INDUSTRIAL CONTROL

SYSTEMS &
COMPUTER PROCESS CONTROL

PRESENTED BY:
1 Kartik Ayyar (PRN 08020771001)
Arpit Desai (PRN: 08020771002)
Abhishek Kumar (PRN 08020771003)
Deepak Kumar (PRN: 08020771004)
INDUSTRIAL CONTROL - DEFINED

The automatic regulation of unit operations and

their associated equipment as well as the
integration and coordination of the unit operations
into the larger production system
 Usually
refers to a manufacturing operation
 Can also apply to material handling or other
equipment

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INDUSTRIAL CONTROL SYSTEMS

 Process Industries vs. Discrete

Manufacturing Industries
 Continuous vs. Discrete Control
 Computer Process Control

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CONTINUOUS AND DISCRETE

VARIABLES AND
PARAMETERS

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 DISCRETE VARIABLES AND
PARAMETERS

Categories:
 Binary - they can take on either of two possible
values, ON or OFF, 1 or 0, etc.
 Discrete other than binary - they can take on
more than two possible values but less than an
infinite number of possible values
 Pulse data - a train of pulses that can be counted

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CONTINUOUS CONTROL
 Usual objective is to maintain the value of an
output variable at a desired level
 Parameters and variables are usually
continuous
 Similar to operation of a feedback control
system
 Most continuous industrial processes have
multiple feedback loops
 Examples of continuous processes:

 Control of the output of a chemical reaction

that depends on temperature, pressure, etc.
 Control of the position of a cutting tool6
relative to workpart in a CNC machine tool
TYPES OF CONTINUOUS PROCESS
CONTROL

 Regulatory control
 Feed forward control

 Steady-State optimization

 Adaptive control

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REGULATORY CONTROL

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FEEDFORWARD CONTROL
COMBINED WITH FEEDBACK
CONTROL

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STEADY STATE (OPEN-LOOP)
OPTIMAL CONTROL

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 ADAPTIVE CONTROL OPERATES IN A
TIME-VARYING ENVIRONMENT
 The environment changes over time and the
changes have a potential effect on system
performance
 Example: Supersonic aircraft operates
differently in subsonic flight than in supersonic
flight
 If the control algorithm is fixed, the system may
perform quite differently in one environment than
in another
 An adaptive control system is designed to
compensate for its changing environment by
altering some aspect of its control algorithm to 11

achieve optimal performance

ADAPTIVE CONTROL SYSTEM

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TWO BASIC REQUIREMENTS FOR
REAL-TIME PROCESS CONTROL
1. Process-initiated interrupts
 Controller must respond to incoming signals
from the process (event-driven changes)
 Depending on relative priority, controller
may have to interrupt current program to
respond
2. Timer-initiated actions
 Controller must be able to execute certain
actions at specified points in time (time-
driven changes)
 Examples: (1) scanning sensor values, (2)
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turning switches on and off, (3) re-
computing optimal parameter values
OTHER COMPUTER CONTROL
REQUIREMENTS

1. Computer commands to process

 To drive process actuators
 System initiated events - communications
between computer and peripherals
 Program initiated events - non-process-related
actions, such as printing reports
2. System- and program-initiated events
3. Operator-initiated events – to accept input from
personnel
 Example: emergency stop
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 FORMS OF COMPUTER PROCESS
CONTROL

1. Computer process monitoring

2. Direct digital control (DDC)
3. Distributed control systems
4. Numerical control and robotics
5. Programmable logic control
6. Supervisory control

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APPLICATION

 Continuous or semi-continuous production

operations involving materials such as chemicals,
petroleum, foods, and certain basic metals.
 In these operations the products are typically
processed in gas, liquid, or powder form to
facilitate flow of the material through the various
steps of the production cycle.

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 Measurement of important process variables such
as temperature, flow rate, and pressure,
 Execution of optimizing strategy.

 Actuation of devices as valves, switches, and

furnaces that enable the process to implement the
optimal strategy

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COMPUTER PROCESS
MONITORING

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Batch Furnace commissioned by Bickley19
Inc., USA
Nominal temperature: up to 900’C
 (A) PROCESS MONITORING, (B) OPEN-
LOOP CONTROL, AND (C) CLOSED-LOOP
CONTROL

(a)

(b)

(c)

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COMPONENTS OF A
DIRECT DIGITAL CONTROL SYSTEM

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 DISTRIBUTED CONTROL SYSTEMS
(DCS)

 Multiple microcomputers connected together

to share and distribute the process control
workload
 Features:
 Multiple process control stations to control
individual loops and devices
 Central control room where supervisory control is
accomplished
 Local operator stations for redundancy
 Communications network (data highway)

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DISTRIBUTED CONTROL SYSTEM

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 DCS ADVANTAGES
 Can be installed in a very basic configuration, then
expanded and enhanced as needed in the future
 Multiple computers facilitate parallel multitasking

 Redundancy due to multiple computers

 Control cabling is reduced compared to central

controller configuration
 Networking provides process information
throughout the enterprise for more efficient plant
and process management

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25
Computerized Process Control impro
 NUMERICAL CONTROL AND
ROBOTICS

 Computer numerical control (CNC) – computer

directs a machine tool through a sequence of
processing steps defined by a program of
instructions
 Distinctive feature of NC – control of the position of
a tool relative to the object being processed
 Computations required to determine tool trajectory
 Industrial robotics – manipulator joints are
controlled to move and orient end-of-arm
through a sequence of positions in the work
cycle
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PLASTIC INJECTION MOLDING MACHINE BLD 280 
CNC USE FOR…
A) MULTIPLE HYDRAULIC CORE PULLING
B) CYLINDER TRANSDUCER CONTROL
C) MULTIPLE OPTIONS OF ...

