EEB 5223/EAB4223

Industrial Automation and Control

Systems
• Process/Industrial Instrumentation and
Measurements
• Automation
• DCS and Fieldbus

Dr. Rosdiazli Ibrahim

Department of Electrical & Electronics Engineering
Universiti Teknologi PETRONAS
22.03.27
Email: rosdiazli@petronas.com.my
Tel: 05-368 7821

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.1- 1

 Topics-Part 1: Topics-Part 2:
1. Basic Concepts of Measurement System 1. PLC: Features
2. Calibration 2. PLC programming
3. Temperature Measurements languages: IEC1131
4. Pressure Measurements 3. Sequential/batch/
5. Flow rate Measurements continuous processes
6. Level Measurements
7. Loop drawing/connections Topics-Part 3:
1. DCS
2. Fieldbus

Assessments:
•50% - Final examination
•20% - Test (10% X 2).
•10 % - Assignment questions.
•20% - Lab reports: Each from Part 1 & 2.

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.1- 2

 The course syllabus is designed to provide students in the key and base areas of
industrial automation, using mixed-mode delivery comprises of lecture-tutorial-
lab activities that covers the technical, theory and practical.

Synopsis
Synopsis Learning
Learning Outcomes
Outcomes
This
This course
coursecover
cover topics
topics related
related to
to measurements
measurements
(PLTF)
(PLTF) and automation in the processindustry.
and automation in the process industry.These
These that
thatstudents
studentsare
areexpected
expectedtotoachieve
achieveafter
after
include
includeaastudy
studyon
onindustrial
industrialsensors
sensorsandandactuators,
actuators, industrial
industrial successfully completing the course
successfully completing the course
controllers
controllers such as computer-based control, PLC, DCSand
such as computer-based control, PLC, DCS and
FF.
FF.

Process
Process ,, Industrial
Industrial Instr.&
Instr.& Meas.
Instr.& Meas.
The learning outcomes related to
Industrial instruments and
Measurements
• Have knowledge and
understanding of the various
process industry instruments,
concept of measurements,
calibration and configuration
requirements and their applications.
• Be able to design and develop a
control loop consisting the process
instruments, based on a prescribed
requirement.
Automation
Automation DCS
DCSand
and Foundation
Foundation Fieldbus
Fieldbus
The learning outcomes related to The learning outcomes related to
Automation and the implementation of DCS and Foundation Fieldbus use
Programmable logic controller in process industries.
• Have knowledge and • Have knowledge and
understanding of the PLC understanding of a DCS and its
architecture and its importance in use in process industries, and
automation. the features and architecture of a
Foundation Fieldbus system, and
• Be able to develop a PLC program
its improvement over the
to perform sequential, and batch
conventional DCS.
control.

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.1- 3

 Learning
Learning Outcomes
Outcomes Assessment
Assessment Criteria
Criteria
To achieve the following Learning Outcomes: Assessment criteria:
• Have knowledge and understanding of the various process To demonstrate student has achieved the learning
industry instruments, the concept of measurements, outcomes
calibration and configuration requirements and their
applications. • Describe the measuring principles, calibration and
configuration requirements of different process
• Be able to design and develop a control loop consisting the industry instruments and their applications.
process instruments, based on a prescribed requirement. • Design and develop a control loop using the relevant
. instruments to meet specifications

Process
Process ,, Industrial
Industrial Instrumentation
Instrumentation &
& Measurement
Measurement
Assessment criteria: Lab experiences Assessment criteria:
• Basic concepts of measurements • Calibration, • Signal Conditioning
configuration of
• Process control terminologies transmitters, • P,T,L,F to mA, V
• Calibration controllers, • V-V,V-mA,mA-V
recorders and
other peripherals,
wiring, selection
and installation.
Assessment criteria: Assessment criteria:
• Design and
• Applications and selections of sensors and actuators implementation of • Design and implement a simple control
used in industries a simple control loop.
• Pressure Level Temperature Flow loop.

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.1- 4

 Learning
Learning Outcomes
Outcomes Assessment
Assessment Criteria
Criteria
To achieve the following Learning Outcomes: Assessment criteria:
• Have knowledge and understanding of the PLC architecture To demonstrate student has achieved the learning
and its importance in automation. outcomes

• Be able to develop a PLC program to perform a sequential, • Describe and discuss the architecture and input-output
and a batch control. features of a PLC, and its importance in automation.
• Develop, design, and use the appropriate instructions
to write a program to perform specific task in particular
. sequential process in automation/process plant, and a
batch process.
.

Automation
Automation
Hardware structure of a PLC Lab experiences Sensors and actuators for
automation
• PLC architecture: CPU, I/O modules, peripheral • Sequential control,
equipments. electropneumatic
systems, conveyor
• Review PLC internal architecture: Timers, counters, belt systems. • Applications and selections of sensors
arithmetic function, and logical operation. and actuators used in industries
• Design and
• Advanced instruction sets. implementation of
PLC system in
automation/proces
Programming
Software structure of a PLC s control.
• Programming sequence function charts
• PLC internal architecture: Timers, counters,
and Grafcet.
arithmetic function, and logical operation.
• Implementation of PLCs for
• Advanced instruction sets.
sequential/batch control

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.1- 5

 Learning
Learning Outcomes
Outcomes Assessment
Assessment Criteria
Criteria
To achieve the following Learning Outcomes: Assessment criteria:
To demonstrate student has achieved the learning
outcomes
• Have knowledge and understanding of a DCS and its use in
process industries, and the features and architecture of a • Explain the structure of a DCS and its use in process
Fieldbus system, and its improvement over the industries, its benefits and limitations.
conventional DCS • Describe the various components of a typical fieldbus
architecture, the control configurations and its
improvement over the conventional DCS architecture.
.
.

