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Ancient Industrial Automatic Control

One of the first feedback control devices on record is believed to be the ancient water

clock of Ctesibius in Alexandria, Egypt around 250 B.C.

1700-1900

1st Industrial Revolution– Mechanical production powered by steam.

1900-1970

2nd Industrial Revolution– Mass production powered by electricity.

1900s

Use of relays and control cabinets in remote rooms to turn things on/off by use of

switches and monitor recorders.

1968

First design concept of a Programmable Controller.

1969

Modicon 084 the first Programmable Controller (PC) implemented. (Modicon stood

for Modular Digital Controller).

1970-2000

3rd Industrial Revolution– Automation of production by electronics.

1975s

Distributed control systems were installed in the plants near to the control room via

proprietary digital communications lines called as Data Hiway. First DCS was

developed by Honeywell, U.S

1980

Uncorroborated report of a Trojan program inserted into SCADA system software that

caused a massive natural gas explosion along the Trans-Siberian pipeline in 1982.

‘Farewell Dossier’.

Industrial Automation

Automation or automatic control, is the use of various control systems for operating

equipment such as machinery, processes in factories and other applications with

minimal or reduced human intervention. Some processes have been completely

automated.

The biggest benefit of automation is that it saves labor.

Also used to save energy and materials

Improve quality, accuracy and precision.

Factory Automation

Building Automation

Process Automation

Smart Transmitters Placed in the field

Field Bus Scanners

Field Cabling

Control Panel

Hardware Controller

SCADA Software

Communication Cable

Field Bus Network

Automation : Advanced Systems

In 1969 Gould Modicon developed the first PLC.

Strength – Programmed with Ladder Logic

Initially called Programmable Controllers PC’s

Now - PLC’s, Programmable Logic Controllers

PLC’s have evolved from simple on/off control to being able to communicate with other control systems, provide production reports, schedule production, diagnose machine and process faults.

Modular

Integrated

CPU

Power Supply

Memory

Input Blocks

Output Blocks

Communications

Expansion

Connections

PROCESSOR

POWER SUPPLY

I M N O P D U U T L E

O M U O T D P U U L T E

PROGRAMMING DEVICE

From SENSORS Pushbuttons,

contacts,

limit switches, etc.

To OUTPUT

Solenoids, contactors,

alarms etc.

The Central Processing Unit (CPU)

Module is the brain of the PLC.

Primary role to read inputs, execute the control program,

update outputs.

The CPU consists of the arithmetic

logic unit (ALU), timing/control circuitry, accumulator, scratch pad

memory, program counter, address

stack and instruction register.

A PLC works by continually scanning a program

Time taken for one scan is called

scan time.

Self Check

Update Outputs

Execute Code

Scan Inputs

PLC Program SCAN

ASI

Devicenet

Interbus-S

Profibus

Interbus

Fieldbus

Ethernet I/P

Smart Distributed System (SDS)

Etc………

The memory includes pre-programmed ROM memory containing

the PLC’s operating system, driver programs and application programs and the RAM memory.

PLC manufacturer offer various types of retentive memory to save user-programs and data while power is removed, so that the PLC can resume execution of the user-written control program as soon as power is restored.

Power Supply 24VDC

or

100 to 240 VAC

OMRON

Allen Bradley

ABB

Schneider (Modicon, Telemecanique, Square D)

GE Fanuc

Siemens

Automation Direct (Koyo)

Toshiba

Mitsubishi

Hitachi

Delta

Number of logical inputs and outputs

Memory

Number of special I/O modules

Expansion Capabilities

Scan Time

Communication

Software

Support

Dollars

RACK

SHOE BOX

MINI

MICRO

Micro PLCs: I/O up to 32 points

Small PLC: I/O up to 128 points

Medium PLC: I/O up to 1024 points

Large PLC: I/O up to 4096 points

Very Large: I/O up to 8192 points

Ladder Logic ( LAD/LD )

Structured Text ( ST)

