This document provides an overview of industrial automation and control systems. It begins with an agenda that covers industries and classifications, introduction to industrial automation, and examples of process and discrete manufacturing. It then defines process and discrete industries, and provides examples of a car assembly line and oil refinery. The document introduces industrial automation as using technology and automatic controls to operate industrial processes without human intervention. It covers the advantages of automation including higher productivity, quality and safety. Finally, it describes the layers of an automation system including the field, control, supervisory and production, and information levels.
Practical Advanced Process Control for Engineers and TechniciansLiving Online
In today's environment, the processing, refining and petrochemical business is becoming more and more competitive and every plant manager is looking for the best quality products at minimum operating and investment costs. The traditional PID loop is used frequently for much of the process control requirements of a typical plant. However there are many drawbacks in using these, including excessive dead time which can make the PID loop very difficult (or indeed impossible) to apply.
Advanced Process Control (APC) is thus essential today in the modern plant. Small differences in process parameters can have large effects on profitability; get it right and profits continue to grow; get it wrong and there are major losses. Many applications of APC have pay back times well below one year. APC does require a detailed knowledge of the plant to design a working system and continual follow up along the life of the plant to ensure it is working optimally. Considerable attention also needs to be given to the interface to the operators to ensure that they can apply these new technologies effectively as well.
WHO SHOULD ATTEND?
Automation engineers
Chemical engineers
Chemical plant technologists
Electrical engineers
Instrumentation and control engineers
Process control engineers
Process engineers
Senior technicians
System integrators
MORE INFORMATION: http://www.idc-online.com/content/practical-advanced-process-control-engineers-and-technicians-26
In this session you will learn:
Self Introduction.
What does control system, industrial automation mean?
What is your expectation from this course?
For more information, visit: https://www.mindsmapped.com/courses/industrial-automation/complete-training-on-industrial-automation-for-beginners/
Distributed Control Systems (DCS) are dedicated systems used to control manufacturing processes that are continuous or batch-oriented, such as oil refining, petrochemicals, central station power generation, fertilizers, pharmaceuticals, food and beverage manufacturing, cement production, steelmaking, and papermaking. DCSs are connected to sensors and actuators and use set point control to control the flow of material through the plant.
The most common example is a set point control loop consisting of a pressure sensor, controller, and control valve. Pressure or flow measurements are transmitted to the controller, usually through the aid of a signal conditioning input/output (I/O) device. When the measured variable reaches a certain point, the controller instructs a valve or actuation device to open or close until the fluidic flow process reaches the desired set point.
Large oil refineries have many thousands of I/O points and employ very large DCSs. Processes are not limited to fluidic flow through pipes, however, and can also include things like paper machines and their associated quality controls (see quality control system QCS), variable speed drives and motor control centers, cement kilns, mining operations, ore processing facilities, and many others.
Innovic India Private Limited provides industrial Training on DCS as well as other automationtechnologies like PLC, SCADA, HMI, VFD and many more.
For Core Engineering jobs and 100% Job Oriented Industrial Training
Feel free to contact us on: +91-9555405045/+91-9811253572
Email: group.innovic2gmail.com
Web: www.innovicindia.com
A distributed control system (DCS) collects data from various parts of an industrial plant, processes the data, and controls the plant equipment. It consists of field control stations that interface with sensors and actuators, operator stations for monitoring and control, and engineering stations for configuration. DCS offers advantages like lower overall cost, improved process interfacing, flexibility, and reliability compared to traditional centralized control systems. It is used across many industries like oil and gas, chemicals, manufacturing, and more.
Instrumentation and process control fundamentalshossam hassanein
Basic course covers:
-Basic understanding of process control
-Important process control terminology
-Major components of a process loop
-Instrumentation P&ID symbols
In this presentation, Javeed introduces the topic of automation, type of automation and associated trends. His interest area lies in robotic automation systems one example that he cites is building software robots to automate clerical processes in service industry.
In this session you will learn:
DCS Introduction
PLC
SCADA
General architecture of DCS
Process or application
Scan time
Input and Output requirement
Redundancy
RTU and LCU
PLC vs DCS
For more information, visit: https://www.mindsmapped.com/courses/industrial-automation/complete-training-on-industrial-automation-for-beginners/
A distributed control system (DCS) provides safe, efficient, and reliable control of critical components in a thermal power plant. Key benefits of a DCS include high reliability, improved response time, improved operator interface, and historical data storage. A DCS uses controller cards, input/output cards, and communication cards to monitor and control elements like valves, pumps, temperatures, and pressures. Operators interact with the DCS through workstations with displays for alarms, graphics, trends, and reports. Automatic controls help optimize processes while interlocks ensure safe operation during startups, run cycles, and shutdowns.
Practical Advanced Process Control for Engineers and TechniciansLiving Online
In today's environment, the processing, refining and petrochemical business is becoming more and more competitive and every plant manager is looking for the best quality products at minimum operating and investment costs. The traditional PID loop is used frequently for much of the process control requirements of a typical plant. However there are many drawbacks in using these, including excessive dead time which can make the PID loop very difficult (or indeed impossible) to apply.
