Industrial automation involves replacing human labor with machines and technology in industrial processes and manufacturing. It allows for increased efficiency, precision, and safety. Key aspects of industrial automation include open and closed loop control systems, continuous and discrete manufacturing processes, and hierarchical control architectures. Automation is widely used across various industries like power generation, manufacturing, storage and transportation to optimize processes, reduce costs, and improve quality and safety. The data needs of automated plants have grown enormously, requiring advanced computing and networking capabilities to manage all process variables.

1. Industrial Automation
Automation Overview
1.1 Automation

2.  UTS : 15%
 UAS : 15%
 TUGAS BESAR : 70%
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3. PEMANASAN 1
 Apa manfaat calon Industrial Engineer mengetahui
Otomasi?
 Hal apa saja yang ingin kalian capai setelah mengikuti
kuliah Otomasi?
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4. Definition
Automation (automation, Automation):
• set of all measures aiming at replacing human work through machines
(e.g. automation is applied science)
• the technology used for this purpose
(e.g. this company has an automation department)
Automation (automatisation, Automatisierung)
• replacement of human work through machines
(e.g. the automatisation of the textile factory caused uproar of the workers)
• replacement of conscious activity by reflexes
(e.g. drill of the sailors allows the automatisation of ship handling)
automation and automatisation are often confounded, in english, it is the same word.
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5. Automation
Living organism Industrial system
brain historian, expert optimizers,
manufacturing execution system
spinal chord data networks
ganglions (reflexes) controllers Automation =
the neural system
axons field busses
neurons sensors and actors
muscles motors, pneumatic movers
organs primary equipment (vessels, turbines)
skeleton buildings and sites
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6. Automation as a hierarchy of services
5 Planning, Statistics, Finances administration
4 Production planning, orders, purchase enterprise
3 Workflow, order tracking, resources (manufacturing) execution
SCADA =
2 Supervisory Supervisory Control
And Data Acquisition
Group control
Unit control
1
Field
Sensors T
& actors A V
0 Primary technology
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7. Automation as a computer network WWW
DB, Historians,
Optimizers, MES Operator Workplaces
Plant Network
OPC Server OPC Server OPC Server
Control Network
Controller IEC 61850 station bus
Fieldbus Protection &
Control
HART mux
Instruments
Process
Instrumentation Substation Power Management
LV Electrification Automation
Power generation
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8. Contents
1 Introduction
1.1 Automation and its importance
1.2 Examples of automated processes
1.3 Types of plants and controls
1.3.1 Open loop and closed loop control
1.3.2 Continuous processes
1.3.3 Discrete processes
1.3.3 Mixed processes
1.4 Automation hierarchy
1.5 Control System Architecture
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9. Automation Applications
Power generation hydro, coal, gas, oil, shale, nuclear, wind, solar
Transmission electricity, gas, oil
Distribution electricity, water
Process paper, food, pharmaceutical,
metal production and processing, glass, cement,
chemical, refinery, oil & gas
Manufacturing computer aided manufacturing (CIM)
flexible fabrication, appliances, automotive, aircrafts
Storage silos, elevator, harbor, retail houses,
deposits, luggage handling
Building heat, ventilation, air conditioning (HVAC)
access control, fire, energy supply, tunnels,
parking lots, highways,....
Transportation rolling stock, street cars, sub-urban trains,
busses, trolley busses, cars,
ships, airplanes, rockets, satellites,...
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10. Automation Systems - World Players
Company (alpha. order) Location Major mergers
ABB CH-SE Brown Boveri, ASEA, CE, Alfa-Laval, Elsag-Bailey
Alstom FR Alsthom, GEC, CEGELEC, ABB Power,..
Ansaldo IT
Emerson US Fisher Rosemount
General Electric US
Hitachi JP
Honeywell US
Rockwell Automation US Allen Bradley, Rockwell,..
Schneider Electric FR Té lé mé canique, Square-D, ...
