Lecture 1.pptx

OVERVIEW OF INDUSTRIAL
AUTOMATION AND NEED OF
I&C ENGINEERING
Prof. (Dr.) Chetan B. Bhatt
Principal,
GMCA, Ahmedabad

PRESENTATION OUTLINE
Overview of Industrial Automation
A brief introduction to I & C
History of I & C
Basics of I & C
Current Trends

GOD OF ENGINEERING
ॐ क
ं बासूत्राम्बुपात्रं वहति करिले पुस्िक
ं ज्ञानसूत्रं ।
हँसारूढ़: त्रत्रनेत्रः शुभमुक
ु टशशरा सवविो वृद्धकाय ॥
त्रैलोकयं येन सृष्टं सकलसुरगृहं राजहम्यावदि ह हम्य। ।
हेवोङसौ सूत्रधारो जगहखिलदि हिः पािु वो ववश्ववकमवन ॥
क
ं बा – a bar of iron or other metal, old land
measurement name/unit
सूत्र – rule
क
ं बासूत्र – metal foot rule
ज्ञानसूत्रं - Plumb bob
Tool
Knowledge,
Algorithms Essence of
life, purity,
sensible
(आर्द्विा)

WHAT IS ENGINEERING?
The main task of engineering is to find and deliver
optimal solutions to real-life problems, within the
given material (components), technological, economic,
social, and environmental constraints, through the
application of scientific, technological, and
engineering knowledge.

WHAT DO ENGINEERS DO?
Conceive
Idea
• Intention to
do
• Perceived
• Identify
problem
Design • Plan
• Assemble
• Simulate
• Create
• Test
Implement
• Operate
• Maintain
• Repair
Waste
Management
• Regain
• Recycle
• Demolish
• Incineration
Create
(ब्रह्मा)
Operate
(ववष्णु)
Managing end of
product life
(रुर्द्/शशव)

WHAT IS INSTRUMENTATION AND
CONTROL?
Instrumentation and Control Engineering is an areas of study which
deals with measurement and control of physical and chemical
parameters of the system.
Physical Parameters: Temperature, flow, pressure, displacement,
velocity, stress, force, voltage, current etc.
Chemical Parameters: pH, dissolved oxygen, gas concentration, etc.

WHAT DO I&C ENGINEERS DO?
Solve real-life problems related to measurement and
control of plant/system/process parameters.
•Design (Components of Automation/Control System, Control
System)
•Operate and Maintain

HISTORY OF
MEASUREMENT AND
CONTROL

WHY WE NEED TO MEASURE?
• Gain knowledge of system under study
• Financial and budgetary aspects (e.g., gas and oil custody transfer)
• Control the system behaviour

DATA → INFORMATION → KNOWLEDGE
→ WISDOM
Data
 Raw signals
 Numbers
Information
 Relation attached to data
Knowledge
 Attach purpose (reason, principal, rationale)
and competence (know – how, ability) to
information
Wisdom
 Generalization of purpose or competence in
multiple domains (Context independent)
Data
Informatio
n
Knowled
ge
Wisdom
Context
Independencies
Understanding

HISTORY OF MEASUREMENT
The history of measurement systems in India/World begins in
early Indus Valley Civilization with the earliest surviving samples
dated to the 5th millennium BCE. Since early times, the adoption of
standard weights and measures has reflected in the
country's architectural, folk, and metallurgical artifacts.
Harrapan civilization has standards for –
• Weight
• Length
• Time

WEIGHT MEASUREMENT
Ratti based measurement is the oldest measurement system in
the Indian subcontinent, it was highly favored because of the
uniformity of its weights. The smallest weight in the Indus Valley
civilization was equal to 8 rattis, (historically called Masha). The Indus
weights were the multiples of Masha (1 Masha = 0.972 gram,
https://hextobinary.com/unit/weight/from/masha/to/gram) and the
16th factor was the most common weight of 128 Ratti or 13.7 g.
The weights were in the proportion of binary number system.
Is word mass having root in Masha?

