Automation and Robotics 20ME51I_ Week_1_Practicals.pdf

PLC, SCADA & HMI: INDUSTRIAL AUTOMATION
PRACTICAL HAND BOOK Page 1

1. Hierarchy of Industrial Automation, Industrial Automation pyramid.
Hierarchy of Industrial Automation,
also known as Industrial Automation
Pyramid that describes the structure and
levels of automation within an industrial
setting. The Industrial Automation Pyramid
is typically divided into five hierarchical
levels,
1. Field Level: The field level is the lowest level of the pyramid and represents the
physical devices and sensors directly involved in the industrial processes. This includes
sensors, actuators, switches, and other input/output devices.
2. Control Level: The control level is responsible for managing the field-level devices. It
consists of programmable logic controllers (PLCs) or remote terminal units (RTUs) that
monitor and control the field devices.
3. Supervisory Level: The supervisory level, also known as the supervisory control and
data acquisition (SCADA) level, focuses on supervising and coordinating multiple
control systems. It collects data from the control level, provides visualization of the
process, and enables operators to monitor and control the overall industrial operations.
4. Manufacturing Execution System (MES) planning level: The MES level manages the
execution of manufacturing operations and serves as a bridge between the supervisory
level and the enterprise level. It gathers data from multiple SCADA systems, analyses
production performance, tracks inventory, and ensures production efficiency.
5. Enterprise Level: The enterprise level represents the highest level of the industrial
automation pyramid and is concerned with the integration of the industrial processes
with the overall business operations. It involves business planning, resource allocation,
product lifecycle management, and enterprise resource planning (ERP) systems.

2. Present an Overview on the
Levels of Automation- Device
level, Machine Level, Cell Level,
Plant Level, Enterprise Level
1. Device Level: The device level is the lowest level of automation and involves individual
machines or devices with limited independent capabilities. These devices typically
perform specific tasks or functions and may have basic sensing, actuating, and control
capabilities. Examples include sensors, actuators, switches, and basic automated tools.
2. Machine Level: At the machine level, automation extends to a single machine or
equipment, integrating multiple devices and components. At this level often have more
advanced control systems, allowing them to perform complex tasks alone. Examples
include CNC machines, industrial robots, and automated assembly lines.
3. Cell Level: The cell level refers to a group of machines or equipment working together
in a coordinated manner to perform a specific task or process. These cells are usually
focused on a particular operation or function within a larger manufacturing system.
4. Plant Level: The plant level encompasses the entire manufacturing or production
facility. Automation at this level involves the integration of multiple cells, machines,
and systems to create a comprehensive and interconnected manufacturing environment.
5. Enterprise Level: The enterprise level represents the highest level of automation and
involves the integration of multiple plants, facilities, or sites within an organization. At
this level, automation focuses on interconnecting various systems, processes, and data
across different locations, departments, and functions.

3. Importance of Industrial automation in the Indian manufacturing industry.
Challenges and Limitations of industrial automations
Industrial automation plays a crucial role in the Indian manufacturing industry for
several reasons.
1. Increased productivity and efficiency: It enable companies to modernize their
manufacturing processes, reduce human error, and improve overall productivity.
2. Quality improvement: They are designed to perform tasks with a high level of
accuracy and precision, reduces defects, resulting in improved product quality.
3. Cost reduction: It can help reduce operational costs in the long run. It can lead to
cost savings through increased production efficiency.
4. Safety and risk reduction: Automation systems can improve workplace safety by
taking over hazardous tasks (Spray painting, welding, etc.)
5. Flexibility and scalability: Automation technologies offer flexibility and scalability
to adapt to changing market demands. Manufacturers can easily reprogram or
reconfigure.
While industrial automation offers numerous benefits, it also faces certain challenges
and limitations.
1. High initial investment: Implementing often requires high investment. The costs related
with purchasing and installing automation equipment, integrating systems, training
employees, and upgrading infrastructure.
2. Complexity of implementation: Industrial automation systems can be complex and
require expertise in engineering, programming, and system integration.
3. Workforce adaptation and retraining: It creates a demand for skilled workers who can
operate, maintain, and program automated systems.
4. Limited suitability for certain tasks: Some manufacturing operations involve complex
decision-making, creative tasks, which are challenging to replicate with automation.
5. Maintenance and reliability: Automation systems require regular maintenance and
upkeep to ensure optimal performance.

