Engineering Institute of Technology

 

Unit Name

AUTOMATION, MEASUREMENT AND CONTROL

Unit Code

BME 209S

 

Unit Duration

Term

Award

Bachelor of Science (Engineering)

 

Duration 3 years

Year Level

Two

Unit Creator/Reviewer

 

Core/Sub-discipline

Sub-discipline

Pre/Co-requisites

BSC104C

Credit Points

3

 

Total Program Credit Points 81 (27 x 3)

Mode of Delivery

Online or on-campus.

Unit Workload

(Total student workload including “contact hours” = 10 hours per week)

Lecture : 1.5 hours

Guided labs / Group work / Assessments : 2 hours Tutorial : 1.5 hours

Personal Study : 5 hours

The objective in presenting this unit is to provide students with a comprehensive overview of the principles of industrial automation, measurement, and control, and to enable them to effectively apply these concepts to automation projects.

 

The subject matter covered in this unit will include: the fundamentals of industrial automation and control systems; the function and application of Programmable Logic Controllers (PLCs) and related devices; Supervisory Control And Data Acquisition (SCADA), Distributed Control System (DCS), and Industrial Data Communications Systems; process measurement and instrumentation concepts; the basics of loop tuning; and, control valve sizing and selection.

 

The topics are structured such that students will gain practical knowledge of each key concept/system individually, and then learn how these concepts/systems can be merged into an efficient control system. Students will also complete a project whereby they will be required to select and size a control valve for a given application, using standard sizing principles and equations.

 

The elements of an industrial control system form part of an interconnected web using Ethernet, field buses, and wireless technology. At the conclusion of this unit, students will have been imparted with the requisite knowledge to effectively navigate, harness, and synthesize the many interconnected and interdependent industrial automation technologies into an efficient control environment.

 

Learning Outcomes

 

On successful completion of this Unit, students are expected to be able to:

  1. Evaluate the fundamentals of industrial automation and control systems.

  2. Examine the function and application of PLCs and related devices.

  3. Discuss the attributes of SCADA, DCS, and Industrial Data Communications Systems.

  4. Explain and apply process measurement and instrumentation concepts.

  5. Apply the basics of loop tuning.

  6. Perform control valve sizing and selection.

    Completing this unit may add to students professional development/competencies by:

    1. Fostering personal and professional skills and attributes in order to:

      1. Conduct work in a professionally diligent, accountable and ethical manner.

      2. Effectively use oral and written communication in personal and professional domains.

      3. Foster applicable creative thinking, critical thinking and problem solving skills.

      4. Develop initiative and engagement in lifelong learning and professional development.

      5. Enhance collaboration outcomes and performance in dynamic team roles.

      6. Effectively plan, organise, self-manage and manage others.

      7. Professionally utilise and manage information.

      8. Enhance technologist literacy and apply contextualised technologist skills.

    2. Enhance investigatory and research capabilities in order to:

      1. Develop an understanding of systematic, fundamental scientific, mathematic principles, numerical analysis techniques and statistics applicable to technologists.

      2. Access, evaluate and analyse information on technologist processes, procedures, investigations and the discernment of technologist knowledge development.

      3. Foster an in-depth understanding of specialist bodies of knowledge, computer science, engineering design practice and contextual factors applicable to technologists.

      4. Solve basic and open-ended engineering technologist problems.

      5. Understand the scope, principles, norms, accountabilities and bounds associated with sustainable engineering practice.

    3. Develop engineering application abilities in order to:

      1. Apply established engineering methods to broadly-defined technologist problem solving.

      2. Apply engineering technologist techniques, tool and resources.

      3. Apply systematic technologist synthesis and design processes.

      4. Systematically conduct and manage technologist projects, work assignments, testing and experimentation.

The Australian Engineering Stage 1 Competency Standards for Engineering Technologists, approved as of 2013. This table is referenced in the mapping of graduate attributes to learning outcomes and via the learning outcomes to student assessment.

 

Stage 1 Competencies and Elements of Competency

1.

Knowledge and Skill Base

1.1

Systematic, theory based understanding of the underpinning natural and physical sciences and the engineering fundamentals applicable to the technology domain.

1.2

Conceptual understanding of the, mathematics, numerical analysis, statistics, and computer and information sciences which underpin the technology domain.

1.3

In-depth understanding of specialist bodies of knowledge within the technology domain.

1.4

Discernment of knowledge development within the technology domain.

1.5

Knowledge of engineering design practice and contextual factors impacting the technology domain.

1.6

Understanding of the scope, principles, norms, accountabilities and bounds of sustainable engineering practice in the technology domain.

2.

Engineering Application Ability

2.1

Application of established engineering methods to broadly-defined problem solving within the technology domain.

2.2

Application of engineering techniques, tools and resources within the technology domain.

2.3

Application of systematic synthesis and design processes within the technology domain.

2.4

Application of systematic approaches to the conduct and management of projects within the technology domain.

3.

