UNIT V ADVANCED TOPICS IN AUTOMATION

UNIT V ADVANCED TOPICS IN AUTOMATION

• Introduction to Networked Control systems –

Plant wide control – Internet of things – Cloud
based Automation – OLE for Process Control –
Safety PLC – Case studies: PLC - SCADA - DCS.
 Networked Control systems
• In a Networked Control System (NCS), a computer
communication network closes the control loop
consisting of sensors, controllers and actuators.
• Controllers, sensors, actuators and other system
components communicate over a computer
network.

• Recent trends in NCS indicate that conventional

field bus networks are being replaced with industrial
versions of TCP/IP over Ethernet.
Networked Control systems
 Networked Control systems
• Communication networks used in industrial control systems are
often fieldbus networks such as ControlNet (Token passing bus),
DeviceNet (CAN bus), etc.
• These networks have been designed to satisfy real-time
performance requirements of control applications .
• The spread of field bus has been limited due to high hardware
costs and difficulty in integrating products from different vendors
• Therefore, the current trend is to make use of the widely available,
economical, commercial off-the-shelf (COTS) technology, i.e. the
Transmission Control Protocol over Internet Protocol (TCP/IP)
running on some form of Ethernet.
• With the advent of Open Architecture (OA) standards, vendors are
starting to unify their efforts to support automation and process
control on networks built around the Common Industrial Protocol.
 ETHERNET IN THE NCS ENVIRONMENT
• The distributed nature of an NCS presents certain serious
challenges that are not present in other control systems;
the store-and-forward network that unifies the various
control system components also introduces variable
latencies when transporting data packets to and from
sensors, actuators, and controllers.
• For instance, delays are introduced in the following
critical operations: reading values from sensors,
calculating and issuing new commands by Programmable
Logic Controllers, and sending new commands to
actuators.
 Industrial Ethernet
• Since Ethernet is the leading networking
solution, many industry organizations are
porting the traditional industrial network
fieldbus architecture to the industrial Ethernet
version of their network: ProfiNet, ModbusTCP,
Ethernet/IP, and Foundation Fieldbus.
• Industrial Ethernet applies the Ethernet
Standards developed for data communication
to automation/manufacturing control networks.
 Internet of Things (IoT)

• Industrial IoT is the application of IoT in the

context of transforming industrial processes
such as manufacturing, agriculture, logistics
etc.
Internet of Things (IoT)
 Internet of Things (IoT) -Industrial
Automation system
• The Internet of Things (IoT) is a key driving factor in enabling the
development of industrial automation systems.
• IoT coupled with computer automation controls helps streamline
industrial systems and improve data automation, with the aim of
removing errors and inefficiencies, primarily from the people.
• To achieve this at the industrial level, several layers of devices are
used. IoT devices from the field (plant floor), analyzers, actuators,
robotics, etc. communicate data upwards to local process control
units, which in turn send data to top-level Supervisory Control and
Data Acquisition (SCADA) software.
• While field level machines may perform tasks automatically, at every
level a human monitor can step in and interface with the system
(provided they have access).
 Fixed Automation Systems —
• Fixed automation is widely known within nearly every industry
where machines are performing simple tasks once done by
people. These systems carry out simple repetitive mechanical
tasks, usually found in production or continuous flow processes,
with much greater production efficiency and speed than could be
done manually.
• These systems can be custom built to perform a task, but many
off-the-shelf solutions are available for common applications.
Sometimes called 'hard automation' because the operation is
fixed by the equipment design.
• Examples of fixed automation include conveyor belts, box folders,
or bottle filling and capping machines, or flow packing machines
for food packaging, etc.
 Programmable Automation Systems
• — Programmable automation systems introduces
programmable computer logic to industrial automation. This
upgrade allows industrial automation machines to switch their
capabilities, though this can incur significant costs in money and
programming time and expertise.
• However, this style of automation is invaluably advantageous for
industries such as auto manufacturing, where capital costs are
high for manufacturing equipment. While auto manufacturing
processes behave like they need fixed automation systems,
since there are millions of repetitive tasks to build thousands of
automobiles, every year new models are designed and
marketed that require similar but different automation.
• Object Linking and Embedding is used to provide
integration among applications, enabling a high degree
of application compatibility, even among diverse types
of information, OLE technology is based on COM, and
allows for the development of reusable, plug-and-play
objects that are interoperable across multiple
applications.
• It also provides for reusable, component-based
software development, where software components
can be written in any language, supplied by any
software vendor.
 Flexible Automation Systems
• Flexible systems use computer-controlled manufacturing systems
that allow individual product customization while automating
production of the entire batch.
• Sometimes this is called 'soft automation' in contrast to hard 'fixed'
automation that is not flexible.
• Flexible automation also differs from programmable automation as
it's able to make adjustments while processing jobs rather than be
reprogrammed for manufacturing new products.
• CNC machines are a common example, like computer-controlled
lathes and routers, that can take a computer code from the
operator, and turn-out a piece specific to the job. For this reason,
flexible automation systems are used in batch processes, small to
medium volumes, and high product varieties.
 OLE for Process Control (OPC):

