UNIT I

INTRODUCTION
 SYLLABUS
Need for automation systems - Architecture of
Industrial Automation system. Introduction to
PLC, SCADA and DCS – Introduction to
Industrial Data Networks:- Foundation Field
Bus and Profibus.
 INDUSTRY

• In a general sense, the term “Industry” is

defined as follows.
• Definition: Systematic Economic Activity that
could be related to Manufacture/Service/
Trade.
• In this course, we shall be concerned with
Manufacturing Industries only.
 AUTOMATION
• The word ‘Automation’ is derived from greek words
“Auto”(self) and “Matos” (moving).
• Automation therefore is the mechanism for systems
that “move by itself”.
• However, apart from this original sense of the word,
automated systems also achieve significantly superior
performance than what is possible with manual
systems, in terms of power, precision and speed of
operation.
Definition: Automation is a set of technologies that
results in operation of machines and systems without
significant human intervention and achieves
performance superior to manual operation
 CONTROL
• The word control is therefore expected to be
familiar and defined as under.
• Definition: Control is a set of technologies
that achieves desired patterns of variations of
operational parameters and sequences for
machines and systems by providing the input
signals necessary.
 AUTOMATION SYSTEMS
1. Automation Systems may include Control Systems but
the reverse is not true. Control Systems may be parts of
Automation Systems.
2. The main function of control systems is to ensure that
outputs follow the set points. However, Automation
Systems may have much more functionality, such as
computing set points for control systems, monitoring
system performance, plant startup or shutdown, job and
equipment scheduling etc.
• Automation Systems are essential for most modern
industries. It is therefore important to understand why
they are so, before we study these in detail in this
course.
 Industrial Automation vs. Industrial
Information Technology
• Industrial Automation
makes extensive use of
Information Technology.
• Fig. 1 below shows some
of the major IT areas that
are used in the context of
Fig.1. Major Areas of IT which are used
Industrial Automation. in the context of Industrial Automation
 Industrial Automation vs. Industrial
Information Technology
• However, Industrial Automation is distinct from IT in the following
senses
A. Industrial Automation also involves significant amount of hardware
technologies, related to Instrumentation and Sensing, Actuation and
Drives, Electronics for Signal Conditioning, Communication and
Display, Embedded as well as Stand-alone Computing Systems etc.
B. As Industrial Automation systems grow more sophisticated in terms of
the knowledge and algorithms they use, as they encompass larger areas
of operation comprising several units or the whole of a factory, or even
several of them, and as they integrate manufacturing with other areas of
business, such as, sales and customer care, finance and the entire supply
chain of the business, the usage of IT increases dramatically. However,
the lower level Automation Systems that only deal with individual or ,
at best, a group of machines, make less use of IT and more of hardware,
NEED FOR AUTOMATION SYSTEMS
• Manufacturing processes, basically, produce
finished product from raw/unfinished material using
energy, manpower and
equipment/infrastructure.
• Since an industry is essentially a “systematic
economic activity”, the fundamental objective of
any industry is to make profit.
• Roughly speaking,
Profit = (Price/unit–Cost/unit) x Production
Volume
• So profit can be maximised by producing good
quality products, which may sell at higher price, in
NEED FOR AUTOMATION SYSTEMS

Fig.2. The Components of per unit Manufacturing Cost

NEED FOR AUTOMATION SYSTEMS
Automation can achieve all these in the
following ways,
• Figure shows how overall production time for
a product is affected by various factors.
• Automation affects all of these factors.
• Firstly, automated machines have significantly
lower production times.
• For example, in machine tools, manufacturing
a variety of parts, significant setup times are
needed for setting the operational
configuration and parameters whenever a new Fig. The major factors that contribute to
part is loaded into the machine. Overall Production Time
• This can lead to significant unproductive for
expensive machines when a variety of
products is manufactured.
• In Computer Numerically Controlled (CNC)
Machining Centers, set up time is reduced
significantly with the help of Automated Tool
Changers, Automatic Control of Machines
from a Part Program loaded in the machine
computer.
NEED FOR AUTOMATION SYSTEMS

• Such a machine is
shown in Figure 4. The
consequent increase in
actual metal cutting
time results in reduced
capital cost and an
increased volume of
production.
Fig.4. A CNC Machine with an Automated
Tool Changer and the Operator Console
with Display for Programming and Control
of the Machine
NEED FOR AUTOMATION SYSTEMS

• Similarly, systems such as Automated Guided Vehicles,

Industrial Robots, Automated Crane and Conveyor Systems
reduce material handling time.
• Automation also reduces cost of production significantly by
efficient usage of energy, manpower and material.
• The product quality that can be achieved with automated
precision machines and processes cannot be achieved with
manual operations.
• Moreover, since operation is automated, the same quality
would be achieved for thousands of parts with little
variation.
• Industrial Products go through their life cycles, which
consists of various stages.
 NEED FOR AUTOMATION SYSTEMS
• At first, a product is conceived based on Market feedbacks, as well as
Research and Development Activities.
• Once conceived the product is designed.
• Prototype Manufacturing is generally needed to prove the design.
• Once the design is proved, Production Planning and Installation must
be carried out to ensure that the necessary resources and strategies for
mass manufacturing are in place.
• This is followed by the actual manufacture and quality control activities
through which the product is mass-produced.
• This is followed by a number of commercial activities through which
the product is actually sold in the market.
• Automation also reduces the over all product life cycle i.e., the time
required to complete (i) Product conception and design (ii) Process
planning and installation (iii) Various stages of the product life cycle
are shown as in Figure 5.
NEED FOR AUTOMATION SYSTEMS

Fig.5. A typical Industrial Product Life

Cycle
TYPES OF PRODUCTION SYSTEMS
• Major industrial processes can be categorized as follows
based on their scale and scope of production.
Continuous flow process: Manufactured product is in
continuous quantities i.e., the product is not a discrete
object. Moreover, for such processes, the volume of
production is generally very high, while the product
variation is relatively low. Typical examples of such
processes include Oil Refineries, Iron and Steel Plants,
Cement and Chemical Plants.
Mass Manufacturing of Discrete Products: Products are
discrete objects and manufactured in large volumes.
Product variation is very limited. Typical examples are
Appliances, Automobiles etc.
 TYPES OF PRODUCTION
SYSTEMS
Batch Production: In a batch production process the product
is either discrete or continuous. However, the variation in
product types is larger than in continuous-flow processes.
The same set of equipment is used to manufacture all the
product types. However for each batch of a given product
type a distinct set of operating parameters must be
established. This set is often referred to as the “recipe” for
the batch. Typical examples here would be Pharmaceuticals,
Casting Foundries, Plastic moulding, Printing etc.
Job shop Production: Typically designed for manufacturing
small quantities of discrete products, which are custom
built, generally according to drawings supplied by
customers. Any variation in the product can be made.
Examples include Machine Shops, Prototyping facilities etc.
 TYPES OF PRODUCTION SYSTEMS

• The types of production

systems are shown in Figure
6 categorized according to
volumes of production and
variability in product types.
• In general, if the quantity of
product is more, there is
little variation in the product
and more varieties of
Fig.6. Types of Production Systems
product is manufactured if
the quantity of product is
lesser.
TYPES OF AUTOMATION SYSTEMS
• Automation systems can be categorized based
on the flexibility and level of integration in
manufacturing process operations. Various
automation systems can be classified as follows:
1. Fixed Automation
2. Programmable Automation
3. Flexible Automation
4. Integrated Automation
TYPES OF AUTOMATION SYSTEMS