HISTORY
The travelling Greek sage Apollodorus of Tyana (3 BC to 97 AD)
observed automated servants and self-propelled carts in the court of
ruler of India, and India was centuries ahead of Europe in the
technologies of distillation and hydraulics.
By third century BC, craftspeople and engineers in the Greek world,
Alexandria, Arabia, India, and China began making self moving
devices, flying bird models, animated machines, and automatons like
those described in myth.
(Adrienne Mayor, Research Scholar Stanford University, Historian of
Ancient Science)
Read more at:
http://timesofindia.indiatimes.com/articleshow/68648962.cms?utm_
source=contentofinterest&utm_medium=text&utm_campaign=cppst

SOME REFERENCES
1010 – 1055 CE

EVOLUTION OF I & C ENGINEERING
We can look at evolution of any engineering discipline in context of –
• Conceptual Knowledge
• Tools
• Technologies
• Changes as need arises and new knowledge generated

HISTORY OF CONTROL 1800 - 1930
This phase occupied 150 years, a period extending roughly from 1790 to
1940; progress was fitful, practical engineers often being far ahead of the
theoretical understanding of what they were trying to achieve. It was to a
large extent the period of the inventor. It was also a period when the
subject boundaries were firmly held; a common control systems language
had not been developed. The development of a coherent subject of
control systems, beginning as it did in the 1930s, falls outside the scope of
this book. It was during the World War II, with the need for
servomechanisms to operate at higher speeds and with much greater
precision than previously thought possible, that engineers and
mathematicians came together to create the control engineer. (page – 3)
•Concept of Feedback (Originated from Political/Economical ideas)
•Stability of Motion (steam governor) (1840 – 1920) era of inventors
•Development of Servomechanism
•Development of electrical devices (almost parallelly)

If we examine three areas in detail — process control,
the electronic negative feedback amplifier and servomechanisms — it is
apparent
that progress was prevented by common problems, but recognition of this
commonality and the development of appropriate abstractions was hindered by
the lack of a common language with which to describe the problems.
Gradually,
during the 1930s, appropriate concepts began to emerge in each of these
areas
and by the end of the decade two distinct approaches to the analysis and
design
of control systems had emerged: a time domain approach based on modelling
the
system using linear differential equations, and a frequency domain approach
based
on plotting the amplitude and phase relationship between the input and output

The body of knowledge developed during the years 1930 to 1955 acquired the
name 'classical control theory' in the early 1960s. This was to distinguish it from
the so called 'modern control theory', a name that began to be used during the
early 1960s for the new time domain approaches to control system design. Both
approaches were based on the assumption that for the purposes of analysis and
design, real systems can be represented by deterministic mathematical models.

WHAT IS SYSTEM?
System is an inter-connection of
components for which there is
cause - and - effect relationship
among the variables.
System can be
 Physical: Air Craft, Industrial Plant, Robot
 Biological: Human Body, Animals, Trees
etc.
 Non-physical: Software, Financial System,
Social System etc.
System has to
 Perform certain task
 Produce desired output

CONTROL SYSTEM
It is required to maintain or alter certain variables of the system in
accordance with some reference to get desired system performance.
Control is a process of causing a system variable to conform to some
desired value or reference value.
Within this context, control system is then defined as an
interconnection of interacting components forming a system
configuration that will provide a desired function.
A control system is a device or process that regulates the behavior of
another device or system.

AIM OF CONTROL SYSTEM
The aims of control systems are –
• Ensure Quality
• Increase profitability/productivity
• Ensure safety (human/equipment/environment)

BASIC CONTROL SCHEMES
There are two basic control
schemes –
• Open loop control
• Special class is Feed Forward Control
• Closed loop control (Feedback Control)
Control algorithm, design, and
structure may very but
fundamental scheme remains
either one of these two or
sometimes both.

