DEPARTMENT OF ELECTRICAL ENGINEERING

INDIAN SCHOOL OF MINES UNIVERSITY, DHANBAD 826004

LECTURE PLAN

VIII semester (B. Tech) L: T: P: 3-0-0

Electrical Engineering
Winter semester: 2021-2022
Subject: Industrial Automation and Control (EEC18116)
Course objective:

To understand components of Industrial processes and their role for automated system.
To understand the different control techniques and their implementation for automated
system.
Learning Outcome:
 Be able to understand the operations of different components of Industrial Automation.
 Be able to understand operating principle of different control techniques and their
implementation for automated industries.

Sl no Topic Lecture
classes
1. Introduction about Industrial Processes and their automation. 4

2. Elements of pneumatic, hydraulic and electrical control systems. 9

3. Valves , Actuators and stepper motors 4

4. PID controllers and their tuning 3

5. Implementation of digital controller, control strategies for industrial processes. 6

6. Programmable Logic Controllers 6

7. Real time issues of signal transmission and control. 4

8. Communication system for industrial automation, Data acquisition, SCADA 3

Total 39
References:
1. Industrial Instrumentation, Control and Automation -- S. Mukhopadhyay, S. Sen and A.K.
Deb, Jaico Publishing House, 2013.
2. Programmable Logic Controllers and Industrial automation- Madhuchhanda Mitra
Samarjit Sen Gupta, Penram International Publishing india (Pvt.) Ltd.
2. Modern Control Engineering -K Ogata, Pearson Education
3. Process/Industrial Instruments and control Handbook-Considine, Mcgra Hill

Prof Somnath Pan Prof. Sanjoy Mandal

 • What is Industrial Automation?
Industrial Automation is a process of operating machines and other industrial equipment with the help of
digital logical programming and reducing human intervention in decision making and manual command
process with the help of mechanized equipment.

• Consider a manual industrial production process, where an operator is observing the temperature of
an oven. Assume the task is to reach a certain temperature and maintain that temperature for about
30 minutes.
So, the operator has to first adjust the amount of fuel to the oven by controlling a valve to rise the
temperature to the desired amount. Once the necessary temperature is achieved, it has to be maintained by
constantly adjusting the valve i.e. either increase or decrease the fuel depending on the temperature for the
next 30 minutes.
• Now, with industrial automation, the whole process is taken care of without the help of an operator.
First, there is a temperature sensor placed near the oven which reports the temperature to a
computer.
Now, there is motorized valve, which is also controlled by the computer, for the fuel to be supplied to the
oven. Based on the temperature readings from the sensor, the computer will open the valve to allow more
fuel in the beginning. Once the desired temperature is achieved, the valve is shutoff.

Now-a-days, the fundamental motivations for implementing industrial automation are:

• Increase production
• Reducing cost, especially, human-related cost
• Improving the quality of the product
• Efficient use of raw materials
• Reduce energy consumption
• Increase business profits
• There are a few secondary motivations for using automation in industrial production process like
providing a safe environment for the operator, reducing the environmental pollution, etc.
 • There are several ways to describe the levels of an Industrial Automation Process, but the simplest
of all is the following hierarchical triangle of three level representation of a typical Industrial
Automation Application.

• Supervisor Level
Sitting at the top of hierarchy, the supervisor level usually consists of an Industrial PC, which
is usually available as a desktop PC or a Panel PC or a Rack-mounted PC. These PCs run on standard
operating systems with a special software, usually provided by the supplier for industrial process control.
The main purpose of the software is process visualization and parameterization. A special
industrial ethernet is used for communication, which can be Gigabit LAN or any wireless topology
(WLAN).
• Control Level
The Control Level is the mid-level in the hierarchy and this is the level where all the
automation related programs are executed. For this purpose, generally, Programmable Logic
Controllers or PLCs are used, which provide real-time computing capability.
PLCs are usually implemented using 16-bit or 32-bit microcontrollers and run on a proprietary
operating system to meet the real-time requirements. PLCs are also capable of being interfaced with
several I/O devices and can communicate through various communication protocols like CAN.
• Field Level
The terminal equipment like Sensors and Actuators are categorized into Field Level in the hierarchy. The
sensors like temperature, optical, pressure etc. and actuators like motors, valves, switches etc. are
interfaced to a PLC through a field bus and the communication between a Field Level device and its
corresponding PLC is usually based on a point-to-point connection.
Both wired and wireless networks are used for communication and using this communication, the PLC can
also diagnose and parameterize various components.
Additionally, an industrial automation process system also requires two major systems. They are:
1) Industrial Power Supply
2) Security and Protection
Considering all the levels and their corresponding components, a typical Industrial Automation System will have the