Professional and Personal Attributes

3.1

Ethical conduct and professional accountability.

3.2

Effective oral and written communication in professional and lay domains.

3.3

Creative, innovative and pro-active demeanour.

3.4

Professional use and management of information.

3.5

Orderly management of self and professional conduct.

3.6

Effective team membership and team leadership.

Successfully completing this Unit will contribute to the recognition of attainment of the following graduate attributes aligned to the AQF Level 7 criteria, Engineers Australia Stage 1 Competency Standards for Engineering Technologists and the Sydney Accord:

 

Graduate Attributes

(Knowledge, Skills, Abilities, Professional and Personal Development)

EA Stage 1 Competencies

Learning Outcomes

A. Knowledge of Science and Engineering Fundamentals

A1. Breadth of knowledge of engineering and systematic, theory-based understanding of underlying principles, and depth of knowledge across one or more engineering sub- disciplines

 

1.1, 1.3

 

1, 2, 3, 6

A2. Knowledge of mathematical, statistical and computer sciences appropriate for engineering technology

 

1.2

 

4, 5, 6

A3. Discernment of knowledge development within the technology domain

1.4

2, 3

A4. Knowledge of engineering design practice and contextual factors impacting the technology domain

 

1.5

 

B. Problem Solving, Critical Analysis and Judgement

B1. Ability to research, synthesise, evaluate and innovatively apply theoretical concepts, knowledge and approaches across diverse engineering technology contexts to effectively solve engineering problems

 

1.4, 2.1, 2.3

 

5, 6

B2. Technical and project management skills to design complex systems and solutions in line with developments in engineering technology professional practice

 

2.1, 2.2, 2.3, 3.2

 

C. Effective Communication

C1. Cognitive and technical skills to investigate, analyse and organise information and ideas and to communicate those ideas clearly and fluently, in both written and spoken forms appropriate to the audience

 

3.2

 

4, 5, 6

C2. Ability to engage effectively and appropriately across a diverse range of cultures

3.2

 

D. Design and Project Management

D1. Apply systematic synthesis and design processes within the technology domain

2.1, 2.2, 2.3

 

D2. Apply systematic approaches to the conduct and management of projects within the technology domain

 

2.4

 

6

E. Accountability, Professional and Ethical Conduct

E1. Innovation in applying engineering technology, having regard to ethics and impacts including economic; social; environmental and sustainability

 

1.6, 3.1, 3.4

 

E2. Professional conduct, understanding and accountability in professional practice across diverse circumstances including team work, leadership and independent work

 

3.3, 3.4, 3.5, 3.6

 

6

Unit Competency and Learning Outcome Map

This table details the mapping of the unit graduate attributes to the unit learning outcomes and the Australian Engineering Stage 1 Competency Standards for the Engineering Technologist.

 

 

 

Graduate Attributes

A1

A2

A3

A4

B1

B2

C1

C2

D1

D2

E1

E2

 

Engineers Australia Stage 1 Competency Standards for Engineering Technologist

1.1

 

 

 

 

 

 

 

 

 

 

 

1.2

 

 

 

 

 

 

 

 

 

 

 

1.3

 

 

 

 

 

 

 

 

 

 

 

1.4

 

 

 

 

 

 

 

 

 

 

1.5

 

 

 

 

 

 

 

 

 

 

 

1.6

 

 

 

 

 

 

 

 

 

 

 

2.1

 

 

 

 

 

 

 

 

 

2.2

 

 

 

 

 

 

 

 

 

 

2.3

 

 

 

 

 

 

 

 

 

2.4

 

 

 

 

 

 

 

 

 

 

 

3.1

 

 

 

 

 

 

 

 

 

 

 

3.2

 

 

 

 

 

 

 

 

 

3.3

 

 

 

 

 

 

 

 

 

 

 

3.4

 

 

 

 

 

 

 

 

 

 

3.5

 

 

 

 

 

 

 

 

 

 

 

3.6

 

 

 

 

 

 

 

 

 

 

 

 

Unit Learning Outcomes

LO1

 

 

 

 

 

 

 

 

 

 

 

LO2

 

 

 

 

 

 

 

 

 

 

LO3

 

 

 

 

 

 

 

 

 

 

LO4

 

 

 

 

 

 

 

 

 

 

LO5

 

 

 

 

 

 

 

 

 

LO6

 

 

 

 

 

 

Student assessment

Assessment Type

When assessed

Weighting

 

(% of total unit marks)

Learning Outcomes Assessed

 

Assessment 1

Type: Multi-choice test / Group work / Short answer questions / Practical / Remote Lab / Simulation

Example Topic: Industrial automation and control system basics.

Students will complete a quiz with MCQ type answers to 30 questions to demonstrate relevant knowledge of the fundamentals governing industrial automation and control systems.

 

Week 3

 

15%

 

1

 

Assessment 2

Type: Multi-choice test / Group work / Short answer questions / Practical / Remote Lab / Simulation

Example Topic: PLCs, SCADA, DCS, and industrial data communications.