• Object Linking and Embedding (OLE) for

process control (OPC) is a set of standards
developed by a joint collaboration of leading
automation industry suppliers.
• OPC's primary mission is to define a uniform
interface for use with any organization or
custom software package.
 Industrial Automation Products
• Integrated Automated Systems — Integrated automation systems
expand automation impact by connecting all systems within a
manufacturing plant, referred to as total automation.
• Sensor data, data analytics, and computer control and decision making
allows these factories to minimize human labor in operations. For
example, these systems are prominent in Computer Aided
Manufacturing (CAM), where engineers can design, plan, and send
manufacturing details to production, and maintain full control over the
entire product manufacturing life cycle.
• These concepts are further developed in Smart Factories, where
interconnected global systems utilize system wide data to make
decisions, such as the inventory levels in manufacturing one location
may trigger the real-time automatic resupply from international
suppliers.
 Higher-order control level

• Supervisory Control and Data Acquisition (SCADA) — SCADA is

software that performs data analysis on the system to find
optimizations to improve operations and output.
• Process control level
• Human Machine Interface (HMI) — HMI devices are wide ranging,
from switches to touchscreens, and allow operators to interface with
machines, give them new instructions, or change configurations.
• Artificial Neural Network (ANN) — Neural networks perform complex
mathematics and are found in data analytics intensive applications,
like finance.
• Distributed Control System (DCS) — These devices work together to
monitor and control large or sprawling systems, like traffic signal
systems, electrical grids, or water management systems.
 Control and automation level

• Programmable Logic Controller (PLC) — PLCs allow

automation equipment to be reprogrammed for
new tasks.
• Robotics — These are the arms of industrial
automation. These robotic devices can be
programmed, automated, and move autonomously
in 3 dimensions.
• Sensors and Analyzers — Various sensors include
thermocouples, Resistor Temperature Detectors
(RTDs), strain gauges, etc.
 Advantages of IoT Automation

• Ability to Scale Production — Scale in production is achieved by

increasing output and becoming more efficient, two objectives the
digital industrial transformation enables and accelerates. It's
unfortunate for workforces that the human component is
sometimes the weakest link in production processes. However, by
removing people from a process, companies can multiply their
throughput by putting production in the hands of robots.
• Increased System Uptime — Much like scale of production is
limited by the human component, so too is uptime. People need
rest, food, a safe working environment, and to be treated ethically.
Machines on the other hand are not limited by breaks and hunger.
It must be mentioned that many factory floors are very safe
because automation practices can improve plant safety.
 Advantages of IoT Automation

• Operational Efficiency — Operational efficiency is a key business benefit

that directly improves due to automation investments. This means more
than using machines to perform mundane repetitive tasks, it means
interconnecting systems and integrating systems to share information and
allow for exponential operational improvements. With computer logic,
systems can respond to other system needs. This basic application is
everywhere now, from turning lights off when unneeded, to immediately
informing supplier's systems around the globe that the factory system will
exhaust its raw materials soon, and request a resupply.
• Improved Safety for Workers — Though automation may reduce the
number of line workers which can improve worker safety by minimizing the
body count, using data analysis and IoT, the same automation can also
improve immediate worker safety. Sensor information can be collected and
analyzed to detect impending machine failures and alert maintenance staff.
 Advantages of IoT Automation

