Industrial Automation and Control

(EE60034/EE40016)
Introduction

Prof. Alok Kanti Deb

Department of Electrical Engineering, IIT Kharagpur
alokkanti@ee.iitkgp.ac.in
Industrial Automation and Control (EE60034/EE40016) • L-T-P Credits-4
• 3-1-0

Faculty: Prof. Alok Kanti Deb Class Timings: E Evaluation:

slot Quiz, Homework & Assignment
WED: E1 (12 PM-1 PM);
3
THU: E2 (11 AM-12 PM);
FRI : E3 (9 AM-9:55 AM) E4 (10 AM-10:55 AM);
Research Overview Thermo-fluidic systems having faster dynamics (SI Engine)
Intake I
θ = 540° θ = 0°
H exHaust C θ = 180°

Compression
Expansion E θ = 360°
General Motors, USA ADA, Bangalore

Solid-Gas mixed flow (Coal Mill) Solid-Gas mixed flow with combustion (Sintering)

DeiTY, Govt. of India

25kV line Phase II Plan Current Project Scope

RDSO, Lucknow
Transformer Converter and Controller Induction Load
Motor
Modeling, Estimation, Diagnosis
 User PC (2) User PC (3)

User PC (1)
User PC (n)

Browser
(Mozilla
http://vlabs.iitkgp.ac.in Firefox,
Internet
explorer)
TCP/IP, CGI.

Web server
(Java,PHP, XML)

Analog Signals, Network and

Measurement Virtual Laboratory
(MoE, Govt. of India)

Robo Soccer (http://krssg.in)

 Syllabus
Benefits and Impact of Automation on Manufacturing and Process Industries;
Architecture of Industrial Automation Systems;
Process Control: P-I-D Control, Controller Tuning
Special Control Structures: Feedforward and Ratio Control, Predictive Control,
Control of Systems with Inverse Response, Cascade Control, Advanced Control
Schemes.
Process and Instrumentation Diagrams;
Sequence Control: PLCs and Relay Ladder Logic, Scan Cycle, RLL Syntax,
Structured Design Approach, Advanced RLL Programming, Hardware
environment.
Control of Machine tools: Introduction to CNC Machines,
Analysis of a control loop
Flow Control Valves
Hydraulic Actuator Systems: Components, Proportional and Servo Valves
Pneumatic Control Systems: System Components, Controllers
Electric Drives: Energy Saving with adjustable Speed Drives, AC and DC
Adjustable Speed Drives, Step motor Drives, Servo Drives
Communication and Networking of Sensors, Actuators and Controllers;
Supervisory Production Control and Management Systems; Integration with
Management and Enterprise Systems 5
 Syllabus
Module A: Introduction; Architecture of Industrial Automation
Systems.
Module B: Special Controller Structures
Module C: Programmable Logic Controllers
Module D: Control of Machine Tools
Module E: Hydraulic Actuator Systems
Module F: Pneumatic Control Systems
Module E: Electric Drives
Module G: Communication and Networking of Sensors,
Actuators and Controllers

6
 Introduction
• Science and Technology of Process Control that includes control of
chemical and petrochemical plants, oil refineries, iron and steel plants,
power plants, cement mills, paper mills, pharmaceuticals, food and
beverages, water and wastewater treatment plants, oil and gas fields
etc.
• Automation is viewed as a versatile tool for solving critical problems of
process and production control, plant supervision and management as
well as solving accompanying financial and organizational problems.

8
 Aims of Plant Automation
Main flows in an industrial process:
• Material
• Energy
• Information

Basic Objective of Plant Automation is to identify the information flow, and to

manipulate the material and energy flows of a given process in a desired and
optimal way.
 Approaches to Automation
Partial Plant Automation
• Removes bottlenecks within an existing plant, and the can gradually be
extended to complete plant automation without total plant shutdown.
Bottom up Approach

Complete Plant Automation

• Suitable for new plants to be installed.
Top down Approach
 Recent Trend: Integrated Plant Automation

Functionally integrates process control, supervisory and

commercial computers. Here the automation aims are

Production Transparency increase

Expedient Commissioning

Market Analysis and Product Planning

Automation of Office work.