Fixed Automation: It is used in high volume

production with dedicated equipment, which has a
fixed set of operation and designed to be efficient
for this set. Continuous flow and Discrete Mass
Production systems use this automation. e.g.
Distillation Process, Conveyors, Paint Shops,
Transfer lines etc.
• A process using mechanized machinery to perform
fixed and repetitive operations in order to produce a
high volume of similar parts.
TYPES OF AUTOMATION SYSTEMS
Programmable Automation:
• It is used for a changeable sequence of operation and
configuration of the machines using electronic
controls with the requirement of non-trivial
programming.
• Investment on programmable equipment is less, as
production process is not changed frequently.
• It is typically used in Batch process where job
variety is low and product volume is medium to
high, and sometimes in mass production also. e.g. in
Steel Rolling Mills, Paper Mills etc.
 TYPES OF AUTOMATION SYSTEMS
Flexible Automation:
• It is used in Flexible Manufacturing Systems (FMS) which is
invariably computer controlled.
• Human operators give high-level commands in the form of codes
entered into computer; identifying product and its location in the
sequence and the lower level changes are done automatically.
• Each production machine receives settings/instructions from computer.
• These automatically loads/unloads required tools and carries out their
processing instructions.
• After processing, products are automatically transferred to next
machine.
• It is typically used in job shops and batch processes where product
varieties are high and job volumes are medium to low.
• Such systems typically use Multi purpose CNC machines,
Automated Guided Vehicles (AGV) etc.
 TYPES OF AUTOMATION SYSTEMS
Integrated Automation:
• It denotes complete automation of a manufacturing plant, with all
processes functioning under computer control and under coordination
through digital information processing.
• It includes technologies such as computer-aided design and
manufacturing, computer-aided process planning, computer numerical
control machine tools, flexible machining systems, automated storage
and retrieval systems, automated material handling systems such as
robots and automated cranes and conveyors, computerized scheduling
and production control.
• It may also integrate a business system through a common database.
• In other words, it symbolizes full integration of process and management
operations using information and communication technologies.
• Typical examples of such technologies are seen in Advanced Process
Automation Systems and Computer Integrated Manufacturing
(CIM)
TYPES OF AUTOMATION SYSTEMS
• As can be seen from above, from Fixed Automation to
CIM, the scope and complexity of automation systems are
increasing.
• Degree of automation necessary for an individual
manufacturing facility depends on manufacturing and
assembly specifications, labor conditions and competitive
pressure, labor cost and work requirements.
• One must remember that the investment on automation
must be justified by the consequent increase in profitability.
• To exemplify, the appropriate contexts for Fixed and
Flexible Automation are compared and contrasted.
TYPES OF AUTOMATION SYSTEMS
Fixed automation is appropriate in Flexible automation, on the other
the following circumstances. hand is used in the following
A. Low variability in product type as situations.
also in size, shape, part count and A. Significant variability in product
material type. Product mix requires a
B. Predictable and stable demand for combination of different parts
2- to 5-year time period, so that and products to be manufactured
manufacturing capacity from the same production system
requirement is also stable B. Product life cycles are short.
C. High production volume desired Frequent upgradation and design
per unit time modifications alter production
D. Significant cost pressures due to requirements
competitive market conditions. C. Production volumes are
So automation systems should be moderate, and demand is not as
tuned to perform optimally for predictable
the particular product.
 ARCHITECTURE OF INDUSTRIAL
AUTOMATION SYSTEM
The Functional Elements of Industrial Automation
• An Industrial Automation System consists of numerous
elements that perform a variety of functions related to
Instrumentation, Control, Supervision and Operations
Management related to the industrial process.
• These elements may also communicate with one another
to exchange information necessary for overall
coordination and optimized operation of the
plant/factory/process.
• The major functional elements typically found in IA
systems are classified and also the nature of technologies
that are employed to realize the functions are described.
 ARCHITECTURE OF INDUSTRIAL
AUTOMATION SYSTEM
Sensing and Actuation Elements
• These elements interface directly and physically to the process
equipment and machines.
• The sensing elements translate the physical process signals such as
temperature, pressure or displacement to convenient electrical or
pneumatic forms of information, so that these signals can be used for
analysis, decisions and finally, computation of control inputs.
• These computed control inputs, which again are in convenient
electrical or pneumatic forms of information, need to be converted to
physical process inputs such as, heat, force or flow-rate, before they
can be applied to effect the desired changes in the process outputs.
• Such physical control inputs are provided by the actuation elements.
 ARCHITECTURE OF INDUSTRIAL
AUTOMATION SYSTEM
Industrial Sensors and Instrument Systems
• Scientific and engineering sensors and instrument systems
of a spectacular variety of size, weight, cost, complexity
and technology are used in the modern industry.
• However, a close look would reveal that all of them are
composed of a set of typical functional elements connected
in a specified way to provide signal in a form necessary.
• The various tasks involved in the automation systems.
• Fig 7 shows the configuration of a typical sensor system.
ARCHITECTURE OF INDUSTRIAL
AUTOMATION SYSTEM

Fig.7. Functional configuration of a typical sensor system

 ARCHITECTURE OF INDUSTRIAL
AUTOMATION SYSTEM
In Fig. 7. a sensor system is shown decomposed into three
of its major functional components, along with the
medium in which the measurement takes place. These
are described below.
A. The physical medium refers to the object where a
physical phenomenon is taking place and we are
interested in the measurement of some physical variable
associated with the phenomenon. Thus, for example, the
physical medium may stand for the hot in a furnace in
the case of temperature measurement or the fluid in a
pipe section in the case of measurement of liquid flow
rate.
 ARCHITECTURE OF INDUSTRIAL
AUTOMATION SYSTEM
B. The sensing element is affected by the phenomenon in the physical medium
either through direct or physical contact or through indirect interaction of the
phenomenon in the medium with some component of the sensing element.
• Again, considering the case of temperature measurement, one may use a
thermocouple probe as the sensing element that often comes in physical contact
with the hot object such as the flue gas out of a boiler-furnace or an optical
pyrometer which compares the brightness of a hot body in the furnace with that
of a lamp from a distance through some window and does not come in direct
contact with the furnace.
• In the more common case where the sensing element comes in contact with the
medium, often some physical or chemical property of the sensor changes in
response to the measurement variable.
• This change then becomes a measure of the physical variable of interest. A
typical example is the change in resistivity due to heat in a resistance
thermometer wire.
• Alternatively, in some other sensors a signal is directly generated in the sensing
element, as is the case of a thermocouple that generates a voltage in response to a
 ARCHITECTURE OF INDUSTRIAL
AUTOMATION SYSTEM
C. The signal-conditioning element serves the function of altering the nature
of the signal generated by the sensing element.
• Since the method of converting the nature of the signal generated in the
sensor to another suitable signal form (usually electrical) depends essentially
on the sensor, individual signal conditioning modules are characteristic of a
group of sensing elements.
• As an example consider a resistance Temperature Detector (RTD) whose
output response is a change in its resistance due to change in temperature of
its environment.
• This change in resistance can easily be converted to a voltage signal by
incorporating the RTD in one arm of a Wheatstone's bridge.
• The bridge therefore serves as a signal-conditioning module.
• Signal conditioning modules are also used for special purpose functions
relating to specific sensors but not related to variable conversion such as
`ambient referencing' of thermocouples.
• These typically involve analog electronic circuits that finally produce
 ARCHITECTURE OF INDUSTRIAL
AUTOMATION SYSTEM
D. The signal processing element is used to process the signal
generated by the first stage for a variety of purposes such as,
filtering (to remove noise), diagnostics (to assess the health of
the sensor), linearisation (to obtain an output which is linearly
related with the physical measurand etc. Signal processing
systems are therefore usually more general purpose in nature.
E. The target signal-handling element may perform a variety of
functions depending on the target application. It may therefore
contain data/signal display modules, recording or/storage
modules, or simply a feedback to a process control system.
Examples include a temperature chart recorder, an
instrumentation tape recorder, a digital display or an
Analog to Digital Converter (ADC) followed by an interface
to a process control computer.
 ARCHITECTURE OF INDUSTRIAL
AUTOMATION SYSTEM
• While the above description fits in most cases, it may be
possible to discover some variations in some cases. The
above separation into subsystems is not only from a
functional point of view, more often than not, these
subsystems are clearly distinguishable physically in a
measurement system.
• Modern sensors often have the additional capability of
digital communication using serial, parallel or network
communication protocols. Such sensors are called
“smart” and contain embedded digital electronic
processing systems.
INDUSTRIAL ACTUATOR SYSTEMS
• Actuation systems convert the input signals
computed by the control systems into forms
that can be applied to the actual process and
would produce the desired variations in the
process physical variables.
• In the same way as in sensors but in a reverse
sense, these systems convert the controller
output, which is essentially information without
the power, and in the form of electrical voltages
(or at times pneumatic pressure) in two ways.
INDUSTRIAL ACTUATOR SYSTEMS
• Firstly it converts the form of the variable into the
appropriate physical variable, such as torque, heat or flow.
Secondly it amplifies the energy level of the signal
manifold to be able to causes changes in the process
variables.
• Thus, while both sensors and actuators cause variable
conversions, actuators are high power devices while
sensors are not.
• It turns out that in most cases, actuators are devices that
first produce motion from electrical signal, which is then
further converted to other forms.
• Based on the above requirement of energy and variable
conversion most actuation systems are structured as shown
in Fig. 8.
INDUSTRIAL ACTUATOR SYSTEMS