• Improved Regulatory Compliance — Certain companies are pressured to maintain a

certain standard quality regulated by the government in their productions, which
automation can help with due to its unwavering productive capabilities. This ability to
eliminate, for the most part, defects in productivity allows companies to adhere to
stringent regulations. For instance, in cases like food producers, the FDA Food Safety
Modernization Act mandates authorities to protect consumers and promote public
health, through many programs like the Current Good Manufacturing Practices (CGMP),
HACCP, the FDA Retail Food Code.
• Strengthened Security Access and Control through Technology — While IoT technology
may introduce many attack vectors to automation systems, it also presents the
solution. Physically, IoT automation can detect the presences of unauthorized
individuals and alert authorities, automatically locking doors, or preventing access
altogether. Advanced computer security can also take advantage of automation to
defend against cyber attackers. Automation helps defenders make visible their entire
network, adhere to a policy-based approach to system configuration, management, and
security, and conduct many of the low-level maintenance tasks automatically while
alerting IT teams of more serious breaches, or patterns that may signal attacks.
 Disadvantages of IoT Automation

• Greater Connectivity Increases Attack Vectors —

Unfortunately, adding more devices means more
vectors for cyber attackers. IoT security is a branch
of security practices that aims to solve this growing
concern.
• Internet Dependency — IoT and automation are
heavily dependent on the Internet to function.
Redundant connectivity systems are advisable,
whereas losing connectivity even for a short while
could seriously cripple production with huge costs.
 Disadvantages of IoT Automation

• Complexity Increases Failure Points — Akin to more

connected devices as attack vectors, the same is true for local
and system failures. As the IoT automation systems grow in
complexity, the weight of the inherent risk of failed
components within the system must be addressed. There are
many practices and designs that help overcome, including
dividing the system up and adding redundancies.
• IoT Planning, Building, Management Complexities — Simply,
there is significant planning, building, and management of the
complexities in IoT automated systems. For all their
advantages, engineers must still be actively involved in these
systems to ensure they continue to operate as intended.
 Cloud based Automation:

• Cloud automation is a broad term that refers to the processes and

tools an organization uses to reduce the manual efforts associated
with provisioning and managing cloud computing workloads.
• IT teams can apply cloud automation to private, public and hybrid
cloud environments.
• Traditionally, deploying and operating enterprise workloads was a
time-consuming and manual process.
• It often involved repetitive tasks, such as sizing, provisioning and
configuring resources like virtual machines (VMs); establishing VM
clusters and load balancing; creating storage logical unit numbers
(LUNs); invoking virtual networks; making the actual deployment;
and then monitoring and managing availability and performance.
• Although each of these repetitive and manual
processes is effective, they are inefficient and
make with errors.
• These errors can lead to troubleshooting,
which delays the workload's availability.
• They might also expose security vulnerabilities
that can put the enterprise at risk.
Cloud Automation Testing Using Selenium
 OLE for Process Control
OLE
• Object Linking and Embedding is used to provide
integration among applications, enabling a high
degree of application compatibility, even among
diverse types of information, OLE technology is
based on COM, and allows for the development of
reusable, plug-and-play objects that are
interoperable across multiple applications.
• It also provides for reusable, component-based
software development, where software
components can be written in any language,
supplied by any software vendor.
 (OLE) - Object Linking Embedding:

• An object is an information • Linked Objects: Stored

unit that can be created separately and can be
and manipulated by users. “partitioned” by
It has intrinsic behaviour
multiple applications;
specified by its type, with
its own commands and • Embedded Objects: are
facilities. In other words, stored together with
objects are data/software the applications. In this
modules that can be case, they are for the
included in software exclusive use of the
packages. They can be same ones.
LINKED or EMBEDDED.
 OLE for Process Control (OPC):

• Object Linking and Embedding (OLE) for

process control (OPC) is a set of standards
developed by a joint collaboration of leading
automation industry suppliers.
• OPC's primary mission is to define a uniform
interface for use with any organization or
custom software package.
 OLE for Process Control (OPC):

• OLE is a communication standard

based on Microsoft's OLE
technology that has greater
interoperability between
automation /control applications,
field systems/devices, and
business/office applications.
• OPC defines standard objects,
methods, and properties built on
OLE technologies for servers of
real-time information like DCS,
PLCs and other software
applications, and communicates
the information they contain to
standard OLE enabled clients.
 Purpose of OPC:

• Standard technique for addressing information

contained in process control devices/systems, efficient
transfer of data from a process device to an
application, the ability for a client to use several
servers simultaneously, and server- support.
• The objective of OPC is to provide a standards-based
infrastructure for the exchange of process control
data.
 Types of OPC data server
• Data Access Server
• Alarm & Event Server
• Historical Data Server
 Architecture of OPC applications:
• OPC - OLE for Process
Control, implements two
large modules: OPC Server
and OPC Client.
• While the OPC Server
specifies standard interfaces
for direct access to
equipment or applications,
the OPC Client specifies the
default interface for
applications to access the
collected data
 OPC data server

Field Management: with the advent of intelligent field equipment, a wide

variety of data equipment, such as configuration and control data, may be
users or even other applications.