Industry 4.0 and Challenges in implementation of Industry 4.0 in India
Industry 4.0, also known as the Fourth Industrial Revolution, refers to the integration
of digital technologies and automation into industrial processes to create smart, interconnected
systems. Key technologies and concepts associated with Industry 4.0 include,
1. Internet of Things (IoT): Connecting physical devices and systems to collect and
exchange data.
2. Cyber-Physical Systems (CPS): Combining physical and digital components to create
intelligent systems.
3. Big Data Analytics: Utilizing large volumes of data to derive valuable insights for
decision-making.
4. Cloud Computing: Providing scalable computing resources and storage for data
processing.
5. Additive Manufacturing: Using 3D printing and other techniques to create products
layer by layer.
6. Artificial Intelligence (AI): Enabling machines to simulate human intelligence and
make independent decisions.
7. Augmented Reality (AR) and Virtual Reality (VR): Enhancing human-machine
interactions and training processes.
Challenges in Implementing Industry 4.0 in India:
1. Infrastructure: Implementation of Industry 4.0 requires robust digital infrastructure,
including high-speed internet connectivity, reliable power supply, and adequate data
storage capabilities.
2. Skilled Workforce: Industry 4.0 technologies demand a skilled workforce talented in
digital technologies, data analytics, and automation.
3. Affordability and Accessibility: The cost of implementing Industry 4.0 technologies
can be a barrier for small and medium-sized enterprises in India.
4. Data Security and Privacy: With the increased connectivity and data exchange in
Industry 4.0, ensuring the security and privacy of sensitive information becomes
critical.
5. Regulatory Framework: Implementing Industry 4.0 requires a supportive regulatory
environment that encourages innovation, investment, and collaboration.

4. Modern tools used for Industrial Automation- PAC, SCADA, HMI, DCS, AI,
IIOT, etc
Programmable Automation Controllers (PACs): PACs are powerful industrial
control systems that combine the capabilities of a PLC (Programmable Logic Controller) and
a PC. They offer advanced processing capabilities, robust networking, and integration with
various devices and protocols.
Features of a Programmable Automation Controller include:
1. Processing Power: PACs are equipped with powerful processors and large memory,
enabling them to handle complex control tasks.
2. Real-time Operation: PACs are designed to execute control logic and respond to
input/output (I/O) signals in real-time, ensuring precise and timely control.
3. Multi-tasking: PACs support multitasking, allowing them to run multiple programs or
tasks simultaneously.
4. Programming Flexibility: PACs typically support multiple programming languages,
including ladder logic (LD), structured text (ST), function block diagrams (FBD), and
more.
5. Communication Protocols: PACs come with various built-in communication interfaces
to communicate with a wide range of devices and systems, such as sensors, actuators,
HMIs (Human Machine Interfaces), and other industrial devices.
6. Data Handling and Storage: PACs have the capability to handle and store large amounts
of data, which is essential for analysing process information.
7. Scalability: PACs can be easily expanded by adding modules for additional I/O points
or communication interfaces.
8. High Reliability: PACs are designed to be rugged and reliable, ensuring continuous
operation in harsh industrial environments.
9. Remote Monitoring and Control: With built-in communication capabilities, PACs can
be accessed remotely for monitoring and control purposes, allowing engineers to
manage processes from a central location.

Differences Between PLCs & PACs
Device PLC PAC
Process Modules 1 per Rack Module Multi-processor per Rack module
Process Chips per
Module
1 Microprocessor
2 or more High Performance chips for
multitasking
Programming Ladder logic Diagram Supports ST, FBDs and LD
Functionality Sequential scan upto 64k
Dual Logic scan, Motion control, Data
acquisition and process control
Memory Memory space upto 64k Memory space upto 32,000k
I/O 3,000 1,28,000
Communication Typically, Single Option
Through open network, multiple
options like Ethernet/IP etc.

