Hierarchical Control and Industrial

Automation

Automation
Automation is the use of control systems such as computers
to control industrial machinery and processes, reducing the
need for human intervention.

Expectations from automations

High reliability and availability.
Fast troubleshooting.
Easily configurable.
Process optimization.
Asset optimization .
Flexibility.
Able to take each & every decision with
minimum assistance from human intervention.

Applications of Automation

Power generation
Manufacturing
Building
Transportation
Mining
Oil & gas industries
Pharmaceutical
And many more..

The famous Pyramid of Automation

Enterprise
Manufacturing Execution

Supervision (SCADA)

Group Control
Individual Control
Field
Primary technology

This pyramid is considered as reference in industries while developing

automation solutions.

Detailed structure of control system hierarchy

A standard functional hierarchy by ANSI/ISA-95

Building blocks of Automation

Sensors and actuators
Analog and digital I/O modules
DDC direct digital control
PLC being replaced by PACs
DCS distributed control systems
SCADA supervisory control and data acquisition
MES manufacturing execution system
ERP enterprise resource planning

Sensors and Actuators

Intelligent sensors
Biosensors
Optical fiber sensors
Digital actuators

Motor with built in DAC

Biosensor

Analog and digital I/O module

Analog I/O module
Digital I/O module
Mixed I/O module
Genius I/O module

Direct Digital control

Mainly used for control of critical process parameters

PLC Programmable Logic Controllers

A programmable logic controller (PLC) or programmable controller is a
digital computer used for automation purposes. PLC is designed for
multiple inputs and output arrangements, extended temperature ranges,
immunity to electrical noise, and resistance to vibration and impact

A typical rack mounted PLC

PAC Programmable Automation Controllers

PAC has all the capabilities of PLC with some added features
like task flexibility, integrated communication interfaces and
very high computing power.

Architecture of PAC

Architecture details of SEL-2411 PAC

Benefits of PAC over PLC

PAC support many standard
communication protocols

PAC can do many tasks simultaneously

DCS Distributed Control System

Architecture of DCS

Control room of a DCS system

DCS system on a plant floor

SCADA Supervisory control and data acquisition system

In early 1970s all instruments were directly wired to the control room

SCADA Supervisory control and data acquisition system

SCADA architecture

Main functions of SCADA

- displays the current state of the process (visualization)

- display the alarms and events (alarm log, logbook)
- display the trends (historians) and analyse them
- display handbooks, data sheets, inventory, expert system (documentation)
- allows communication and data synchronization with other centres

Knowledge management for design and manufacturing

MES Manufacturing Execution System

Manufacturing Execution Systems (MES) manage and monitor work-inprocess on the factory floor including manual or automatic labor and
production reporting, as well as on-line inquiries and links to tasks that take
place on the production floor. Manufacturing Execution Systems may include
one or more links to work orders, receipt of goods, shipping, quality control,
maintenance, scheduling or other related tasks. Here we are dealing with
the Level 3 of ANSI/ISA-95 standard which is shown in figure

Reasons to implement MES

Automate management of recipes (process manufacturers)

Scheduling, including the management of priorities
Production reporting
Key Performance Indicator (KPI) tracking
Event or exception management
Product or materials tracking
Intelligent decisions to influence production and cost
management
Measure and manage operational equipment efficiency, or
OEE
Ease management of resources, including inventory and
personnel

Standardized MES architecture by ISA-95

S95.01

There are eleven generic functions found in an MES suite, which are defined by
the S95.01 standard provided by the Instrumentation, Systems and Automation
(ISA). These functions are not the be all and end all of MES functionality but are
meant to provide a solid category of capabilities. The eleven functions are:
Operations/Detailed Scheduling
Resource Allocation & Status
Dispatching Production Units
Document Control
Product Tracking & Genealogy
Performance Analysis
Labor Management
Maintenance Management
Process Management
Quality Management
Data Collection Acquisition.

Link between SCADA and MES systems

Plant intelligence links between SCADA and MES

Benefits of implementing MES

ERP Enterprise Resource Planning

ERP is an enterprise-wide information system designed to coordinate all the

resources, information, and activities needed to complete business processes such
as order fulfillment or billing.

Interactions between ERP and plant floor

Current ERP vendors (SAP) provide over 30 different interactions between plant
floor and ERP, some of them are shown below

Response time and hierarchical level

ERP

Planning
Level

(Enterprise Resource
Planning)

MES
Execution
Level

(Manufacturing
Execution System)

SCADA

(Supervisory Control
and Data Acquisition)

Supervisory
Level

DCS
(Distributed
Control System)

Control
Level

PLC
(Programmable
Logic Controller)

ms

seconds hours

days

weeks

month

years

Complexity and Hierarchical levels

Conclusion
Industrial Automation is a discipline that includes knowledge
and expertise from various branches of engineering Industrial
Automation Engineers have always drawn new technologies
and implemented original or enhanced versions to meet their
requirements. As the range of technology diversifies the
demand on the innovative ability of these Engineers has
increased. Hence in order to survive in todays competitive
manufacturing markets, manufacturing systems need to adapt
at an ever-increasing pace to incorporate new technology
which can lower the cost of production, while maintaining
quality and delivery schedules.