Instruction List ( IL )

Sequential Function Chart ( SFC )

Function Block Diagram ( FBD )

Instruction List

Sequential Flow Chart Structured Text Function Block

Ladder

N.O

C

I/P

L

N

MOTOR

O/P

CONTACTOR

L

FIELD WIRING O/P

I/P

•SOLENOID

•VALVES

•LAMP

•BUZZER

Digital I/O

N

Typical Analogue Input signals

◦ Flow sensors

◦ Humidity sensors

◦ Load Cells

◦ Potentiometers

◦ Pressure sensors

◦ Temperature sensors

◦ Vibration

Analogue Output signals control ◦ Analogue Valves ◦ Actuators ◦ Chart Recorders ◦ Variable Speed Drives ◦ Analogue Meters

Typical Analogue Signal Levels ◦ 4-20mA ◦ 1-5 Vdc ◦ 0-10 Vdc ◦ -10 – 10Vdc

PLC’s remain a predominate piece of equipment on the factory floor and will probably remain so for some time to come.

The advantages they offer are: ◦ Cost effective for controlling complex systems ◦ Flexible and can be reapplied to control other systems quickly and easily ◦ Computational abilities allow more sophisticated control ◦ Trouble shooting aids make programming easier and reduce downtime ◦ Reliable components (high MTBF) ensure operation for years ◦ Variety of I/O interfaces ◦ Small size ◦ Growing with technology, faster scan times, capability etc ◦ Quick I/O disconnects that aids in field servicing ◦ Modularity in hardware architecture ◦ Modularity in software design (programmer dependant) ◦ Software Timers/Counter, Relays ◦ Clean failure mode ◦ On-line programming ◦ Self inspecting for operation code during execution ◦ Availability of programmers/trouble shooters/integrators ◦ Availability of replacement parts

SCADA (Supervisory Control and Data Acquisition)

allows users to view and monitor all types of data from remote sources

SCADA allows users to control field devices remotely through the operator interface

Basically consists of data accessing feature and controlling process remotely.

Conversion of data is possible i.e. analog to digital . Can communicate to any of the protocols available in

market. Completely rely on window based operating systems Distance as such doesn’t hamper scada operation. Scada is not dedicated to any one type of application

or industry.

Previously without a scada a industrial process was entirely controlled by PLC, CNC , PID & microcontrollers having programmed in certain languages or codes.

These codes were either written in assembly language or relay logic without any true animation that would explain the process running.

In the left side u see the ladder program which is written for PLC and on the right side is the process for which the logic is written.

Now we can easily understand the process if it is shown with some animations rather then written codes.

Hence Scada came to exist and with him he brought some exclusive features that amazed the industrial peoples.

SCADA related to industrial process is called industrial scada.

It works like a supervisor who supervises the entire plant area ,if needed it also controls the process as well 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 logging the various values. Scada can do for you.

Scada is not a 100% controller it is just a software which has to be linked with controllers. ultimately it has to connected to PLC / PID / DCS systems which in turn are connected to field instruments.

SCADA is installed in the computers and

through serial port it is linked to PLC .

All the field devices are connected to PLC and

they get signals or commands from PLC.

Whatever applications we want to run can be

executed either through PLC or SCADA.

Database connectivity

Device connectivity

Alarms

Trends

Scripts

Security

Recipe Management

Networking

Wonderware : InTouch

Intellution : iFix

Merz : Aspic

Allen Bradley : Rsview 32

Siemens : WinCC

GE Fanuc : Cimplicity

PLC Programs

Communication Processor

•Analog-Input •Value-AI-0 •Value-AI-1

•Analog-Output •Value-AO-0 •Value-AO-1

Field Bus

•Analog-Input •Vacuum_VALUE •Pressure_VALUE

•Analog-Output •Valve_1_OUT •Heater_1_OUT

Mapping

SCADA

Manufacturing / Machining

Food / Beverage

Metals

Power

Mining

Petrochemical / Chemical

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