PULP BATCH BLENDING:

The PLC controls sequence operation,ingredient measurement and recipe storage for the blending process.the system allow the operator to modify batch entry of each quantity,if necessary provides hard copies print out for inventory control and for accounting of ingredients used.
BATCH PREPARATION FOR PAPER - MAKING PROCESSING:
Application includes control of the complete stock preparation system for paper manufacturing.Recipe of each batch task are selected and adjusted via operators entries PLC can control feed back logic for chemical addition based on tank level measurement signals.At the completion of each shift the PLC system provides management reports on materials used.
PAPER MILL DIGESTER: The PLC controls process of making power pulp from wood chips.The system controls the amount of chips based on density and digested volume.Then the percent of the required cooking liquors and these amount are added to the sequence. The PLC ramps and hold the cooking temperature until the cooking is completed..
PAPER MILL PRODUCTION:The controller regulates the average basic weight and moisture variable for paper grades. The system manipulates the steam flow values, adjust the stock value to regulate weight, monitor and control total flow.
RUBBER AND PLASTICS:
TYRE- CURING PRESS MONITORING:The PLC perform individual press monitoring for time,pressure and temperature during each press circle.The system alerts the operator of any press malfunction.information concerning machine status which is stored in table for latter use.Report generation printouts for each shift include a summary of good cures and press downtime due to malfunctions..

ENERGY MANAGEMENT:

POWER:
Power Plant System:The programmable controllers regulate the proper distributions of available electricity,gas or steam in addition,the PLC  monitors power house facilities, schedule the distribution of energy, and generate the distribution of reports. ,
Energy Management : Through the reading of inside and outside temperatures,The PLC control heating and cooling limit in a manufacturing plant.The PLC system controls the loads, recycling them during the predetermined cycles,and keeping track of how long each should be on or off during the cycle time.The cycle provides scheduled reports on the amount of energy used by the heating and cooling units The PLC controls the loads during operation of the plant as well as automatic load shedding or restoring driving power outages.
COOL FLUIDIZATION PROCESSING.The PLC monitors how much energy is generated from given amount of coal and regulate the coat crushing and mixing with crushed limestone,The PLC monitors and control burning rates,temperature generated,sequencing of values.compressor efficiency control,The PLC control several compressors at a typical compressor station.The system haloed safety interlocks,start up and short down sequences and compressors recycling. The PLC  keep compressors running at maximum efficiency using the non linear curves of the compressor

PROGRAMMABLE LOGIC CONTROLLER APPLICATIONS CONT.

CONVEYOR STSTEM: The conveyor system controls all of the sequence operations,alarm and safety logic necessary to load and calculates the parts on main line conveyor.It also sorts products to their correct lanes and cam schedule lane sorting to optimize appetizer duty.Records detailing the ratio of good parts.
AUTOMATED WAREHOUSING:The PLC controls and optimizes the movements of stacking cranes and provides high turn around of materials rejects in an automated high cube, vertical warehouse. The PLC also controls aisels conveyors and case to significantly reduce manpower requirement.Inventory control figures are maintained and could be provided on request
METALS:
STEEL MAKING: The PLC controls and operate the furnace to reduce metal in accordance with present specification.The controllers also calculate oxygen requirement,alloy addition and proper requirements.
COLD ROLLING: The PLCs controls the conversion of semi- finished products into finished goods through cold rolling mills.The system controls motor speed to obtain correct tension and provide adequate gauging of the rolled material.
ALUMINIUM MAKING:Controllers monitor the refining process, bauxite by heat and chemicalsThe system grinds and mixes the ore with chemicals and them pump them into pressure containers,where they are heated filtered and combined with more chemicals.
POWER PLANT SYSTEM.
The programmable controllers regular the proper distributions of available electricity,gas or steam in addition,the PLC monitors power house facilities, schedule distribution of energy,generate distribution reports The PLC controls the load during operation of the plants as well as the automatic load shedding or restoring driving power outages.
ENERGY MANAGEMENT:Through the reading of inside and outside temperatures,the PLC control heating and cooling unit in a manufacturing plant.
..

MANUFACTURING AND MACHINING.