Process Management:
• The use of SCADA and SDCDA control systems allows the decentralized
control of industrial processes.
• The data provided can be considered together to allow effective and
integrated of the entire Industrial Process.

Business Management:
The integration of factory floor information and individual management
data from each controlled process with the company’s corporate data,
administrative and financial aspects.
The data and information can be used by client applications to optimize the
 Benefits of OPC

• Simple to develop
• Flexibility to “accommodate” the features of multiple
manufacturers
• High level of functionality
• Enables efficient operation.
• Hardware manufacturers must only develop a set of
components to access their equipment
• Software developers do not have to rewrite drivers because
of changes in equipment
• Users have more options to develop international and
integrated systems
 Case study of Bottle Filling System (Continues Process Control)

• In this example, implement a • Figure illustrates the PLC ladder

control program that detects the implementation of the bottle-
position of a bottle via a limit filling application.
switch, waits 0.5 seconds, and • Once the start push button is
then fills the bottle until a photo pushed, the outfeed motor
sensor detects a filled condition. (output 031) will turn ON until the
• After the bottle is filled, the stop push button is pushed.
control program will wait 0.7 • The feed motor M1 will be
seconds before moving to the energized once the system starts
next bottle. (M2 ON); it will stop when the
• The program will include start and limit switch detects a correct bottle
stop circuits for the out feed position. When the bottle is in
motor and the start of the process. position and 0.5 seconds have
elapsed, the solenoid (032) will
These assignments include the
open the filling valve and remain
start and stop process signals.
ON until the photoeye (PE) detects
I/O address assignment
Bottle Filling System _Process Diagram
Ladder Diagram for Bottle Filling System
Continues Box Filling System (Continues
Process Control)
Continues Box Filling System (Continues
Process Control)
 Continues Box Filling System
Sequence of operations

• Start the conveyor when the START button is momentarily pressed.

• Stop the conveyor when the STOP button is momentarily pressed;
• Energize the RUN status light when the process is operating;
• Energize the STANDBY status light when the process is stopped;
• Stop the conveyor and energize the STANDBY light when the right
edge of the box is first sensed by the photo sensor;
• With the box in position and the conveyor stopped open the
solenoid valve and allow the box to be fill;
• Filling should stop when the LEVEL sensor goes true;
• Energize FULL light when the box is full; the FULL should remain
energized until the box is moved clear of the photo sensor.
Batch Mixing System (Batch Process Control)

• This is another commonly applied application

of PLC where two liquids are mixed in required
proportion to form a batch. Rate of the flow is
already fixed. We only control the time of the
flow. Level of the liquids in the tank is sensed
by the level sensor switches.
Batch Mixing System (Batch Process Control)

• Application of PLC where two liquids are mixed in required

proportion to form a batch. Rate of the flow is already fixed. We
only control the time of the flow. Level of the liquids in the tank is
sensed by the level sensor switches.
• We try a simple blending of water and acid in a container where
we only have three level sensors (L1, L2, and L3) and two liquids
flowing in through two solenoid valves, solenoid a (water control)
and solenoid b (acid control) and draining out through solenoid c
(blend outflow).
• The batch is to be controlled by timer. After required level of blend
is sensed (by L1) the mixer runs for 3 mins. by the motor. They are
mixed in ratio of 3:2. The process initiates with the drain valve
open, water and acid valves closed, mixer motor is off, and the
tank is empty.
Batch Mixing System
Batch Mixing System-Ladder diagram
 Batch Mixing System
Sequence of operations