Advanced Process Control (APC) is thus essential today in the modern plant. Small differences in process parameters can have large effects on profitability; get it right and profits continue to grow; get it wrong and there are major losses. Many applications of APC have pay back times well below one year. APC does require a detailed knowledge of the plant to design a working system and continual follow up along the life of the plant to ensure it is working optimally. Considerable attention also needs to be given to the interface to the operators to ensure that they can apply these new technologies effectively as well.
WHO SHOULD ATTEND?
Automation engineers
Chemical engineers
Chemical plant technologists
Electrical engineers
Instrumentation and control engineers
Process control engineers
Process engineers
Senior technicians
System integrators
MORE INFORMATION: http://www.idc-online.com/content/practical-advanced-process-control-engineers-and-technicians-26
In this session you will learn:
Self Introduction.
What does control system, industrial automation mean?
What is your expectation from this course?
For more information, visit: https://www.mindsmapped.com/courses/industrial-automation/complete-training-on-industrial-automation-for-beginners/
Distributed Control Systems (DCS) are dedicated systems used to control manufacturing processes that are continuous or batch-oriented, such as oil refining, petrochemicals, central station power generation, fertilizers, pharmaceuticals, food and beverage manufacturing, cement production, steelmaking, and papermaking. DCSs are connected to sensors and actuators and use set point control to control the flow of material through the plant.
The most common example is a set point control loop consisting of a pressure sensor, controller, and control valve. Pressure or flow measurements are transmitted to the controller, usually through the aid of a signal conditioning input/output (I/O) device. When the measured variable reaches a certain point, the controller instructs a valve or actuation device to open or close until the fluidic flow process reaches the desired set point.
Large oil refineries have many thousands of I/O points and employ very large DCSs. Processes are not limited to fluidic flow through pipes, however, and can also include things like paper machines and their associated quality controls (see quality control system QCS), variable speed drives and motor control centers, cement kilns, mining operations, ore processing facilities, and many others.
Innovic India Private Limited provides industrial Training on DCS as well as other automationtechnologies like PLC, SCADA, HMI, VFD and many more.
For Core Engineering jobs and 100% Job Oriented Industrial Training
Feel free to contact us on: +91-9555405045/+91-9811253572
Email: group.innovic2gmail.com
Web: www.innovicindia.com
A distributed control system (DCS) collects data from various parts of an industrial plant, processes the data, and controls the plant equipment. It consists of field control stations that interface with sensors and actuators, operator stations for monitoring and control, and engineering stations for configuration. DCS offers advantages like lower overall cost, improved process interfacing, flexibility, and reliability compared to traditional centralized control systems. It is used across many industries like oil and gas, chemicals, manufacturing, and more.
Instrumentation and process control fundamentalshossam hassanein
Basic course covers:
-Basic understanding of process control
-Important process control terminology
-Major components of a process loop
-Instrumentation P&ID symbols
In this presentation, Javeed introduces the topic of automation, type of automation and associated trends. His interest area lies in robotic automation systems one example that he cites is building software robots to automate clerical processes in service industry.
In this session you will learn:
DCS Introduction
PLC
SCADA
General architecture of DCS
Process or application
Scan time
Input and Output requirement
Redundancy
RTU and LCU
PLC vs DCS
For more information, visit: https://www.mindsmapped.com/courses/industrial-automation/complete-training-on-industrial-automation-for-beginners/
A distributed control system (DCS) provides safe, efficient, and reliable control of critical components in a thermal power plant. Key benefits of a DCS include high reliability, improved response time, improved operator interface, and historical data storage. A DCS uses controller cards, input/output cards, and communication cards to monitor and control elements like valves, pumps, temperatures, and pressures. Operators interact with the DCS through workstations with displays for alarms, graphics, trends, and reports. Automatic controls help optimize processes while interlocks ensure safe operation during startups, run cycles, and shutdowns.
This document provides an overview of PLC and SCADA systems. It defines PLC as an industrial computer that monitors inputs, makes decisions based on its program, and controls outputs to automate processes. The history and components of PLCs are described, including the power supply, I/O modules, processor, and programming devices. Programming languages for PLCs include ladder logic, functional block diagrams, and sequential function charts. SCADA is defined as software used for process control that allows users to monitor, control, generate alarms and acquire data from remote facilities. The document discusses the composition, advantages, and applications of SCADA systems.
Power point presentation on Industrial AutomationJaiPrakash337
This document summarizes a seminar presentation on industrial automation. It discusses automation tools like PLCs and SCADA used to automate industrial processes. It defines automation and describes the advantages it provides like improved accuracy, reduced costs, and increased production. PLCs are described as programmable devices that can automate industrial tasks by reading sensor inputs, running user-defined logic, and controlling outputs. SCADA systems allow remote monitoring and control of distributed industrial processes. The document outlines the components and applications of PLCs and SCADA and concludes that combining them provides an effective way to safely operate and monitor industrial machines.
The document discusses automation and tools used for automation including PLCs and SCADA systems. It provides an overview of what PLCs and SCADA are, including their components and programming. PLCs are microprocessor-based devices that interface inputs and outputs to control industrial automation applications. SCADA systems are used for supervisory control and data acquisition in industrial processes allowing remote monitoring and control. Common PLC and SCADA manufacturers and software are also mentioned.