Fig.8. Functional configuration of a typical actuator system

INDUSTRIAL ACTUATOR SYSTEMS
• In Fig.8 an actuator system is shown decomposed into its
major functional components, The salient points about the
structure are described below.
A. The electronic signal-processing element accepts the
command from the control system in electrical form. The
command is processed in various ways. For example it may
be filtered to avoid applying input signals of certain
frequencies that may cause resonance. Many actuators are
themselves closed feedback controlled units for precision of
the actuation operation. Therefore the electronic signal-
processing unit often contains the control system for the
actuator itself.
INDUSTRIAL ACTUATOR SYSTEMS

B. The electronic power amplification element sometimes

contains linear power amplification stages called servo-
amplifiers. In other cases, it may comprise power
electronic drive circuits such as for motor driven actuators.
C. The variable conversion element serves the function of
altering the nature of the signal generated by the electronic
power amplification element from electrical to non-
electrical form, generally in the form of motion. Examples
include electrohydraulic servo valve, stepper/servo motors,
Current to Pneumatic Pressure converters etc.
D. The non-electrical power conversion elements are used to
amplify power further, if necessary, typically using
hydraulic or pneumatic mechanisms.
INDUSTRIAL ACTUATOR SYSTEMS

E. The non-electrical variable conversion elements may be

used further to tranform the actuated variable in desired
forms, often in several stages. Typical examples include
motion-to-flow rate conversion in flow-valves, rotary to
linear motion converters using mechanisms, flow-rate to
heat conversion using steam or other hot fluids etc.
F. Other Miscellaneous Elements such as Auxiliaries for
Lubrication/Cooling/Filtering, Reservoirs, Prime Movers
etc., sensors for feedback, components for display, remote
operations, as well as safety mechanisms since the power
handling level is significantly high.
 INDUSTRIAL CONTROL SYSTEMS
• By industrial control systems, we denote the sensors
systems, actuator systems as a controller.
• Controllers are essentially (predominantly electronic, at
times pneumatic/hydraulic) elements that accept
command signals from human operators or Supervisory
Systems, as well as feedback from the process sensors
and produce or compute signals that are fed to the
actuators. Control Systems can be classified into two
kinds.
1. Continuous Control
2. Sequence/Logic Control
 CONTINUOUS CONTROL
• This is also often termed as Automatic Control,
Process Control, Feedback Control etc.
• Here the controller objective is to provide such inputs
to the plant such that the output y(t) follows the input
r(t) as closely as possible, in value and over time.
• The structure of the common control loop with its
constituent elements, namely the Controller, the
Actuator, the Sensor and the Process itself is shown.
• In addition the signals that exist at various points of
the system are also marked.
• These include the command (alternatively termed the
set point or the reference signal), the exogenous
inputs (disturbances, noise).
CONTINUOUS CONTROL

Fig.9. Typical control loop

 CONTINUOUS CONTROL
• The difficulties in achieving the performance
objective is mainly due to the unavoidable
disturbances due to load variation and other
external factors, as well as sensor noise, the
complexity, possible instability, uncertainty
and variability in the plant dynamics, as well
as limitations in actuator capabilities.
 CONTINUOUS CONTROL
• Most industrial control loop command signals are piecewise
constant signals that indicate desirable levels of process variables,
such as temperature, pressure, flow, level etc., which ensure the
quality of the product in Continuous Processes.
• In some cases, such as in case of motion control for machining,
the command signal may be continuously varying according to the
dimensions of the product.
• Therefore, here deviation of the output from the command signal
results in degradation of product quality.
• It is for this reason that the choice of the feedback signals, that of
the controller algorithm (such as, P, PI pr PID), the choice of the
control loop structure (normal feedback loop, cascade loop or
feedforward) as well as choice of the controller gains is extremely
important for industrial machines and processes.
 CONTINUOUS CONTROL
• Typically the control configurations are well known for a
given class of process, however, the choice of controller gains
have to be made from time to time, since the plant operating
characteristics changes with time. This is generally called
controller tuning.
• A single physical device may act as the controller for one or
more control loops (single-loop/multi-loop controller).
• Today, many loop controllers supplement typical control laws
such as PID control by offering adaptive control and fuzzy
logic algorithms to enhance controller response and operation.
• PID and startup self-tuning are among the most important
features.
 CONTINUOUS CONTROL
• Among other desired and commonly found characteristics are,
ability to communicate upward with supervisory systems, as well
as on peer-to-peer networks (such as Fieldbus or DeviceNet),
support for manual control in the event of a failure in the
automation.
• Software is an important factor in loop controllers.
• Set-up, monitoring and auto-tuning and alarm software for loop
controllers is now a common feature.
• The controllers also accept direct interfacing of process sensors
and signals.
• Choice of inputs includes various types of thermocouples, RTDs,
voltage to 10 V dc, or current to 20 mA.
• While most sophisticated controllers today are electronic,
pneumatic controllers are still being used.
• Pneumatic controllers are easy to use, easy to maintain, and
 SEQUENCE / LOGIC CONTROL
• Many control applications do not involve analog process
variables, that is, the ones which can assume a continuous
range of values, but instead variables that are set valued, that is
they only assume values belonging to a finite set.
• The simplest examples of such variables are binary variables,
that can have either of two possible values, (such as 1 or 0, on
or off, open or closed etc.).
• These control systems operate by turning on and off switches,
motors, valves, and other devices in response to operating
conditions and as a function of time.
• Such systems are referred to as sequence/logic control systems.
• For example, in the operation of transfer lines and automated
assembly machines, sequence control is used to coordinate the
various actions of the production system (e.g., transfer of parts,
changing of the tool, feeding of the metal cutting tool, etc.).
 SEQUENCE / LOGIC CONTROL
• There are many industrial actuators which have set of command inputs.
• The control inputs to these devices only belong to a specific discrete set.
• For example in the control of a conveyor system, analog motor control is
not applied. Simple on-off control is adequate.
• Therefore for this application, the motor-starter actuation system may be
considered as discrete having three modes, namely, start, stop and run.
• Other examples of such actuators are solenoid valves, discussed in a
subsequent lesson.
• Similarly, there are many industrial sensors (such as, Limit Switch /
Pressure Switch/ Photo Switch etc.) which provide discrete outputs which
may be interpreted as the presence/absence of an object in close
proximity, passing of parts on a conveyor, or a given pressure value being
higher or lower than a set value.
• These sensors thus indicate, not the value of a process variable, but the
particular range of values to which the process variable belongs.
 SEQUENCE / LOGIC CONTROL
• A modern controller device used extensively
for sequence control today in transfer lines,
robotics, process control, and many other
automated systems is the Programmable
Logic Controller (PLC).
• In essence, a PLC is a special purpose industrial
microprocessor based real-time computing
system, which performs the following functions
in the context of industrial operations
 SUPERVISORY CONTROL
Supervisory control performs at a hierarchically higher level over
the automatic controllers, which controls smaller subsystems.
Supervisory control systems perform, typically the following
functions:
♦ Set point computation: Set points for important process
variables are computed depending on factors such as nature of
the product, production volume, mode of processing. This
function has a lot of impact on production volume, energy and
quality and efficiency.
♦ Performance Monitoring / Diagnostics: Process variables are
monitored to check for possible system component failure,
control loop detuning, actuator saturation, process parameter
change etc. The results are displayed and possibly archived for
subsequent analysis.
 SUPERVISORY CONTROL
♦ Start up / Shut down / Emergency Operations : Special
discrete and continuous control modes are initiated to carry
out the intended operation, either in response to operator
commands or in response to diagnostic events such as
detected failure modes.
♦ Control Reconfiguration / Tuning: Structural or Parametric
redesign of control loops are carried out, either in response to
operator commands or in response to diagnostic events such
as detected failure modes. Control reconfigurations may also
be necessary to accommodate variation of feedback or
energy input e.g. gas fired to oil fired.
♦ Operator Interface: Graphical interfaces for supervisory
operators are provided, for manual supervision and
intervention.
 SUPERVISORY CONTROL
• Naturally, these systems are dependent on
specific application processes, in contrast with
automatic control algorithms, which are
usually generic (e.g. PID).
• Computationally these are a mixture of hard
and soft real time algorithms.
• These are also often very expensive and based
on proprietary knowledge of automating
specific classes of industrial plants.
 PRODUCTION CONTROL
Production control performs at a hierarchically higher level over
the supervisory controllers. Typical functions they perform are:
♦ Process Scheduling: Depending on the sequence of operations
to be carried on the existing batches of products, processing
resource availability for optimal resource utilization.
♦ Maintenance Management: Decision processes related to
detection and deployment of maintenance operations.
♦ Inventory Management: Decision processes related to
monitoring of inventory status of raw material, finished goods
etc. and deployment of operations related to their management.
♦ Quality Management: Assessment, Documentation and
Management of Quality
Typically, the algorithms make use of Resource Optimisation
Technology and are non-real-time although they may be using
production data on-line.
 THE ARCHITECTURE OF ELEMENTS:
THE AUTOMATION PYRAMID

