Industrial Automation & Instrumentation

Transcription

1 Industrial Automation & Instrumentation November 16, 2017 By: ENGR. GAMALIEL F. ITAO, P.E.E, M.Entr. President, ICC-MTC

2 ABSTRACT The paper deals with the definition of Instrumentation and (Industrial) Automation, the basic differences between the two ; The presentation with examples and illustrations can help electrical engineers and technical people decide which technology to specialize in or to use in their particular field of work.

3 AUTOMATION (Industrial) The use of methods for controlling Industrial processes automatically with the aim of reducing human intervention to a minimum. It is also the act or process of Making Automatic or Self Acting.

4 INSTRUMENTATION OR PROCESS AUTOMATION is commonly applied in Chemical and process plants with the process variables namely; Pressure, Level, Flow and temperature. They are commonly found and applied.

5 While Industrial Automation or Mechatronics is more commonly called Machine Automation. -It s using PLC as the basic building block of Automation.

6 While INDUSTRIAL AUTOMATION OR MECHATRONICS is more commonly called Machine Automation. It is using PLC as the basic building block of Automation.

7 Increase Quality and Flexibility in Your Manufacturing Process Earlier the purpose of automation was to increase productivity (since automated systems can work 24 hours a day), and to reduce the cost associated with human operators (i.e. wages & benefits). However, today, the focus of automation has shifted to increasing quality and flexibility in a manufacturing process.

8 CONTROL SYSTEM I. OPEN LOOP SYSTEM INPUT LOGIC OUTPUT -Pushbuttons -Limit Switches -Level Switches -Flow Switches -Relays -Timers -Counters -Motors -Solenoid valves -Lamps PLC

9 A TYPICAL CONTROL SYSTEM (ELECTROMECHANICAL) INPUT DEVICES PUSHBUTTON LIMIT SWITCH CONTROLLER RELAY COIL LATCHING COIL OUTPUT DEVICES MOTOR SOLENOID THUMB WHEEL SWITCH LEVEL SWITCH FLOW SWITCH TIMER COIL CLOCK COUNTER CNT RESET ELECTRONIC CARDS LED DISPLAY HEATER LAMP 8 8 HEATER

10 MECHATRONICS IS DEFINED AS THE SYNERGESTIC INTEGRATION OF MECHANICAL, ELECTRICAL, ELECTRONICS, AND INFORMATION TECHNOLOGY TO PRODUCE INTELLIGENT EQUIPMENT OR MACHINE AUTOMATION

11

12 INDUSTRIAL AUTOMATION (MECHATRONICS) CORE COMPETENCIES Certification Requirements Core Competencies Required Knowledge Mechatronics and Automation Engineer Mechatronics and Automation Specialist Mechatronics and Automation Master Technician Mechatronics Technician NC IV + PRC Registered Engineer (REE, RME, RECE) +( MRSP Certification Exams) NC IV + BS Engineering /Technology degree Course, Vocational Course with 5 years experience NC II NCIII + BS Engineering /Technology Course + Vocational Course with 2 years relevant experience NC II + Any Voctech course NC IV Competencies : -Develop PLC and HMI software application program -Diagnose and Troubleshoot Mechatronics and Automation System -Commission PLC and HMI-based Mechatronics and Automation System -Develop Mechatronics and Automation Control Circuits & PLC Software Application Programs -Maintain and Repair PLC-based Mechatronics and Automation System -Develop Motion Control and System Configuration -Install Mechatronics and Automation Devices -Configure & Test Mechatronics and Automation System NC IV Required Knowledge : - Advanced PLC programming -Human machine interface (HMI) - Intro to SCADA -Basic PLC programming -Intermediate PLC Programming -Motion control : inverters and servo motors - Electro pneumatics / hydraulics - Industrial motor - Sensors -Intro to PLC

13 MECHATRONICS INDUSTRIAL AUTOMATION

14 UNDERPINNING KNOWLEDGE Electro Pneumatic / Hyrdaulics Sensors Basic PLC Industrial Motor

15 ELECTRO-PNEUMATIC Term is defined from words of electro, which mean electrical and pneumatic, which mean air pressure. The electro-pneumatic system is an integration of electrical and mechanical Components with compressed air source.