Industrial automation is the use of control systems, such as computers or robots, and information technologies for handling different processes and machineries in an industry to replace a human being. It is the second step beyond mechanization in the scope of industrialization.
Increase Quality and Flexibility in Your Manufacturing Process
Earlier the purpose of automation was to increase productivity (since automated systems can work 24 hours a day), and to reduce the cost associated with human operators (i.e. wages & benefits). However, today, the focus of automation has shifted to increasing quality and flexibility in a manufacturing process. In the automobile industry, the installation of pistons into the engine used to be performed manually with an error rate of 1-1.5%. Presently, this task is performed using automated machinery with an error rate of 0.00001%.
Advantages of Industrial Automation
Lower operating cost: Industrial automation eliminates healthcare costs and paid leave and holidays associated with a human operator. Further, industrial automation does not require other employee benefits such as bonuses, pension coverage etc. Above all, although it is associated with a high initial cost it saves the monthly wages of the workers which leads to substantial cost savings for the company. The maintenance cost associated with machinery used for industrial automation is less because it does not often fail. If it fails, only computer and maintenance engineers are required to repair it.
Hi friends
This PPT consist of automation information ,what is PLC,need of PLC applications,components of PLC ,PLC operations,Timers , Some Program, etc
instead of this it consists SCADA ,what is SCADA,need of SCADA,brands of SCADA, tags ,features of SCADA, Dynamic process graphic , script security etc.......
Process control involves using computers or microprocessors to control industrial processes. There are three main types of process control: batch process control which combines specific amounts of raw materials together for a set time like making prepackaged meals; continuous process control which regulates uninterrupted processes like fuel production; and discrete process control which produces specific items through manufacturing applications like robotic assembly lines. Process control is used across many industries like oil refining, chemicals, food production, and automotive manufacturing.
The presentation gives you the basics of Programmable logic controller(PLC) and its use in industrial Automation along with
Supervisory control and Data Acquisition(SCADA).
contact for any info "nikhilbrahmas@gmail.com"
This document discusses process control systems. It defines a process as a sequence of interdependent procedures that transforms inputs into outputs. Control involves regulating all aspects of a process. There are three main types of processes: continuous, batch, and discrete. A process control system uses controllers and feedback to maintain process variables like pressure, temperature and flow within desired ranges. It consists of sensors, actuators and an operator interface. The two main types are open-loop and closed-loop systems. Process control has applications in industries like food production, manufacturing, and waste water treatment. Future areas of development include smart cities and transportation.
This document provides an overview of instrumentation and process control. It defines key terms like instrumentation, process, transducer, signal, loop, controller, and interlock. It describes common process parameters measured like pressure, level, temperature, and flow. It discusses primary measuring devices and principles for each process variable. It also covers control valves and automation systems like DCS, PLC, and SCADA.
The document is a PowerPoint presentation on industrial automation submitted by Tamanna Taneja. It discusses key concepts of automation including what automation is, why it is required in industry, and its history. It also covers components used in automation like sensors, transmitters, PLCs, and actuators. Specific automation tools covered are PLCs, SCADA, and HMIs. The presentation provides details on what constitutes a PLC, its programming, inputs and outputs, power supply and memory. It also discusses SCADA features, architecture, trending and applications in various plants.
This document summarizes key concepts from a course on process instrumentation and control. It discusses servo and regulatory control, distinguishing between responses to setpoint changes versus disturbances. It also contrasts continuous versus batch processes. Continuous processes have constant inputs and outputs, while batch processes involve discrete batches undergoing separate processing stages. The document provides examples and compares characteristics of batch and continuous processes. Finally, it defines self-regulating versus non-self-regulating processes, using a water tank example to illustrate inherent feedback in self-regulating systems.
The document discusses control system trends and different distributed control system (DCS) architectures. It describes the evolution of DCS from centralized to distributed control with fieldbus connectivity. It provides examples of DCS installations and components of DCS systems from manufacturers like Honeywell, Yokogawa, and ABB. These include control stations, input/output modules, networks, and the use of Windows-based control.
SCADA systems are used to monitor and control geographically dispersed industrial processes. A SCADA system consists of field devices like PLCs and RTUs that connect to sensors and convert signals to digital data. This data is communicated to a control center via telemetry where it is processed by a data acquisition server and presented to human operators through an HMI. The system allows operators to monitor and control the industrial process. SCADA has evolved from early monolithic centralized systems to modern distributed and networked systems that utilize open standards and protocols to distribute functionality across a wide area network. SCADA is commonly used in applications like power generation, water treatment, oil and gas pipelines, and more.
This document discusses industrial automation and provides an overview of programmable logic controllers (PLCs) and supervisory control and data acquisition (SCADA) systems. It describes how PLCs were developed to replace mechanical relays and control industrial processes automatically. The document focuses on the Micrologix 1000 PLC, explaining its architecture, programming, and applications. It also gives an introduction to SCADA software like Intouch Wonderware, describing how it allows users to monitor and visualize industrial processes connected to PLCs.
PowerPoint Presentation on Industrial Automation In which we discuss About PLCs, SCADA,HMI,VFD and various tools of Automation which is used in Industries.
