprietary channels (PROFIBUS, FMS)
 Communication to 3rd-party PLC’s via OPC ,OPC Data Access
Intrduction ,OPC Data Access XML
 More channels available as
SCADA
Architecture  Add-Ons SCADA OPC
client

Functions
3rd-party OPC
server

Applications
PLC_2 Rack PLC
PLC_1

PLC_ 4
SCADA/HMI
Areas Of Application

SCADA/HMI

Intrduction

Ethernet
Architecture
Data Server Data Server
PLC’s
Functions

Applications

Field Bus
SCADA/HMI
SCADA/HMI Functionality

SCADA/HMI

Intrduction

Architecture

Functions

Applications
SCADA/HMI
Graphic Design
 Support of tag structures
SCADA/HMI  Application of faceplate
block technology
Intrduction 1) Input fields
2) Faceplate blocks
Architecture  Creation of a specific project
 And symbols library
Functions

Applications
SCADA/HMI
Alarm Handling
 Based on limit and status checking
SCADA/HMI  More complicated expressions developed by creating derived
parameters
Intrduction  Alarms are time stamped and logically centralised
 Notifications (audible, visual, Email, GSM)
Architecture  Multiple alarm priority levels
 Grouping of alarms and handling of groups is possible
Functions  Suppression and masking of alarms either individually or as a
complete group
Applications  Filtering of alarms is possible
SCADA/HMI
Report
 Configurable layouts and Print
SCADA/HMI
 Time or event driven reports

Intrduction  Configuration, Runtime, Historical and external data (e.g. from

databases)
Architecture

Functions

Applications
SCADA/HMI
User Administration
 Free configurable user groups and administration of rights
SCADA/HMI  Plant wide user management (scalable for Web-solutions)
 Integrated with the user management of Microsoft
Intrduction

Architecture

Functions

Applications
SCADA/HMI
Trending
 Multiple trending charts
SCADA/HMI  Charts are pre-defined or configured on-line
 Charts contain multiple pens,
Intrduction  Zooming, scrolling, panning, ‘Hairline’
 Real-time and historical trending
Architecture  Write data to RDB

Functions

Applications
SCADA/HMI
Interfaces to H/W and S/W
Hardware
SCADA/HMI  Multiple communication protocols supported in a single system
(in particular CERN supported Field busses)
Intrduction  Support for major PLCs/DCSs but not VME
Software
Architecture  API
 ODBC, DDE and OLE I/F to PC Products
Functions  OPC Client and OPC Server
 ActiveX Containers
Applications  Web clients
SCADA/HMI
Development Tool
 Project editor
SCADA/HMI  Graphics editor
 Configuration through parameter templates
Intrduction  Scripting language
 Most processing tools based on IEC 1131
Architecture  Batch configuration according to S88.1
 Driver Development Tool Kit
Functions

Applications
SCADA/HMI
Areas Of Application of SCADA

SCADA/HMI

Intrduction

Architecture Electric power generation, Manufacturing: manage parts Mass transit: regulate
transmission and distribution: inventories for just-in-time electricity to subways, trams
Electric utilities detect current and trolley buses; to
manufacturing, regulate industrial
Functions flow and line voltage, to monitor automation and robots, and
the operation of circuit breakers,
automate traffic signals for
rail systems; to track and
monitor process and quality
and to take sections of the power control. locate trains and buses; and
grid online or offline. to control railroad crossing
Applications Buildings, facilities gates. Water and sewage:
and environments: State and municipal
Facility managers water utilities use
use SCADA to SCADA to monitor and
control HVAC, regulate water flow,
refrigeration units, reservoir levels, pipe
lighting and entry pressure and other
systems. factors.
Thank you for your attention!

Siemens ltd
I IA AS SUP FA
India(mumbai)
• https://support.automation.siemens.com/WW/llisapi.dll?func=
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