Industrial Automation

Learn the current and leading-edge research on SCADA security

Vikalp Joshi, Vikalp Joshi, Manoj Singh Adhikari, Raju Patel, Rajesh Singh, Anita Gehlot

• Publisher: BPB Publications
• Year: 2019
• eBook ISBN: 9789388511735
• Topic: Technology & Engineering
• Subtopic: Civil Engineering
• Index: Technology & Engineering

Explores the components of automation Key Features

• The book provides basic concepts of industrial automation
• It is beneficial for engineering students having interest in the field of automation
• The unique feature of this book is the inclusion of multiple-choice questions to help prepare students for competitive exams and interviews
• It covers the roles of SCADA and PLC in automation

Description
Automation is a process to perform controlled activities with minimal human assistance. A lot of research is being carried out in this field. Students are also opting for research and studies in automation. The objective of this book is to explain the role of industrial automation. This book will help engineering students to understand the basic concepts of industrial automation. The unique feature of this book is the inclusion of multiple-choice questions to help prepare students for competitive exams and interviews. Automation has grown into a vast field and this book will be helpful to understand it comprehensively. What Will You Learn

• SCADA and its application in Industrial Automation
• Supervisory and Control Functions
• SCADA Communication Network
• Human Machine Interface
• SCADA in EMS
• Programmable Logic Controller
• Automation Software
• Field Instrumentation Device
• Utility Information System

Who This Book Is For
Engineering students having research interests in the field of automation. Table of Contents

• SCADA in Industrial Automation
• Supervisory and Control Functions
• SCADA Communication Network
• Human Machine Interface
• SCADA in EMS
• Programmable Logic Controller
• Applications of SCADA
• Automation Software
• Field Instrumentation Device
• Utility Information System
• About the Author
  Mr.Vikalp Joshi
  holds a B.Tech(Instrumentation) degree from University Science Instrumentation Center, H.N.B.G.U, Srinagar (Garhwal), and M.Tech (Instrumentation and Control) from Graphic Era University, Dehradun. He has two years of industrial experience in the field of industrial automation in packaging industries and around five years of teaching experience in reputed engineering institutes and central university. Currently, he is working as an automation engineer at Shivansh controls, Dehradun, Uttarakhand. He has published many research papers on national and international journals. His area of interest covers Industrial Automation, Industrial instrumentation, and Process Control Instrumentation. Dr. Manoj Singh Adhikari
  received his B.Tech. degree in Electronics and Communication Engineering from Dev Bhoomi Institute of Technology, Dehradun, India, in 2010 and M.Tech. degree in Digital Signal Processing Engineering from the G. B. Pant Institute of Engineering and Technology (formerly known as G. B. Pant Engineering College), Pauri Garhwal, India, in 2013. He received his Ph. D. in Jan. 2019 from the same institution.Currently, he is working as an Assistant Professor in Lovely Professional University, Phagwara, Punjab. His research interests are simulation and modeling of power semiconductor devices. He has published more than ten research papers in reputed journals/conferences like IET, IEEE, ELSEVIER, Springer, and so on. He is serving as a reviewer for IEEE Transactions on Electron Devices, AEÜ - International Journal of Electronics & Communications, and Springer. Dr. Raju Patel
  is working as an Assistant Professor in Department of Electronics & Communications Engineering, MBM Engineering College, Jodhpur, Rajasthan, India. He received his Ph.D. and M.Tech. (Specialization - VLSI Design) degrees from Malaviya National Institute of Technology, Jaipur, India, in 2014 and 2018 respectively. Bachelor of Engineering degree in Electronics & Communication Engineering from S.B.C.E.T., Jaipur, University of Rajasthan, 2007. He has a teaching and research experience for over eleven years. His research interests include design, simulation, fabrication, and characterization of Film Bulk Acoustic Resonator as a RF filter and gas sensing applications. Dr. Rajesh Singh
  is currently associated with Lovely Professional University as a Professor with more than fifteen years of experience in academics. He has been awarded as gold medalist in M.Tech and honors in his B.E. His area of expertise includes embedded systems, robotics, wireless sensor networks, and Internet of Things. He has organized and conducted a number of workshops, summer internships, and expert lectures for students as well as faculty. He has twenty three patents in his account. He has published around hundred research papers in referred journals/conferences.
  Under his mentorship, students have participated in national/international competitions including the Texas competition in Delhi and Laureate award of excellence in robotics engineering in Spain. He has been awarded with "certificate of appreciation" and "Best Researcher award- 2017" twice in last four years from University of Petroleum and Energy Studies for exemplary work. He got "certificate of appreciation" for mentoring the projects submitted to Texas Instruments Innovation challenge India design contest, from Texas Instruments, in 2015.He has been honored with young investigator award at the International Conference on Science and Information in 2012. He has published fifteen books in the area of Embedded Systems and Internet of Things with reputed publishers. He is an editor to special issues published by AISC book series, Springer with title "Intelligent Communication, Control and Devices"-2017 and 2018. Dr. Anita Gehlot
  is currently associated with Lovely Professional University as an Associate Professor with more than ten years of experience in academics.She has twenty patents in her account. She has published more than fifty research papers in referred journals and conference. She has organized a number of workshops, summer internships, and expert lectures for students. She has been awarded with "certificate of appreciation" from University of Petroleum and Energy Studies for exemplary work. She has published fifteen books in the area of Embedded Systems and Internet of Things with reputed publishers. She is aneditor to a special issue published by AISC book series, Springer with title "Intelligent Communication, Control and Devices-2018".
  