Like Comment & Share
Introduction of SCADA, Architecture of SCADA, Software and hardware architecture, Components of a SCADA system, Functions of SCADA, Alarms and events, alarm logging, comparision between scada and DCS
The document discusses automation and its various tools. It provides an overview of automation, including its history and concepts. It describes programmable logic controllers and supervisory control and data acquisition systems. It discusses the advantages and disadvantages of automation as well as some of its applications.
The document discusses control systems and their evolution. It provides an overview of analog control systems, digital control systems, centralized control systems, and distributed control systems. It then focuses on Yokogawa's CENTUM distributed control system (DCS), describing its components, configurations, and I/O modules.
Session 02 - Introduction to Industrial AutomationVidyaIA
This document provides an overview of industrial automation and control systems. It begins with an introduction to different types of industries and their classification as either discrete or process manufacturing. It then discusses industrial automation, describing it as the use of technologies and automatic control devices to operate industrial processes without significant human intervention. The document outlines the advantages of automation, such as improved productivity, quality, safety and information accuracy. It also describes the different levels or layers of an automation system, including the field, control, supervisory and enterprise levels. Finally, it provides an agenda for future training sessions on topics related to industrial automation.
In this session you will learn:
History of Industrial Automation
Types of Industrial Automation
Process Industries
Overview of Continuous & Batch Process
For more information, visit: https://www.mindsmapped.com/courses/industrial-automation/complete-training-on-industrial-automation-for-beginners/
This document provides an overview of PLC and SCADA systems. It defines PLC as an industrial computer that monitors inputs, makes decisions based on its program, and controls outputs to automate processes. The history and components of PLCs are described, including the power supply, I/O modules, processor, and programming devices. Programming languages for PLCs include ladder logic, functional block diagrams, and sequential function charts. SCADA is defined as software used for process control that allows users to monitor, control, generate alarms and acquire data from remote facilities. The document discusses the composition, advantages, and applications of SCADA systems.
Power point presentation on Industrial AutomationJaiPrakash337
This document summarizes a seminar presentation on industrial automation. It discusses automation tools like PLCs and SCADA used to automate industrial processes. It defines automation and describes the advantages it provides like improved accuracy, reduced costs, and increased production. PLCs are described as programmable devices that can automate industrial tasks by reading sensor inputs, running user-defined logic, and controlling outputs. SCADA systems allow remote monitoring and control of distributed industrial processes. The document outlines the components and applications of PLCs and SCADA and concludes that combining them provides an effective way to safely operate and monitor industrial machines.
The document discusses automation and tools used for automation including PLCs and SCADA systems. It provides an overview of what PLCs and SCADA are, including their components and programming. PLCs are microprocessor-based devices that interface inputs and outputs to control industrial automation applications. SCADA systems are used for supervisory control and data acquisition in industrial processes allowing remote monitoring and control. Common PLC and SCADA manufacturers and software are also mentioned.
Industrial automation is the use of control systems, such as computers or robots, and information technologies for handling different processes and machineries in an industry to replace a human being. It is the second step beyond mechanization in the scope of industrialization.
Increase Quality and Flexibility in Your Manufacturing Process
Earlier the purpose of automation was to increase productivity (since automated systems can work 24 hours a day), and to reduce the cost associated with human operators (i.e. wages & benefits). However, today, the focus of automation has shifted to increasing quality and flexibility in a manufacturing process. In the automobile industry, the installation of pistons into the engine used to be performed manually with an error rate of 1-1.5%. Presently, this task is performed using automated machinery with an error rate of 0.00001%.
Advantages of Industrial Automation
Lower operating cost: Industrial automation eliminates healthcare costs and paid leave and holidays associated with a human operator. Further, industrial automation does not require other employee benefits such as bonuses, pension coverage etc. Above all, although it is associated with a high initial cost it saves the monthly wages of the workers which leads to substantial cost savings for the company. The maintenance cost associated with machinery used for industrial automation is less because it does not often fail. If it fails, only computer and maintenance engineers are required to repair it.
Hi friends
This PPT consist of automation information ,what is PLC,need of PLC applications,components of PLC ,PLC operations,Timers , Some Program, etc
instead of this it consists SCADA ,what is SCADA,need of SCADA,brands of SCADA, tags ,features of SCADA, Dynamic process graphic , script security etc.......
Process control involves using computers or microprocessors to control industrial processes. There are three main types of process control: batch process control which combines specific amounts of raw materials together for a set time like making prepackaged meals; continuous process control which regulates uninterrupted processes like fuel production; and discrete process control which produces specific items through manufacturing applications like robotic assembly lines. Process control is used across many industries like oil refining, chemicals, food production, and automotive manufacturing.
The presentation gives you the basics of Programmable logic controller(PLC) and its use in industrial Automation along with
Supervisory control and Data Acquisition(SCADA).
contact for any info "nikhilbrahmas@gmail.com"
This document discusses process control systems. It defines a process as a sequence of interdependent procedures that transforms inputs into outputs. Control involves regulating all aspects of a process. There are three main types of processes: continuous, batch, and discrete. A process control system uses controllers and feedback to maintain process variables like pressure, temperature and flow within desired ranges. It consists of sensors, actuators and an operator interface. The two main types are open-loop and closed-loop systems. Process control has applications in industries like food production, manufacturing, and waste water treatment. Future areas of development include smart cities and transportation.