The production machining are controlled and monitored by programmable logic controller on automatic mode production machines at high efficiency rates.the PLC also monitor piece - count production and machines status,corrective actions can be taken as soon as possible assuming there is an upsurge,
METALS: Steel making: The PLC controls and operate furnace to produce metals in accordance with preset specification.The controllers also calculates oxygen requirement,alloy addition and power requirements.
LOADING AND LOADING ALLOYS:Through accurate weighing and loading sequences,the systems control and monitors the quantity of coals,iron ore and limestone to be welted,  it can also control unloading sequence of the steel to a torpedo car.
c
CONTINUE CASTINGS:It direct the molten steel reports ladles to the continuous casting machine,where the steel is pored into a water-cooled mould solidification.
.

MANUFACTURING AND MACHINING:

PRODUCTION MACHINES:The PLC controls and monitor automatic production machines at high efficiency rates. It also monitor piece count production and machines output corrective action can be taken immediately if it detects a failure.
TRANSFER LINES MACHINES: The PLCs monitor and control all transfer lines machining station operations and interlocking between each station.This system receives input from the operator to check the operating condition on the line mounted control and reports any malfunctions.These arrangement provides greater machine efficiency,higher quality products and lower scrap level.
WIRE MACHINE:The controllers monitor the line and on and off cycles of a wire drawing machines. The system provides ramping and control and synchronization of electric motor drives.
All cycles are corded and reported on demand to obtain the machines efficiency as calculated by the PLC.
TOOL CHANGING:The PLCs control the synchronous metal cutting machines with several tool groups.the system keeps the track on when each tool that should be released which is based on the number of parts it manufactures.It also displace the count and replacement of all the tool groups.
PAINT SPRAYING:The PLCs controls the painting sequences in automobile manufacturing.The operators or a host computer inters styles and colour information and track the parts through the conveyor until it reaches the spray booth.The control decodes the part information and then controls the spray gun to paint the part.The spray gun movement is optimized to conserve and increase part throughout.
AUTOMATIC PLATING LINE:The PLC controls a set of pattern for the automated host which can traverse left. right. up and down through the various plating solutions.The system knows where the host is at times,
STORAGE AND RETRIEVAL SYSTEM:The PLC is used to load parts and carry them in role to the storage and retrieved system. The controller tracks information like -line numbers,the parts to a specific lanes, and the quantity of parts in a particular lane.The PLC arrangement allows rapid change  in the status of parts loaded or unloaded from the system. The controller also provides inventory printouts,and inform the operator of any malfunctions.
CONVEYOR:The system controls all of the sequence of operation.,alarm and safety logic necessary to load and calculate  parts on main conveyor.It also sorts product to their correct lanes and earn schedule lane sorting to optimizer duty.Records,detailing the ratio of good parts .
AUTOMATED WAREHOUSING:The PLC controls and optimizes the movement of stacking cranes and provides high turn around of material requests in automated high cube,vertical warehouse.The PLC also controls aisles of conveyors and case palletizes to significantly reduce manpower requirement. Inventory control figures are maintained and could be provided on request.

PLC APPLICATION : GAS TRANSMISSION AND DISTRIBUTION

Programmable controllers monitor and regulate pressure and flow of the gas transmission and distribution systems,data is gathered and measured in the field and transmitted to the PLC system.
PIPELINE AND PUMP STATION CONTROL The PLC control machines and booster pump for crude oil distribution.it measures flow suction, discharge and tank low and high limits,possible communication with SCADA (Supervisory control and data acquisition) system can provide total supervision of the pipeline.
OIL FIELDS:The PLC provides on side gathering and processing pertinent to characteristics such as depth and density of fluid for drilling rigs.The PLC control and monitor the total rig operations and alert the operators of any possible malfunction.
GLASS PROCESSING:The PLC controls the lehr to remove the internal stress of glass products.This system controls the operation by  the following: i)the annealing temperature curve during the reheating,annealing straining and rapid cooling process through different heating and cooling zones,improvement are made in the ratio of glass to scrap reduction in labour cost and energy utilization
GLASS BATCHING: The programmable controller controls the batch weighing according to the store glass formular (s).The system also controls the electromagnetic feeders for in-feed to and out feed from the weighing hoppers,manual shot-off gates,and other equipment.
CULLET WEIGHING: The PLC directs the cullet system by controlling the vibratory outlet feeder,weight belt scale and shuttle conveyor.All sequences of inventory of the quantities weighted are kept by the PLC in future use,
BATCH TRANSPORT: The PLC also control the batch transport system including reversible belt conveyors,transfer conveyors to the cullet house, holding hoppers,shuttle conveyor,and magnetic seperators. The controller, takes action after the discharge from the mixer and transfer the mixed batch to the furnace shuttle, where it is discharged to the full length of the furnace field hopper.