following structure .
 • Types of Industrial Automation Systems
Now that we have seen a little bit about the layout of a typical industrial automation system, let us proceed
with the discussion of the different type of Industrial Automation Systems. Industrial Automation Systems
are usually categorized into four types.
1. Fixed Automation System
2. Programmable Automation System
3. Flexible Automation System
4. Integrated Automation System

• Fixed Automation System

In a Fixed Automation System, the production equipment is fixed with a fixed set of operations or tasks and
there are rarely any changes to these operations. Fixed Automation System is usually used in continuous flow
processes like conveyors and mass production systems.
• Fixed automation, also known as “hard automation,” refers to an automated production facility in
which the sequence of processing operations is fixed by the equipment configuration. In effect, the
programmed commands are contained in the machines that is not easily changed over from one
product style to another. This form of automation is characterized by high initial investment and
high production rates. It is therefore suitable for products that are made in large volumes. Examples
of fixed automation include machining transfer lines found in the automotive assembly machines,
and certain chemical processes etc.

• Example:
An automotive assembly line is an example of fixed automation:
Automotive assembly line starts with a bare chassis. Components are attached successively as the growing
assemblage moves along a conveyor. Parts are matched into subassemblies on feeder lines that intersect
the main line to deliver exterior and interior parts, engines, and other assemblies. As the units move by,
 each worker along the line performs a specific task, and every part is delivered to its point of use in
synchronization with the line. A number of different assemblies are on the line simultaneously, but an
intricate system of scheduling and control ensures that the appropriate body type and colour, trim,
engine, and optional equipment arrive together to make the desired combinations.
• Programmable Automation System
Programmable automation is a form of automation for producing products in batches. The products are made
in batch quantities ranging from several dozen to several thousand units at a time. For each new batch, the
production equipment must be reprogrammed and changed over to accommodate the new product style.
This reprogramming and changeover take time to accomplish, and there is a period of nonproductive time
followed by a production run for each new batch. Production rates in programmable automation are
generally lower than in fixed automation, because there is a facility that the equipment is designed
for product changeover rather than for product specialization.

Example:
• A computer-numerical-control(CNC) is a good example of programmable automation. The program is
coded in the memory of a computer for each different product style, and the machine tool is
controlled by the programme. The NC part program represents the set of machining instructions for
the particular part. The coded numbers in the program specify x-y-z coordinates in a Cartesian axis
system, defining the various positions of the cutting tool in relation to the work part. By sequencing
these positions in the program, the machine tool is directed to accomplish the machining of the part.
A position feedback control system is used in most NC machines to verify that the coded instructions
have been correctly performed.
• Another variation in the implementation of numerical control involves sending part programs over
telecommunications lines from a central computer to individual machine tools in the factory. This
form of numerical control is called DNC or direct numerical control.