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29
ROBOTS

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PROGRAMMABLE LOGIC CONTROLLER
(PLC)

Microprocessor-based controller that executes a

program of instructions to implement logic,
sequencing, counting, and arithmetic functions to
control industrial machines and processes
 Introduced around 1970 to replace
electromechanical relay controllers in discrete
product manufacturing
 Today’s PLCs perform both discrete and continuous
control in both process industries and discrete
product industries
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PLC

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BLOW MOLDING MACHINE

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PONGRASS MODEL 32H
32MM CAPACITY MANDREL TUBE BENDING
MACHINE
PLC CONTROL USE FOR RISING CLAMP & LENGTH STOP BAR

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SUPERVISORY CONTROL

In the process industries, supervisory control

denotes a control system that manages the
activities of a number of integrated unit
operations to achieve certain economic
objectives
In discrete manufacturing, supervisory control is
the control system that directs and coordinates
the activities of several interacting pieces of
equipment in a manufacturing system
 Functions: efficient scheduling of production,
tracking tool lives, optimize operating parameters
 Most closely associated with the process 35
industries
SUPERVISORY CONTROL
SUPERIMPOSED ON PROCESS LEVEL
CONTROL SYSTEM

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Introduction to SCADA
 A subset of PCS systems that manage
systems over very large geographic areas
are typically referred to as Supervisory
Control and Data Acquisition systems or
SCADA systems. SCADA systems make up
the critical infrastructure associated with
electric utilities, water and sewage treatment
plants, and large-scale transportation
systems like interstate rail.
 Supervisory Control and Data Acquisition
systems are basically Process Control
Systems (PCS), specifically designed to
automate systems such as traffic control, 37
power grid management, waste processing
etc.
Aspects of SCADA
 Most often, a SCADA system will
monitor and make slight changes to
function optimally
 SCADA systems are considered closed
loop systems and run with relatively
little human intervention
 One of key processes of SCADA is the
ability to monitor an entire system in
real time
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SCADA systems in INDIA
 SCADA systems are still to come into
widespread infrastructural use in India
 Now, they are being used primarily for
automation in industrial production, and to
some extent for specialized process control
 Ranbaxy Labs and Voltas are two of the
companies in India using SCADA systems for
controlling a variety of processes
 Other examples of pseudo-SCADA usage also
observed
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Components of SCADA
 The basic structure of PCS systems is made
up of a wide range of components and
several different communication protocols.
The operation of such a large and diverse
infrastructure requires an extensive network
of electronic devices, communications, and
control and monitoring systems, such as:
 Field Devices

– Remote Terminal Units (RTU)

– Programmable Logic Controllers (PLC)
– Intelligent Electronic Devices (IED)
– Programmable Automation Controller (PAC) 40
Components of SCADA
 Management systems to monitor and control
field equipment
– Human Machine Interface (HMI)
– SCADA Controller or Real Time Processor
– Historian
 Communications

– Ethernet, Wireless, Serial

– Modbus, DNP3
– ICCP, OCP

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Construction of SCADA
 SCADA systems are primarily control
systems. A typical control system consists of
one or more remote terminal units (RTU)
connected to a variety of sensors and
actuators, and relaying information to a
master station.

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A typical 3-tiered approach to SCADA
systems

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Sensors & Actuators
 Sensors perform measurement, and
actuators perform control.
 Sensors get the data (supervision and
data acquisition)
 Actuators perform actions dependent
on this data (control).
 The processing and determination of
what action to take, is done by the
master control system (i.e. SCADA).

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RTU/ PLC
 Remote Terminal Units (RTUs) connect
to sensors
 Convert sensor signals to digital data
and sending digital data to the
supervisory system
 Operate actuators as per control
signals received/ generated
 Provide local processing capability
 Applications that had previously been
programmed at the central master
station can now be programmed at the 45

RTU.
Master Station
Master stations have two main
functions:
• Periodically obtain data from
RTUs/PLCs (and other master or sub-
master stations)
• Control remote devices through the
operator station
Other duties include trending, alarm
handling, logging and archiving, report
generation, and facilitation of
automation. These duties may be
distributed across multiple PCs, either 46
standalone or networked.
Segregation of functions of a SCADA
system into a functional representation

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Data Flow
 Data acquisition begins at the RTU or PLC
level and includes meter readings and
equipment status reports that are
communicated to SCADA as required
 Data is then compiled and formatted in such
a way that a control room operator using the
HMI can make supervisory decisions to adjust
or override normal RTU (PLC) controls
 Data may also be fed to a Historian, often
built on a commodity Database Management
System, to allow trending and other
analytical auditing.
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SCADA of Cooling System

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Applications of SCADA
 Electric power generation, transmission &
distribution (USA)
 Water supply, sewage & drainage (UK &
Netherlands)
 Buildings, facilities & environment

 Manufacturing (Robots-Toyota, Porsche, VW)

 Traffic Signals (USA)

 Mass transit (Rail crossing gates, USA)

 Suburban Railway system (Mumbai, Western

Railway)
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Bibliography
 SCADA-IBM whitepaper
 Whitepaper on SCADA systems security-Arjun
Venkatraman
 SACAD-A. Daneels-CERN, Geneva

 www.wikipedia.org

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Thank You

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