This document provides an overview of instrumentation and process control. It defines key terms like instrumentation, process, transducer, signal, loop, controller, and interlock. It describes common process parameters measured like pressure, level, temperature, and flow. It discusses primary measuring devices and principles for each process variable. It also covers control valves and automation systems like DCS, PLC, and SCADA.
The document is a PowerPoint presentation on industrial automation submitted by Tamanna Taneja. It discusses key concepts of automation including what automation is, why it is required in industry, and its history. It also covers components used in automation like sensors, transmitters, PLCs, and actuators. Specific automation tools covered are PLCs, SCADA, and HMIs. The presentation provides details on what constitutes a PLC, its programming, inputs and outputs, power supply and memory. It also discusses SCADA features, architecture, trending and applications in various plants.
This document summarizes key concepts from a course on process instrumentation and control. It discusses servo and regulatory control, distinguishing between responses to setpoint changes versus disturbances. It also contrasts continuous versus batch processes. Continuous processes have constant inputs and outputs, while batch processes involve discrete batches undergoing separate processing stages. The document provides examples and compares characteristics of batch and continuous processes. Finally, it defines self-regulating versus non-self-regulating processes, using a water tank example to illustrate inherent feedback in self-regulating systems.
The document discusses control system trends and different distributed control system (DCS) architectures. It describes the evolution of DCS from centralized to distributed control with fieldbus connectivity. It provides examples of DCS installations and components of DCS systems from manufacturers like Honeywell, Yokogawa, and ABB. These include control stations, input/output modules, networks, and the use of Windows-based control.
SCADA systems are used to monitor and control geographically dispersed industrial processes. A SCADA system consists of field devices like PLCs and RTUs that connect to sensors and convert signals to digital data. This data is communicated to a control center via telemetry where it is processed by a data acquisition server and presented to human operators through an HMI. The system allows operators to monitor and control the industrial process. SCADA has evolved from early monolithic centralized systems to modern distributed and networked systems that utilize open standards and protocols to distribute functionality across a wide area network. SCADA is commonly used in applications like power generation, water treatment, oil and gas pipelines, and more.
This document discusses industrial automation and provides an overview of programmable logic controllers (PLCs) and supervisory control and data acquisition (SCADA) systems. It describes how PLCs were developed to replace mechanical relays and control industrial processes automatically. The document focuses on the Micrologix 1000 PLC, explaining its architecture, programming, and applications. It also gives an introduction to SCADA software like Intouch Wonderware, describing how it allows users to monitor and visualize industrial processes connected to PLCs.
PowerPoint Presentation on Industrial Automation In which we discuss About PLCs, SCADA,HMI,VFD and various tools of Automation which is used in Industries.
Like Comment & Share
Introduction of SCADA, Architecture of SCADA, Software and hardware architecture, Components of a SCADA system, Functions of SCADA, Alarms and events, alarm logging, comparision between scada and DCS
The document discusses automation and its various tools. It provides an overview of automation, including its history and concepts. It describes programmable logic controllers and supervisory control and data acquisition systems. It discusses the advantages and disadvantages of automation as well as some of its applications.
The document discusses control systems and their evolution. It provides an overview of analog control systems, digital control systems, centralized control systems, and distributed control systems. It then focuses on Yokogawa's CENTUM distributed control system (DCS), describing its components, configurations, and I/O modules.
Session 02 - Introduction to Industrial AutomationVidyaIA
This document provides an overview of industrial automation and control systems. It begins with an introduction to different types of industries and their classification as either discrete or process manufacturing. It then discusses industrial automation, describing it as the use of technologies and automatic control devices to operate industrial processes without significant human intervention. The document outlines the advantages of automation, such as improved productivity, quality, safety and information accuracy. It also describes the different levels or layers of an automation system, including the field, control, supervisory and enterprise levels. Finally, it provides an agenda for future training sessions on topics related to industrial automation.
In this session you will learn:
History of Industrial Automation
Types of Industrial Automation
Process Industries
Overview of Continuous & Batch Process
For more information, visit: https://www.mindsmapped.com/courses/industrial-automation/complete-training-on-industrial-automation-for-beginners/
Session 03 - History of Automation and Process IntroductionVidyaIA
In this session you will learn:
History of Industrial Automation
Types of Industrial Automation
Process Industries
Overview of Continuous & Batch Process
1) The document provides an introduction to industrial automation, including definitions, basic elements, types, and reasons for automating manufacturing processes.
2) It describes the three main types of automation systems - fixed, programmable, and flexible - and how they relate to product variety and production quantity.
3) Key factors that influence whether to automate including production volume needed, product complexity, and changeover flexibility requirements. Automation can increase productivity, quality, and worker safety.
This presentation is focused on the topic of automation and its various applications. It is my pleasure to share with you the information and insights that we have gathered on this subject.
Automation Notes on Manufacturing in Industries.pptPrabhuSwamy24
1. Automation is a technology that uses mechanical, electronic, and computer-based systems to operate processes without human assistance. This allows manufacturing processes to increase speed and reduce costs while improving quality.