CHAPTER 1

SCADA in Industrial Automation

Objectives

You will be able to understand:

• Introduction and classification of Automation
• Benefits of automation system
• Role of SCADA in Automation industry
• SCADA Architectures
• SCADA Generations
• “Regulatory Function” in SCADA

1.1 Automation

Automation is a process to accomplish a specific task by a machine in the particular time period without any human intervention. It is a self-governing execution of a function by a device or the system which was previously carried out by a human. The Automation (automatic control) is useful in numerous process control systems for operating equipment such as a machine, a variable frequency drive (VFD), AC, DC and the servo motors in the manufacturing plants, to control the heater, boiler, compressor, and actuators in chemical process plant, switching in electrical transmission lines, telephone networks, regulation and stabilization of ships, flying machine, radar and missile system in space program and other applications with minimal human intervention. Automation involves the following:

• Capture the measurement and control command for particular operation
• Transmute specific command into controlling action for particular operation

It is analogous to an ear, eye, brain and hand, working together in a human body. In the progressing world, automation grows to be more powerful, intelligent, adaptable, reliable, and more responsive. The reason behind increase in the demand of automation, is high industrial efficiency, security and low power consumption. Automation includes the combination of the instrumentation, electrical, electronics, and computer systems to monitor and control the process.

The Production systems are dividing into two groups:

• Automation Manufacturing systems
• Computerization of the manufacturing and maintenance systems

In the current automation industries, these two groups overlap towards the certain extent because an automation manufacturing systems functioning on the plant. These are often executed by the computer control systems and linked to the computerization manufacturing maintenance systems.

1.1.1 Automation Manufacturing Systems

The Automation manufacturing systems are used to develop the final product from raw material. The systems perform multitasking operations such as handling, assembling, coating, printing, raw material handling, and many more. In highly automated manufacturing systems, virtually there is no human interaction.

The Prime Objective of automation manufacturing systems includes:

• Transfer of raw material and manufacturing product into several different types of operation units
• The system is used to do material processing using the industrialized robots
• Automatic material control and packing systems
• Automatic inspection for quality purpose with high resolution sensors and cameras

Types of Automation

Mainly, three types of automations are involved in the automation manufacturing systems which are as follows:

1. Fixed automation
2. Programmable automation
3. Flexible automation

1 Fixed Automation

In fixed automation, the sequence of operation process is fixed and programmed by the system configuration and each process control operation is performed serially. Generally, the process control operations involve the linear, translational and rotational motion, or a basic combination of the two or three. For example, in a bottle manufacturing company, the whole process is in sequence of operations like melting, coating, printing, and so on. These operations are fixed and handled by the machines.

The features of fixed automation are as follows:

• Simple structure and easy installation
• Initial investment of assembly machine is very high
• Variations of production rates with respect to quality of the final product
• Uncompromising in the acceptance of the product variety

2 Programmable Automation

In programmable automation, machines are used which are capable of changing or modifying the series of the operations, according to the configurations of the final product. The order of execution is monitored by application software which consists of a set of commands to be understood by the system. The program for production machine is created or modified according to the configuration of the final product.