PLC APPLICATION: CHEMICAL AND PETROCHEMICAL

AMMONIA AND ETHYLENE PROCESSING: Programmable controllers monitor and control large compressors that are using ammonia and ethylene manufacturing.The PLC monitors bearing temperature, operation of clearance pockets,compressor speed,power consumption vibration, discharge temperature,pressure and suction flow.
DYES : PLC monitors and control the dye processing used in the textile industry. They match and blend colour to pre-determined values.
CHEMICAL BATCHING:The programmable logic controller controls the batching ratio of two or more material in a continues process.The system determine the rate of discharge of each materials and keeps inventory records. Several batch recipes can be logged and retrieve automatically or on command from the operator.
FAN CONTROL: PLC control fan based on a level of logic gases in a chemical production environment.This system effectively remove gases,when at a preset level of contamination reached,the PLC control the fan starting and stopping,recycling and speeds,so that the safety level are maintained while energy consumption are minimized.

AUTOMOTIVE: INTERNAL COMBUSTION ENGINE MONITORING.

A PLC acquire data recorded from sensors located at the internal combustion engine. The  measurement that would be taken includes the following: water temperature, oil temperature revolution per minute,torque, exhaust temperature,oil pressure, timing,manifold pressure. etc.
CABURETOR PRODUCTION TESTING:The programmable logic controller provides online analysis of automotive carburetors in a production assembly line.the system significantly reduce the testing time,while providing greater yield and better quality carburetors,pressures, vacuum,and fuel and air flow are some of the variables tested.
MONITORING AUTOMOTIVE PRODUCTION MACHINES:The systems monitors total parts,rejected parts,parts produced,machine cycle time and machine efficiency,Statistical data is available to the operator at any time or after each shift.

TYPICAL AREAS OF PLC APPLICATION.

The PLC systems has been successfully applied in virtually every segment of the industry,including steel mills,paper plant , food processing plants,chemical plants and power plant since the inception.The programmable logic controllers perform a great deal or variety of control tasks,from repetitive ON and OFF control of simple machines to sophisticated manufacturing and process control.The list below indicates some of the industries that the programmable controllers are applied as well as some of their typical applications.
CHEMICAL AND PETROCHEMICAL:Batch process,finished product handling,material handling,mixing,offshore drilling,piping control,water and waste treatment.
MANUFACTURING AND MACHINING:Assembly machines, cranes ,energy demand,cranes,grinding, injection blow moulding,material conveyors.metal casting,mulling,painting,plating, test stand tracer lathes,welding.
GLASS AND FILM.Weighing,finishing,forming,lehr control, packing processing.
METALS: Blast furnace control, continuous casting,rolling mills,scaling pits.
FOODS AND BEVERAGE:Accumulating conveyors,blending,brewing container handling,distilling,filing,load forming,carburetors in a production assembly lines,the system significantly reduce the testing time,while providing greater yield and better quality carburetors.pressures, vacuum and fuel air flow are some of the variables tested.