2. There are three basic types of automated manufacturing systems - fixed automation with a set sequence of operations, programmable automation where the sequence can be changed through programming, and flexible automation that can continuously produce a variety of products with minimal changeover time.
3. The benefits of automation include increased productivity and labor efficiency, reduced labor costs, improved quality and worker safety, and the ability to accomplish processes that cannot be done manually.
1. Automation is a technology that uses mechanical, electronic, and computer-based systems to operate processes without human assistance. This allows manufacturing processes to increase speed and reduce costs while improving quality.
2. There are three basic types of automated manufacturing systems - fixed automation with a set sequence of operations, programmable automation where the sequence can be changed via a program, and flexible automation which can continuously produce a variety of products with minimal changeover time.
3. The benefits of automation include increased productivity and quality, reduced costs and labor needs, and improved worker safety. Automation allows for specialized, simultaneous, and integrated operations along with enhanced process control and computer integration of manufacturing.
This document discusses how organizations use information and communication technology (ICT) in various applications. It provides examples of control systems, such as air conditioning, refrigeration, and central heating systems. It also discusses how ICT is used in manufacturing processes like car production using robots, medical applications like intensive care and surgery, process control in industries, and embedded web technology for remote control systems.
This document discusses instrument maintenance practices at National Fertilizers Limited, a chemical process industry. It outlines the importance of instrumentation in process industries and describes various types of control loops used. It then discusses different types of maintenance practices including day-to-day, preventative, shutdown, and breakdown maintenance. Finally, it outlines upgrades made to instrumentation systems, including implementing a distributed control system and programmable logic controllers, to improve reliability, efficiency, and use of latest technologies.
This document discusses instrument maintenance practices at National Fertilizers Limited, a chemical process industry. It outlines the importance of instrumentation in process industries and describes various types of control loops used. It then discusses different types of maintenance practices including day-to-day, preventative, shutdown, and breakdown maintenance. Finally, it outlines upgrades made to instrumentation systems, including replacing old pneumatic and single loop controllers with a distributed control system and programmable logic controllers to improve reliability, efficiency, and optimization.
Production is the process of transforming inputs into outputs through a value-adding process. It involves converting raw materials, labor, capital equipment, information, and energy into finished goods and services. Productivity measures the efficiency of production by dividing total outputs by total inputs. It can be improved by increasing worker skills, adopting new technology, boosting employee motivation, and optimizing resource management. Measuring productivity helps evaluate how efficiently an organization utilizes its resources to produce outputs.
Energy conservation security and complete automationKishorKhandge1
Automation will turn on and off the fan and lights with the help of timers and counter sensors which will save energy.
Energy saving is a need of the hour
With the help of automation we can make security
With the help of automation we can turn the motor on or off if the water in the water tank is low the motor will start and shut off after filling the water tank which will save both energy and water
Automation In Industry deals with PLC.pdfPratheepVGMTS
This document discusses automation in industrial processes. It defines automation as the use of technology to replace human decision-making and manual tasks to increase productivity. The document outlines the three main flows in an industrial process - material, energy, and information flow. It also describes different types of industrial processes based on their application, operation, and physical characteristics. The document then discusses the evolution of automation from early reliance on mechanical devices to modern computer-based automation. It provides examples of automation in various industries like dairy, automotive, and pulp and paper. Finally, it discusses the basic elements, types, objectives, benefits and evolution of plant automation systems.
This document discusses different types of manufacturing systems. It defines a manufacturing system as a collection of integrated equipment and human resources that perform processing and/or assembly operations to transform raw materials into a finished product. Manufacturing systems involve input, transformation, and output processes. Key factors in selecting a manufacturing system include volume, capacity, flexibility, lead time, efficiency, and environmental impact. Examples of manufacturing systems provided include single station cells, machine clusters, manual assembly lines, automated transfer lines, and flexible manufacturing systems. Components of manufacturing systems are production machines, material handling systems, computer systems, and human resources. The document further classifies manufacturing systems as intermittent or continuous production systems based on whether production flows are started and stopped irregularly or operate
This document discusses automation in the pharmaceutical industry. It defines automation and describes its advantages such as improved quality, reduced costs, and increased safety. Automation can occur at various stages of manufacturing like material handling, production processes, and quality control. The document also discusses process control and variables like temperature, pressure, and flow that are important to measure. It provides examples of automation in tablet manufacturing that can improve material handling and specific unit operations.
Messung Group, based in Pune, India, is a diversified conglomerate offeringholistic technology solutions for industry.From being a leading PLC manufacturer and industrial automation systems provider, the Group has evolved to encompass three broad businesses, namely Automation & Control, Electrical Engineering and Workplace Technologies. Messung is now a one-stop source for a complete package of technology solutions for practically every need in the Food &Beverage (F&B) industry.
With an integrated approach to technology, extensive portfolio of innovative products, and four decades of industry experience, Messung goes beyond standard solutions to develop customised, holistic solutions that add value and drive performance in the F&B industry.
Manufacturing is the process of converting raw materials into finished goods through various production methods. Historically, manufacturing occurred on a small scale through apprenticeships or putting-out systems, but the Industrial Revolution led to large-scale manufacturing using machines powered by steam engines. Major technological developments during this period included advances in textiles, metallurgy, mining, chemicals and other industries. Manufacturing systems can involve discrete, process, repetitive, or assemble-to-order production depending on factors like market demand and complexity of the product.