• Industrial automation
systems are very complex
having large number of
devices with confluence of
technologies working in
synchronization.
• In order to know the
performance of the system
we need to understand the
various parts of the system.
Industrial automation Fig.10. Automation pyramid
systems are organized
hierarchially as shown in
the figure 10.
THE ARCHITECTURE OF ELEMENTS:
THE AUTOMATION PYRAMID
• Various components in an industrial automation system can
be explained using the automation pyramid. Here, various
layers represent the wideness ( in the sense of no. of
devices ), and fastness of components on the time-scale.
Sensors and Actuators' Layer: This layer is closest to the
processes and machines, used to translate signals so that
signals can be derived from processes for analysis and
decisions and hence control signals can be applied to the
processes. This forms the base layer of the pyramid also
called ‘level 0’ layer.
Automatic Control Layer: This layer consists of automatic
control and monitoring systems, which drive the actuators
using the process information given by sensors. This is called
THE ARCHITECTURE OF ELEMENTS:
THE AUTOMATION PYRAMID
• Supervisory Control Layer: This layer drives the
automatic control system by setting target/goal to the
controller. Supervisory Control looks after the equipment,
which may consist of several control loops. This is called
as ‘level 2’ layer.
• Production Control Layer: This solves the decision
problems like production targets, resource allocation, task
allocation to machines, maintenance management etc. This
is called ‘level 3’ layer.
• Enterprise control layer: This deals less technical and
more commercial activities like supply, demand, cash flow,
product marketing etc. This is called as the ‘level 4’ layer.
 THE ARCHITECTURE OF ELEMENTS:
THE AUTOMATION PYRAMID
• The spatial scale increases as the level is increased e.g. at lowest level a sensor
works in a single loop, but there exists many sensors in an automation system
which will be visible as the level is increased.
• The lowest level is faster in the time scale and the higher levels are slower. The
aggregation of information over some time interval is taken at higher levels.
• All the above layers are connected by various types of communication systems.
• For example the sensors and actuators may be connected to the automatic
controllers using a point-to-point digital communication, while the automatic
controllers themselves may be connected with the supervisory and production
control systems using computer networks. Some of these networks may be
proprietary.
• Over the last decade, with emergence of embedded electronics and computing,
standards for low level network standards (CANBus, Fieldbus etc.) for
communication with low level devices, such as sensors and actuators are also
emerging.
 AN EXAMPLE INDUSTRIAL SPECIFICATION FOR
AUTOMATIC AND SUPERVISORY LEVEL AUTOMATION
SYSTEMS

• It contains the specification of a section of a Cold

Rolling Mill complex, referred to here as PL-TCM
which stands for Pickling Line and Tandem Control
Mill.
• Such specification documents are prepared when
automation systems for industrial plants are procured
and installed.
• The document captures the visualisation of
automation functionality of the customer.
• Here basic level refers to the automatic control
supervisory control levels, while process control level
refers to a level.
AN EXAMPLE INDUSTRIAL SPECIFICATION
FOR AUTOMATIC AND SUPERVISORY LEVEL
AUTOMATION SYSTEMS
Platforms: The above levels of controls shall be achieved through
programmable controllers PLCs, micro-processor based systems
as well as PCs / Work stations, as required.
• Each of the automation systems of the PL-TCM shall be
subdivided in accordance with the functional requirements and
shall cover the open loop and closed loop control functions of the
different sections of the line and the mill.
Modes of Operation: The systems shall basically have two modes of
operation. In the semi-automatic mode the set point values shall
be entered manually for different sections of the line through
VDU and the processors shall transmit these values to the
controls in proper time sequence. In fully automatic mode the
process control system shall calculate all set point values through
mathematical models and transfer the same to the subordinate
AN EXAMPLE INDUSTRIAL SPECIFICATION
FOR AUTOMATIC AND SUPERVISORY LEVEL
AUTOMATION SYSTEMS
• The functions to be performed by the basic level automation shall cover
but not be limited to the following.
Functionality at Basic Level: The Basic Level shall cover control of all
equipment, sequencing, interlocking micro-tracking of strip for specific
functions, dedicated technological functions, storage of rolling schedules
and look-up tables, fault and event logging etc. Some of these are
mentioned below.
♦ All interlocking and sequencing control of the machinery such as for entry
and exit handling of strips, shear control etc. Interlocking, sequencing,
switching controls of the machines. This shall also cover automatic coil
handling at the entry and exit sides, automatic sequential operation of
welding/rewelding machine and strip threading sequence control as well
as for acid regeneration plant.
♦ Calculation of coil diameter and width at the entry pay-off reels.
♦ Position control of coil ears for centrally placing of coils on the mandrels.
AN EXAMPLE INDUSTRIAL SPECIFICATION
FOR AUTOMATIC AND SUPERVISORY LEVEL
AUTOMATION SYSTEMS
♦ Generation of master speed references for the line
depending on operator's input and line conditions and down
loading to drive control systems.
♦ Speed synchronizing control of the drives, as required.
♦ Strip tension, position and catenary control through control
of related drives and machinery.
♦ Initiation of centre position control for Power Operated
Rolls, steering/dancer rolls; Looper car position control.
Automatic pre-setting control, measurement and control of
tension and elongation for tension leveller. Auto edge
position control at tension reels if required.
AN EXAMPLE INDUSTRIAL SPECIFICATION
FOR AUTOMATIC AND SUPERVISORY LEVEL
AUTOMATION SYSTEMS
♦ Control of entry shear for auto-cutting of off-gauge
strip.
♦ Control of pickling parameters for correct pickling with
varying speed of strip in the pickling section.
♦ Side trimmer automatic setting control.
♦ Interlockings, sequencing and control of scrap baller, if
provided.
♦Auto calibration for position control/precision
positioning shall be provided as necessary.
♦ Manual/Auto slowdown/stoppage of strip at weld point
at tension leveller, side trimmer, mill and exit shear.
AN EXAMPLE INDUSTRIAL SPECIFICATION
FOR AUTOMATIC AND SUPERVISORY LEVEL
AUTOMATION SYSTEMS
♦ Control of technological functions for tandem mill such as :
-Automatic gauge control along with interest and tension control.
- Shape control
- Roll force control
♦ Storage of tandem mill rolling schedules, for the entire product
mix and all possible variations. Suitable look-up tables as
operators guidance for line/equipment setting.
♦ Automatic roll changing along with automatic spindle
positioning.
♦ Constant pass line control based on roll wear as well as after roll
change.
♦ Automatic control of rotary shear before tension rells.
♦ Automatic sequence control of inspection reel.
AN EXAMPLE INDUSTRIAL SPECIFICATION
FOR AUTOMATIC AND SUPERVISORY
LEVEL AUTOMATION SYSTEMS
♦ Provision of manual slow down/stoppage of strip as well
as chearing for `run' for inspection of defects at tension
leveller, side trimmer entry and exit of the Tandem Mill
through push button stations.
♦ Micro-tracking of strip and flying gauge change (set point
change) for continuous operation with varying strip sizes.
♦ Setting up the mill either from the stored rollings
schedule with facility for modification by the operator of
down-loading from process control level system.
♦ Automatic control of in-line coil weighing, marking and
circumferential banding after delivery tension reels.
AN EXAMPLE INDUSTRIAL SPECIFICATION
FOR AUTOMATIC AND SUPERVISORY LEVEL
AUTOMATION SYSTEMS
Supervisory Functions at Basic Level:
Centralised supervisory and monitoring
control system shall be provided under basic
level automation with dedicated processors
and MMI. All necessary signals shall be
acquired through drive control system as well
as directly from the sensors/instruments as,
required. The system shall be capable of
carrying out the following functions.
AN EXAMPLE INDUSTRIAL SPECIFICATION
FOR AUTOMATIC AND SUPERVISORY LEVEL
AUTOMATION SYSTEMS
♦ Centralised switching and start up of various line drives and
auxiliary systems through mimic displays.
♦ Status of plant drives and electrical equipment for displaying
maintenance information.
♦ Monitoring and display of measured values for tandem mill main
drives and other large capacity drives such as winding
temperature, for alarm and trip conditions.
♦ Centralised switching and status indication of 33 kV and 6.6 kV
switchboards.
♦ Display of single line diagram of 33 kV and 6.6 kV switchboards,
main drives, in-line auxiliary drives etc.
♦ Acquisition of fault signals from various sections of the plant with
facility for display and print-out of the fault messages in clear text.
 COMPREHENSIVE DIAGNOSTIC FUNCTIONS