• Computer Numerically Controlled (CNC) machine have an embedded system involving several
microprocessors and related electronics as the Machine Control Unit (MCU). In CNC systems
multiple microprocessors and programmable logic controllers work in parallel for simultaneous
servo position and velocity control of several axes of a machine for contour cutting as well as
monitoring of the cutting process and the machine tool. Over a period of time, several additional
features were introduced, leading to increased machine utilization and reduced operator
intervention. Some of these are:
(a) Tool/work monitoring: For enhanced quality, avoidance of breakdowns. (b) Automated tool magazine
and palette management: For increased versatility and reduced operator intervention over long hours of
operation (c) Direct numerical control (DNC): Uses a computer interface to upload and download part
programs in to the machine automatically.
 • Flexible Automation System
Flexible automation is an extension of programmable automation. The disadvantage with programmable
automation is the time required to reprogram and change over the production equipment for each batch
of new product. This is lost production time, which is expensive. In flexible automation, the variety of
products is sufficiently limited so that the changeover of the equipment can be done very quickly and
automatically. The reprogramming of the equipment in flexible automation is done off-line; that is, the
programming is accomplished at a computer terminal without using the production equipment itself.
Accordingly, there is no need to group identical products into batches; instead, a mixture of different
products can be produced one right after another.
• Integrated Automation System
It denotes complete automation of a manufacturing plant, with all processes functioning under
computer control and under coordination through digital information processing. It includes technologies
such as computer-aided design and manufacturing, computer-aided process planning, computer
numerical control machine tools, flexible machining systems, automated storage and retrieval systems,
automated material handling systems such as robots and automated cranes and conveyors, computerized
scheduling and production control. It may also integrate a business system through a common database.
In other words, it symbolizes full integration of process and management operations using information
and communication technologies. Typical examples of such technologies are seen in Advanced Process
Automation Systems and Computer Integrated Manufacturing (CIM)
• Fixed Automation to CIM the scope and complexity of automation systems are increasing. Degree of
automation necessary for an individual manufacturing facility depends on manufacturing and
assembly specifications, labor conditions and competitive pressure, labor cost and work
requirements. One must remember that the investment on automation must be justified by the
consequent increase in profitability. To exemplify, the appropriate contexts for Fixed and Flexible
Automation are compared.
Major industrial processes can be categorized as follows based on their scale and scope of production.
• Continuous flow process: Manufactured product is in continuous quantities i.e., the product is not a
discrete object. Moreover, for such processes, the volume of production is generally very high, while
the product variation is relatively low. Typical examples of such processes include Oil Refineries, Iron
and Steel Plants, Cement and Chemical Plants.
• Mass Manufacturing of Discrete Products: Products are discrete objects and manufactured in large
volumes. Product variation is very limited. Typical examples are Appliances, Automobiles etc.
• Batch Production: In a batch production process the product is either discrete or continuous.
However, the variation in product types is larger than in continuous-flow processes. The same set of
equipment is used to manufacture all the product types. However for each batch of a given product
type a distinct set of operating parameters must be established. This set is often referred to as the
“recipe” for the batch. Typical examples here would be Pharmaceuticals, Casting Foundries, Plastic
moulding, Printing etc.
• Job shop Production: Typically designed for manufacturing small quantities of discrete products,
which are custom built, generally according to drawings supplied by customers. Any variation in the
product can be made. Examples include Machine Shops, Prototyping facilities etc.
• Industrial Automation makes extensive use of Information Technology. Fig. below shows some of
the major IT areas that are used in the context of Industrial Automation.
However, Industrial Automation is distinct from IT in the following senses :
• Industrial Automation also involves significant amount of hardware technologies, related to
Instrumentation and Sensing, Actuation and Drives, Electronics for Signal Conditioning,
Communication and Display, Embedded as well as Stand-alone Computing Systems etc.
• As Industrial Automation systems grow more sophisticated in terms of the knowledge and algorithms
they use, as they encompass larger areas of operation comprising several units or the whole of a
factory, or even several of them, and as they integrate manufacturing with other areas of business,
such as, sales and customer care, finance and the entire supply chain of the business, the usage of IT
increases dramatically. However, the lower level Automation Systems that only deal with individual
or , at best, a group of machines, make less use of IT and more of hardware, electronics and
embedded computing.
Advantages of Industrial Automation:
• The task performed by human operators involving tedious physical work can be easily replaced.
• Human operators can avoid working in dangerous production environments with extreme
temperatures, pollution, intoxicating elements or radio-active substances.
• The tasks that are difficult for a typical human operator can be easily done. These tasks include lifting
heavy and large loads, working with extremely tiny objects etc.
• Production is always faster and the cost of the product is significantly less (when compared to the
same product that is produced with manual operation).
• Several quality control checks can be integrated into the production process to provide consistency
and uniformity.
• The economy of the industry can be significantly improved, which has a direct impact on the standard
of the living.