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2. Page 1Classification: Restricted
Agenda
• Industries and their classification
• Introduction to Industrial Automation
• Process manufacturing- Oil and Gas Refinery
• Discrete manufacturing- Car Assembling Process
• Process manufacturing- Oil and Gas Refinery
• Industrial Automation
• Layers of automation
• Supervising and production control level
3. Page 2Classification: Restricted
Industries and their Classification
• The following details can be told by looking at the industries.
• Size( Geographical Extent).
• Complexity of Operation.
• Type of Industry
• Assembling to Product.
• Raw material to Product/Products.
• How is the process done.
• Consequences of Failure.
• With a better understanding the following can be better explained,
• Quality and Quantity
• Efficiency in production
• Fail safe conditions
• Shutdown and consequences
• Value of industry and products
4. Page 3Classification: Restricted
Introduction to Industrial Automation
• Industries are generally classified based on how the final product is
manufactured/ produced, and they are as follows,
• Process Industries.
• Discrete Industries
• Discrete industries
• Discrete industry term for the manufacturing of finished products that
are distinct items capable of being easily counted, touched or seen. In
theory, a discrete product can be broken down at the end of its
lifecycle so its basic components can be recycled. An automobile is a
product of discrete manufacturing.
• Process industries
• In process industry, the product is created by using a formula or recipe
to refine raw ingredients and the final product cannot be broken down
to its basic components. Process manufacturing industries include
chemicals, food and beverage, gasoline, paint and pharmaceutical.
5. Page 4Classification: Restricted
Introduction to Industrial Automation
• Discrete manufacturing is all about assembling things, and making things
that are exact.
• The products are typically manufactured in individually defined lots.
• The sequence of work centers through production varying for each one of
these.
• Thus in discrete manufacturing, the product is made by sequential steps
made in the same process or by the same craftsman.
• Discrete manufacturing based on the production orders and products
change frequently from order to order.
• Discrete manufacturers are making a finished good that may have screws,
nuts, handles, etc. that can be taken apart and used on something else if
need be.
• In discrete manufacturing, the manufacturing floor works on shop orders to
build something. The individual products are easily identifiable.
7. Page 6Classification: Restricted
Introduction to Industrial Automation
• Process Manufacturing is when you have a product that requires a set of
processes to be finished, each process in turn has certain needs.
• Thus each process is separated from the other while planning and setting
the Manufacturing requirements to ensure that the individual processes
are better controlled and maintained if they are dealt separately.
• Process manufacturers build something that cannot be taken apart,
technically you can take the mix out of the container and reuse the
container, but you can’t take the ingredients out of the finished goods
produced.
• This makes process manufacturers ‘process’ or formula based.
• In process manufacturing, you can’t tell the difference between one
product and another.
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INDUSTRIAL AUTOMATION
• When we look at both the above industries it becomes clear that lot of
complex processes have to be done with accuracy and precision.
• Thus it is going to be a labor intensive task if it’s a manually operated
industry.
• The risk for humans also rises in case of process industries due to the usage
of chemicals and the condition of parameters(temperature, pressure, flow,
etc..) which are controlled.
• Due to the above mentioned factors and other such factors, industries have
long been looking for alternative techniques where in the process can be
done accurately resulting in better quality of products as well as providing
safe work environment.
• This requirement led to the replacement of humans with various control
equipment's to control the process. This is called as industrial automation.
10. Page 9Classification: Restricted
INDUSTRIAL AUTOMATION
• Industrial Automation: Industrial Automation is a combination of two word
namely Industry and Automation.
• Industry: An industry is a group of manufacturers or businesses that
produce a particular kind of goods or services.
• Automation: The word Automation is derived from the Greek words
‘Auto’ and ‘Matos’ where auto means self while Matos means moving
which gives the meaning ‘self dictating’ or ‘a mechanism moved by itself’.
• Industrial automation can be defined as the use of set of technologies and
automatic control devices that result in the automatic operation and
control of industrial processes without significant human intervention and
achieving superior performance than manual control.
11. Page 10Classification: Restricted
• To understand the above definition better let us look into an example of a
heat exchanger process commonly found in all industries.
• The heat exchanger is used to provide water at a defined higher
temperature.
• In most industries there is a requirement of hot water for various purposes
, in our case we will look at the supply of water to a number of cleaning
stations, where the water temperature needs to be kept constant in spite
of the demand.
INDUSTRIAL AUTOMATION
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INDUSTRIAL AUTOMATION
Process: Steam and cold water are fed into a heat exchanger, where heat
from the steam is used to bring the cold water to the required working
temperature. A thermometer is used to measure the temperature of the
water from the process or exchanger.
•How would you maintain the water at the defined temperature irrespective
of the changes in the demand of water at outlet.
•If the temperature has to be maintained there should be a constant
monitoring of the thermometer and adjustment of the steam flow.
•This can be done by two ways : the earlier manual control and the
automated control.
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INDUSTRIAL AUTOMATION
• In manual control the temperature is observed by an operator who
adjusts the flow of steam into the heat exchanger to keep the water
flowing from the heat exchanger at the constant set temperature.