Functionality at Process Control Level:

• The Process Control Level shall be responsible for
computation and control for optimization of operation.
• Functions like set point generation using mathematical
models, learning control, material tracking within the
process line/unit including primary data input, real time
control of process functions through basic level
automation, generation of reports etc. shall be
implemented through this level of automation.
• Some of the specific functions to be performed by the
process control level automation are the following.
 COMPREHENSIVE DIAGNOSTIC FUNCTIONS

♦ Coil strip tracking inside the process line/unit by sensing punched

holes at weld seams.
♦ Primary Data Input (PDI) of coils at entry to PL-TCM with
provision for down loading of data from production control level.
♦ Generation of all operating set points for the mill using PDI data,
mill model, roll force model, power model, strip thickness control
model, shape/profile control model with thermal strip flatness
control as well as for other sections of the line.
♦ Learning (Adaptive) control using actual data and the
mathematical model for set-up calculations.
♦ Storage of position setting values of levellers, side trimmer. Input
of strip flaw data manually through inspection panel at the inline
inspection facility after side trimmer.
♦ Processing of actual data on rolling operation, generation of
reports logs and sending data to production control level.
COMPREHENSIVE DIAGNOSTIC FUNCTIONS

Information System Functions: The information system shall

generally comply with the following features.
♦ Data of importance shall be available with the concerned
personnel in the form of logs and reports.
♦ Output of logs and reports at preset times or on occurrence
of certain events.
♦ It shall be possible to change the data items and log formats
without undue interference to the system.
♦ Logged information shall be stored for adequate time period
ensuring the availability of historical data record.
♦ Data captured by the system shall be checked for integrity
with respect to their validity and plausibility with
annunciation.
 COMPREHENSIVE DIAGNOSTIC FUNCTIONS

Man Machine Interface: The visualisation system for both the

automation levels shall be through man-machine interface
(MMI) for the control and operation of the complete line. The
system shall display the following screens, with facilities for
hard copy print out.
♦ Process mimics for the complete line using various screens with
status information of all important in-line drives as well as the
references and actual values of important parameters.
♦ Dynamic information’s in form of bar graph for indication of
reference and actual values of important parameters.
♦ Screens providing trends of the important process variables.
♦ Acquisition of actual parameters (averaging/maximum/minimum)
for the complete line, on coil to coil basis through weld seam
tracking or TCM exit shear cut for the generation of logs on
 COMPREHENSIVE DIAGNOSTIC
FUNCTIONS
Standards:
• The programmable controllers and other micro
processor based equipment offered shall
generally be designed/structured,
manufactured and tested in accordance with
the guidelines laid down in IEC-1131 (Part 2)
apart from the industry standards being
adopted by the respective manufactures.
 COMPREHENSIVE DIAGNOSTIC FUNCTIONS

Hardware:
• The hardware of each basic controller/equipment of a system
will generally comprise main processing unit, memory units,
stabilised power supply unit, necessary communication
interface modules, auxiliary storage where required.
• I/O modules in the main equipment, remote I/O stations
where required and the programming and debugging tool
(PADT).
• The hardware and software structure shall be modular to
meet wide range of technological requirements.
• I/Os shall be freely configurable depending on the
requirement.
• The programming units shall preferable be lap-top type.
 COMPREHENSIVE DIAGNOSTIC FUNCTIONS

Networking: The networking would conform to the following

specifications.
♦ In each of the two automation levels, all the controllers of a system
shall be connected as a node over suitable data bus forming a LAN
system using standardised hardware and software.
♦ The LAN system shall be in line with ISO-Open system Interconnect.
♦ All drive level automation equipment shall be suitably linked with the
basic level for effective data/signal exchange between the two levels.
However, all the emergency and safety signals shall be directly
hardwired to the respective controllers.
♦ Similarly, the LAN systems for the basic level and process control level
shall be suitably linked through suitable bridge/interface for effective
data/signal exchange. Provision shall also be made for interfacing
suitably the process control level with the production level automation
system specified in item.
 COMPREHENSIVE DIAGNOSTIC
FUNCTIONS
♦ The data highways shall be designed to be optimally
loaded and the same shall be clearly indicated in the
offer.
♦ The remote I/Os, the microprocessor based measuring
instruments and the micro-processor based special
machines like coil weighing, marking and
circumferential banding machines shall be connected
over serial links with the respective controllers.
♦ The personal computers and work stations shall be
connected as a LAN system of the corresponding
level.
 COMPREHENSIVE DIAGNOSTIC FUNCTIONS

