Process Automation

Introduction
 Automation
 Derived from Greek words “Auto”(self)
and “Matos” (moving)

 Automation is a set of technologies

that results in operation of machines
and systems without significant
human intervention and achieves
performance superior to manual
operation
Automation & Control
 Automation Systems may include Control Systems
but the reverse is not true.

 Control systems: ensures set points tracking.

 Automation Systems: includes more functionality

⚫ computing set points for control systems
⚫ monitoring system performance
⚫ plant startup or shutdown
⚫ equipment scheduling etc.
Architecture of Industrial Automation
Systems

 Sensor System

 Control System

 Actuator Systems
Sensor Systems

Actuator Systems
Industrial Control Systems

 Continuous Control
 Sequence / Logic Control
 Supervisory Control
 Production Control
Continuous Control
Sequence / Logic Control

 These control systems operate by

turning on and off switches, motors,
valves, and other devices in
response to operating conditions
and as a function of time.
Supervisory Control

 Set point computation

 Performance Monitoring /
Diagnostics
 Start up / Shut down / Emergency
Operations
 Control Reconfiguration / Tuning
 Operator Interface
Production Control

 Process Scheduling
 Maintenance Management
 Inventory Management
 Quality Management
Industrial Automation vs. Industrial
Information Technology
Role of automation in industry
 Types of Automation Systems
⚫ Fixed Automation
 High volume production with dedicated equipment
- Distillation Process, Conveyors
⚫ Programmable Automation
 changeable sequence of operation/ machine
config. - Steel Rolling Mills, Paper Mills
⚫ Flexible Automation
 Human operated computer controlled processes.
loads/unloads required tools - Multi purpose CNC
machines, Automated Guided Vehicles
⚫ Integrated Automation
 complete automation with all processes
functioning under computer control
What kind of automation would you
recommend for manufacturing

 Textile  Programmable

 Light bulbs  Fixed

 Printing  Flexible

 Cement  Programmable

 Pharmaceuticals  Flexible
Automation Pyramid
 Sensors and Actuators Layer: signals derived from
processes for analysis and decisions and hence control
signals can be applied to the processes.
 Automatic Control Layer: This layer consists of
automatic control and monitoring systems, which drive
the actuators using the process information given by
sensors.
 Supervisory Control Layer: This layer drives the
automatic control system by setting target/goal to the
controller. Supervisory Control looks after the
equipment, which may consist of several control loops.
 Production Control Layer: This solves the decision
problems like production targets, resource allocation,
task allocation to machines, maintenance management
etc.
 Enterprise control layer: This deals less technical
and more commercial activities like supply, demand,
cash flow, product marketing etc.