OPEN LOOP CONTROL
A system in which the control
action is independent of the
output of a system is known
as open loop control system . An
open loop control system is
shown in figure 1.3.1 (a).
Reference input r(t) is applied to
the controller which generates
actuating signal u(t) to adjust
input to give desired system
output c(t).
Inaccurate, unreliable

OPEN LOOP CONTROL
Constant
speed is
assumed,
controller is
simple timer
Constant
temperature of
heating medium
is assumed,
controller is
simple
reference-%
valve opening
Controlled
Variable
(Product
Temperature)
Control/Manipulat
ed Variable (flow)

FEED-FORWARD CONTROL
In a feed-forward control system
a variation (disturbance) in one
or more input, other than control
variable, is measured and
controller is used to adjust the
control (manipulated) variable to
compensate the effect of
disturbances on controlled
variable.
Safety critical parameters (effect
of critical disturbance affecting
the safety is not acceptable).
Simple example is driving a car

CLOSED LOOP CONTROL
(FEEDBACK CONTROL)
A system in which the control
action is some how depends on
the output (controlled variable) is
known as closed loop control
system.
A reference input r(t) and
controlled output c(t) are
compared which generates error
signal e(t) . This error
signal e(t) is applied to controller
which generates actuating
signal u(t) to adjust input
(control variable) to system to
get desired controlled

Primary
Industries
•Mining
•Crude
•Raw Mix
Secondary
Industries
•Assembly
•Green/Brown field
•Discrete Processing
Tertiary
Industries
•Testing
•O&M
•Coding
&Tuning
Quaternary
Industries
•R&D
•Quality
•Predictive
Maintenance
TYPES OF INDUSTRIES

TYPES OF INDUSTRIAL
PRODUCTION SYSTEM
Continuous production system
 Process Production Flow
 Mass Production Flow
Intermittent production system
 Batch production system
 Job-shop production system
 Project production system

SEGMENTATION OF AUTOMATION
Continuou
s Flow
Process
Quantity
Variety
Mass
Manufacturin
g of Discrete
Products Batch
Processe
s Job shop
producti
on
Oil Refinery
Appliances,
Automobile
Pharma, Food
Machine
Tools,
Prototype
Fixed
Automatio
n Programmab
le
Automation
Flexible
Automatio
n Integrated
Automation
Continuous/Repetitive
Production System
Intermittent/Non-continuou
Production System
Project
Producti
on
Road, Building,
Customised system

PROCESS VS. DISCRETE
INDUSTRIES
Process industries
 Production operations are performed on amounts of materials
 Liquids, gases, powders, etc.
Discrete manufacturing industries
 Production operations are performed on quantities of
materials
 Parts, product units
M D KHEDIYA IC DEPT. VGECG 33

SERVICES OTHER THAN
MANUFACTURING
Transportation services
Financial services
Social services etc.

TYPES OF CONTROL SYSTEM
Based on Set-Point variation with respect to time, Control System can
be classified into two categories.
1. Regulatory Control System
2. Servo Control System
Another special Control Systems are
1. Numerical Control System
2. Discrete State Control System

REGULATORY CONTROL
• Set point is time invariant
(fix),
• Usually single set point per
loop.
• Usually, PID type of control
action is used
• Final Control Element is
adjusted to maintain fix set
value.
• Examples are, room
temperature control, level

SERVO (TRACKING) CONTROL
• Set point is time variant
• Usually single set point in a
loop.
• Usually, PID type of control
action is used
• Final control element is
adjusted to follow the change
in set point
• For example, firing angle of
missile, pen recorder
Collisio
n point

Temp
Temp
DISCRETE STATE CONTROL
•Set point is system (process)
state rather than physical or
chemical variables.
• Multiple set-point/state in a
system (minimum two)
• Set-point may be time variant
or in-variant
• Types of controller is usually
ON/OFF
• Example traffic light control,
elevator etc.
M
LL
UL
A B
C
Temp