Invensys UK Foxboro, Siebe, BTR, Triconex,…
Siemens DE Plessey, Landis & Gyr, Stä fa, Cerberus,..
Yokogawa JP
€ 80 Mia / year business
(depends on viewpoint),
growing 5 % annually
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11. Terms
plant: the object of automation
F: site, usine, centrale (électricité)
D: Prozess, Werk, Fabrik, Kraftwerk
E: planta, fabrica, instalación
general contractor: organizes the suppliers of the different components.
turnkey factory: the client only hires consultants to supervise the contractor
increasingly, the general contractor has to pay itself by operating the plant.
increasingly, the suppliers are paid on results….
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12. Four distinct businesses
primary technology automation equipment engineering & maintenance
(mechanical, electrical) (control & command) commissioning & disposal
seldom offered by the same company
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13. Life-phases of a Plant (Example: Rail Vehicle)
Manufacturers
Equipment Design control air conditioning brakes
(développement, Entwicklung)
Equipment Production
(production, Herstellung)
car body design by assembler
Assembler (ensemblier)
Engineering
Sleeping Wagon XL5000
(bureau d’étude, Projektierung) Plus
Commissioning
(mise en service, Inbetriebnahme) Start on
Client, Service service
brakes
Maintenance replacement
(entretien, Unterhalt) brakes
Out of service
Recycling
(Recyclage, Wiederverwertung)
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14. Technical necessity of automation
• Processing of the information flow
• Enforcement of safety and availability
• Reduction of personal costs
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15. Expectations of automation
Process Optimisation
• Energy, material and time savings
• Quality improvement and stabilisation
• Reduction of waste, pollution control
• Compliance with regulations and laws, product tracking
• Increase availability, safety
• Fast response to market
• Connection to management and accounting (SAP™)
-> Acquisition of large number of “Process Variables”, data mining
Personal costs reduction
• Simplify interface
• Assist decision
• Require data processing, displays, data base, expert systems
-> Human-Machine Interface (MMC = Man-Machine Communication)
Asset Optimisation (gestion des moyens de production)
• Automation of engineering, commissioning and maintenance
• Software configuration, back-up and versioning
• Life-cycle control
• Maintenance support
-> Engineering Tools
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16. Data quantity in plants
Power Plant 30 years ago
100 measurement and action variables (called "points")
Analog controllers, analog instruments
one central "process controller" for data monitoring and protocol.
Coal-fired power plant today
10'000 points, comprising
8'000 binary and analog measurement points and
2'000 actuation point
1'000 micro-controllers and logic controllers
Nuclear Power Plant
three times more points than in conventional power plants
Electricity distribution network
100’000 - 10’000’000 points
information flow to the personal: > 5 kbit/s.
human processing capacity: about 25 bit/s
without computers, 200 engineers (today: 3)
Data reduction and processing is necessary to operate plants
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17. Worldwide Consolidation Process: the Big Eight
Hartmann & Fisher Rockwell
SACDA Foxboro Schneider Turbi-Werke
Braun Rosemountl Software
Control Triconex
Fisher &
Techniques Profimatics
Porter Vickers
AVANTIS
Télémécanique
Combustion Intellution P&F Safety
Dodge
Engineering Systems APV Moore
PC&E
Alfa-Laval PACSIM
L&N
Automation Square D
Milltronics
CSI Wonderware
August
Measurex Allen-Bradley
Systems
Westinghouse Eurotherm
PCD Axiva
Elsag Interplant Modicon
Bailey Consulting SimSci-Esscor
Kenonics
Esscor ORSI
Cellier
Allied Signal Reliance
Engineering MDC
Merlin Gérin
Baan
Saab Marine Compex
Skyva GE Fanuc POMS Walsh
Electronics
Automation
Rockwell Schneider
ABB Emerson GE Industrial Honeywell Invensys Siemens
Automation Electric
umbrella IndustrialIT Delta V, Cimplicity Experion PKS, ArchestA RSview “Transparent "Totally
architecture Plantweb TotalPlant Factory” Integrated
Automation"
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