 Classical Approaches to Plant Automation
Direct Manual Process Control

SENSORS ACTUATORS

PROCESS

20’s – ON/OFF control in process industry

Late 20’s – Proportional control

30’s – Regulators with PID action.

Zeigler-Nichols rules (1942)
 Modular Presentation of a Control Loop
Parameters

SET POINT VALUE CONTROLLER

TRANSMITTER TRANSMITTER

SENSORS ACTUATORS

PROCESS

Large Production Units

Co-ordination of Plant
Large Number of Measurements Operators in Central
Control Room
Interaction between variables
 Computer based Plant Automation
50’s – Sampled Data Control System

Digital Control becomes an alternative to analog control

Initial Digital computers were large, slow, expensive and unreliable. Used
only for Supervisory mode.
OPERATOR GUIDANCE MODE SET POINT CONTROL MODE

PROCESS CONTROL COMPUTER PROCESS CONTROL COMPUTER

SENSORS ACTUATORS SENSORS ACTUATORS

PLANT PLANT
 Early 60’s: Digital computer for process control in chemical industries
(Direct Digital Control, DDC)

PROCESS CONTROL COMPUTER Benefits

Easy Configuration
SPV CONTROL
ALGORITHM Easy Controller Parameter tuning
ADC DAC Realizing Advanced Control algorithms
Data Acquisition

Drawbacks
Low fail Safety
SENSORS ACTUATORS
Higher Investment
PLANT

T – sampling period k – selected sampling interval

 T k
ek   ek  1 
u k   k p ek    e   TD 
 Ti  0 T 
15
P I D
 Dual Computer System for DDC

ACTIVE COMPUTER STANDBY COMPUTER

PROCESS
PROCESS
INTERFACE INTERFACE

SENSORS ACTUATORS

PLANT

Drastic reduction in repair and maintenance time

A Power Plant Control room A Modern Control room

An Aircraft Cockpit
Air Traffic Control Room17
 Electrical Grid Control

Remotely managed Substation

Load control in NE India 18
 Hierarchical Automation System

CENTRAL COMPUTER

INTERMEDIATE INTERMEDIATE
INTERMEDIATE
COMPUTER 1 COMPUTER 2 COMPUTER 3

μC μC μC μC
μC μC

PLANT UNIT 1 PLANT UNIT 2 PLANT UNIT 3

COAL HANDLING PLANT WATER TREATMENT PLANT BOILER

PLANT

19
 Hierarchical Computer System of Company
Remote COMPUTER Commercial Production
Terminals
CENTRE Computers Scheduling Level
Level 4

CENTRAL COMPUTER Production Control Level

Level 3

INTERMEDIATE INTERMEDIATE Plant Supervisory Level

COMPUTER 1 COMPUTER 2 Level 2

μC μC μC μC
Direct Control Level
Level 1

PLANT UNIT PLANT UNIT Field Level

Level 0
PLANT
Level 1:Direct Process Control Level 2:Plant Supervisory Control Level 3:Production Scheduling & Control
• Data Acquisition • Performance Monitoring • Production Despatching
• Data Check • Plant Co-ordination • Inventory Control
• Reporting • Optimal Process Control • Production Supervision
• Plant Monitoring • Adaptive Control • Production Re-Scheduling
• O/L & C/L Control 20
• Failure Detection • Production Reporting
 Level 4: Plant Management
• Market and Customer Analysis
• Production Planning
• Order and Sales Statistics
• Order Despatching
• Financial Surveys
• Price Calculation
 System Elements
1) Field Stations
Lowest hierarchical level distributed and placed in the field.
Collect and pre-process analog and digital signals
Monitor and log the alarm messages
Perform open-loop and closed-loop control functions.

Analog Inputs: 0-20mA (4-20mA)

0-5V (1-5V) and 0-10V (1-10V)
Analog Outputs: 0-20mA (4-20mA)
0-5V (1-5V)
Binary Inputs: 0/10mA, 0/100mA, 0/200mA, 0/300mA, 0/24V

Binary Outputs: 0/100mA, 0/200mA, 0/24V

Special Digital Inputs: Timers, Counters, Dosing Counter

Special Digital Outputs: Stepper Motor Output

2) Intermediate Stations
State observation of process variables.
Calculation of reference values for control loops at “Lower” level.