• When start button is pressed water is filled upto L2 and it ends as L2

is closed. First of all as start is pressed output O:0/15 turns ON and
remains ON until tank is emptied.
• Rung 2 closes normally open drain valve, before timer T:4 activates.
• Rung 3 energises solenoid a until L2 doesn’t signal, once it signals
solenoid a gets de-energised.
• Then motor is turned ON and mix it for 3 mins. Similarly acid is filled
up to L3 by solenoid b, as level gets detected by L3 solenoid b de-
energises.
• Then mixer gets started and it runs for 3 minutes. After time delay of
3 mins solenoid c opens and the blend gets drained out. Once the
blend gets out completely, the process cycle restarts.
 SCADA implementation in 220 kV
substation
• 200/110/11kV Shivgiri substation Bijapur is
newly installed substation.
• Under IES project, automation of new
substation is done through Substation
Automation System (SAS) using IEC 61850.
• The functions performed by Substation
Automation (SA) system are in, general, switch
control, data monitoring, protection etc.
SCADA implementation in 220 kV substation

• In IEC 61850, these functions are broken into

low-level functions called sub-functions.
• Each sub-function is performed by the IED
installed in the substation. Each IED can
perform one or many sub functions. A set of
sub-functions is integrated together to realize
a substation automation function. These
communicate with each other through Local
Area Network in the substation.
SCADA implementation in 220 kV substation
SCADA system Network
SCADA implementation in 220 kV substation

• Specific syntax and semantics are defined for

communication between sub-functions.
• All the possible sub-functions have been standardized in IEC
61850. Information produced and required by each
substation is given in the IEC 61850 standard.

• The sub functions are assigned at three levels as shown in

Figure above:
• •Process level
• •Bay level
• •Station level
Case Studies in DCS:Iron and steel plant
• Iron and steel plant Steel making processes are
highly energy intensive and comprised of many
complex unit operations.
• Iron ore and coal need pre-processing before
feeding into a reactor, and molten metal from
different reactors needs to be carefully drawn into
a solid metal and then rolled into sheets.
• Each of these operations has a stake in the quality
of steel produced, and needs constant monitoring.
 Case Studies in DCS:Iron and Steel plant
• There are many systems monitoring and controlling
each unit operations, but there are not many system
applications available that can be used for total
integrated monitoring of plant operations that
includes energy optimization across plants,
production scheduling and a plant-wide
comprehensive reporting system that users can view
on computers, tablets or smart phones.
Steel Manufacturing and Automation
Automation in steel manufacturing is complex and
varied as there are many operations to be monitored.
 Iron and steel plant
• Crushed iron, coal and limestone from respective mines are
brought to the plant by wagons /ships.
• A stacker helps in piling the ore and the bucket wheel
reclaimer reclaims the ore and puts it onto conveyor belts
that transport the ore to the plant area.
• Iron ore fines are agglomerated into lumps in a sinter plant
• As raw coal has poor crushing strength and is volatile matter,
the coal is baked in the absence of air in coke oven batteries
to produce Coke
• Iron ore, coke and limestone are fed into a blast furnace, and
hot air from the stoves reduces iron ore to molten iron
• Molten iron is sent to a Basic Oxygen Furnace to reduce the
carbon content by treating with pure oxygen. Excess carbon
goes out as carbon monoxide, and molten steel is born.
 Iron and steel plant
• Molten steel is slowly rolled and cooled to a solid slab in
a slab caster or continuous caster
• Slabs are taken to the hot roll to mill where they are
reheated to bring them to a correct temperature for
rolling.
• They are then rolled to smaller thickness by passing over
a series of rolls, and finally made into a rolled coil of
steel. The coil is shipped or sent to a cold mill.
• The cold roll mill reduces the thickness further. Annealing
and galvanizing is done on the steel to meet the
specifications of its intended use.
• Recycled steel or scrap steel is melted in an electric arc
furnace, and joins the processes as molten steel.
Iron and steel plant
 Challenges in Steel Plant Automation
• As there many control systems in play in a steel
plant, getting a complete view of the entire
plant operations from ore handling to the
transportation of finished steel requires a
supervisory system like a Manufacturing
Execution System (MES).
• In plants that do not have an MES, data
consolidation is done manually is some form,
leading to error and inconsistencies.
 Challenges in Steel Plant Automation

• It becomes difficult for operators to collate information

from all these different sources
• Operators lose track of productivity improvement
measures and efficiency monitoring
• Key performance indicators across the plant are
cumbersome to calculate, and many times are done
manually
• Synchronized archival and playback of past data from
different units cannot be done for the complete plant,
and moreover, not all individual systems support
archival and
• playback features
 Benefits of Using DCS:
• Data collected from different sources is time stamped
and stored in a central database. The Maqplex dashboard
uses the data to present reports, plots and predictions.
• Some of typical dashboard presentations include:
• Real-time and archived graphical data plotting
• KPI indicators from sinter, blast furnace, basic oxygen
furnace and mills
• Energy and mass balance for each unit operation
• Inventory management and waste tracking
• Condition monitoring of equipment
• Video analytics using thermal imaging
• Analytics with Hadoop
• Data/graphics on mobile platforms
 Plant-Wide Data Collection