DISTRIBUTED ASSEMBLY STATION
Ford Assembly line (1940) Various operations are
performed manually at different
stations. Such production line
have issues related to –
• Quality
• Production rate
• Coordination between station
• Overall monitoring and
supervision

TYPICAL INDUSTRIAL CONTROL
LOOP
Process
Controll
er
SET-POINT
Process
Input
Process
Inputs
Control
Valve

EVOLUTION OF FIELD COMMUNICATION
Market Size
Time
3 – 15 psi
4 – 20 mA
Digital
1930 1960 1990 2020

EVOLUTION OF COMMUNICATION
TECHNIQUES
Communication techniques between field level and process control
level has been evolved as below:
Pneumatic communication (3 to 15 psi)
Analog communication (4 to 20mA)
Analog + Digital communication (Hybrid)
Digital communication

COMPONENTS OF PNEUMATIC
LOOP
A typical pneumatic loop transmitter requires
 Sensor/Transducer
 Air supply
 Compressor
 Dryer
 Air Filter
 Air Regulator
 Indicator (pressure gauge)
 Pneumatic Controller (Receiver)

PNEUMATIC INSTRUMENT
APPLICATION
Now – a – days it is rare to find complete pneumatic loop, however it
is used
 Control valve actuation (common application encounter today).
 Safety is crucial

PNEUMATIC COMMUNICATION
Advantages
 Intrinsically safe
 Immune to noise
Disadvantages
 The time lag increases with the increase in distance between transmitter and
receiver
 More hardware require, more tubing
 More maintenance
 Difficult to install

TYPES OF ANALOG TRANSMITTER
(ANSI/ISA – S50.1 1982, R1992)
 Two wire system (Supply + signal, ground), Type2
 Four wire system (two power supply lines and two signal lines), T
 Three wire system (supply, signal and ground), Type3
Cont
Cont
24V DC
24V DC
Cont
24V DC
Transmitter
Transmitter
Transmitter

CURRENT LOOP COMPONENTS
A typical current loop circuit is made up of following four elements –
 Sensor/transducer
 Voltage – to – current converter (commonly referred to as transmitter or signal
conditioner)
 Loop power supply
 Receiver/monitor

ANALOG COMMUNICATION
Advantages
 Fast transmission
 Long distance
 Multiple series load can be connected in a loop
 Wide variation in supply voltage
Disadvantages
 Susceptible to noise
 More hardware, more cabling
 Maintenance

Instrument Room
Plant
Interface &
Local
Controllers
Plant Bus
Central Control Room
Control Room Bus
From
Other
Instrume
Room
CONVENTIONAL
ANALOG CABLING

INDUSTRIAL COMMUNICATION
PROTOCOLS
Protocol Year Technology Developer
AS-I 1993 AS-I Consortium
CAN 1995 CAN in
automation,philips
DeviceNet 1994 Allen-Bradley
ControlNet 1996 Allen-Bradley
HART 1989 Rosemount
Modbus 1978 Modicon
Foundation
Fieldbus –H1
1995 Fieldbus Foundation
Profibus –
DP/PA/FMS
DP:1994
PA:1995
FMS:1991
German Government

ICT ENABLED
INSTRUMENTATION AND
CONTROL

APPLICATIONS OF THE COMPUTER
Today we use computer daily, knowingly or unknowingly..
We use computers for processing data, information, and knowledge
We use computers for –
 Acquisition (through sensors or input devices)
 Computation (for various purpose)
 Simulation
 Automation
To perform above task, we have various computer hardware
and software based on complexity and applications.

APPLICATIONS OF THE COMPUTER
We use computers for –
 Acquisition (through sensors or input devices)
 Computation (for various purpose)
 Simulation
 Automation
To perform above task we have various computer hardware and
software
The hardware and software requires depends on applications.

