Industrial Automation &

Instrumentation
November 16, 2017

By: ENGR. GAMALIEL F. ITAO, P.E.E, M.Entr.

President , ICC-MTC
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.
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.
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.
While Industrial Automation or
Mechatronics is more commonly
called Machine Automation.
-It’s using PLC as the basic building
block of Automation.
While INDUSTRIAL AUTOMATION OR
MECHATRONICS is more commonly
called Machine Automation.
It is using PLC as the basic building
block of Automation.
 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.
 CONTROL SYSTEM

I. OPEN LOOP SYSTEM

INPUT LOGIC OUTPUT

-Pushbuttons -Relays -Motors

-Limit Switches -Timers -Solenoid
-Level Switches valves
-Counters
-Flow Switches -Lamps

PLC
 A TYPICAL CONTROL SYSTEM (ELECTROMECHANICAL)
INPUT DEVICES CONTROLLER OUTPUT DEVICES
RELAY
PUSHBUTTON MOTOR
COIL

LATCHING COIL SOLENOID

LIMIT SWITCH

LED DISPLAY
THUMB TIMER COIL
WHEEL 8 8
SWITCH
8 8 8
CLOCK
HEATER
LEVEL SWITCH COUNTER HEATER

CNT
LAMP
RESET
FLOW SWITCH
ELECTRONIC CARDS
MECHATRONICS
IS DEFINED AS THE SYNERGESTIC
INTEGRATION OF MECHANICAL, ELECTRICAL,
ELECTRONICS, AND INFORMATION
TECHNOLOGY TO PRODUCE INTELLIGENT
EQUIPMENT OR MACHINE AUTOMATION
 INDUSTRIAL AUTOMATION (MECHATRONICS)
CORE COMPETENCIES
Certification Requirements Core Competencies Required Knowledge
NC IV + NC IV Competencies : NC IV Required Knowledge : -
Mechatronics and PRC Registered Engineer
Automation Engineer (REE, RME, RECE) -Develop PLC and HMI software Advanced PLC programming
+( MRSP Certification application program -Human machine interface (HMI)
Exams) - Intro to SCADA
Mechatronics and -Diagnose and Troubleshoot
Automation Specialist NC IV + Mechatronics and Automation
BS Engineering System
/Technology degree
Course , Vocational -Commission PLC and HMI-based
Course with 5 years Mechatronics and Automation
experience System
-Develop Mechatronics and -Basic PLC programming
Mechatronics and NC II –NCIII + Automation Control Circuits & PLC -Intermediate PLC Programming
Automation Master BS Engineering Software Application Programs -Motion control :
Technician /Technology Course + -Maintain and Repair PLC-based inverters and servo motors
Vocational Course with 2 Mechatronics and Automation
years relevant experience System
-Develop Motion Control and
System Configuration
-Install Mechatronics and - Electro pneumatics / hydraulics
Mechatronics NC II + Any Voctech Automation Devices - Industrial motor
Technician course -Configure & Test Mechatronics - Sensors
and Automation System -Intro to PLC
MECHATRONICS
INDUSTRIAL AUTOMATION
UNDERPINNING KNOWLEDGE
Electro Pneumatic / Hyrdaulics
Sensors
Basic PLC
Industrial Motor
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.
YOU WILL FIND APPLICATION OF
ELECTROPNEUMATIC IN MOST
AUTOMATION SYSTEM
Intelligent plastic injection
molding machine
 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
ASSEMBLY LINE
Pneumatic Press
(STAMPING LINE)
PACKAGING LINE
MECHATRONICS NCIV
CORE COMPETENCIES
COMMISSION MECHATRONICS SYSTEM
DIAGNOSE AND TROUBLESHOOT
MECHATRONICS SYSTEM
UNDERPINNING KNOWLEDGE
Advance PLS Programming
Human Machine Interface (HMI)
SCADA
MCS NC IV : ADV.PLC/ HMI
SUGGESTED
MCS NC V: SCADA
■ SCADA : Supervisory Control and Data Acquisition
15MW HFO PEAKING
POWER PLANT
SCADA SYSTEM
NOVEMBER 22 2012
SCADA WORKSTATIONS
SCADA SCREEN: ENGINE
OVERVIEW

SAMPLE SCREEN
INSTRUMENTATION
PROCESS AUTOMATION
 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 1.3 Process Control - control of temperatures,
deals mostly with the Process pressures, flows, levels, and analytical measures
Control. of physical and chemical properties
 CONTROL SYSTEM
CLOSED LOOP (FEEDBACK SYSTEM)
Controller
Error
Final Control
Control Unit Process
Element
Pressure
Set Point
Level
+ _ Temperature
Flow

