Industrial Automation

PLC & SCADA

By:Rahul Gunde

What is Automation ?

Making Automate

Automate To do by
itself

What happens if man

works,
Constantly and Continuously
?
ERRORS !!! ERRORS !!! ERRORS!!!
Why ?
Due to fatigue and over confidence.

In Other Words,
Using Technology
in the places
where humans errors
are possible.
And using manpower in
appropriate way

What is Automation ?

Automation is a step beyond mechanization.

Automation is the use of control systems and

information technologies to reduce the need
for human work in the production of goods and
services.

What is Industrial
Automation ?

Making products under the control of

computers and programmable controller is
known as Industrial Automation.

Automation is a delegation of human control

functions of technical equipment for increasing
productivity, better quality, increasing safety
in working conditions reducing manpower and
cost.

How do you do ?
Simplification
through applying ideas of
appropriate branch of engineering
ELECTRICAL
ELECTRONICS
MECHANICAL
INSTRUMENTATION
MECHATRONICS
OPTICAL
COMPUTERS,
Almost You apply Al l branches of SCIENCE & ENGINEERING

If We
Consider, MAN
Then,
EYE
Systems
EAR
SKIN

NOSE
TONGUE

: MACHINE
: Photo Electric Sensors, Vision
:Ultrasonic Sound, Vibratory Sensors
INPUTS
: Temperature, Magnetic, Tactile,
Shock, Viscosity, Flow, etc.
: Chemical Sensors
: Bio Sensors
OUTPUTS

HANDS
LEGS
MOUTH

: Grippers, Motion Controllers

: Motion Controllers,
: Speakers, Indication, Communication
CONTROLLING SYSTEM

BRAIN

: Controllers

Devices

TRANSMITTERS

Automation
Components

Sensor for sensing physical conditions

Transmitters
Control Systems
Output Devices

History of Automation ?

Programmable Logic Controller

Electronic Control using Logic Gates
Hard wired logic Control
Pneumatic Control
Manual Control

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.

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

Electronic Control using logic

Gates

In 1960s with the advent of electronics, the logic gates started

eplacing the relays and auxiliary contactors in the control circuits.
The

hardware timers & counters were replaced by

electronic
timers
Advantages
Reduced space requirements
Energy saving
Less maintenance & greater reliability
Drawbacks
Changes in control logic not possible
More project time

Programmable Logic
Controllers
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 PLC

Reduced space
Energy saving
Ease of maintenance
Economical
Greater life & reliability
Tremendous flexibility
Shorter project time
Easier storage, archiving and documentation

Industrial Automation
Components
Field Instruments
Control Hardware
Control Software

Automation Advantages

Replacing human operators in tasks that involve

hard physical or monotonous work.
Replacing humans in tasks done in dangerous
environments (i.e. fire, space, volcanoes, nuclear
facilities, underwater, etc.)
Performing tasks that are beyond human
capabilities of size, weight, speed, endurance, etc.
Economy improvement

Automation
Disadvantages

Unemployment rate increases due to machines

replacing humans and putting those humans out of
their jobs.
Technical Limitation
Security Threats/Vulnerability
Unpredictable development costs
High initial cost

Automation Application

Automated video surveillance

Automated highway systems
Automated manufacturing
Home automation
Industrial automation

Introduction to Programmable
Logic Controller (PLC)

A PLC is a solid state / industrial computer that

performs discrete or sequential logic in a factory
environment.
It was originally developed to replace
mechanical relays, timers, counters.
A sequence of instructions is programmed by the
user to the PLC memory. Its purpose is to monitor
crucial process parameters and adjust process
operations accordingly.

PLC v/s Microcontroller

PLC is an Industrial Microcontroller

Areas of Applications
Any application in any
industry that requires
electrical control
Packaging
Bottling & Canning
Material Handling Machining
Power Generation HVAC/ Building
Automation
Security Systems
Automated Assembly
Paint Lines
Water treatment
Industry
Cement Automobile Chemicals
Plastics
Metals Paper
F&B

Supervisory Control and Data

Acquisition (SCADA) Systems
SCADA systems
used to monitor and control a plant or equipment
in industries
such as:
telecommunications, water and waste control,
energy, oil and gas refining and transportation

Purpose
A SCADA SYSTEM
Gathers information from Remote Terminal Units
(RTUs) and/or (PLCs), and the central host and the
operator terminals(such as where a leak on a
pipeline has occurred).
Transfers the information back to a central site,
then alerts the home station that a leak has
occurred
carries out necessary analysis and control,

DEVICE CONNECTIVITY
Every
manufacturer
have
there
one
communication or follow different protocols.

way

SCADA S/W should have connectivity to different h/w

used in automation

Benefits of SCADA

Standard frame for application

Rich functionality
Limited specific development
Technical support and maintenance
Once installed reduces the cost and provides more
efficiency.

Roles of Engineers in
Industrial Automation

Designing of the Automation system

Erection and Commissioning
Maintenance and Troubleshooting of existing
system

Job Prospects for

Engineer in Industrial
Automation

Manufacturing Industries like

Reliance, Ceat, Godrej,

Colgate .
Automation Solution Products
manufacturer/developer like
Rockwell, Siemens, Schneider,
Yokogawa, ABB, Honeywell.
System Integrators for Schneider,
Rockwell, Siemens, etc

Sree Vahini Institute of Science & Technology

E-Mail:- Rahul252592@gmail.com
Ph No:- +91 901 412 7090