Data and Visualisation: The following specifications would apply in

respect of data security, validity and its proper visualisation.
♦ All the operator interfaces comprising colour VDU and keyboard as
MMI for interacting with the respective system and located at
strategic locations, shall be connected to the corresponding LAN
system.
♦ Key lock/password shall be provided to prevent unauthorized entry.
♦ Entry validity and plausibility check shall also be incorporated.
♦ An Engineer's console comprising of necessary processor, color
VDU, keyboard/mouse and a printer unit shall be provided for the
automation systems. The console shall have necessary hardware
and software of communicating with the LAN and shall have
access to the complete system. Basic functions of this console shall
be off-line data base configuration, programme development,
documentation etc.
 COMPREHENSIVE DIAGNOSTIC
FUNCTIONS
Application Software:
• The application software shall be through functional block type
software modules as well as high level language based software
modules.
• The software shall be user friendly and provided with help
functions etc.
• Only one type of programming language shall be used for the
complete system.
• However, ladder type programming language may be used for
simple logical functions.
• Only industrially debugged and tested software shall be
provided.
BASIS OF SYSTEM SELECTION
• Future Expandability: The selection of equipment, standard
software and networking shall be such as to offer optimum
flexibility for future expansion without affecting the system
reliability.
• Fault Tolerance: The system shall be designed to operate in
automatic or semi automatic mode of operation under failure
conditions.
• Spare Capacity: The system shall have sufficient capacity to
perform all functions as required. A minimum of 30 per cent
of the total memory shall be kept unallocated for future use.
• Loading: The data highway shall be designed to be optimally
loaded and the same shall be clearly indicated in the offer.
BASIS OF SYSTEM SELECTION
• Software Structure and Quality Programs: shall be in high
level language that is effective and economical for the
proposed system in respect of Modularization, rate of
coding, store usage and running time. The software structure
of the system shall be suitably distributed/centralised for
supervision and control of the related process areas
following the state of the art architecture.
• Integration: The communication software shall be such that
the systems shall be able to communicate independently
among themselves as well as with the lower level Basic
Control/Process control automation system, as required.
Provision shall be made for interfacing the production
control system with the higher level Business Computer
system to be provided for the entire steel plant in future.
BASIS OF SYSTEM SELECTION
• Programmability: The information system shall
generally be designed such that it shall be possible
to change the data items and log formats without
undue interference to the system.
• Data Integrity and Protection: Logged information
shall be stored for adequate time period ensuring
the availability of historical data record. Data
captured by the system shall be checked for
integrity with respect to their validity and
plausibility with annunciation. Storing of essential
data to be protected against corruption when the
system loses power supply or during failure.
INTRODUCTION TO PLC
 INTRODUCTION TO PLC
• Programmable logic controllers (Figure 1-1) are now the
most widely used industrial process control technology.
• A programmable logic controller (PLC) is an industrial
grade computer that is capable of being programmed to
perform control functions.
• The programmable controller has eliminated much of the
hardwiring associated with conventional relay control
circuits.
• Other benefits include fast response, easy programming
and installation, high control speed, network
compatibility, troubleshooting and testing convenience,
and high reliability.
 INTRODUCTION TO PLC
• The PLC is designed for multiple input and output arrangements, extended
temperature ranges, immunity to electrical noise, and resistance to
vibration and impact.
• Programs for the control and operation of manufacturing process
equipment and machinery are typically stored in battery-backed or
nonvolatile memory.
• A PLC is an example of a real-time system since the output of the system
controlled by the PLC depends on the input conditions.
• The PLC is, then, basically a digital computer designed for use in machine
control.
• Unlike a personal computer, it has been designed to operate in the
industrial environment and is equipped with special input/output interfaces
and a control programming language.
 INTRODUCTION TO PLC
• The common abbreviation used in industry for these devices,
PC, can be confusing because it is also the abbreviation for
“Personal Computer.”
• Therefore, most manufacturers refer to their programmable
controller as a PLC, which stands for “Programmable Logic
Controller.”
• Initially the PLC was used to replace relay logic, but its ever-
increasing range of functions means that it is found in many
and more complex applications.
• Because the structure of a PLC is based on the same
principles as those employed in computer architecture, it is
capable not only of performing relay switching tasks but also
of performing other applications such as timing, counting,
calculating, comparing, and the processing of analog signals.
 INTRODUCTION TO PLC
• Programmable controllers offer several advantages over a
conventional relay type of control.
• Relays have to be hardwired to perform a specific function.
When the system requirements change, the relay wiring has to
be changed or modified.
• In extreme cases, such as in the auto industry, complete control
panels had to be replaced since it was not economically
feasible to rewire the old panels with each model changeover.
• The programmable controller has eliminated much of the
hardwiring associated with conventional relay control circuits
(Figure 1-2).
• It is small and inexpensive compared to equivalent relay-based
process control systems.
• Modern control systems still include relays, but these are
rarely used for logic.
INTRODUCTION TO PLC
 INTRODUCTION TO PLC
PLCs provide many other benefits including:
Increased Reliability:
• Once a program has been written and tested, it can be
easily downloaded to other PLCs.
• Since all the logic is contained in the PLC’s memory, there
is no chance of making a logic wiring error (Figure 1-3).
• The program takes the place of much of the external wiring
that would normally be required for control of a process.
• Hardwiring, though still required to connect field devices,
is less intensive.
• PLCs also offer the reliability associated with solid-state
components.
 INTRODUCTION TO PLC
More Flexibility:
• It is easier to create and change a program in a PLC than
to wire and rewire a circuit.
• With a PLC the relationships between the inputs and
outputs are determined by the user program instead of
the manner in which they are interconnected (Figure 1-
4).
• Original equipment manufacturers can provide system
updates by simply sending out a new program.
• End users can modify the program in the field, or if
desired, security can be provided by hardware features
such as key locks and by software passwords.
 INTRODUCTION TO PLC
Lower Cost:
• PLCs were originally designed to replace relay control logic,
and the cost savings have been so significant that relay control
is becoming obsolete except for power applications.
• Generally, if an application has more than about a half-dozen
control relays, it will probably be less expensive to install a
PLC.
Communications Capability:
• A PLC can communicate with other controllers or computer
equipment to perform such functions as supervisory control,
data gathering, monitoring devices and process parameters,
and download and upload of programs (Figure 1-5).
INTRODUCTION TO PLC
 INTRODUCTION TO PLC
Faster Response Time:
• PLCs are designed for high speed and real-time applications
(Figure 1-6).
• The programmable controller operates in real time, which means
that an event taking place in the field will result in the execution
of an operation or output.
• Machines that process thousands of items per second and objects
that spend only a fraction of a second in front of a sensor require
the PLC’s quick-response capability.
Easier to Troubleshoot:
• PLCs have resident diagnostics and override functions that allow
users to easily trace and correct software and hardware problems.
• To find and fix problems, users can display the control program
on a monitor and watch it in real time as it executes (Figure 1-7)·
 INTRODUCTION TO PLC
Easier to Test Field Devices:
• A PLC control panel has the ability to check field
devices at a common point.
• For example, a control system consisting of hundreds
of input and output field devices may be contained
within a very large manufacturing area.
• Thus, it would take a considerable amount of time to
check each device at its location.
• By having each device wired back to a common point
on a PLC module, each device could be checked for
operation fairly quickly.
 INTRODUCTION TO SCADA
• SCADA (Supervisory Control and Data Acquisition)
has been around as long as there have been control
systems.
• The first “SCADA” systems utilized data acquisition
by means of panels of meters, lights and strip chart
recorders.
• Supervisory control was exercised by the operator
manually operating various control knobs.
• These devices were and still are used to do
supervisory control and data acquisition on plants,
factories and power generating facilities.
 FUNDAMENTAL PRINCIPLES OF MODERN
SCADA SYSTEMS

• SCADA refers to the combination of telemetry and data

acquisition.
• SCADA encompasses the collecting of the information,
transferring it back to the central site, carrying out any
necessary analysis and control and then displaying that
information on a number of operator screens or displays.
• The required control actions are then conveyed back to the
process.
• The PLC or Programmable Logic Controller is still one of the
most widely used control systems in industry.
• As needs grew to monitor and control more devices in the plant,
the PLCs were distributed and the systems became more
intelligent and smaller in size. PLCs and DCS or (Distributed
PC TO PLC OR DCS WITH A FIELDBUS AND SENSORS

PC to PLC or DCS with a fieldbus and sensors

 ADVANTAGES
The advantages of the PLC / DCS SCADA system are:
• The computer can record and store a very large
amount of data.
• The data can be displayed in any way the user
requires.
• Thousands of sensors over a wide area can be
connected to the system.
• The operator can incorporate real data simulations
into the system.
• Many types of data can be collected from the RTUs.
• The data can be viewed from anywhere, not just on
site.
 DISADVANTAGES
The disadvantages are:
• The system is more complicated than the
sensor to panel type.
• Different operating skills are required, such as
system analysts and programmer.
• With thousands of sensors there is still a lot of
wire to deal with.
• The operator can see only as far as the PLC.
SCADA Hardware
 SCADA Hardware
• One distinguishes two basic layers in a SCADA system: the
"client layer" which caters for the man machine interaction and
the "data server layer" which handles most of the process data
control activities.
• The data servers communicate with devices in the field through
process controllers.
• Process controllers, e.g. PLCs, are connected to the data servers
either directly or via networks or fieldbuses that are proprietary
(e.g. Siemens H1), or non-proprietary (e.g. Profibus).
• Data servers are connected to each other and to client stations
via an Ethernet LAN.
• The data servers and client stations are NT platforms but for
many products the client stations may also be W95 machines.
 SCADA Hardware
• A SCADA System consists of a number of Remote
Terminal Units (or RTUs) collecting field data and
sending that data back to a master station via a
communications system.
• The master station displays the acquired data and also
allows the operator to perform remote control tasks.
• On a more complex SCADA system there are essentially
five levels or hierarchies:
– Field level instrumentation and control devices
– Marshalling terminals and RTUs
– Communications system
– The master station(s)
– The commercial data processing department computer
system
 Software Architecture
• The products are multi-tasking and are based
upon a real-time database (RTDB) located in one
or more servers.
• Servers are responsible for data acquisition and
handling (e.g. polling controllers, alarm checking,
calculations, logging and archiving) on a set of
parameters, typically those they are connected to.
• However, it is possible to have dedicated servers
for particular tasks, e.g. historian, datalogger,
alarm handler.
Software Architecture
 SCADA Software