Supervisory Control and Data Acquisition (SCADA): SCADA systems provide
centralized control and monitoring of industrial processes. They collect real-time data from
sensors, manage and control devices, and present information to operators.
Applications of SCADA system are:
1. Manufacturing: Used to monitor and control production processes, assembly lines,
and equipment.
2. Energy and Utilities: Extensively used in the power generation, distribution, and
transmission.
3. Water and Wastewater Management: SCADA is applied to monitor water quality,
control pumping stations, manage reservoir levels, and ensure efficient water
distribution.
4. Oil and Gas: Used to monitor and control remote pipelines, drilling operations,
refineries, and storage facilities. SCADA helps detect leaks, optimize production, and
ensure safety compliance.
5. Transportation: Employed in transportation systems, such as railways, airports, and
traffic management, to monitor and control operations, track vehicle movements, and
enhance safety.
6. Building Automation: SCADA is used in commercial and industrial buildings for
energy management, HVAC control, and monitoring of various systems.
7. Telecommunications: SCADA systems are applied in telecommunications networks
to monitor the performance of network elements, track signal quality, and manage
network traffic.
8. Environmental Monitoring: Used for environmental monitoring and control in areas
like air quality, pollution monitoring, and weather stations.
9. Agriculture: In agricultural applications, SCADA can be used for irrigation control,
greenhouse automation, and livestock management.
10. Pharmaceuticals: SCADA systems are employed in pharmaceutical manufacturing for
process monitoring.

Human-Machine Interface (HMI): HMI stands for Human-Machine Interface, and it
refers to the technology that allows humans to interact with machines or computer systems.
These are graphical interfaces (GI) that allow operators to interact with automation
systems. They provide a user-friendly way to monitor processes, control devices, and receive
alarms or notifications. HMIs display real-time data, trends (Graph), and reports, enabling
operators to make decisions.
Applications and features of HMIs are:
1. Process Monitoring and Control: HMIs provide real-time data visualization, allowing
operators to monitor the status of various processes, machines, and equipment.
2. Machine Control: HMIs allow operators to control individual machines or entire
production lines.
3. Parameter Setting and Adjustment: HMIs provide a user-friendly interface for setting
and adjusting parameters for different processes and equipment.
4. Data Logging and Historical Trend Analysis: HMIs store and log historical data,
allowing operators and engineers to analyze trends over time.
5. Alarms and Notifications: HMIs can generate alarms and notifications to alert operators
about critical events or abnormal conditions.
6. Safety Integration: HMIs often incorporate safety features, such as emergency stop
buttons and safety interlocks, to provide quick and easy access to safety functions for
operators.
7. Remote Monitoring and Control: Some HMIs support remote access, enabling
operators and maintenance personnel to monitor and control the industrial processes
from a central control room or even via mobile devices.
8. Integration with PLCs and SCADA Systems: HMIs interface with Programmable Logic
Controllers (PLCs) and Supervisory Control and Data Acquisition (SCADA) systems,
allowing seamless communication between different components of the automation
system.
9. Maintenance and Diagnostics: HMIs can display equipment status, maintenance
schedules, and diagnostic information, helping maintenance personnel.

A Distributed Control System (DCS) is a specialized type of control system used in
various industries, particularly in large-scale industrial processes. It is designed to control and
monitor multiple devices, processes, and equipment distributed throughout a manufacturing
plant or an industrial facility. The key features and characteristics of a DCS include:
1. Distributed Architecture: Unlike traditional centralized control systems, a DCS is
distributed across the plant or facility. It consists of multiple control units or nodes,
each responsible for specific purpose.
2. Redundancy: DCS often incorporates redundant hardware and communication paths.
Redundancy helps to prevent system failures and minimize downtime, critical for
continuous and safe industrial operations.
3. Communication Network: DCS relies on a robust communication network to facilitate
data exchange between the different control units and devices.
4. Real-time Control: DCS provides real-time control capabilities, enabling rapid response
to process changes.
5. Scalability: Additional control units and devices can be easily integrated into the system
as the process expands or new equipment is added.
6. Process Optimization: DCS systems often include advanced control algorithms that can
optimize the process by adjusting parameters dynamically. This leads to increased
efficiency, reduced energy consumption, and improved product quality.
7. Data Logging and Historization: DCS systems log process data, alarms, and events over
time.
8. Safety and Emergency Shutdown: DCS can integrate safety features and emergency
shutdown systems to protect the process from potential hazards.
DCS finds applications in various industries, such as oil and gas, petrochemicals, power
generation, pharmaceuticals, water treatment, and manufacturing. By providing a
comprehensive and distributed control approach, DCS enhances process efficiency, reliability,
and safety, contributing to improved overall productivity and reduced operational costs.