INFORMATION AND
COMMUNICATION SYSTEM:
COMPONENTS
Hardware
 Processors
 Modem
 Communication Media
Software
 Operating Systems
 Database Management
 Application

APPLICATION DRIVEN COMPUTER
ARCHITECTURE
Numerical Simulation
 Floating point
 Main memory capability
Transaction Processing
 I/O per second
 Integer CPU performance
Embedded Control
 I/O timing
Media Processing
 Low precision ‘pixel’
arithmetic

INFORMATION AND
COMMUNICATION “TECHNOLOGY”
Information (computation)
 Database
 Markup Languages
 Object oriented approach
Communication (digital)
 Protocols
 Wired and wireless
 Public and Private Networks

INSTRUMENTATION & CONTROL
REQUIREMENT
Control
 Real time
 Deterministic
 Reliable
 Robust
 Secure
 Operator
 Ease of
operation
 Easy to maintain
 Demand more
data
 Reliability
 Management
 No down time
(highly reliable)
 Optimal
performance
 Excessive data
 Secure
 Integrator
 Easy to design
 Install
 Commission

MODERN PLC/DCS/SCADA
Section – 1
Plant device:
Transmitters,
Control valves,
Drives etc.
Section - n
Plant Level
Control Level
Supervisory
Level
PLC/MLPC
:
:
:
Management Level
Corporate
Level

SMART INSTRUMENTS
Digital communication
 Less cable
 Easy to design instrumentation
Self configurable
 Easy to install
Self Diagnostic
Remote calibration/Reranging
 Easy to maintain

CONTROLLERS (PLC/MLPC)
Real Time Operating System (RTOS)
 Real time processing
 Multi tasking
 Fault tolerant (Robust)
 Advance control algorithms
 Controller tuning

OPERATING SYSTEMS
Control Systems require deterministic (real time), fault tolerant, fail
proof, secure operating system
Following are various OS used at various level in Control Systems
(DCS/SCADA/PLC)
 Server and Desktop
 Windows (NT,XP, Server 2003)
 Linux
 Embedded System: Real Time OS (RTOS)
 WinCE
 RTLinux
 VxWorks
 QNX (Quantum Linux): Support for safety critical system in automotive, industrial, medical, and defense,
complies to IEC61508

DATABASE MANAGEMENT
TECHNOLOGY
Database Management System
 Data Servers
 Database Base Connectivity (ODBC)
 Distribution of Temporal Data (Data object like JavaBean)
 Safe and validated data transaction
 Technology (SQL, XML)

DEVICE DESCRIPTION LANGUAGE
Device Description Language (DDL) is used in smart instruments.
A Device Description ("DD") is a formal description of the data and
operating procedures for a field device, including commands, menus
and display formats. It describes exactly what you can do to that
particular device.
Old DDL does not support graphics. Electronic DDL being used today
supports graphics also.

WHAT IS DDL?
The main things the DD describes are Variables, Commands, Methods
and Menus. Every accessible variable in the device is included. That
means the process measurements, any derived values, and all the
internal parameters such as range, sensor type, choice of
linearisation, materials of construction.
 Variable, the DD specifies, among other things, the data type, how it
should be displayed, a name for display to an operator, any associated
units, and help text, perhaps describing the meaning of the variable or how
it is used.
 Command, the DD specifies the data structure of the command and its
response, and the meaning of any command response status bits.
 Methods describe operating procedures, so that a user can be guided
through a sequence of actions, for example to re-calibrate an instrument.
 The DD also defines a Menu structure which a host can use for an operator
to find each variable or method.

EDDL (IEC 61804 – 3)
Electronic DDL (EDDL) is relatively unheard, but for more than 15
years, is responsible for interoperability between devices.
EDDL is based on DD technology. It represents a significant extension
to the DD language, including:
 Additional graphic support (images, charts trends and graphs)
 Extended windowing support (windows, tabs, dialogs, parameter groups)
 Better computation capabilities (full math library support)
 File and data store and access (for history and trend access).