• SCADA Software can be divided into two types,

Proprietary or Open.
• Companies develop proprietary software to
communicate to their hardware.
• These systems are sold as “turn key” solutions.
• Open software systems have gained popularity because
of the Interoperability they bring to the system.
• Citect and WonderWare are just two of the open
software packages available on the market for SCADA
systems
 SCADA and Local Area Networks

• To enable all the nodes on the SCADA network to share

information, they must be connected by some transmission
medium.
• The method of connection is known as the network topology.
• Nodes need to share this transmission medium in such a way
as to allow all nodes access to the medium without disrupting
an established sender.
• Ethernet is the most widely used LAN today because it is
cheap and easy to use.
• Connection of the SCADA network to the LAN allows
anyone within the company, with the right software and
permission, to access the system.
• Since the data is held in a database the user can be limited to
reading the information.
 MODEM USE IN SCADA SYSTEMS

•Often in SCADA systems the RTU (Remote Terminal Unit

(PLC, DCS or IED)) is located at a remote location.
•This distance can vary from tens of meters to thousands of
Kilometers.
•One of the most cost-effective ways of communicating with the
RTU over long distances can be by dialup telephone connection.
•With this system the devices needed are a PC, two dialup
modems and the RTU (assuming that the RTU has a built in
COM port). The modems are put in the auto answer mode and the
RTU can dial into the PC or the PC can dial the RTU.
 SYSTEM IMPLEMENTATION
• When first planning and designing a SCADA
system, consideration should be given to
integrating new SCADA systems into existing
communication networks in order to avoid the
substantial cost of setting up new infrastructure
and communications facilities.
• This may be carried out through existing LANs,
private telephone systems or existing radio
systems used for mobile vehicle communications.
 SCADA SYSTEMS SOFTWARE
• The typical components of a SCADA system, with emphasis
on the SCADA software are indicated in the Figure.
 SCADA KEY FEATURES

User Interface
• Keyboard
• Mouse
• Trackball
• Touch screen
Graphics Displays
• Customer-configurable, object orientated and bit mapped
• Unlimited number of pages
• Resolution: up to 1280 x 1024 with millions of colors
Alarms
• Client server architecture
• Time stamped alarms to 1 millisecond precision (or better)
• Single network Acknowledgment and control of alarms
• Alarms shared to all clients
• Alarms displayed in chronological order
• Dynamic allocation of alarm pages
 SCADA KEY FEATURES

• Up to four adjustable trip points for each analog alarm

• Deviation and rate of change monitoring for analog
alarms
• Selective display of alarms by category (256
categories)
• Historical alarm and event logging
• Context-sensitive help
• On-line alarm disable and threshold modification
• Event-triggered alarms
• Alarm-triggered reports
• Operator comments that can be attached to alarms
 SCADA KEY FEATURES
Trends
• Client server architecture
• True trend printouts (not screen dumps)
• Rubber band trend zooming
• Export data to DBF, CSV files
• X/Y plot capability
• Event based trends
• Pop-up trend display
• Trend gridlines or profiles
• Background trend graphics
• Real-time multi-pen trending
• Short and long term trend display
• Length of data storage and frequency of monitoring that can be
• specified on a per-point basis
• Archiving of historical trend data
• On-line change of time-base without loss of data
• On-line retrieval of archived historical trend data
• Exact value and time that can be displayed
• Trend data that can be graphically represented in real time
 SCADA KEY FEATURES
RTU (and PLC) Interface
• All compatible protocols included as standard
• DDE drivers supported
• Interface also possible for RTUs, loop controllers, bar
code readers and other equipment
• Driver toolkit available
• Operates on a demand basis instead of the conventional
predefined scan method
• Optimization of block data requests to PLCs
• Rationalization of network user data requests
• Maximization of PLC highway bandwidth
 INTRODUCTION TO DCS
A distributed control system (DCS) refers to a
control system usually of a manufacturing system,
process or any kind of dynamic system, in which the
controller elements are not central in location (like the
brain) but are distributed throughout the system with
each component sub-system
DCS (Distributed Control System) is a computerized
control system used to control the production line in
the industry controlled by one or more controllers.
DCS is a very broad term used in a variety of
industries, to monitor and control distributed
equipment.
 APPLICATION AREA
Electrical power grids and electrical generation plants
Environmental control systems
Traffic signals
Radio signals
Water management systems
Oil refining plants
Metallurgical process plants
Chemical plants
Pharmaceutical manufacturing
Sensor networks
Dry cargo and bulk oil carrier ships
 HISTORY
•The DCS was introduced in 1975.
•Both Honeywell and Japanese electrical engineering firm
Yokogawa introduced their own independently produced DCSs at
roughly the same time, with the TDC 2000 and CENTUM
systems, respectively.
•US-based Bristol also introduced their UCS 3000 universal
controller in 1975.
•In 1978 Metso (known as Valmet in 1978) introduced their own
DCS system called Damatic (latest generation named Metso
DNA).
•In 1980, Bailey (now part of ABB) introduced the NETWORK
90 system.
•Also in 1980, Fischer & Porter Company (now also part of
ABB) introduced DCI-4000 (DCI stands for Distributed Control
Instrumentation).
 DISTRIBUTED CONTROL SYSTEMS

• Collection of hardware and instrumentation

necessary for implementing control systems

• Provide the infrastructure (platform) for

implementing advanced control algorithms
DISTRIBUTED CONTROL SYSTEMS

Supervisory (host)
Computer
•Most
comprehensive Operator
Control
Main
Control
Operator
Control
Archival
Data
Panel Computer Panel Storage

Data highway
To other Processes To other Processes

Local data acquisition and Local Local Local

control computers Computer Computer Computer
Local Display Local Display

PROCESS
 DCS Elements-1
• Local Control Unit: This unit can handle 8 to 16
individual PID loops.
• Data Acquisition Unit: Digital (discrete) and
analog I/O can be handle.
• Batch Sequencing Unit: This unit controls a
timing counters, arbitrary function generators, and
internal logic.
• Local Display: This device provides analog
display stations, and video display for readout.
• Bulk Memory Unit: This unit is used to store and
recall process data.
 DCS Elements-2
• General Purpose Computer : This unit is programmed
by a customer or third party to perform optimization,
advance control, expert system, etc
• Central Operator Display: This unit typically contain
several consoles for operator communication with the
system, and multiple video color graphics display units
• Data Highway : A serial digital data transmission link
connecting all other components in the system. It allow
for redundant data highway to reduce the risk of data
loss
• Local area Network (LAN)
 Advantages of DCS
 Access a large amount of current information
from the data highway.
 Monitoring trends of past process conditions.
 Readily install new on-line measurements
together with local computers.
 Alternate quickly among standard control
strategies and readjust controller parameters in
software.
 A sight full engineer can use the flexibility of
the framework to implement his latest controller
design ideas on the host computer.
 DCS VENDORS
• Honeywell
• Fisher-Rosemont
• Baily
• Foxboro
• Yokogawa
• Siemens
• GE Fanuc Intelligent Platform
• Schneider Electrics
• ABB
 INTRODUCTION TO INDUSTRIAL
DATA NETWORKS

