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SEMINAR ON AUTOMATION SUMBITTED BY: DIKSHA VAID
AUTOMATION-DEFINATION Delegation of human control function to technical equipments to increase production to reduce cost to reduce manpower to improve safety working conditions to reduce power consumption to improve quality
TYPES OF AUTOMATION
AUTOMATION
SCIENTIFIC AUTOMATION
INDUSTRIAL AUTOMATION
OFFICE AUTOMATION
LAYOUT OF INDUSTRIAL AUTOMATION
ROLE OF COMPUTERS
When an automated machine is placed under the control of a computer a large number of operations can be performed. The computer can analyze a vast number of sensory inputs from a system and decide which of many responses it should make.
SMALL COMMUNITIES
ENDLESS CHALLENGES
Remoteness of site Limited financial resources Limited staff Limited access to technology and supplies Limited access to training
ADVANTAGES
REPLACING HUMAN OPERATOR
ECONOMY IMPROVEMENT
MAKING TASK BEYOND HUMAN CAPABILITIES
SUPERVISORY CONTROL AND DATA ACQUISITION(SCADA)
WHAT IS SCADA SCADA stands for Supervisory Control And Data Acquisition. SCADA refers to a system that collects data from various sensors at a factory, plant or in other remote locations and then sends this data to a central computer which then manages and controls the data.
TYPES OF PROCESSES INDUSTRIAL PROCESSES
FACILITY PROCESSES
INFRASTRUCTURE PROCESSES
WHAT IS DATA ACQUISITION Data acquisition is the process of retrieving control information from the equipment which is out of order or may lead to some problem or when decisions are need to be taken according to the situation in the equipment. So this acquisition is done by continuous monitoring of the equipment to which it is employed. The data accessed are then forwarded onto a telemetry system ready for transfer to the different sites.
HARDWARE ARCHITECTURE
SCADA AS A SYSTEM
TYPICAL SCADA SYSTEM
SUBSYSTEMS OF SCADA SYSTEM
Human-Machine Interface is the apparatus which presents process data to a human operator, and through this, the human operator monitors and controls the process. Remote Terminal Units connecting to sensors in the process, converting sensor signals to digital data and sending digital data to the supervisory system.
Programmable Logic Controller used as field devices because they are more economical, versatile, flexible, and configurable than specialpurpose RTUs. Communication infrastructure connecting the supervisory system to the Remote Terminal Units
SYSTEM COMPONENTS OF SCADA SYSTEM MULTIPLE REMOTE TERMINAL UNIT
COMMUNICATION INFRASTRUCTURE
CENTRAL HOST COMPUTER
FEATURES OF SCADA
REAL TIME AND HISTORICAL TREND
The trend play very important role in the process operation. If your batch fails or the plant trips, you can simply go to the historical trend data and do the analysis. You can have better look of the parameters through the trend.
ALARMS have a very critical role in automation. Generally we have alarm states for each inputs/outputs. . Most of the SCADA software support four types of alarms like LOLO,LO,HI and HIHI. RECIPE MANAGEMENT When you have different products to manufacture, you just have to load the recipe of the particular product.
SECURITY You can allocate certain facilities or features to the operator, process people, engineering dept and maintenance dept. DEVICE CONNECTIVITY SCADA software should have connectivity to the different hardware used in automation.
USEFULNESS OF SCADA
Production department Quality department Maintenance department Enterprise information Engineering department Manufacturing department
GENERAL TERMINOLOGY
TAG ANALOG TAGS DISCRETE TAGS SYSTEM TAGS STRING TAGS TOUCH PUSH BUTTONS COLOUR LINKS
VISIBILITY BLINK ORIENTATION DISABLE VALUE DISPLAY LINK PERCENTAGE FILL APPLICATION SCRIPT WINDOW SCRIPT KEY SCRIPT CONDITION SCRIPT APPLICATION SECURITY
Flow control and continuous totalizer
Transportation belt application Speed or mass control with adjustable PID Weight totalization of product transported ± 1% accuracy with 1s sample rate and 1 to 10 speed max/min ratio
Packaging Weigher
One scale dosing of a preset load for 99 recipes Dosing with an intermediate hopper or within the packaging operation Automatic correction of dose values Tuning and production alternated cycles Automatic in-flight error correction at the end of tuning cycle Rate optimization at every cycle Adaptable reset frequency Average and standard deviation calculation at the end of tuning cycle Printing during production cycle Rate example : 1200 bags of 25 kg per hour (on one scale)
WHAT IS INTOUCH
Wonderware InTouch provides a single integrated view of all your controls and information resources. Intouch enables engineers, supervisors, operators and managers to view and interact with the working of entire operation through graphical representations of their production processes.