16 YOU WILL FIND APPLICATION OF ELECTROPNEUMATIC IN MOST AUTOMATION SYSTEM

17 Intelligent plastic injection molding machine

18 Electro-pneumatics plays a very significant role in Mechatronics. It is the ARM of Automation Replaced the conventional mechanical work: Manual drill press, Air powered drill press

19 ASSEMBLY LINE

20 Pneumatic Press (STAMPING LINE)

21 PACKAGING LINE

22 MECHATRONICS NCIV CORE COMPETENCIES COMMISSION MECHATRONICS SYSTEM DIAGNOSE AND TROUBLESHOOT MECHATRONICS SYSTEM

23 UNDERPINNING KNOWLEDGE Advance PLS Programming Human Machine Interface (HMI) SCADA

24 MCS NC IV : ADV.PLC/ HMI

25 SUGGESTED MCS NC V: SCADA SCADA : Supervisory Control and Data Acquisition

26 15MW HFO PEAKING POWER PLANT SCADA SYSTEM NOVEMBER

27 SCADA WORKSTATIONS

28 SCADA SCREEN: ENGINE OVERVIEW SAMPLE SCREEN

29 INSTRUMENTATION PROCESS AUTOMATION

30

31 INSTRUMENTATION & PROCESS CONTROL 1. Instrumentation Definition of Instrumentation The application of instruments to an industrial process for measuring or controlling its activity. 1.1 Instrument - in process measurement and control, this term is used broadly to describe any device that performs a measuring or controlling function 1.2 Industrial Process - those activity in a factory, such as chemicals, petroleum, metals, paper, textiles, food. and beverage, water management, etc. which deals mostly with the Process Control. 1.3 Process Control - control of temperatures, pressures, flows, levels, and analytical measures of physical and chemical properties

32 CONTROL SYSTEM CLOSED LOOP (FEEDBACK SYSTEM) Controller Error Control Unit Final Control Element Process Set Point + _ Measured Variable Measuring Element Primary Element / Transducer Pressure Level Temperature 1. Process Variables - a quantity that can be measured in an industrial process. This maybe regulated or simply measured. Example: Pressure, Level, Temperature, Flow 2. Measuring Element the element which converts a measurable variable into a form or signal that the controller can understand. Example: Transmitter - A transmitter sense the actual value of a system and transforms the value to a standardized signal ma is common for analog signals - as input for the control system. Flow

33 3. CONTROLLER A controller consists of: 3.1 a measuring unit with an appropriate instrument to measure the state of process, a temperature transmitter, pressure transmitter or similar. 3.2 an input set point device to set the desired value. 3.3 a comparator for comparing the measured value with the set point, calculating the difference or error between the two. 3.4 a control unit to calculate the output magnitude and direction to compensate the deviation from the desired value. 3.5 an output unit converting the output from the controller to physical action, a control valve, a motor or similar. CONTROL SYSTEM

34 Electrotechnical Trade Core Competencies ROADMAP FOR INSTRUMENTATION AND CONTROL SERVICING Core Competencies (Practical Skills to be Assessed) NCII -Install instrumentation and control devices -Calibrate instrumentation and control devices -Configure instrumentation and control devices Training Workshops Required (Underpinning Skills & Knowledge) -Basic instrumentation - Process & instrument diagrams - Process measurements (Pressure, level, flow & temp.) - Calibration techniques - Instrument installation & hook up details Job Qualifications/Positions Qualified - Instruments installer - Instrument fitter - Calibration technician - Instrumentation craftsman - Instrumentation technician NCIII -Loop-check instrumentation and control loops -Maintain and repair instrumentation and control devices NCIV -Start-up commissioning instrumentation and control devices -Diagnosese and troubleshoot instrumentation and control devices -Process measurements & control -Process loop controllers - loop diagram details -Instruments function test -Control valve stroke check - Advance instrumentation - PID fine tuning - Instrumentation system test and commissioning - Analytical instrumentation - DCS - Test and process control Loop check technician - Repair and maintenance technician/supervisor - Senior instrument technician - Testing and commissioning technician/engr. - Process automation technician/ - Instrumentation Engineer