EDDL FEATURES
EDDL is a declarative technology (similar to XML/HTML) with method
script which are interpreted and not executed and hence malicious
code cannot be embedded.
Because EDDL is a declarative technology, not a software program, it
is platform independent supporting software and sophisticated device
management systems on Windows workstations as well as embedded
devices such as handheld field communicators and blind gateways
having web server interface. Data servers such as for OPC also utilize
EDDL to build name space etc. Thus EDDL provides a single universal
solution.

FDT/DTM
Field Device Tool/Device Type Manager (FDT/DTM) is a Windows
component object model (COM) based technology supported by the
FDT group in Belgium.
The technology standardizes the communication interface between
field devices and systems. The device supplier develops a DTM for
each of its devices or group of devices. The DTM encapsulates all of
the device-specific data, functions and business rules such as:
 The device structure
 Its communication capabilities
 Internal dependencies
 Human-machine interface (HMI) structure.

FDT/DTM FEATURES
DTMs are programmed software components for Microsoft Windows
Operating Systems requiring COM and .Net.
FDT does not supports Handheld filed communicators, embedded
web servers, and device not supporting Windows. (in contrast EDDL is
platform independent and run on any device)
FDT has access to hard disk, and windows registry hence FDT for one
device can interact with FDT of other device and make it possible to
implement higher functionality (note: at the cost of security and
robustness).

OPC SERVER
EDDL and FDT/DTM are used by OPC (Object Linking Embedding for
Process Control).
OLE (Object Linking and Embedding) is Microsoft's component
document technology. With OLE, you can dynamically link files and
applications together. An object is a combination of data and the
application needed to modify that data. You can embed objects in or
link them to documents created with a different application.
OPC is an open standard method for transferring data between
software applications, used for example to obtain data from devices.
Once an OPC server is configured, external software in HMI clients
and other users can easily access the wealth of detailed diagnostics
and information in hundreds or thousands of intelligent devices
around the plant.

OPC CLASSIC ARCHITECTURE
OPC server/client
meets need of end –
user for plug – and –
play interoperability,
robust behavior, and
meet minimum
performance
expectations by
providing well –
defined behavior,
documentation, and
Test tools.

CONCEPT OF OO
IEC 61131 -3 Standards
 Addresses limitation of ladder programming
 Introduction of OO and higher programming techniques
 Programming languages
 Ladder
 Structured Text
 Instruction List
 Sequential Function Chart
 Function Block Diagram

CYBER PHYSICAL SYSTEM
• IoT
• IIoT

CLOUD COMPUTING
Cloud computing in an “Internet – based Computing”, whereby shared
resources, software, and information are provided to computers and
other devices on demand, like electrical grid.
MICROSOF
T
:
SUN
AMAZONE GOOGLE
:
:
:
:

GRID COMPUTING
A form of distributed computing and parallel computing, whereby a
'super and virtual computer' is composed of a cluster of networked,
loosely coupled computers acting in concert to perform very large
tasks

RESEARCH ISSUES

RESEARCH ISSUES
Networked based control
Data communication (throughput/media access)
Security and authentication
Knowledge processing
Cloud/Grid computing

AREAS OF APPLICATION
Industrial Instrumentation
Scientific Instrumentation
 AFM, STM, Spectro-photo Meter, etc.
Medical Instrumentation
 EEG, ECG, Robotic Surgery, etc.
Agriculture Instrumentation
 Soil Measurement, Precision Irrigation, etc.
Space Instrumentation
 Solar Optical Telescope (SOT), EUV Imaging Spectrometers, X-ray Telescope etc.
I & C is having wide areas of applications in different domain
including physical and non-physical systems

Dr. Chetan Bhatt
chetan_bhatt@yahoo.com
IF (QUESTIONS == TRUE)
{ASK}
ELSE;
{THANKS.FOR.YOUR.ATTEN
TION
LET.US.MOVE.TO.NEXT.SESSION
}

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