Industrial Process Automation: Safety and Control

Module 24: Automation and Control of Industrial Processes

• This relates to Electrical Engineering for specialized technicians.
• This is edition 2021.
• This is a practical manual.
• This can be accessed via QR codes.

Objectives and Approach to Realization

• Aims to ensure safety, outlining rules, methods, and objectives.

Safety Objectives and Rules

• Practical sessions provide opportunities to familiarize with materials, methods, and used techniques, also to concretize the teaching content.
• Students should comprehend the operation of setups and devices, understand the importance of measurements, and know how to utilize results.
• Several tasks include determining the manipulation's objective, defining measurable quantities and conditions (charge, power factor, temperature, speed, etc.), and determining a setup with adjustment and safety elements.
• It includes defining the apparatus based on its characteristics relevant, implementing an operational mode, performing setup verification and tests, recording measurements, and analyzing results.
• Editing the report that represents the formatting stage.
• The report can be completed within the session if manipulation goes well.
• Preparing for practical work is essential.

Safety Precautions

Prevention

• Electrotechnical practical work involves significant power devices, where voltage sources can provide substantial currents without voltage drop, necessitating caution.
• Do not assemble/disassemble under voltage.
• Modifications to control circuits can cause dangerous effects in power circuits.
• Avoid abrupt current cuts in a coil, short-circuiting loaded capacitors, or using defective wires.
• Always think before acting.

Material Safety

• All systems with sources capable of high dangerous currents.
• "Return" conductors to the negative terminal are black and the negative alternative cables are blue.
• Rotating machines rotate, thus posing potential hazards, so avoid wearing loose items.

Material Preservation

• Electrotechnology practical work involves power devices and voltage sources, so the tools must be protected from:
• Excessive voltage causing insulation breakdown.
• Intense current causing a short circuit.
• Over speed can damage the machine.
• A temporary configuration can cause constant overload or super intensity/voltage.
• Check the nameplates of used machines to know the peak values during manipulation.

Approach and Instructions

• The practical work has 4 pedagogical steps, promoting active trainee participation.
• The trainee will reinforce their sense of autonomy, motivation, research, and teamwork.
• Stages alternate between learning modes: face-to-face, video-conference, e-learning, and lab work.
• Phase 1 involves introduction, objective explanation, and risk awareness in a classroom.
• Phase 2 involves setup, simulation, measurements, and implementation in the lab.
• Phase 3 involves A synthesis presentation of a TP report

Lab Preparation Phase

• Arrange a complete and organized setup on the clean workstation.
• Select and arrange components according to the practical flowchart.
• Always ensure instruments are in the "stop" position.
• Verify supply voltage(s) are set to zero.

Instructions

• Essential course recaps are provided, with theoretical calculations possibly required.
• Report any defective device to the in-charge teacher, and he will replace it.
• Only start manipulation post-instructor verification for circuit correctness.
• Read and adhere to manipulation and safety instructions, or heed the teacher's guidance.
• During the session, at least one student per team will be quizzed, receiving a grade.
• Document results during manipulation and interesting observations.
• Remember end-of-manipulation steps: switch off appliances, unplug cables, and arrange the workplace neatly.
• Students will remise a TP report at the end of each session.
• Students are evaluated on punctuality and discipline.
• All students need respect regulations, materials, and safety.
• All students must work properly and with care.

Permanent Instructions

• Never energize a setup without instructor approval.
• Avoid live circuit intervention.
• Before using measurement devices, ensure proper settings, correct magnitude and maxes.
• Consult the teacher at the smallest mistake or doubt.
• Use the emergency stop in case of any incident which was to be known.

Report Writing

• Reports should apply legibility, syntax, technical accuracy, and graphics.
• Curves are traced using millimetered paper or appropriate documents.
• Each axis is labeled with symbol units
• Always include a conclusion

Presentation of the Report

• The report will include the main goal that synthesizes the work.
• The report will include material used, and setting up.
• The report will explain the precautions that need to taking.
• Tables with different measures.
• Charts and diagrams to explain data.
• Finally a conclusion.

TP Assessment

• Evaluation includes understanding, compliance, and is formative.

• The points in question during the evaluation should be:

• Lab report grade by pair counts for 1/3 of the grade.

• Assessing trainee behavior counts as 1/3 of the grade.

• Individual final exam which counts as 1/3 of the grade.