Tracking of order processing

Efficiency Analysis

Data exchange with “Higher” level station

3) Central Computer Station

Enables Centralized Plant Monitoring
Direct Operating of Plant Instrumentation
System Diagnostic Services

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4) Monitoring and Command Facilities
a) Screen Partition Message Area
Overview Area
Main display area
Operator Instruction Area

b) Display Organization
c) Standard Displays Plant overview display
Unit of Area Overview
Group Display
Loop Display
Alarm Survey
Trend Display
d) User Defined Display Plant Mimic Diagram
Batch Control Diagram
5) Operating Keyboards and Control Panels
Pushbuttons Switches Binary Indicator Digital Display

24
 Communication Links
Data communication between individual system parts.
Plant data has to be exchanged between intelligent monitoring and control
stations, that need a bus or data highway

Due to hierarchical nature of the systems, different types of buses and data
communication networks will be needed.

4 different hierarchical levels of communication.

1) Field Level: Classical Plant Instrumentation

2) Process Control Level

3) Supervisory Level Different Buses

4) Management Level Honeywell: TDC 2000

Foxboro : FOXNET

Siemens: TELEPERM M 25
 SOFTWARE
1) Real Time Operating System

System Software which arbitrates and controls the resources of a computer

system such as processors, memories, mass storage devices and input
and output facilities.

• Processor Time Management

• Memory Management
• Device Management
• Database Management
• Process Interrupt Handling

2) Communication Software

For data transfer between individual system or database parts

Transfer takes place on the buses and LANs.

26
3) Process Oriented Language

For logic controllers, Ladder diagram oriented languages exist

Frequently used languages in automation are

BASIC
PASCAL
FORTRAN
Ada
PEARL (Process and Equipment Automation Real Time Language)
C
Some Special Purpose Languages
TELEPERM M - SIEMENS

MOD 300 (Taylor Instruments) – Taylor Control Language (TCL)

4) Application Software

Dedicated Software for some particular application

27
5) Knowledge Based Software

AI methods have been applied to solve problems that cannot

algorithmically defined. eg.

Monitoring and Supervision

Failure Diagnosis
Adaptive and Self Tuning Control

Knowledge based software superimposed on the conventional software can

substantially enhance the intelligence of the system.

AI Programming languages

LISP : List Processing

PROLOG – Programming in Logic

Fuzzy Logic

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 V001
FROM
PREVIOUS
PROCESS TANK Sequence Control for a
LA Simple Cooling Process
COOLING 01
WATER V002

LA
02

SEQUENCE TABLE 1 2 3 4 5
TA
01
V003 PB01 START BUTTON
√
LA01 HI LIMIT SW
√
LA02 LO LIMIT SW
√ √
TA01 TEMP SW
√
V001 INJECTION VALVE χ
√
V002 COOLING VALVE
√ χ
V003 DISCHARGE VALVE χ √ χ
NEXT THEN
STEP
2 3 4 5 1
 Algorithms
Mathematical Expressions and Procedures on which the application software is
based.

 u1 y1 
 u2 y 2  OUTPUTS
INPUTS  F(U,P) 

 u  y m 
 n

p1 p 2 pk

PARAMETERS

30
 Closed Loop Control Algorithms

et  u t 
SPV +- PID SYSTEM yt 

Three term (PID) controller

 det  
t
1
u t   k c et    et dt  TD 
 T I 0 dt 
Proportional Gain Reset Time Rate Time

kc
- Integral Gain k cTD - Derivative Gain
TI
Some manufacturers calibrate controllers as proportional band (PB)