• Maqplex has data adapters to collect data

from PLC, control systems and even directly
from wireless devices or Ethernet networks.
• Data from the stacker reclaimer to the cold
mill and wagon tracking system can be
archived on Maqplex.
 Energy and Material Balance
• As 6 million Kcal are used to produce 1 ton of steel, energy
conservation plays a very important role in steel manufacturing.
• As process data across the plant is collected, energy and
material balance, especially where gaseous fuels are used, can
be computed for:
• Coke oven heating
• Blast furnace stoves
• Soaking pits
• Reheating furnace in hot strip mill energy Balance
• Reveals actual energy consumption by allocation of the actual
use of energy in each of the unit operations
• Identifies areas in which waste heat or gas are not harnessed.
• Generates energy consumption forecasts that can be used when
integrated to smart grid
 Scheduling

• Scheduling of production is challenging in a steel plant with

many dependent unit operations.
• Steel plant operation is a batch process – coke oven batteries
operate in cycles, blast furnace and BOF furnaces operate in
batches. So it is important that the batch production cycle is
optimized to ensure there is continuous output of finished
steel with minimal latency time.
• The solution fills a critical gap between the company’s
enterprise resource planning (ERP) system and the plant’s
real-time production control system (DCS) by optimizing the
daily production process.
• Maqplex is seamlessly interfaced with “R” – an open source
statistical package that has over 3,000 built-in algorithms. The
library of R algorithms gets updated periodically as they
become proven.
 Scheduling

• Scheduling can be performed at three levels:

• Hot molten steel – Blast furnace, BOF and slab caster
constraints are considered to guarantee continuous supply
of hot metal to slab casters.
• The hot strip mill scheduler considers the activities of the
slab yard, reheating furnaces and rolling mills to optimize
the production schedule
• The finishing mills scheduler optimizes the resource
utilization required for annealing and galvanization to
meet
• Requirements of the end customer required output
 Condition Monitoring of Equipment

• Online vibration analysis can be performed on

drive trains in hot strip and cold rolling mills.
• Pattern recognition algorithms are used to
detect any deviation from normal vibration
levels to alert operators
 Thermal Imaging
• Maqplex can display thermal images sent from
fixed thermal cameras and perform video analytics
to detect abnormalities.
Typical locations for thermal imaging include:
• Steel from slab caster to hot strip mill is monitored
on a thermal camera to compare the actual
temperature with the computed, pre-scheduled
temperature at various points to optimise the
process
• Exterior refractory inspections locate "hot spots"
in furnaces and process vessels, indicating thinning
or missing refractory lining or insulation
 Analytics with Hadoop
• Maqplex is integrated with Hadoop. Real-time
data collected from hundreds of sensors can be
archived in distributed servers and effectively
analysed for potential breakdown of
equipment, pattern matching to compare
current plant data with past data to check how
plant upsets were handled.
• As Maqplex can be integrated with the cloud,
performing data analytics with Hadoop and the
cloud becomes a very cost-effective and
feature-rich solution.
 Data on Mobile Platforms