DCS
DCS &
& Foundation
Foundation Fieldbus
Fieldbus
MMI DCS Fieldbus

• Explain the man-machine • Describe the structure of a • Describe the overall layout of a
interface and the features of a DCS and its use in process fieldbus system used in industry.
control room. plant and other industries.

• FF Topologies
• Interoperability, Reliability
• CIF
• Simple implementation example

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.1- 6

References:
Curtis D. Johnson,”Process Control Instrumentation
Technology”, Pearson.
Dally, Riley & Mc Connell, “Instrumentation for
Engineering Measurements”, Wiley
E. O. Doebelin, “Measurement Systems Application
and Design”, Mc Graw Hill.

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.1- 7

Lab Part 1 (week 2- 7):
•Process Instrumentation for T,P,L,F, using single
station controller, recorder, transmitter etc.
•Design and implementation of a simple control loop

Lab Part 2 (week 8- 11):

•PLC for sequential control – conveyor belt system,
electropneumatic actuators.
•Design and implementation of PLC in automation

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.1- 8

 Emphasize learning through the accessibility to lab-based activities using real
instruments, formal reports and continuous assessments...
Conveyor
belt system
Calibration
Calibration of
of & PLC
transmitters
transmitters (T)
(T)
Electro-
pneumatic
Configuration of actuators & PLC
Controller &
Recorder
Lab Calibration
Calibration of
of
Briefing & transmitters
transmitters LOOP design &
Grouping (P,
(P, L,
L, F)
F) interconnection

2 weeks

2 weeks
3 weeks
1 week

1 week

TEST 1 TEST 2
ASSIGNMENT 1 ASSIGNMENT 2

Formal Lab Report

Formal Lab Report
Calibration,
PLC and
Configuration
Electropneumatic
and
systems
Loop design

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.1- 9

 Concepts of Measurements

Basic Concepts of Measurement Systems

• Objective of measurements

To establish the value or the tendency of some

variable based on the value or the tendency suggested by the
measurement device.

• General Measurement System

A measurement assigns a specific value to a physical
variable, measured variables.

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.1- 10

 A Measurement System

Sensor Transducer Signal

Stage Stage Conditioning

Control
Stage
Process
Output
Stage

A general template for a measurement system

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.1- 11
Components for Measurements
• Sensor
– Sensor is a physical element that uses some natural
phenomenon to sense the variable being measured
– Sensor selection, placement, and installation are
particularly important, because the input to the
measurement system is the information sensed by the
sensor
– The interpretation of all information passed through and
indicated by the system depends on that which is actually
sensed by the sensor

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.1- 12

Components for Measurements
Transducer
– The transducer converts the sensed information into
a detectable signal form, such as electrical,
mechanical, optical or otherwise
– Convert the sensed information into a form that can
be easily quantified
– The term “transducer” often used in reference to a
packaged device, may contain a sensor, transducer,
and even some signal conditioning elements

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.1- 13

 Components for Measurements

• Signal Conditioning
– It will take the transducer signal and modifies it to a desired
form
– This optional intermediate stage might be used to perform
task such as
• to increase the magnitude of the signal through
amplification
• to remove some portions of the signal through some
filtering technique
• to provide mechanical/optical linkage between transducer
and output stage

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.1- 14

 Components for Measurements

• Output stage
– This stage provides an indication of the value of the
measurement.
– The equipment might be a simple readout display or a marked
scale or it might contain a device that can record the signal for
later analysis.

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.1- 15

 Components for Measurements

• Control stage
– This stage contains a controller that interprets the measured
signal and makes a decisions regarding the control of the
process.
– This decision results in a change in a process parameter that
effects the magnitude of the sensed value

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.1- 16

 In process control …
• Puts emphasis on the four (4) major control variables
in process control, P,L,F,T needed for
implementation of automatic control.
• Allows the application of transmitters, controller, and
recorders in the control loop to achieve a required
control.
• Allows investigation on the limitations of
instruments for process control, and the importance
of correct measurements, in a control system.

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.1- 17

Signal conditioning : Digital I/Os

4-20mA Output terminal

block Digital output from
DCS

24VDC 24VDC To client

DCS PC

alve Open command

Input terminal Digital input

block to DCS
24VDC
24VDC

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.1- 18

Signal conditioning : Analog I/Os
Input terminal Signal
block conditioner

4-20mA To client
DCS PC

4-20mA 0-10V
Pressure transmitter
4-20mA

Flow transmitter

4-20mA

Temperature transmitter

Output terminal Signal

block conditioner

4-20mA To client
DCS PC

4-20mA 0-10V

4-20mA
Control valve 1

Control valve 2
EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.1- 19
 Selection of Process Instruments

The influential factors that determine the

selection of process instruments
for process plant
• Size or Range • Certification by Government
• Operating Conditions Agencies
• Cost • Maintenance Capability
• Compatibility • Confidence, Known Past
Performance
• Standardisation
• Design Features
• Delivery
• Supplier Backup. Credibility
• Life Expectancy
End
End of
of Lecture
Lecture notes
notes on
on Basic
Basic Concepts
Concepts of
of Measurements
Measurements

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.1- 20

Questions?

EEB5223/EAB4223 Industrial Automation & Control Systems Topic 1.1- 21