NEW GENERATION PROGRAMMING CONTROLLER - 2.
Many controllers advances in the programmable controllers are effectively ongoing today. These advances are not only the effect of the programmable controller design, but also the philosophical to control system architecture,changes include hardware ( physical components ) and software (control programmed upgrades. The following list describe some recent PLC hardware enhancement.
In using new advanced microprocessor and electronic technology faster scan time are being achieved.
-Faster scan time are being achieved using new advanced microprocessor and electronic technology.
-Small low cost PLCs which could replace four to ten relays,the new PLCs have more power than their predecessor, the simple relay replacer.
-High - density input and output i and o system provides space and efficient interface at low cost .
-Intelligent microprocessor based i and o interface have expanded distributed processing.Typical interfaces includes PID ( Proportional integral derivative),network ,CANbus, Fieldbus,ASCII,communication positioning,host computer and language modules (e.g:BASIC,PASCAL)..
-Mechanical design improvements have included rugged input and output enclosures and input and output systems that .have made the terminal an integral unit.
-Special interfaces have allowed certain devices to be connected directly to the controllers. Typical interfaces include thermo-couples,strain gauges and fast response inputs.
-Peripheral equipment has improved operator interface techniques,and system documentation is now a standard part of the systems.
  All of these hardware enhancements have led to the development of the programmable controller faimilies ,These family consist of a product line that ranges from very small microcontrollers with as few as 10 i and o points,to very large and sophisticated PLC,with as many as 800 i and o points and 128000 words of memory. These family member using common i and o systems and programming peripherals,could interface to a load communication network.The family concepts is an important cost saving development for users.

THE FIRST PLC - 3 THE GENERATION PROGRAMMABLE CONTROLLERS continue.

: Many technology advances in the programmable controllers industry continue today and these advance are not only the programmable controller design, but also the philosophical approach to control systems architecture, changes include both  hardware (physical components) and software (control programme) upgrades. The following list describes some recent PLC hardware enhancement..In using new advanced microprocessor and electronic technology.,faster scan time are being achieved.
-It is obvious that as hardware advances, so the software are also making changes to balance the trend of development in information network technology..
PLC;s have incorporated object oriented programming tools and multiple languages based on the JEC 1131 - 3 standard.
Small PLC;s have been provided with powerful instructions, which extend the area of application for these small controllers
-High level languages, such as Basic and Cobol have been implemented in some controllers modules to provide greater programming flexibility when communicating with peripheral devices and manipulating data.
 -Advanced functional block instruction have been implemented for ladder diagram instruction sets to provide enhanced software capability using simple programming command.
- Diagnostics and fault detection have been expanded from simple diagnostics,which diagnose controls malfunctions to includes machines which diagnose failures or the malfunction of the control machine or process.
- Floating point math has made it possible to perform complex calculations in control applications that require gauging and balancing which are statistical computation.
Data handling and manipulation instruction has been approved and simplified to accommodate complex control and data acquisition application that when storage,tracking and retrieving of large amount of data.
programmable controllers are now matured control system offering many more capabilities than were ever anticipated.they are capable of communicating with other control system providing production report,scheduling production,and diagnosis their own failures and those of the machine or process.
These enhancement have made programmable                                                                             controllers important.contributors in meeting today;s demand for higher quality and productivity.Despite the fact that programmable controllers have become much sophisticated, they still retain the simplicity and ease of operation that indented in their original design.

THE FIRST PLC - 1

The first plc offered functionality,thus replacing the original hardware relay logic which used electrically separated device to mechanically switch electrical circuits.They met the requirement of modularity, expand ability, and programmability and ease to use in an industrial environment.These controllers were easily installed  because it uses space and were reusable.The controller programming although was a bit tedious but it had recognizable plant standard of the ladder diagram format.in a short period, programmable controllers usage started to spread to other industrial areas, By 1971.PLC;s were being used to provide relay replacement which was the first step towards the application of control automation in other industries,such as food and beverages, metal manufacturing, pulp and papers (Bryan,1968).
The conceptual designed of the PLC: The first programmable controllers were more or less replacers and their primary function was to perform the segmental operations that were previously implemented with relays .These operation include ON and OFF control machines and process that required repetitive operation such as transfer lines and grinding machines, jig saw,and boring equipment and machine.However this programmable machines were a vast improvement over relays.they were easily installed and considerable less space and energy, had diagnostic indications that aided trouble shooting and unlike transfer relays, were reusable if a project was scrapped.
The programmable controller could be considered as new devices when they are compared to their predecessors in traditional control equipment technology, such as old hard wired relay systems, analog instrumentation and other types of early solid - state logic. Although PLC function such as speed of operation, types of interfaces, and data processing capabilities,have improved through out the years,their specification still holds to their designers original intension they are simple to maintain.

