Course

Lab Exercises

Ladder programming for boolean operations & math operations, Development of combinational and sequential logic applications using PLC languages, Interfacing of Electro-Pneumatic system with PLC, Speed control of DC motor using PLC, Interfacing HMI with PLC.

Interfacing PLC real-time TAG with SCADA, Flow and pressure measurement and control using SCADA, and Development of SCADA for control of processes. Study of HART and Field bus protocol P&I diagram development using simulation software for complex processes. Study of Distributed Control System and different instruction sets

Unit I

Automation in the manufacturing system, Principles, and strategies of automation, Basic elements of an automated system, Advanced automation functions, Levels of automation, Automated flow lines and transfer mechanisms, Programmable Logic Controllers: Introduction, Types of PLC, CPU unit architecture, Memory classification, Input/output devices and their interfacing, Digital-Analog modules, Communication modules, Special function modules, Basic Ladder logic, electrical wiring diagram, scan cycle. Programming languages for PLC, PLC module addressing, registers basics, basic relay instructions, timer-counter instructions, Math functions, data handling, and program control instructions.

Unit II

SCADA: Introduction to computer-based industrial automation- Direct Digital Control (DDC), Distributed Control System (DCS), and Supervisory Control And Data Acquisition (SCADA) based architectures and HMI Components, HMI Development, Data Processing, Control Algorithm, Programming, Data Acquisition from PLCs/RTUs, Database Connectivity and Report generation. OPC Configuration with RTUs (PLC), Cyber Security for Industrial Control Systems.

Unit III

Distributed Control System- Local Control Unit (LCU) architecture, LCU Process Interfacing Issues, Block diagram and Overview of different LCU, security design approaches, Networking of DCS. Introduction to communication protocols Profibus, Field bus, HART protocols. Data gathering, Data analytics, Real-time analysis of data stream from DCS, Historian build, Integration of business inputs with process data.

Levels of process safety through the use of PLCs, Integrating Process safety PLC and DCS, Application of international standards in process safety control.

Course Objectives

• To provide the student with the fundamentals of PLC, SCADA, and DCS
• To facilitate the design of automated systems using software

Course Outcomes

CO-PO Mapping

Skills Acquired

PLC programming, SCADA, automation using DCS, development of HMI

1. R. Mehta and Y. J. Reddy, Industrial Process Automation Systems Design and Implementation, Elsevier Inc. 2015.
2. Lukas P, “Distributed Control Systems,” Van Nostrand Reinhold Co., New York, 1986.
3. L.Sharma, Overview of Industrial Process Automation, Elsevier, 2011
4. Petruzella, Frank Programmable logic controllers. Tata McGraw-Hill Education, 2005.
5. Frank Lamb, Industrial Automation: Hands On, McGraw-Hill Professional, 2013