• In automatic control the output variable is sensed and the amplitude of
the output parameter is compared to the desired or set level and an
error signal is sent to controller and the corrective signal is sent to
control the process at desired condition.
•
In our case steam a temperature sensor is attached to the outlet pipe, it
senses the temperature of the water flowing. As the demand for hot
water increases or decreases, a change in the water temperature is
sensed and converted to an electrical signal, amplified, and sent to a
controller that evaluates the signal and sends a correction signal to an
actuator. The actuator adjusts the flow of steam to the heat exchanger to
keep the temperature of the water at its predetermined value.
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INDUSTRIAL AUTOMATION
• This is how the manual control to automated control changes occur in
the industries.
• The thermometer is replaced by a sensor which produces electrical
signal.
• The human response is provided by a controller.
15. Page 14Classification: Restricted
INDUSTRIAL AUTOMATION
ADVANTAGES OF INDUSTRIAL AUTOMATION: The following are seen as the
advantages when industry is automated.
• High productivity: Automation of factory or manufacturing or
process plant improves production rate through a better control of
production. With manual control of the production line there is
always a requirement to have some down time to ensure effective
working of work force. Where as the automated control systems will
be able to work for long hours without compromising on accuracy.
Hence increased productivity and efficiency per hour of labor input.
• High Quality: The automation system performs operations with
greater conformity and uniformity to the quality specifications once
it is designed and programmed. Thus by using the automation
systems, industrial processes are controlled and monitored at all
stages in order to produce a qualitative end product.
•
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INDUSTRIAL AUTOMATION
• High flexibility: When making changes or upgrading task is done
humans require training but, robots can be programmed to do any
task. This makes the manufacturing process more flexible.
• High Information Accuracy: The automated systems are enabled
with easy data collection techniques, which allows us to collect key
production information, improve data accuracy, and reduce data
collection costs. This provides with the facts to make the right
decisions enabling in reducing waste and improving processes.
• High safety: Work environment is made safer by transferring the
workers from an on location role in the process to the supervising
role. The automated machines designed to work in the hazardous
environments and other extreme environments. Industrial
automation makes the production line safe for the employees by
deploying robots to handle hazardous conditions.
•
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INDUSTRIAL AUTOMATION
LAYERS OF AUTOMATION
Industrial automation can be complex in nature, they have large number of
devices working in synchronization with automation technologies. The
figure below describes the hierarchical arrangement of an automation
system.
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FIELD LEVEL
This is the lowest level of the automation hierarchy, which includes the field
devices like sensors and actuators. The main task of these field devices is to
transfer the data of processes and machines to the next higher level for
monitoring and analysis.
• Sensors convert the real time parameters like temperature, pressure,
flow, level, etc into electrical signals. The sensor data is transferred to
the controller to monitor and analyze the real time parameters. Sensors
include thermocouple, proximity sensors, RTDs, flow meters, etc.
• Actuators converts the electrical signals from the controllers into
mechanical means to control the processes. Flow control valves,
solenoid valves, pneumatic actuators, relays, DC motors and servo
motors are the examples of actuators.
INDUSTRIAL AUTOMATION
19. Page 18Classification: Restricted
CONTROL LEVEL
• The control level consists of various automation devices like CNC machines,
PLCs, DCSs, etc., which acquires the process parameters from various
sensors. The automatic controllers drive the actuators based on the
processed sensor signals and program or control technique.
• Programmable Logic Controllers (PLCs) are the most widely used robust
industrial controllers which are capable of delivering automatic control
functions based on inputs from sensors and the programs downloaded into
the PLC.
• DCS is the advanced or more integrated controller used for large process
industries.
INDUSTRIAL AUTOMATION
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SUPERVISING AND PRODUCTION CONTROL LEVEL
• In this level, automatic devices and monitoring system facilitates, the
continuous viewing (supervising) of the process and also provides for
controlling and intervening functions like Human Machine Interface (HMI).
• These systems enable supervising various parameters, setting production
targets, historical archiving, setting machine start and shutdown, etc.
• Mostly, either Distribution Control System (DCS) or Supervisory Control and
Data Acquisition (SCADA) and HMIs are popularly used in this level.
21. Page 20Classification: Restricted
INFORMATION OR ENTERPRISE LEVEL
• This is the top most level of the industrial automation which manages the
whole automation system. The tasks of this level include production
planning, customer and market analysis, orders and sales, etc. So it deals
more with commercial activities and less with technical aspects.
• Industrial communication networks are most prominent in industrial
automation systems, they transfer the information from one level to the
other. So these are present in all the levels of automation system to
provide continuous flow of information. The communication network can
vary from one level to the other. Example of some of these networks
include RS485, CAN, DeviceNet, Foundation Field bus, Profibus, Ethernet
etc.
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INDUSTRIAL AUTOMATION
• In this hierarchy there is continuous information flow from high level to low
level and vice-versa. This can be represented in graphical way, like a
pyramid in which as we go up, the information gets aggregated and while
going down, we get detailed information about the process.
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Topics to be covered in the next session:
• History of Industrial Automation
• Types of Industrial Automation
• Process Industries
• Overview of Continuous & Batch Process