APPLICATION OF ADVANCED GAS POWER PLANT SYSTEM MANAGEMENT AND CONTROL. ( schematic drawings)

I n view of the fact that gas plants and other facilities are forced to increase the performance and profitability of their production systems,mean that, engineering parameters of the operating machines  and the process networks have to be operated within their designed limits, to avoid backlashes on their performance effectiveness and control . It would creates sequential justification of the network operation and prevent production losses.In most cases needs for effective inspection of the instrument devises are very imperative to avoid unprecedented situation.. The increasing demand for petroleum products requires optimal maintenance planning, monitoring measures and operational development through adequate orientation.. Facility performance and  derivative of the necessary by- product are very important, but achieving these steps means setting out milestones through good team efforts. Manpower development  also improves adequate implementation of maintenance effectiveness., Its justification for the available maintenance safety devices should be  updated and kept to its required operational standard, through adequate inspection and site evaluation report..Since the beginning of mechanical maintenance area and primary protection has been very important in other to prevent production delay in case of failures and faults.In recent times maintenance of plants and operating facility seem to be very important to the entire society that large efforts has to made to accelerate efficient system performance integrity which militate the consequence of failure..this situation will make engineering maintenance increasingly depending on modern information technology that provide wide area protection to counteract wide area disturbance and minimize process outages.






























The prerequisite is communication network not only for supervisory control and data acquisition (SCADA) and energy management systems (EMS) but also for providing he protection, maintenance and planning department with direct access from remote to information. from the operating plants. primary and secondary equipment  fig1.0. and fig 1.2.
It will be ideal to split the communication system into two practical networks. one for real data change control and fast automatic interactions between varuous controls and system (plant stations ) amd maintenance management systems.(WAN) the non real time data e,g parameter ,measurement and monitoring data

LITERATURE REVIEW

Many researcher have conducted thesis dissertation to enhance proper automation strategy of maintenance management and control of industrial facilities and plants. And consistent efforts are being projected  towards achieving good performance  and reliability of  the automation  management system in the industry..The intents are directed on alleviation of management of companies,industries and other production facilities.Some service company such as Airlines, Production, Maintenance experts and many Manufacturing companies, including Oil refineries and Production have very high precision investment in Equipment that is vital for both efficient management of these devices and  their safety implication, for successful business attainment.The basic achievable objective in the overall interest is dependability of service, which is one of the fulcrum of performance measures , by which a company could distinguish itself.

ENGINE AND MACHINES PROGRAMMABLE LOGIC CONTROLLERS

In most of the power generation industry. ranging from automobile food packing, oil industry and banking, programmable are used for their day to day operations in order to expand and enhance production operations.In this project some aspect of these powerful and versatile automation tools would be illustrated, It will also bring to mind the basis of programmable controllers from their operation to their vast range of application.The internal configuration of the design philosophy behind their creation with a brief overview of their evaluation would also be expatiated. It will also be compared to other types of controls to highlight their benefit and backdrop as well as where it can efficiently be operated.
Programmable logic controllers are also called programmable controllers or PLC which are also solid members of the computer family using integrated circuit instead of electro - mechanical devices to implement control functions.They are capable of storing instruction such as sequencing ,timing,counting, arithmetic data manipulation, other control logic.industrial machines and processors,




                                                                 1



                                        3*                                          * 4


                                                       
                                                     
                                                              2      
                                                       5            6


Fig.3.0 conceptual diagram of a plc.
(the arrow moves from 1).