Practical Works List

• TP1: Introduction to Siemens' TIA PORTAL software which is a 4-hour practical session.
• TP2: Process simulation with Siemens' PLCSIM which is a 2-hour practical session.
• TP3: Command of a crossroads fire which is a 4-hour practical session.
• TP4: Command of a system of sorting pieces, which is a 4-hour practical session.
• TP5: Command of a regulator Hydraulics, which is a 4-hour practice session.
• TP6: Regulation of water-level with a Siemens PAC, which is a 4-hour practice session.
• TP7: Command of a lift with Siemens's Control cabinet, which is a 2-hour practice session.
• TP8: CONTROLS a AUTOMATIC deburring SYSTEM by a Control cabinet, which is a practice session of 4 hours.
• TP9: DESIGN of a HMI with TIA PORTAL of Siemens which is a 4-hour practice session.

TP1: Introduction to Siemens' TIA PORTAL Software

• Designed to familiarize users with the programming environment and write/simulate applications on a Siemens Programmable Logic Controller (PLC).
• With using a Ladder Diagram programming language
• Duration: 4 hrs.
• Equipment : PC. A Siemens PLC. TIA PORTAL.

TIA Portal Environment

• TIA Portal is a software combining Siemens' software and hardware.
• This allows creating modular automation solutions, providing simulations.
• TIA Portal configures/programs S7-300/400/1200/1500.
• However old modules S7-300/400, aren't supported.
• Also integrates SIMATIC STEP 7, SIMATIC WinCC, SINAMICS Startdrive, SIMOCODE ES and SIMOTION SCOUT TIA
• TIA Portal features unique features like multiuser engineering and energy management.
• S7-400H isn't supported by current TIA versions.

Application Configuration with TIA Portal

• General program structure for Siemens PLCs follows specific forms utilizing OBs, FBs, and FCs.
• OB: Organize blocks for the connection concerning the exploitation system
• FB: Blocks, that can be reused parametrically (blocks of memory) by standard IEC
• FC: Functionality by standard IEC, simple blocks waiting to be applied

Material Configuration

• The first step prior to working with a structure is to configure the hardware.
• This can be done by opening the TIA Portal and follow the upcoming steps.
• The program interface allows you to create or to open a project already created.
• A project needs to state a name, location and comment before saving it to the directory assigned.
• The menu is separated by the main tasks that can be performed.

Component Configuration

• The components need to be added for its program to be completed
• One can simply browse components to be added like the CPU.
• Pick a CPU as specified in the menu
• Make to to pick the exact modules that is being requested.
• Select the Add option for the CPU to be applied to the program.
• Determine a addresses of the modules to be used in the program by clicking on the module.
• The variable 10 shows the address can be edited in the table.

Software Setup

• Select the view portion which leads to the Programming screen with the applied information.
• This programming space opens a new window and leads to code and other settings.
• Write the first code ladder into this space.
• Compile and upload the newly create program into the unit to be applied.

Next Steps

• The next steps after finishing writing the first program is as followed.
• Testing for functionality of the program being applied.
• Finding and fixing any bugs that need fixing.
• Reconfiguration for new additions that are going to be required.
• All code must abide by the the following format.

Simulation of a Process

• The goal is to use the PLCSIM module of TIA Portal, moving one step further with the use of a simulation and its various options.
• Transfer a STEP 7 program to the PLCSIM to simulate
• Programing and simulate with of TIA PRTAL

Execution

• For easy manipulation follow these steps and rules.
• Exécute the program PLCSIM from the desktop for its program manipulation.
• Upload the program to PLCSIM to simulate the program and modules to be applied.
• The next icon needs to be followed in the screen with its assigned data for the simulation.
• Enter into MPI to connect the program to the interface that is being used.
• Add the module of inputs, timers, and simulation.
• After the insertion of all programing data insert new modules which is crucial for the program to function.
• To start the program you can select run and begin to see to result.

Rules Applied

• By applying the previous mentioned the previous.
• The result can then be applied to the equations and the functions.
• The use of DB1 can then be implemented across the program for more variables to be applied.
• Int needs to also be integrated like DB for its information.
• Always view each stage of the program for its information for the simulation.

Traffic Light Control

• Program the system in a basic, and automation function to allow the system to work with the most amount of safety.
• Always connect the application to the assigned automation device.
• Debug how the system run in the best form that can be applied to the current build. Add adjustment and enhancement for the automation for its optimal build.

Automation

• The light will switch back and forth with its pedestrian crossing in a safe manor.
• Follow the sequence of the applied data. Traffic Light Table | Step | Rp | Op | Vp | Rs | Os | Vs | Rpi | Vpi | Duration | | ---- | --- | --- | --- | --- | --- | --- | --- | --- | -------- | | 1 | 1 | 0 | 0 | 1 | 0 | 0 | 1 | 0 | 1 | | 2 | 0 | 0 | 1 | 1 | 0 | 0 | 1 | 0 | 10 | | 3 | 0 | 1 | 0 | 1 | 0 | 0 | 1 | 0 | 2 | | 4 | 1 | 0 | 0 | 0 | 0 | 1 | 1 | 0 | 8 | | 5 | 1 | 0 | 0 | 0 | 1 | 0 | 1 | 0 | 2 | | 6 | 1 | 0 | 0 | 1 | 0 | 0 | 0 | 1 | 30 |
  • The light will switch back and forth with its pedestrian crossing in safe way.
• Cables need to follow data for which side needs to connect.
• The process for programming starts at Tia Portal with 7 of automation

Synthesis

• Summarize the findings and draft a report which needs contain previously clear the element namely: purpose, and the necessary data.
• A report should be in a well presentable form.