MAJOR PROGRAMS OF INTOUCH
INTOUCH
INTOUCH APPLICATION MANAGER
WINDOWMAKER
WINDOWVIEWER
WONDERWARE SCADA SOFTWARE
Easy-to-use, easy to implement Easy configuration, simplified maintenance High security and availability Virtually unlimited scalability
PRACTICAL USES OF SCADA
SCADA used as a control mechanism for chemical plants, electricity generation, electric power transmission, electricity distribution, district heating. Control mechanisms are described in Process Control.
ADVANTAGES CHEAPER CONTINOUS OPERATION RELIABLE IMPROVES MAINTAINANCE, OPERATION, CUSTOMER SERVICE FEW OPERATORS CONTROL LARGE NO. OF INDIVIDUAL ASSETS PROVIDE RAPID RESPONSE TO EMERGENCIES
DISADVANTAGES
TROUBLED ALARMS LACK OF TRAINED PERSONS
INITIAL CAPITAL INVESTMENT
SCADA MANUFACTURER AND NAME OF THE SOFTWARE WONDERWARE ALLEN BRADLEY SIEMENS MODICON G E FANUC INTELLUSION KPIT
Intouch R.S View Wincc Moriecon Cimplicity I Fix Ashtra
BENEFITS OF SCADA
Long distance monitoring Long distance training Protection against terrorism/vandalism-alarm Data management (engineering and operations) Automated operations with real time control
CONCLUSION SCADA is a control system with ● More interfaces and efficient storage ● More record or device oriented configuration ● But system wide configuration tools are needed ● Are less expensive than DCS, but offer different functionality than DCS ● And finally various applications
THANK YOU
AUTOMATION-DEFINATION Delegation of human control function to technical equipments to increase production to reduce cost to reduce manpower to improve safety working conditions to reduce power consumption to improve quality
TYPES OF AUTOMATION
AUTOMATION
SCIENTIFIC AUTOMATION
INDUSTRIAL AUTOMATION
OFFICE AUTOMATION
LAYOUT OF INDUSTRIAL AUTOMATION
ROLE OF COMPUTERS
When an automated machine is placed under the control of a computer a large number of operations can be performed. The computer can analyze a vast number of sensory inputs from a system and decide which of many responses it should make.
SMALL COMMUNITIES
ENDLESS CHALLENGES
Remoteness of site Limited financial resources Limited staff Limited access to technology and supplies Limited access to training
ADVANTAGES
REPLACING HUMAN OPERATOR
ECONOMY IMPROVEMENT
MAKING TASK BEYOND HUMAN CAPABILITIES
SUPERVISORY CONTROL AND DATA ACQUISITION(SCADA)
WHAT IS SCADA SCADA stands for Supervisory Control And Data Acquisition. SCADA refers to a system that collects data from various sensors at a factory, plant or in other remote locations and then sends this data to a central computer which then manages and controls the data.
TYPES OF PROCESSES INDUSTRIAL PROCESSES
FACILITY PROCESSES
INFRASTRUCTURE PROCESSES
WHAT IS DATA ACQUISITION Data acquisition is the process of retrieving control information from the equipment which is out of order or may lead to some problem or when decisions are need to be taken according to the situation in the equipment. So this acquisition is done by continuous monitoring of the equipment to which it is employed. The data accessed are then forwarded onto a telemetry system ready for transfer to the different sites.
HARDWARE ARCHITECTURE
SCADA AS A SYSTEM
TYPICAL SCADA SYSTEM
SUBSYSTEMS OF SCADA SYSTEM
Human-Machine Interface is the apparatus which presents process data to a human operator, and through this, the human operator monitors and controls the process. Remote Terminal Units connecting to sensors in the process, converting sensor signals to digital data and sending digital data to the supervisory system.
