Discrete Automation
Solutions to meet the operational optimization: In order to meet today’s diverse, complex and competitive market, discrete solutions throughout any process plant can significantly increase the production, reduce waste and maintain proper product quality which is one of key vital points for sustainable growth. To increase or improve the overall process efficiency the very first step is to identify and improve the efficiency of a particular process point. Here comes the discrete automation solution which is ultimately a part of any process plant. Rather than thinking of a complex improvement or complex integration, it’s always a better solution to improve the process productivity discretely. The data retrieved from discrete segments can be further monitored, recorded and analyzed in order to find the gap between the expected production capacities and actual production capacities. If the discrete productions can be optimized up to the maximum level, the overall process efficiency becomes the expected result.
The typical discrete automation system consists of -
- Input Devices – to collect status data from the different field devices
- Controller – Designed to get feedbacks from the input devices, make decision based on pre-programmed logic and generate output signals to accomplish the decision taken.
- Output Devices – Based on the decision made by controller receives signals and actuates necessary components
- Human Machine Interface (HMI) – Interprets the machine data with the user, take necessary commands to process further and finally acts as an interactor with the control system
- Network (Optional) - This is used to communicate between the core elements of the control system in a faster and easier way.
Distributed Control System (DCS)
Known as a group of smaller PLC systems or Discrete Automation Systems or Controllers to distribute the control signals for the complete industrial process plant. Actually, DCS is a combination of controllers to control the complete plant operation by splitting individual tasks or operations among themselves.
- Safety; Reliability
- The in-built redundancy functionality into Distributed Control Systems enables safe and disruption-free operation to be maintained in the event of a problem.
- Reduced downtime
- As the process performance can be monitored continuously, DCS can predict when & where the faults are likely to happen which activates alarms to take necessary actions. Some of the functionalities related to faults or alarms can be automated which ultimately reduces the chances of mishandling or miss-operating.
- Visualization
- Necessary filed data or detailed plant conditions controlled and monitored by DCS is represented to central operator station for visualization. Fault history logging, alarm history logging, fault management, alarm management can be analyzed and respective decisions are made based on current plant condition.
- Scalability
- One of the key functionality influencing the DCS users to have the system to meet today’s challenging market trends. System extension can be done by adding I/O modules to the system controller.
- Security
- DCS also offer definable access level as per convenient with multiple layers of security.
Supervisory, Control & Data Acquisition (SCADA)
SCADA stands for “Supervisory Control and Data Acquisition”. The name itself clearly explains what are the functions and objectives of a SCADA system, which are -- Supervision,
- Control and
- Data acquisition based on real time.
- One or more work stations (Operator Panel), connected with each other to perform and implement the supervisory functions based the field data collected
- A series of peripheral devices such as RTUs, I/O modules, PLCs that interface to the process (machinery, plant, etc.) through sensors and actuators.
- A communication network, with a variety of transmission media and communication protocols, able to ensure the correct exchange of data between peripheral devices and supervisory computers
- A set of development tools to sort and process the information acquired from the process in order to generate reports for production and quality managers. Reports usually refer to a specific production batch, highlighting its characteristics and certifying its compliance with the requirements.
- Data acquisition
- The foundation of SCADA systems; sensors collect data and deliver it to field controllers, which, in turn, feed data to the SCADA computers
- Remote control
- This is achieved through the control of field actuators, based on the data acquired from field sensors.
- Networked data communication
- This enables all SCADA functions. Data collected from sensors must be transmitted to SCADA field controllers, which, in turn, communicate with the SCADA supervisory computers; remote control commands are transmitted back to actuators from the SCADA supervisory computers.
- Data presentation
- This is achieved through HMIs, which represent current and historical data to the operators running the SCADA system.
- Real-time and historical data
- Both are important parts of the SCADA system, as they enable users to track current performance against historical trends.
- Alarms
- Alert SCADA operators to potentially significant conditions in the system. Alerts can be configured to notify operators when processes are blocked, when systems are failing, or when other aspects of SCADA processes need to be stopped, started or adjusted.
- Reporting
- This operation can include reports on system status, process performance and reports customized to specific uses.
- Scalability: Modern SCADA systems are more scalable than legacy systems for several reasons, including better availability of supported hardware and software and use of cloud computing to meet workload demand.
- Interoperability: Legacy SCADA systems rely on proprietary hardware and software, resulting in vendor lock-in.
- Communications. Modern SCADA systems support more widely supported and modern communications protocols, which enable greater accessibility to SCADA data and controls.
- Support: Legacy SCADA systems may have limited options for support, while modern systems are more likely to be well supported by vendors. Use of commercial off-the-shelf hardware, open networking standards and modern software development platforms makes third-party support more accessible as well.