The features of programmable automation are as follows:

• Preliminary cost of general purpose device is high
• Lesser production rate in comparison with the fixed automation
• Suppleness to deal with the deviations and changes in the product pattern
• Most appropriate for the batch production

The programmable automation production systems are used to produce low and medium amount and size of the final products. The final products are typically made in batches or chain of operations. According to program instructions, the process of control system may be modified with the set of the device instructions which are resembled to the final product.

Fig. 1.1 Demand of automations (in percentage) in the industries

3 Flexible Automation

Increase in the demand of automation in the manufacturing sector, increased need of modification, thus the modified version of the programmable automation comes into the role as Flexible automation. A flexible automation enables the user to produce a variety of final products without changing the machine tools and programming software. Flexible automation reduces time taken in tool changing and reprogramming the software.

The features of flexible automation are as follows:

• Time taken to change the machine tools has reduced
• Continuous production of the final products
• Suppleness to deal with final product design deviations

1.1.2 Computerization of Manufacturing Maintenance System

The objective of introducing automation in any engineering field is to reduce the manual and clerical effort to accomplish the particular task or process. Almost all present manufacturing support systems are realized by computer systems. The computerized manufacturing maintenance system also reduces cost of human labor. It enables the user to design and simulate the product using advance system software. The computerized manufacturing maintenance system combines many functions in one system which operates all over the enterprise.

Fig. 1.2 shows the block diagram with major factors which affect the plant operations. In a process control industry, the fabrication activities which take place in the plant can be illustrated by the information processing activities, such as manufacturing planning and control product design and sales.

Fig. 1.2 Factors affecting the manufacturing maintenance system

The process plant activities consists of the processing, assembly, material handling, and quality control operations which are executed on the product in the plant. These operations are initiated with the raw material and come with the final.

1.1.3 Classification of Automation

Automation provides high quality products with a wide range of volume and reliability. This leads to an increase in the demand of automotive systems which are capable to handle multiple tasks without human intervention. The classification of Automation depends on the applications and requirements of the process plant. Fig. 1.3 shows the classifications of automation based on the application:

Fig. 1.3 Classification of automation

The demand of automation is increased in every field of industry. SCADA, PLC, and DCS are heart of Oil, Rubber, Chemical, Packing, and Robotics industries. The process plant associated with the various types of sensors and actuators is known as ‘Field Instrumentation device (FID)’. FID monitors and controls the process parameters. FID has the ability to sense the parameters of the process and convert the electrical signal into necessary control action.

Fig. 1.4 Block diagram of industrial automation

Fig. 1.4 shows a block diagram of industrial automation. The output signal of the field instruments device is connected to the input module of PLC (Programmable Logic Controllers), which is connected to the SCADA monitoring system. The user can see the graphical representation of process components and series operation on the computer screen of SCADA. According the to requirement of final product, the set point (S.P)of the process can be changed by a user. A PLC receives the measured input signal from FID and provides the output based on user program and sets the value.

1.1.4 Automation Functions

The automation functions vary with the management level of company. Table 1.1 shows the automation function for the type of company.

Table 1.1 Automation Function

Company level	Automation function
Business control management	Sales and cost analysis of the product, audit of various operations
Production control management	Capacity of the machine, handling capability of the operator, and analysis of the process output
Process control management	Measurement and control of regulatory variables in and out of the process

1.1.5 Benefits of Automation System

There are several benefits of automation systems, a few of them are as follows:

1) Increase in labor productivity: Automation increases the efficiency of production, production amount, and employment productivity. This turns into larger output per hour.

2) Reduce labor cost: Automation in process plant reduces the labor cost due to less human intervention. Automation based machines have high initial installation cost, however, once installed, it reduces the labor cost.

3) Moderate labor shortages: There are general shortages of labors in developed countries. To overcome these difficulties, automation based system is a better substitute for any process plant.

4) Eliminate routine manual and clerical tasks: A routine manual task comes out to be boring and tedious. Automation also reduces such type of argument and creates job with interests.

5) Improve worker safety: Aut...

Table of contents

• Cover Page
• Title Page
• Copyright Page
• Preface
• About the Authors
• Table of Contents
• 1. Scada in Industrial Automation
• 2. Supervisory and Control Functions
• 3. SCADA Communication Network
• 4. Human Machine Interface
• 5. Scada in Ems
• 6. Programmable Logic Controller
• 7. Applications of Scada
• 8. Automation Software
• 9. Field Instrumentation Device
• 10. Utility Information System