Programmable Logic Controller used as field devices because they are more economical, versatile, flexible, and configurable than specialpurpose RTUs. Communication infrastructure connecting the supervisory system to the Remote Terminal Units
SYSTEM COMPONENTS OF SCADA SYSTEM MULTIPLE REMOTE TERMINAL UNIT
COMMUNICATION INFRASTRUCTURE
CENTRAL HOST COMPUTER
FEATURES OF SCADA
REAL TIME AND HISTORICAL TREND
The trend play very important role in the process operation. If your batch fails or the plant trips, you can simply go to the historical trend data and do the analysis. You can have better look of the parameters through the trend.
ALARMS have a very critical role in automation. Generally we have alarm states for each inputs/outputs. . Most of the SCADA software support four types of alarms like LOLO,LO,HI and HIHI. RECIPE MANAGEMENT When you have different products to manufacture, you just have to load the recipe of the particular product.
SECURITY You can allocate certain facilities or features to the operator, process people, engineering dept and maintenance dept. DEVICE CONNECTIVITY SCADA software should have connectivity to the different hardware used in automation.
USEFULNESS OF SCADA
Production department Quality department Maintenance department Enterprise information Engineering department Manufacturing department
GENERAL TERMINOLOGY
TAG ANALOG TAGS DISCRETE TAGS SYSTEM TAGS STRING TAGS TOUCH PUSH BUTTONS COLOUR LINKS
VISIBILITY BLINK ORIENTATION DISABLE VALUE DISPLAY LINK PERCENTAGE FILL APPLICATION SCRIPT WINDOW SCRIPT KEY SCRIPT CONDITION SCRIPT APPLICATION SECURITY
Flow control and continuous totalizer
Transportation belt application Speed or mass control with adjustable PID Weight totalization of product transported ± 1% accuracy with 1s sample rate and 1 to 10 speed max/min ratio
Packaging Weigher
One scale dosing of a preset load for 99 recipes Dosing with an intermediate hopper or within the packaging operation Automatic correction of dose values Tuning and production alternated cycles Automatic in-flight error correction at the end of tuning cycle Rate optimization at every cycle Adaptable reset frequency Average and standard deviation calculation at the end of tuning cycle Printing during production cycle Rate example : 1200 bags of 25 kg per hour (on one scale)
WHAT IS INTOUCH
Wonderware InTouch provides a single integrated view of all your controls and information resources. Intouch enables engineers, supervisors, operators and managers to view and interact with the working of entire operation through graphical representations of their production processes.
MAJOR PROGRAMS OF INTOUCH
INTOUCH
INTOUCH APPLICATION MANAGER
WINDOWMAKER
WINDOWVIEWER
WONDERWARE SCADA SOFTWARE
Easy-to-use, easy to implement Easy configuration, simplified maintenance High security and availability Virtually unlimited scalability
PRACTICAL USES OF SCADA
SCADA used as a control mechanism for chemical plants, electricity generation, electric power transmission, electricity distribution, district heating. Control mechanisms are described in Process Control.
ADVANTAGES CHEAPER CONTINOUS OPERATION RELIABLE IMPROVES MAINTAINANCE, OPERATION, CUSTOMER SERVICE FEW OPERATORS CONTROL LARGE NO. OF INDIVIDUAL ASSETS PROVIDE RAPID RESPONSE TO EMERGENCIES
DISADVANTAGES
TROUBLED ALARMS LACK OF TRAINED PERSONS
INITIAL CAPITAL INVESTMENT
SCADA MANUFACTURER AND NAME OF THE SOFTWARE WONDERWARE ALLEN BRADLEY SIEMENS MODICON G E FANUC INTELLUSION KPIT
Intouch R.S View Wincc Moriecon Cimplicity I Fix Ashtra
BENEFITS OF SCADA
Long distance monitoring Long distance training Protection against terrorism/vandalism-alarm Data management (engineering and operations) Automated operations with real time control
CONCLUSION SCADA is a control system with ● More interfaces and efficient storage ● More record or device oriented configuration ● But system wide configuration tools are needed ● Are less expensive than DCS, but offer different functionality than DCS ● And finally various applications
THANK YOU
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