• Maqplex has a ready interface to mobile

devices like tablets and smart phones.
• Graphics and plant data can be viewed, and if
need be, also controlled from mobile devices.
Internet based DCS Configuration
 Cement Plant
• The raw material and the clinker burning process are classified
as the wet process and the dry process respectively.
• Transfer of Raw Material from Quarry to Different Silos
Most of the raw materials used for making cement are
extracted through mining and quarrying.
• Those are lime , silica , alumina , and iron (ferriferous).
• Limestone is the prime constituent of cement; the major
cement plants are located near the good quality lime stone
quarries.
• First, the lime stones and quarry clays are fed to “primary
crusher house” for raw crushing.
• Then the materials are transferred to “secondary crusher
house”.
 Cement Plant
• After that the crushed materials are fed to the stock pile,
inside the stock pile there is a stacker/reclaimer which
segregates the raw material in to different stacks.
• The stacking and reclaiming systems operate independently.
Four additives: iron ore, bauxite, laterite and fluorspar are in
the stack pile to get required composition of cement.
• The conveyor C4 brings the adding the stack pile, then as per
the requirement limestone, iron ore, bauxite, laterite and
fluorspar are transferred to different silos.
• Inside each silo there are three level detectors which detect
the level of materials inside it. Figure shows the process.
 Wet Process
• In the wet process, raw materials other than plaster are
crushed to a diameter of 20 mm by a crusher and mixed in
an appropriate ratio.
• Then, with water added, the mixture is further made finer
by a combined tube mill with a diameter of 2 to 3.5 m and a
length of 10 to 14 m into slurry with a water content of 40%.
• The slurry is transferred to a storage tank then mixed to be
homogenized and sent to a rotary kiln for clinker burning.
• In the wet process, the slurry can be easily mixed but
greater energy is consumed in clinker burning due to water
evaporation.
 Dry Process

• For the dry process of manufacturing cement,

crushed raw materials are dried in a cylindrical
rotary drier, mixed, ground and placed in
storage tanks then sent to a rotary kiln for
clinker burning.
• For the wet process, plant construction cost is
low and products are high-quality: but the dry
process consumes less energy and its running
cost is lower therefore it is preferred.
 Actuators and Sensors

• The sensors connected to the process are simple

• Examples of traditional discrete (switch) sensors
include the limit switch, temperature switch,
pressure switch, flow switch, level switches, photo
eyes, and input devices such as push buttons and
pilot lights.
• Switches are digital devices that provide a simple
contact which indicate their state of on or off.
• Instruments such as thermocouples or pressure
transmitters are analog devices capable of providing
a continuous range of measurement readings from
0 to 100% of range and reporting their data with a
 Actuators and Sensors

• As for outputs, motor starters and solenoids are generally

digital devices, opening or closing depending on whether
they are fed with power from a system output.
• These intelligent instruments have microprocessors allow
for functionality beyond the basic measurement of the
primary variable. They monitor and report additional
process variables, support multiple configurations,
monitor and report.
• Motor starters now monitor various aspects of the
operator of the motor. They report current, phase voltage,
motor power, motor power factor, and running hours and
can tell exactly why a trip occurred (i.e., overload, ground
fault, or short circuit?).
 Intelligent Devices and Subsystems

• Intelligent subsystems are available with controller

cards that will reside in the same card rack as the PLC.
• These include scales and load cell controllers, radio
frequency tag readers, motion controllers, and forms
of communication interfaces, from basic RS-232 to
any network protocols.
• Actuators with small amounts of I/O are equipped
with the ability to communicate over I/O networks.
For example intelligent valve controllers that will
reside on the I/O network.
 Automation of Process

• Material Transfer from Different Silos to Homo- geneous

• Silo Normally there are various types of lime stone quarry so the
quality of limestone differs.
• In order to get homogeneous mixture those four additives with
required percentage, as suggested are mixed with the lime stone.
• This is done using a RBF placed in each silo and with the help of
conveyor C15. The RBFs and corresponding conveyors (i.e.C10,
C11, C12, C13, C14) will move with a speed to maintain the
actual ratio of the five components i.e. user defined.
• C15 transferred the raw materials to the vertical roller mill
(VRM) as the raw materials should be finish-ground before being
fed into the kiln for clinkering. This process is done in the VRM.
 Automation of Process

• The raw materials are simultaneously dried using hot air in

order to get good quality cement.
• The Hot air is comes from conditioning tower or from grate
cooler.
• Hot air along with the dust is introduced in the electrostatic
precipitator (ESP).
• Then the exhausted air existed in the air, through chimney
with the help of ID Fan. After grinding, the materials
are transferred to homogeneous silo with the help of bucket
elevator (BE).
• There is a screen vibrator (SV) in between the BE and
homogeneous silo for Proper blending and to sort-out the
large granules. Then the large granules are feedback to the
VRM by Feedback conveyor C18.
 Automation of Process