10 % PB – A 10% change in controller input causes a full-scale (100%)

change in controller output
100
kc  31
PB
Digital implementation of PID control algorithms is based on some discrete
measured process variables available only at some equidistant time instants,
t0, t1, … , tn of sampling.
Derivatives → Differences Integrals → Sums
 det  
t
1
u t   k c et    et dt  TD 
 T I 0 dt 
 1 
Taking the derivative, u t   k c et   et   TD et 
 TI 
Derivatives can be approximated at each sampling point kt by the
corresponding sampled value of u(t) and e(t)
u k   u k  1 ek   ek  1
u k   e
 k  
t t
ek   ek  1 ek   2ek  1  ek  2
ek   
t t 2
u k   u k  1  ek   ek  1 1 ek   2ek  1  ek  2
 kc   ek   TD 
t   t T I  t 2

 t TD   2T  T 
u k   u k  1  k c 1   ek   k c   1  D ek  1  k c  D ek  2
 TI t   t   t 
u k   u k  1  d 0 ek   d1ek  1  d 2 ek  2
Position version of PID algorithm
 t TD   2T  T 
d 0  k c 1    d1  k c   1  D  d 2  kc  D 
 TI t   t   t 
Defining, u k   u k   u k  1
 d 0 ek   d1ek  1  d 2 ek  2
u k   u k  1  u k  Velocity type PID algorithm

Control Law can also be obtained by direct digitization

 1 k
ek   ek  1 
u k   k c ek    ei t  TD 
 TI i 0 t 
Ideal Non-interacting PID Controller
(3 controller terms are mutually independent)
 TD' s  1   1 
U s   k  '
'
c 1  ' 
0.05    0.3

 DT s  1  T I s

Interacting PID Controller

 Optimum Sampling Rate
Optimum sampling time t to be selected depends on control algorithms applied,
process dynamics and on signals to be sampled.
Generally sampling time is chosen between 1/6 and 1/3 of the smallest time
constant of the system.

Liquid flow control: 1 to 1.5s

Pressure control : 3 to 5s

Temperature control: ~ 20s

Adjustment Features of Industrial Controllers
uM
rL
u PROCESS
uC y
r e
+ PID
PID Control Unit MANUAL/AUTOMATIC
re
 Controller Tuning
I) Determination of Ultimate Gain and Period
i) Use only P control (under closed loop)
ii) Increase P gain in steps.
After each increase, disturb the loop by introducing small step change in set-
point and observe the response
When the amplitude of the oscillations remains approximately constant, ultimate
controller gain has been reached.
Record kcu
iii) Measure the period from trend recording. This parameter is Tu

II) Tuning by Quarter-Decay Ratio Response

i) As in (I)
ii) As in (II)
Stop at that value of P gain, where for a step change,
each oscillation has an amplitude that is 1/4th of the
previous oscillation
Note kcu and Tu 35
 CONTROLLER Kc TI TD

P 0.5kcu - -
PI 0.45kcu Tu/1.2
PID (Noninteracting) 0.75kcu Tu/1.6 Tu/10

PID (Interacting) 0.6kcu Tu/2 Tu/8

36
 iii) Zeigler-Nicholls Tuning based on Process Reaction Curve

Put the controller in “MANUAL”.

A step change u in the control signal u(t) is applied to produce a
consequent change y(t) in the process output

u(t) Model to characterize the

process reaction curve

u
Y s  Ke  D s
 G s  
t U s  s  1
y(t) S curve y ss
K = steady state gain =
u
y ss
 D  Effective process dead time
t
 Effective time constant
 y(t) S curve
Tangant Method

y ss

D  t

y(t) S curve Tangant and Point Method

0.632y ss
y ss

D  t
Two Point Method

y(t) S curve t1  Time when y(t)=0.283yss

0.632y ss t 2  Time when y(t)=0.632yss
y ss 3
0.283y ss   t 2  t1 
2
t1 t2 t  D  t2   38
 CONTROLLER Kc TI TD

P  - -

K D
PI 0.9 -
3.33 D
k D
PID (Noninteracting) 1.5
2.5 D 0.4 D
k D
PID (Interacting) 1.2
2 D 0.5 D
k D
 Tuning Rules for Digital Controller
ek uk ut
rk 
Co+ntrol Process yt
+
 D/A
Algorithm

A/D
Reconstructed signal
y(t) Continuous signal

t
T 2T 3T 4T 5T 6T

During reconstruction, approximately one-half of the sample interval is delayed

T
Corrected dead time  CD   D
2
No correction of tuning formula based on kCU and Tu
40
4
1

References

1) D. Popovic and V. P. Bhatkar, “Distributed Computer Control for Industrial

Automation,” Marcel Dekker, 1990.
2) M. Gopal, “Modern Control Design" TMH.
Thank You

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