35 MAJOR COMPONENTS TO CREATE AUTOMATIC CONTROL SYSTEM PROCESS: Equipment or manufacturing process to be controlled. PRIMARY ELEMENT: Component that measures the process and transmit signal proportional to process condition to controller. CONTROLLER: Decision making of the system FINAL CONTROL ELEMENT: Directly regulates the flow of energy or material to the process

36

37

38

39 INSTRUMENTATION ENGINEERING

40 UNDERPINNING KNOWLEDGE Basic Instrumentation Process & Instrumentation Diagram Process Measurement Calibration Techniques Instrument Installation & Hook Up Details

41 WATER TREATMENT LINE

42

43

44 WATER TREATMENT LINE

45

46

47 WHAT According to ISA.. CALIBRATION is a comparison of Measuring equipment against a standard instrument of higher accuracy to detect, correlate, adjust, rectify, and document the accuracy of instrument being compared.

48 ACCURATE For a calibration to be accurate it is necessary to make sure that all standard instrument to be use are within known accuracy.

49 COMMON CALIBRATION TERMS UNIT UNDER TEST: The device or instrument being compared to standard. Example: Pressure Gauge, Sensors (RTD), Pressure/Flow/Level/Temperature, Transmitter

50 COMMON CALIBRATION TERMS STANDARD TEST EQUIPEMNT: A standard measuring device use to verify the correctness of a test instrument. Also known as Calibrators.

51 WHY? Instrument drift during time. To keep high and consistent product quality. Comply with regulations/quality systems. Safety reasons. Maintenance purpose.

52 WHERE? Bench/Shop Calibration Done in a laboratory or calibration room. Field/On-Site Calibration Done on-site or directly on field

53 LABORATORY: CALIBRATION SET-UP

54 LABORATORY # 1 Differential Pressure Transmitter Smart Pressure Transmitter I/P Transducer Temperature Transmitter Temperature Controller

55 LABORATORY # Power Supply High Side 24 Vdc + _ D/P Transmitter + - Ammeter Pneumatic Calibrator

56 LABORATORY # 2 SMART Pressure Transmitter ohms Power Supply 24 Vdc + _ High Side SFC + - Ammeter Pneumatic Calibrator

57 LABORATORY # 3 I/P Transducer + - Supply: 20 psi Output 3-15 psi Current Generator Pneumatic Calibrator Standard Gauge

58 LABORATORY # 4 Power Supply Temp. Transmitter-RTD Input Vdc + - A B B Resistance Box Ammeter

59 ICS NC III NCIV

60 Conventional Control Panel (WW Pumping Station)

61 Old Panel Indicators

62 Conventional Control System

63

64

65 Equipment

66 PLC-SCADA BASED SYSTEM

67 Picture Documentations NOW: SCADA Based Control Panel

68 Picture Documentations Manila Waters Sewerage, Inc. Lift Station 2005 March RAYMOND RICOHERMOSO Main Screen Rockwell Automation

69 Picture Documentations

70

71 INDUSTRIAL CONTROLS CORPORATION The Automation and Instrumentation Systems Solutions Provider, General Construction, General Engineering, MEPF MECHATRONICS TECHNOLOGIES CORPORATION The Mechatronics and Instrumentation Training and Assessment Center GLOBAL TECHNICAL MAINTENANCE SERVICES The Plant Maintenance Specialist

72 END THANK YOU! GAMALIEL F. ITAO