Command with a Tri

• Programs needs basic safety automation to go over the other
• always debug the program in its fullest for basic code functions.
• Always program with adjustment enhanced for optimal speed.
• When using programs make to code is as safe as possible.
• The machine needs to work on several variables working with the Tri mode.
• The system can be used in several variables of unique functions.
• Work the information in sections to optimize each section to apply it.
• Program is to be written like the Ladder which is a main point of use.
• Variables need to be programable.
• Each part needs has its safety for safe manual use.

Hydraulic

• The purpose of the present labor is to perform the verification of components from automation of which command and assure to be automation.
• Each labor must perform, or affect verification of each type of component, and handle correct installation.
• Has to be done by each student and verified for its safety.

Equipment

• The equipment needs to be in place to execute the lab and program to the unit.
• Program needs to be uploaded to the new PLC unit for the information to be shown fully.
• Then it must be connect to the PC for it connect and do its primary function to the hydraulic unit that its doing.
• Then it must be connected to the main portion and components to its proper data section of the diagram.
• Code must be done in program by Step7 from Tia portal

Control

• Assuring the control of the square cycle like the following.
• The synthesis is in the end to make it safe as possible, that the unit does not short circuit and does not over heat. D1+; D2+; D3+; D4+ ; D4- ; D3- ; D2-; D1-;
• Summaries these results find, and writes up a report LABOR which must contain cleat it the elements previously, notably: and the goal, the theoretical calculations, the material used, the diagrams of fitting, the boards of measures, the interpretation of results and the conclusion

Water Regulation

• The student must learn to program the unit that the software is using.
• As well as knowing the link to the PAC so there are not short circuits or damage components.
• Students have 4 hours to make up of the tests.
• They must learn how to connect to unit with the computer.
• Program the test to ensure for function and safety of both people and equipment.
• Each student must complete each test to finish with the correct result for its function.
• Each variable must be tested and working for the unit to be fully finish.

Elevator Controls

• The goal is to maintain and sustain the automatic systems so there can be an equal spread function.
• There must have good knowledge of the systems function so there are not shorts, are malfunctions.
• Lab Time is about 2 hours.
• There may be some missing pieces to that may need to be added.
• Each student must complete with the right settings and components.
• Safety is also top priority so to make sure in this high traffic system
• There must be some functions for safety as a base.

Cabling

• When the correct values are added, the project can have its settings programmed from the PLC unit.
• The program would upload to the server for it work in motion.
• As stated in the previous sections there most be many tests that work.
• Test each function and if found do a step back through other variables to see cause and source.

Automatic Degreasing System

• System has an automated system for all the pieces are to be worked on.
• To assure optimal performance test and keep an eye on the process.
• It’s a 4 hours lab that needs to take in all the steps.

Implementation

• Always learn to code the software.
• PLC unit is to be known by heart for its settings and connections.
• Learn process for its complex industrial value.
• The test needs to be made by a group to assure safe and proper installation and use.

Process

• The program will dip and clean the process by and automation system.
• The part for the software to work is the button.
• Each move is a new line.
• Each part that is loaded to for its cycle.
• The data then will be charted graph for each part.

Code

• The system needs correct and secure code.
• Need know ladder program to follow data.
• Follow each step in the process to know what the machine is doing.

HMI design

• Goal is create interface of which people and workers know so workers can interface with equipment.
• Also be used by machine and personnel.
• The test takes for 4 hours and must program by people.

Steps For program

• Needs several automated system and must be made with people that know the system well.
• There a touch is a screen on the HMI where to program.
• The PLC codes the screen and its functions.
• The main goal is to learn how to interface the PLC to the HMI.

Process Code

• Follow the data from the Tia portal and check the connections..
• Each variable needs a graphic.
• Always test the device.

Equipment List

• Essential Equipment. Automated device to be applied like and automatic PLC device Electronic supply system Oscilloscope A maquette is a educational machine A interactive screen such as a tactile screen And a fully functioning PC
• Recommended and Needed Quality Projectiles

Explore the principles of automation and control in industrial processes, focusing on safety protocols and practical applications. This manual provides guidance on understanding the operation of setups and devices, the importance of measurements, and the utilization of results. Learn to define measurable quantities and conditions for effective automation.