Disadvantages of Industrial Automation:

• Loss of jobs. Since, majority of the work is done by machines, the requirement for manual labor
is very less.
• All the desired tasks cannot be automated using the current technology. For example, products
with irregular shapes and sizes are best left for manual assembly. (This trend seems to be changing
with advanced computers and algorithms).
• It is feasible to use automation for certain process i.e. high-volume production, repeatable and
consistent products.
• The initial cost of implementing an automation system is very high.
• A set of skilled personnel is always a requirement for maintenance and service.
Temperature Measurement:
• Temperature measurement can be broadly classified in the following groups:
• 1. Liquid and gas thermometer
• 2. Bimetallic strip
• 3. Resistance thermometers (RTD and Thermistors)
• 4. Thermocouple
• 5. Junction semiconductor sensor
• 6. Radiation pyrometer

• Measurement of pressure inside a pipeline or a container in an industrial environment is a

challenging task, keeping in mind that pressure may be very high, or very low (vacuum); the
medium may be liquid, or gaseous.
• Diaphragms:
Diaphragms may be of three types:
1) Thin plate,
2) Membrane
3) Corrugated diaphragm.
• Potentiometer
• Linear Variable Differential transformer (LVDT)
• Inductive type Sensors

Fig.: LVDT Fig.: Inductive Transducer

• Capacitance Sensors
• Optical Sensors
• Speed measurement

• Accurate measurement of flow rate of liquids and gases is an essential requirement for
maintaining the quality of industrial processes. In fact, most of the industrial control loops control
the flow rates of incoming liquids or gases in order to achieve the control objective. As a result,
accurate measurement of flow rate is very important.
 Basic Principle :

• So if there is an obstruction in the flow path that causes the variation of the cross sectional area
inside the closed flow channel, there would be difference in static pressures at two points and by
measuring the pressure difference, one can obtain the flow rate.
• If there is a sudden large change in set point, the error between the set point and the process
output will suddenly shoot up and the integrator output due to this error will build up with time.
As a result, the controller output may exceed the saturation limit of the actuator. This windup,
unless prevented may cause continuous oscillation of the process. let us consider the input-output
characteristics of an actuator as shown in the following Fig.
 • The method uses a switch to break the integral action, whenever the actuator goes to saturation.
When the switch is closed, transfer function of the controller can be obtained as:

• So when the switch is closed, the controller acts as a P-I controller. On the other hand, if the switch
is open, it is a simple P- controller. The switch is activated by the position of the actuator. If the
actuator is operating in the linear range, the switch is closed, and the controller is in P-I mode.
But whenever the actuator is in the saturation mode, the switch is automatically opened; the
controller becomes a P-controller. As a result, any windup due to the presence of integral mode
is avoided.
• Electronic PID Controllers Electronic PID controllers can be obtained using operational amplifiers and
passive components like resistors and capacitors. A typical scheme is shown below.
 • Digital P-I-D Control :

Guideline for selection of P-I-D controller:

1. Proportional Controller: It is simple regulating type; tuning is easy. But it normally introduces
steady state error. It is recommended for process transfer functions having a pole at origin,
or for transfer functions having a single dominating pole.
2. Integral Control: It does not exhibit steady state error, but is relatively slow responding. It is
particularly effective for: (i) very fast process, with high noise level (ii) process dominated by
dead time (iii) high order system with all time constants of the same magnitude.
3. Proportional plus Integral (P-I) Control: It does not cause offset associated with proportional
control. It also yields much faster response than integral action alone. It is widely used for
process industries for controlling variables like level, flow, pressure, etc., those do not have
large time constants.
4. Proportional plus Derivative (P-D) Control: It is effective for systems having large number of
time constants. It results in a more rapid response and less offset than is possible by pure
proportional control. But one must be careful while using derivative action in control of very
fast processes, or if the measurement is noisy (e.g. flow measurement). 5. Proportional plus
Integral plus Derivative (P-I-D) Control: It finds universal application. But proper tuning of the
controller is difficult. It is particularly useful for controlling slow variables, like pH,
temperature, etc. in process industries.
Set Point Kick in PID controlled system:
Feed forward control: When the disturbance is measurable, feed forward control is an effective means
for cancelling the effects of disturbance on the system output.

Ratio control:

In Ratio control the disturbance is measured and the ratio of the process output and the disturbance is held
constant. It is mostly used to control the ratio of flow rates of two streams. Flow rates of both the stream are
measured, but only one of them is controlled. There can be many examples of application of ratio control.
Few examples are:
1. fuel-air ratio control in burners,
2. control of ratio of two reactants entering a reactor at a desired ratio,
3. maintaining the ratio of two blended streams constant in order to maintain the composition
of the blend at the desired value.
4. In Ratio Control, the ratio of flow rates of two streams is measured and compared with the desired ratio. The
error is fed to the controller and the controller output is used to control the flow rate of stream B.