Measuring
Measured Element
Variable
Primary Element /
Transducer

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 - 4-20 mA is common for analog signals - as input for the
control system.
 CONTROL SYSTEM
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.
 Electrotechnical Trade Core Competencies
ROADMAP FOR INSTRUMENTATION AND CONTROL SERVICING
Core Competencies Training Workshops Required Job Qualifications/Positions
(Practical Skills to be Assessed) (Underpinning Skills & Qualified
Knowledge)
NCII
-Install instrumentation and -Basic instrumentation - Instruments installer
control devices - Process & instrument diagrams - Instrument fitter
-Calibrate instrumentation - Process measurements - Calibration technician
and control devices (Pressure, level, flow & temp.) - Instrumentation
-Configure instrumentation - Calibration techniques craftsman
and control devices - Instrument installation & - Instrumentation
hook up details technician

NCIII
-Loop-check instrumentation and control -Process measurements & control - Test and process control
loops -Process loop controllers Loop check technician
- loop diagram details
-Maintain and repair instrumentation and - Repair and maintenance
-Instruments function test
control devices -Control valve stroke check technician/supervisor
- Senior instrument
technician
NCIV
-Start-up commissioning instrumentation - Advance instrumentation - Testing and
and control devices - PID fine tuning commissioning
- Instrumentation system test
-Diagnosese and troubleshoot technician/engr.
and commissioning
instrumentation and control devices - Analytical instrumentation - Process automation
- DCS technician/
- Instrumentation Engineer
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
INSTRUMENTATION ENGINEERING
 UNDERPINNING KNOWLEDGE
Basic Instrumentation
Process & Instrumentation Diagram
Process Measurement
Calibration Techniques
Instrument Installation & Hook Up Details
WATER TREATMENT LINE
WATER TREATMENT LINE
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.
ACCURATE
For a calibration to be accurate it is
necessary to make sure that all
standard instrument to be use are
within known accuracy.
COMMON CALIBRATION
TERMS
UNIT UNDER TEST: The device or instrument
being compared to standard.
Example: Pressure Gauge, Sensors (RTD),
Pressure/Flow/Level/Temperature, Transmitter
 COMMON CALIBRATION
TERMS
STANDARD TEST EQUIPEMNT: A standard
measuring device use to verify the correctness of a
test instrument. Also known as “Calibrators”.
WHY?
■ Instrument drift during time.
■ To keep high and consistent product quality.
■ Comply with regulations/quality systems.
■ Safety reasons.
■ Maintenance purpose.
 WHERE?

Bench/Shop Calibration

•Done in a laboratory or calibration room.

Field/On-Site Calibration

•Done on-site or directly on field

LABORATORY:
CALIBRATION SET-UP
LABORATORY # 1

Differential Pressure Transmitter

Smart Pressure Transmitter

I/P Transducer

Temperature Transmitter

Temperature Controller
LABORATORY # 1
+ Power Supply
-
24 Vdc
+ _
High Side

D/P
Transmitter
+ -
Ammeter

Pneumatic Calibrator
LABORATORY # 2
+
250 ohms
Power Supply
SMART
Pressure -
24 Vdc
Transmitter
+ _

High Side

+ -
Ammeter
SFC

Pneumatic Calibrator
 LABORATORY # 3
+
I/P Transducer
-

Current
Output Generator
3-15 psi
Supply: 20 psi

Pneumatic Calibrator Standard Gauge

LABORATORY # 4
Power Supply

24 Vdc
Temp. Transmitter-RTD
+ -
Input + -

A B B

Resistance Box
Ammeter
ICS NC III –NCIV
Conventional Control Panel
(WW Pumping Station)
Old Panel Indicators
Conventional Control System
Equipment
PLC-SCADA BASED SYSTEM
Picture Documentations

NOW: SCADA Based Control Panel

Picture Documentations

Manila
Waters
Sewerage,
Inc.
Lift Station
2005 March

RAYMOND RICOHERMOSO

Main Screen
Rockwell
Automation
Picture Documentations
 INDUSTRIAL MECHATRONICS GLOBAL
CONTROLS TECHNOLOGIES TECHNICAL
CORPORATION CORPORATION MAINTENANCE
SERVICES
“The Automation and Instrumentation “The Mechatronics and Instrumentation
Training and Assessment Center” “The Plant Maintenance Specialist”
Systems Solutions Provider, General
Construction, General Engineering, MEPF”
 END
THANK YOU!
GAMALIEL F. ITAO
[email protected]
09189119153