• Bucket elevator, screen vibrator and conveyor

C16 are used to transfer the raw materials to
Homogeneous silo.
• The large granules are fed back to the VRM by
conveyor C18, to remove the dust particles,
exhausted gas produced during cement making is
sent to electrostatic precipitator (ESP).
• The gas is sent to the co-generation power plant
for captive power generation, then the exhausted
clean gas is removed by fan through chimney and
the fine dust is fed back to the homogeneous
silo.
 Pyroprocessing and Finish Milling
• The raw mix is heated up to (1600-1700) °C to produce Portland
cement clinkers.
• Clinkers are created from the chemical reactions between the
raw materials.
• The pyroprocessing takes place in a kiln. It is basically a long
cylindrical pipe which rotates in a horizontal position having
(1600-1700) °C temperature. The clinker is sent to the cooling
section for cooling to room temperature.
• The cooled clinker is then transferred to the storage silo. The
Clinkers are hard, gray, spherical nodules with diameters ranging
from 0.32 - 5.0 cm.
• To reduce the size and to impart special characteristics to the
finished cement, the clinker is ground with other materials such
as 5% gypsum and other chemicals which regulate flow ability.
• The finished cement is finally transferred to the packaging
section.
 Plant wide control:

• Plantwide control can be defined as the

ensemble of control loops needed to operate
an entire process and achieve its design
objectives .
• considers plantwide control as the control
philosophy of the overall plant with emphasis
on the structural decisions such as placement
of measurements, selection of manipulated
variables and decomposition of the overall
problem into smaller sub-problems.
Plant wide control
 Plant wide control:

• The plant-wide control problem is a

formidable and almost hopeless combinatorial
problem, involving a large number of discrete
decision variables
• The overall plant objective, which is to
minimize cost, that is, maximize profit, while
satisfying operational constraints imposed by
the equipment, marked demands, product
quality, safety, environment and so on.
 Real-World Control

• The main simplification is to deconstruct the overall

control problem into many simple control problems. This
deconstruction involves two main principles:
• Decentralized (local) control. This "horizontal
deconstruction" of the control layer is mainly based on
separation in space, for example, by using local control of
individual process units.
• Hierarchical control. This "vertical deconstruction" is
mainly based on time scale separation.
• We generally have more centralization as we move
upwards in the hierarchy. Such a hierarchical (cascade)
deconstruction with layers operating on different time
Real-World Control
 Real-World Control

• The upper three layers deal explicitly with economic

optimization, and are not considered here.
• There are two lower control layers, where the main
objective is to track the setpoints specified by the upper
layers.
• A very important structural decision, probably more
important than the controller design itself, is the choice
of controlled variables (CVs) that interconnect the layers.
• More precisely, the decisions made by each layer (are
sent as setpoints for the CVs to the layer below.
 A Plant-Wide Control Procedure:

• Decision 1—Select "economic" (primary) controlled

variables (CV1) for the supervisory control layer (the
setpoints CV1 link the optimization layer with the control
layers);
• Decision 2—Select "stabilizing" (secondary) controlled
variables (CV2) for the regulatory control layer (the
setpoints CV2 link the two control layers);
• Decision 3—Locate the throughput manipulator (TPM);
• Decision 4—Select pairings for the stabilizing layer, that is,
pair inputs (valves) and controlled variables (CV2). By
"valves," I mean original dynamic manipulated variables.
Overview of Plant-Wide Control Procedure—Top Down:

• Step 1—Define operational objectives

(economic cost J to be minimized) and
constraints.
• Typical operational constraints are minimum
and maximum values on flows, pressures,
temperatures and compositions.
• For example, all flows, pressures and
compositions must be non-negative.
Overview of Plant-Wide Control Procedure
—Top Down:
• Step 2—Identify degrees of freedom (MVs) and
optimize the operation for important
disturbances (offline analysis) to identify
regions of active constraints.
• Step 3—Selection of primary controlled
variables (CV1) (Decision 1).
• Step 4—Select location of throughput
manipulator (TPM) (Decision 3).
Inventory Control
 Plant-Wide Control Overview–Bottom Up

• Step 5—Choose structure of regulatory (stabilizing) layer.

The purpose of the regulatory layer is to stabilize the
plant, preferably using a simple control structure with
single-loop PID controllers.
• Step 6—Select structure of supervisory control layer.
• Step 7—Select structure of (or need for) optimization
layer (RTO).
• Implementation:
• Alternative 1—"Advanced single loop control"
• Alternative 2—Multivariable control (usually MPC).
 Cloud based Automation:

• Cloud automation is a broad term that refers to

the processes and tools that an organization uses
to reduce the manual efforts associated with
provisioning and managing cloud computing
workloads.
• IT teams can apply cloud automation to private,
public and hybrid cloud environments.
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