Difference Between SCADA, HMI and DCS
Criterion SCADA HMI DCS
Scope and Scale It provides
centralized
monitoring and
control of
geographically
dispersed processes
or systems.
It interacts with a
single machine or a
small portion of a
process.
It covers a broader
range of processes
compared to HMI
but is generally
limited to a single
facility or plant.
Architecture and
Distribution
SCADA systems
have a centralized
architecture with a
master station that
communicates with
remote terminal
units (RTUs) or
programmable logic
controllers (PLCs)
placed at various
field locations.
HMIs are part of a
larger control
system, such as
SCADA or DCS,
and are often located
near the equipment
or process they
control. They may
also be integrated
into individual
machines or devices.
DCS has a
distributed
architecture,
consisting of
multiple control
units or nodes.
Application Focus Well-suited for
industries that
require remote
(isolated) monitoring
and control.
HMI is primarily
used for local
monitoring and
control of individual
machines.
DCS is personalised
for managing and
controlling complex
processes within an
industrial plant.
Data Acquisition and
Visualization
SCADA focuses on
real-time data
acquisition and
visualization of
remote locations.
HMI offers a
graphical and user-
friendly interface for
local operators to
visualize and
interact.
DCS provides real-
time data acquisition
and visualization for
the entire industrial
process, offering
insights into various
interconnected units
and equipment.

Artificial Intelligence (AI) plays a significant role in revolutionizing industrial
automation. It empowers machines and systems to exhibit intelligent behaviours, making them
more adaptive, efficient, and capable of handling complex tasks.
Here are some key applications of AI in industrial automation:
1. Predictive Maintenance: AI-powered predictive maintenance systems analyze data
from sensors and equipment for predicting when machines might fail, maintenance can
be performed.
2. Process Optimization: AI algorithms can optimize industrial processes by adjusting
parameters in real-time based on data analysis. This helps improve efficiency, reduce
energy consumption, and enhance overall productivity.
3. Autonomous Robots: AI enables robots to perceive their surroundings, make decisions,
and carry out tasks without human intervention.
4. Quality Control: AI-powered vision systems can inspect products for defects and ensure
adherence to quality standards.
5. Supply Chain Management: AI is used to optimize supply chain operations, including
demand forecasting, inventory management, and route optimization.
6. Process Monitoring and Control: AI systems continuously monitor processes, analyzing
data to maintain optimal control.
7. Energy Management: AI can optimize energy usage in industrial facilities, reducing
energy waste and optimizing energy consumption patterns.
8. Decision Support Systems: AI provides valuable visions and decision support for
human operators and managers.

Industrial Internet of Things (IIoT): IIoT refers to the integration of modern Internet
of Things (IoT) technologies with industrial processes, machinery, and systems. It extends the
concept of IoT from consumer devices and applications to the industrial sector, focusing on
improving efficiency, productivity, safety, and overall performance in various industries.
Key features and components of the Industrial Internet of Things (IIoT) include:
1. Connected Devices and Sensors: IIoT relies on a network of smart devices and sensors
embedded in industrial equipment, machinery, and infrastructure. These devices gather
data, monitor operations, and provide real-time insights to optimize processes.
2. Data Communication and Connectivity: IIoT relies on reliable and secure
communication protocols to transfer data between devices and the central processing
system. Common communication technologies include Wi-Fi, Ethernet, Bluetooth, etc.
3. Cloud Computing and Data Analytics: Collected data is often sent to cloud-based
platforms for storage, processing, and analysis.
4. Artificial Intelligence (AI) and Machine Learning (ML): IIoT leverages AI and ML
algorithms to analyze vast amounts of data and extract meaningful insights. Predictive
maintenance, anomaly detection, and optimization are common AI/ML applications in
IIoT.
5. Industrial Automation: IIoT enables enhanced automation in manufacturing, logistics,
and other industrial processes. This includes automated workflows, and robotic control.
6. Cybersecurity: IIoT systems must prioritize robust cybersecurity measures to safeguard
sensitive industrial data and protect critical infrastructure from cyber threats and
attacks.
7. Industry-specific Applications: IIoT can be applied in various sectors, such as
manufacturing, energy, healthcare, transportation, agriculture, and more.