HART_Highway Addressable Remote Transducer

FIELD BUS
PROFIBUS
 HART
• For many years, the field communication standard for
process automation equipment has been a milliamp (mA)
analog current signal.
• The milliamp current signal varies within a range of 4-20mA
in proportion to the process variable being represented.
• In typical applications a signal of 4mA will correspond to
the lower limit (0%) of the calibrated range and 20mA will
correspond to the upper limit (100%) of the calibrated
range.
• If the system is calibrated for 0-100 PSI, then an analog
current signal of 12mA (50% of range) will correspond to a
pressure of 50 PSI.
• Virtually all installed systems use this international standard
for communicating process variable information between
process automation equipment.
 HART COMMUNICATION PROTOCOL
• HART Field Communications Protocol extends this
4- 20mA standard to enhance communication with smart
field instruments.
• The HART protocol was designed specifically for use
with intelligent measurement and control instruments which
traditionally communicate using 4-20mA analog signals.
• HART preserves the 4-20mA signal and enables two-way
digital communications to occur without disturbing the
integrity of the 4-20mA signal.
• Unlike other digital communication technologies, the
HART protocol maintains compatibility with existing
4-20mA systems, and in doing so, provides users with a
uniquely backward compatible solution.
• HART Communication Protocol is well established as the
"de facto" industry standard for digitally enhanced
4-20mA field communication.
 FEATURES
• Proven in practice, simple design, easy to maintain and
operate.
• Compatible with conventional analog instrumentation.
• Simultaneous analog and digital communication.
• Option to point-to-point or multidrop operation.
• Flexible data access via up to two master devices.
• Supports multivariable field devices.
• Sufficient response time(500ms).
• Open de-facto standard and freely available to any
manufacturer or user.
 HART PROTOCOL….
• The HART protocol makes use of the Bell 202 Frequency
Shift Keying (FSK) standard to superimpose digital
communication signals at a low level on top of the 4-20mA.
• This enables two-way field communication to take place
and makes it possible for additional information beyond just
the normal process variable to be communicated to/from a
Figure 1 - HART uses Frequency Shift Keying to encode
digital information on top of the 4-20mA analog signal smart
field instrument.
• The HART protocol communicates at 1200 bps without
interrupting the 4-20mA signal and allows a host application
(master) to get two or more digital updates per second from a
field device.
• As the digital FSK signal is phase continuous, there is no
interference with the 4-20mA signal.
HART SIGNAL
HART SIGNAL…
HART COMMUNICATION MODES
• HART is a master/slave protocol which means that a field
(slave) device only speaks when spoken to by a master.
• The HART protocol can be used in various modes for
communicating information to/from smart field
instruments and central control or monitoring systems.
• HART provides for up to two masters (primary and
secondary).
• This allows secondary masters such as handheld
communicators to be used without interfering with
communications to/from the primary master, i.e.
control/monitoring system.
• The most commonly employed HART communication
mode is
1. Master/slave or Poll/Response mode
2. Burst or Broadcast mode
 MASTER/SLAVE OR
POLL/RESPONSE MODE
• HART is a master-slave communication protocol, which
means that during normal operation, each slave (field device)
communication is initiated by a master communication device.
• Two masters can connect to each HART loop.
• The primary master is generally a distributed control system
(DCS), programmable logic controller (PLC), or a personal
computer (PC).
• The secondary master can be a handheld terminal or another
PC.
• Slave devices include transmitters, actuators, and controllers
that respond to commands from the primary or secondary
master.
 MASTER/SLAVE OR
POLL/RESPONSE MODE…
 BURST OR BROADCAST MODE
• Some HART devices support the optional
burst communication mode.
• Burst mode enables faster communication
(3–4 data updates per second).
• In burst mode, the master instructs the slave
device to continuously broadcast a standard
HART reply message (e.g., the value of the
process variable).
• The master receives the message at the higher
rate until it instructs the slave to stop bursting.
BURST OR BROADCAST MODE…
 HART NETWORKS
HART devices can operate in one of two
network configurations
1. Point-to- point network
2. Multidrop network.
 POINT-TO- POINT NETWORK
• In point-to-point mode, the traditional 4–20 mA signal is
used to communicate one process variable, while
additional process variables, configuration parameters,
and other device data are transferred digitally using the
HART protocol (Figure 2).
• The 4–20 mA analog signal is not affected by the HART
signal and can be used for control in the normal way.
• The HART communication digital signal gives access to
secondary variables and other data that can be used for
operations, commissioning, maintenance, and diagnostic
purposes.
POINT-TO- POINT NETWORK…..
HART COMMUNICATION VIA
MULTIPLEXER
 HART COMMUNICATION VIA
MULTIPLEXER….
• Fig shows the use of a multiplexer system, which
enables a large number of HART devices to be
connected in a network.
• The user selects a particular current loop for
communication via the operating program.
• As long as the communication takes place, the
multiplexer connects the current loop to the host.
• Due to the cascaded multiplexer structure, the host
can communicate with many (> 1000) devices, all
with the address zero.
 MULTIDROP NETWORK
• The multidrop mode of operation requires only a
single pair of wires and, if applicable, safety barriers
and an auxiliary power supply for up to 15 field
devices (Figure3).
• All process values are transmitted digitally.
• In multidrop mode, all field device polling addresses
are >0, and the current through each device is fixed to
a minimum value (typically 4mA).
MULTIDROP NETWORK….
HART NETWORK FOR SPLIT-
RANGE OPERATION
 HART NETWORK FOR SPLIT-
RANGE OPERATION….
• There are special applications which require that several -
usually two -Actuators receive the same control signal.
• A typical example is the split-range operation of control
valves.
• One valve operates in the nominal current range from 4 to 12
mA, while the other one uses the range from 12 to 20 mA.
• In split-range operation, the control valves are connected in
series in the current loop.
• When both valves have a HART interface, the HART host
device must be able to distinguish with which valve it must
communicate.
• Each device is assigned to an address from 1 to 15.
• The analog 4 to 20 mA signal preserves its device-specific
function, which is, for control valves, the selection of the
required travel.
 HART COMMANDS
• The HART command set provides uniform and
consistent communication for all field devices.
• The command set includes three classes:
[Link] commands
[Link] practice commands
[Link] specific commands
• Host applications may implement any of the
necessary commands for a particular application.
 UNIVERSAL
• All devices using the HART protocol must
recognize and support the universal
commands.
• Universal commands provide access to
information useful in normal operations
(e.g., read primary variable and units).
 COMMON PRACTICE
• Common practice commands provide
functions implemented by many, but not
necessarily all, HART communication devices.
 DEVICE SPECIFIC
• Device-specific commands represent functions that
are unique to each field device.
• These commands access setup and calibration
information, as well as information about the
construction of the device.
• Information on device-specific commands is
available from device manufacturers.
COMPARISON
CONTROL SYSTEM INTERFACE
Analog

HART Interface

Digital

Multiple Masters
Up to 3000 m

(Same cable as today)

CONTROL SYSTEM INTERFACE….
• HART is a master/slave protocol which means that a
field (slave) device only speaks when spoken to by a
master.
• HART provides for up to two masters (primary and
secondary) as shown in Figure.
• This allows secondary masters such as handheld
communicators to be used without interfering with
communications to/from the primary master, i.e.
control/monitoring system.
HART AND OSI MODEL
 HART AND OSI MODEL….
• The HART protocol utilizes the OSI reference model.
• As is the case for most of the communication
systems on the field level, the HART protocol
implements only the layers 1, 2 and 7 of the OSI
model.
• The layers 3 to 6 remain empty since their services
are either not required or provided by the application
layer 7
 FIELDBUS INTRODUCTION
• Fieldbus is the technological evolution to digital
communication in instrumentation and process
control.
• It differs from any other communication protocol,
because it is designed to resolve process control
applications instead of just transfer data in a digital
mode.
• The Fieldbus technology is explained along this
overview so you can check its advantages, feel its
power and go a little further using fieldbus as an
outstanding and reliable technology into your control
system.
 INTRODUCTION….
• Fieldbus is an all-digital, serial, two-way
communication system, which interconnects
“field” equipment such as sensors, actuators and
controllers.
• Fieldbus is a Local Area Network (LAN) for
instruments used in both process and
manufacturing automation with built-in capability
to distribute the control application across the
network.
INTRODUCTION….
 ADVANTAGES
• Bidirectional digital communication
• Simple cabling and cross-wiring
• Reduction of planning costs and maintenance
• Higher safety through self-monitoring
• Higher resolution of process values
• Lower installation and maintenance costs
• Improved performance
• Interoperability
FIELDBUS ARCHITECTURE
 FIELDBUS ARCHITECTURE….

• Foundation Fieldbus does not implement

layers three, four, five, and six of the OSI
model because the services of these layers are
not required in a process control application.
• A very important part of Foundation Fieldbus
is the defined user layer, often referred to as
layer eight.
 PROFIBUS
Three different versions of PROFIBUS exist:
PROFIBUS-FMS (Fieldbus Message Specification) is
used based on the Client-Server model for the
communication between automation devices (control
level).
PROFIBUS-DP (Decentralized Periphery) is used for
fast remote inputs and outputs, to connect sensors and
actuators to a controlling device.
PROFIBUS-PA (Process Automation) is used for the
connection of field devices and transmitters to a
process control device. It allows intrinsic safe
transmission and power on the line.
• Parameters and function blocks are defined covering
the need of the process engineering.
PROFIBUS