Students will provide evidence of their grasp of the principles of PLCs, SCADA, DCS, and industrial data communication systems by responding to descriptive type questions.

 

Week 6

 

20%

 

2, 3

 

Assessment 3

Type: Multi-choice test / Group work / Short answer questions / Practical / Remote Lab / Simulation / Project

/ Report

Example Topic: Instrumentation, process control.

Students will demonstrate their knowledge of instrumentation and process control concepts by providing answers to short essay questions or undertake a practical exercise using Codesys software for example.

 

Week 9

 

20%

 

4, 5

 

Assessment 4

Type: Project or Examination

Example Topic: Control valve selection and sizing, all topics.

Students will be asked to select and size a control valve for a given application, using standard sizing principles and equations or an examination with a mix of descriptive type questions, numerical problems to be completed within 3 hours.

 

Final Week

 

40%

 

1 to 6

 

Attendance / Tutorial Participation

Example: Presentation, discussion, group work,

 

Continuous

 

5%

 

1 to 6

Assessment Type

When assessed

Weighting

 

(% of total unit marks)

Learning Outcomes Assessed

exercises, self-assessment/reflection, case study analysis, application.

 

 

 

 

Prescribed and recommended readings

 

Required textbook

Fundamentals of Industrial Automation, IDC Technologies, Perth

Doebelin, EO 2003, Measurement Systems: Application and Design, 5th edn, McGraw Hill, ISBN-13: 978-0072922011

Reference

Beckwith, TG, Marangoni, RD & Lienhard, JH 2008, Mechanical Measurements,6th edn, Pearson Education, ISBN-13: 978-0136093763

Raghavendra, NV & Krishnamurthy, L 2013, Engineering Metrology and Measurements, 1st edn, Oxford University Press, ISBN-13: 978-0198085492

 

Journal, website

Peer-reviewed journals and websites (advised during lectures)

 

Notes and Reference texts

Knovel library: http://app.knovel.com IDC Technologies

Other material advised during the lectures

 

Unit Content

One topic is delivered per contact week, with the exception of part-time 24-week units, where one topic is delivered every two weeks.

 

Topic 1

Introduction to Industrial Automation

  1. History of industrial automation

  2. Industrial automation basics

  3. Basic measurement and control concepts

  4. Instrumentation and transducer considerations

  5. P&ID symbols for instrumentation

 

Topic 2

Fundamentals of Control Systems

  1. Basic concepts and control terminology

  2. Modes of feedback control

  3. Reverse or direct acting controllers

  4. Open loop characterization of the process

  5. Dead zone

  6. The industrial process in practice

 

Topic 3

Introduction to PLCs

  1. PLC basics

  2. Components of the PLC system

  3. PLC and process interaction

  4. Programmable Automation Controllers (PACs)

  5. Soft PLCs

  6. Standard programming languages

 

Topic 4

SCADA and DCS

  1. Fundamental principles of modern SCADA systems

  2. SCADA hardware and software

  3. Remote terminal units

  4. Operator panels

  5. DCSs

 

Topic 5

Industrial Data Communications

  1. OSI model

  2. Serial communications (RS-232/RS-485)

  3. Industrial Ethernet and TCP/IP

  4. Field buses (DeviceNet, Profibus, Foundation Fieldbus H1)

  5. Industrial wireless

  6. Industrial network security

  7. OPC

 

Topics 6 and 7

Instrumentation

  1. Introduction to process measurement

  2. Pressure measurement

  3. Level measurement

  4. Temperature measurement

  5. Flow measurement

  6. Process considerations

  7. System integration

  8. Conversion between analogue values and SCADA displayed values

  9. Effects of filtering

  10. Aliasing and too low scan rates

 

Topics 8 and 9

Process Control and Business Systems

  1. Basic definitions and terms used in process control

  2. Process dynamics and time constants

  3. PID control

  4. Cascade control

  5. Implementation of control

  6. Fundamentals of loop tuning

  7. Tuning rules

    1. Ziegler Nichols open loop tuning

    2. Ziegler Nichols closed loop tuning

    3. Trial & error tuning

  8. Tuning of valves

  9. Simple tuning of more complex systems

  10. Manufacturing Execution Systems (MES)

  11. S88 batch language

  12. System integration models and concepts

  13. S95 standard

 

Topics 10 and 11

Control Valves

  1. Control valve principles

  2. Different types of control valves

  3. Control valve characteristics

  4. Selecting right type of control valve for given application

  5. High pressure drop applications

  6. Actuators

  7. Positioners

  8. Materials

  9. Installation and maintenance

  10. Control valve sizing:

    1. Manually

    2. With software

 

Topic 12

Unit Review

In the final week students will have an opportunity to review the contents covered so far. Opportunity will be provided for a review of student work and to clarify any outstanding issues. Instructors/facilitators may choose to cover a specialized topic if applicable to that cohort.

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