BEIA612 

Module Name Lifecycle of an Industrial Automation Project 
  Module Code BEIA612 
    Level Six 
  Credits 15 

  

  

Module Description and General Aims 

The objective in presenting this module is to give students a systematic view of the professional tasks and practices employed in the engineering of automation systems. The aim is to enable the students to recognize the context of any particular engineering task within the discipline field by having knowledge of a typical C& I project life cycle. Knowledge of well-established top-down design procedures will assist in the development of a professional and responsible approach to working within a project team, to provide automation solutions. 

The subject matter covered in this module will include: the development of an automation system – beginning with consideration of the industrial context of the application, and the influences affecting the design of the control system equipment; the project life cycle stages; functional design specifications; control system architecture; and implementation of hardware and software solutions. 

  

Learning Outcomes 

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

  1. Prepare a set of design guidelines and objectives for an automation system that will be appropriate for the industrial context and business objectives of the application. 
    Bloom’s Level 6 
  1. Describe the characteristic features and performance expectations of automation systems according to the industry that they serve. 
    Bloom’s Level 2 
  1. Design a project plan for the implementation of an automation system. 
    Bloom’s Level 6 
  1. Generate control system architecture diagrams for integrating field instrumentation with control units, operator interfaces, and data acquisition systems. 
    Bloom’s Level 6 
  1. Produce an outline functional design specification for a small automation application. 
    Bloom’s Level 6 
  1. Compare alternative design proposals for an automation system and justify the most suitable version for the required lifetime of the plant. 
    Bloom’s Level 5 

  

Student Assessment 

Assessment Type When assessed Weighting (% of total module marks) Learning Outcomes Assessed 
Assessment 1 Type: Multi-choice test / Group work / Short answer questions / Practical / Remote Lab / Simulation Example Topic: Automation needs in industry sector; understanding of equipment selection and matching. Students may complete a quiz with MCQ type answers and solve some simple equations to demonstrate a good understanding of the fundamental concepts Due after Topic 3 15% 1, 2 
Assessment 2 Type: Multi-choice test / Group work / Short answer questions / Practical / Remote Lab / Simulation Example Topic: Automation system implementation. Automation needs of a given manufacturing process and project plan to deliver the solution Students may provide solutions to simple problems on the listed topics Due after Topic 6 20% 3 
Assessment 3 Type: Multi-choice test / Group work / Short answer questions / Practical / Remote Lab / Simulation / Project / Report Example Topic: Selection of appropriate types of automation equipment based on functional design specifications. Or Simulate – design a simple automatic control function complete with operator displays and alarm and data recording. Students may complete a quiz with MCQ type answers or solve some simple problems or using software to complete a practical. Due after Topic 9 20% 1, 4, 5 
Assessment 4 Type: Examination Example Topic: All topics An examination with a mix of detailed report type questions and/or simple numerical problems to be completed in 3 hours Final Week 40% 1 to 6 
Assessment Type When assessed Weighting (% of total module marks) Learning Outcomes Assessed 
Attendance / Tutorial Participation Example: Presentation, discussion, group work, exercises, self-assessment/reflection, case study analysis, application. Continuous 5% 1 to 6 

  

Prescribed and Recommended Readings 

Textbook 

  • M. P. Groover, Automation, Production Systems, and Computer-Integrated Manufacturing, 4th Edition. Pearson, 2015. ISBN: 9781292076126 

Reference 

  • Fundamentals of Industrial Automation, Revision 2, IDC Technologies, Perth. 
  • J. Stenerson, Industrial Automation and Process Control. Prentice Hall, 2002. ISBN-13: 9780130330307. 
  • Reddy, YJ 2015, Industrial Process Automation Systems – Design and Implementation, Elsevier, ISBN 978-0-12801-098-3.  
  • Caro, D 2014, Wireless Networks for Industrial Automation, 3rd ed, ISA, ISBN 978-0-876640-18-0. Online version available at:  

Journal, website 

  • www.Controldesign.com 

Notes and Reference Texts 

  • Other material advised during the lectures 

  

Module Content 

  

Topics 1 and 2: Industry sectors and their automation needs 

  1. Machinery automation (typical requirements of a single machine, such as an injection moulding machine) 
  1. Manufacturing (factory) automation (production lines and cell manufacturing concepts) 
  1. Application and role of robotics 
  1. Concepts of manufacturing systems 
  1. Characteristics of mining automation 
  1. Chemical Process Automation (characteristic features and functional requirements) 

  

Topics 3 and 4: Automation system components and choices 

  1. Terminologies used across the automation field 
  1. Automation controllers with examples of DCS, SCADA, PLC 
  1. Control Room Displays, Machinery User Interfaces, Data Capture Devices 
  1. Review of control and automation preferences by industry sector 

  

Topic 5: Typical functions and services of an automation system 

  1. Local and remotely controlled operations 
  1. Human-Machine Interface (HMI) for local supervision 
  1. Area supervision and control room operations including alarm management 
  1. Production recording and performance monitoring 

  

Topic 6: Development of the Functional Design Specification 

  1. User requirements specification 
  1. Functional design specification (key elements and their impact on the project) 
  1. Software user requirements specification 

  

Topics 7 and 8: Equipment selection practices 

  1. PLC system benefits 
  1. DCS Solution benefits 
  1. Instrumentation networks and maintenance facilities 
  1. Consideration of expansion and lifetime support for hardware and software 

  

Topic 9: Documenting the automation requirements 

  1. Standards for system representation, instrumentation, and application software 
  1. Presentation of control system functionality on the P&ID 
  1. Instrument and signal lists 
  1. Exercises in defining instrument and control functions 

  

Topics 10 and 11: Engineering stages of the automation system 

  1. Typical PLC and DCS system project life cycle stages from FDS to commissioning 
  1. The duties of clients and contractors 
  1. The role of the systems integrator 
  1. Cost estimating principles and key components of cost in automation 

  

Topic 12: Topics and Module 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. 

  

  

Software/Hardware Used 

Software 

  • Software: Citect SCADA 
  • Version: N/A 
  • Instructions: N/A 
  • Additional resources or files: N/A 

Hardware 

  • N/A