5. Importance of IEC, ISO, NEMA, JIC and other standards used in automation.
IEC, ISO, NEMA, JIC, and other standards play a crucial role in automation. These
standards ensure consistency, compatibility, safety, and efficiency in various aspects of
automation.
IEC (International Electrotechnical Commission):
1. Safety: IEC standards provide guidelines and specifications for the safe design,
installation, and operation of electrical and electronic systems, including
automation equipment.
2. Interoperability: IEC standards promote compatibility and interoperability among
different automation devices and systems, allowing continuous integration and
communication between them.
3. Performance: These standards define performance criteria, test methods, and
measurement techniques for automation products.
4. Global Acceptance: IEC standards are internationally recognized and adopted,
facilitating the global trade and exchange of automation products.
ISO (International Organization for Standardization):
1. Quality Management: ISO standards, such as ISO 9001, provide a framework for
implementing effective quality management systems in automation companies.
2. Environmental Management: ISO 14001 standards address environmental
management systems, helping organizations minimize their environmental impact
and promote sustainable practices in automation processes.
3. Risk Management: ISO 31000 provides guidance on risk management principles,
processes, and frameworks. In automation, this helps identify risks associated with
equipment, processes, and cybersecurity.
4. Data Exchange: ISO standards like ISO 15926 enable efficient data exchange and
interoperability between different software applications.

NEMA (National Electrical Manufacturers Association):
1. Electrical Equipment Standards: NEMA develops standards for electrical
equipment used in automation, including motors, drives, control systems,
enclosures, and connectors. These standards ensure compatibility, safety, and
performance of electrical products.
2. Advocacy and Industry Representation: NEMA represents the interests of electrical
manufacturers in policy-making, code development, and regulatory matters related
to automation. They work to promote efficient and sustainable electrical systems.
JIC (Joint Industrial Council):
1. Standardization: JIC standards provide guidelines for the design and installation of
electrical control equipment in industrial applications. These standards ensure
uniformity, safety, and reliability in automation systems.
2. Wiring and Schematic Diagrams: JIC standards define conventions for wiring and
schematic diagrams, making it easier to understand and interpret electrical drawings
in automation.
Other standards organizations, such as ISA (International Society of Automation),
IEEE (Institute of Electrical and Electronics Engineers), and UL (Underwriters Laboratories),
also contribute to automation standards development, focusing on specific areas like
instrumentation, communication protocols, and safety certifications.

6. Programming with IEC 61131-3 Languages
IEC 61131-3 is a standard that defines a set of programming languages for PLCs. The
standard includes five languages, each with its own characteristics and purpose.
Ladder Diagrams
Ladder Diagrams are one of the most widely used programming languages in the PLC.
They are graphical representations of relay logic circuits. Ladder Diagrams consist of rungs
that contain various ladder elements such as contacts, coils, timers, and other logic functions.
Structural Text language
Structural Text is a high-level text-based language similar to structured programming
languages like Pascal or C. It allows the programmer to write structured code using statements
and control structures such as loops and conditionals.
Sequential function Chart
Sequential Function Chart is a graphical language used to model complex sequential
processes. It consists of steps, transitions, and actions. Steps represent states or sub-procedures,
transitions define the conditions for moving between steps, and actions represent operations to
be executed. SFCs provide a visual representation of the control flow and allow for hierarchical
structuring of the program.
Functional block diagram
Function Block Diagram is a graphical language that enables modular and reusable
programming. It represents the program as a network of interconnected function blocks, which
are graphical representations of reusable software components.
Instruction list
List is a low-level, text-based language that resembles assembly language. It uses
mnemonics to represent PLC instructions and operates on registers and memory locations.
Instruction List provides a way to write code in a more direct and efficient manner, suitable for
tasks that require fine-grained control over hardware resources.

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