1  programmable machine,
2 programmable controller
3 measure
4. control
5 field input
6 field output.                                                

AUTOMATION UTILIZATION EFFECTS

The increase of automation utilization is steadily reducing the time of work force employed in the production and maintenance area.Electronics data processing enhance the activities of the engineers but the optimal trend are increasing both for the evaluation of cost or the complexities of maintenance requirements. The opportunity and needs for improving maintenance performance are also growing at a rapid pace due to the improvement of automation process in almost every aspect of the industry.
The problem encounter in applying intelligent management to maintenance may be very complex but sometimes it may require very great deal of data for effective management system. The development of the maintenance history and records are essential for adequate maintenance performance and strategical problems planning.But these records are often quite voluminous and time consuming in both preparation, usage and implementation.The methods apply for material and assembling of information from this records represents an excellent area for work simplification.
AUTOMATION ADVANTAGES:
i)   In operating an automated machinery less number of personnel are involved.
ii)  The internal defect and configuration of plant  are easily traceable through a borescopic survey or      through the programming module.
iii) It provides security to plant and facility.
iv) It provides information for trouble shooting.
v)  It provides unnecessary equipment repair approach.
There are many factors which may affect the department ability to control cost, among these are the age and condition of the equipment, the skill of labour force,the amount and capability of information available to make decisions, the size and value of the store inventory etc.

THE DISTRBUTED CONTROL SYSTEMS ( DCS)

The distributed control systems ( DCS ) are the product of the control industry, the DCS was developed in 1970 as a replacement of single loop digital and analog controllers as control computer systems. Analog  digital controls ( ADCs) typically consist of unit controllers which could handle multiple loop, multiplexer unit to handle a large amount of I and O operator and engineering interface workstation, a historian foreign device gateways and advance control  in a system box or computer, All these are fully integrated and usually connected via communication network ( Bryan,1997).
The digital control systems (DCS) suppliers have traditionally the approach of welding technology and application expertise to solve specific problems. The programming method is called the function block programming which allow a developer to programme the system by mimicking the actual process and data flow The digital control system (DCS) allow reliable communication and control within process and takes hierachical to control with the majority of the intelligence housed in a centralized computer.(Somogyl,2004).
A good analogy for the (DCS) is the main frame computer and desktop computers. In time past it was unheard of,  for computer to based their cooperate computing on anything  order than a mainframe computer, but due to advancement of technology in PC hardware and software, many components now use a network of powerful desktop computer to run their information system. This architecture gives then more power in a flexible user friendly network environment, and at a fraction of the cost of maintenance likewise DCS systems are more distributed than in the past.
The digital control systems are generally used in application where the proposition of analog to digital I and O is higher than 60 and 40 ratio and the control function are more sophisticated .The digital control system DCS are ideal for industries where the process is continuous ,has a high analog system and is distributed across a large geographical region, It is also suited for application;s where down time is very expensive, such as oil processing and refining, industrial pulp and paper including chemical production etc ( Somogyl, 2004 ) .

AUTOMATION OF GAS POWER PLANT SYSTEM.

Enhancing the gas power plant management and performance have been one of the most essential element that attracts serious strategical handling. The management and performance makes lots of difference because of the original equipment manufacturer recommendation and standard of maintenance application and handling which conform to specification.. Although .gas power plant are discussed globally in most conferences for its optimal function by several professional but its effectiveness and efficiency cannot be compared . It is percievable also that there are lots of new technologies available which will assist planners and operators to re - evaluate the technological advances.or trend for marketability.And  that will enable the operators to find new solution to maximize the  application of maintenance system management, through various optimal solution.and adapt to the fast changing micro -environment.. There are three areas where the advanced information technology(IT) could contributes significant benefits in terms of better monitoring performance and reduction of operating and maintenance costs.
i) Advanced monitoring systems management, which really results in higher reliability of plant         performance.
ii) Intelligent plants station automation which assures higher reliability and control of performance and efficiency.
iii) Industrial plant systems monitoring which allows detection of faults and saves maintenance costs.

CONFIRMATION OF AUTOMATION STRATEGY AND SPECIFICATION

CONTROL LOGIC'S:The first programmable controllers were developed 1970 ,by plant engineers and technician in response to a demand for a solid state system that had the flexibility of a computer,yet easier to program and maintained.These early programmable controller took up, less space than the relays,counter timers and other control components they played and offered much flexibility in terms of their programming and capability.The initial programming language was keyed to industry acceptance of the programming controllers, which was based on the ladder diagram and electrical symbols commonly used by electricians..Fixed programmable controllers as self contain unit with a processor,power supply, and a predetermined number of discrete and or analog inputs and outputs (I and O).
A fixed programmable controller may have separate interconnected components for expansion and is small inexpensive and simple to install,(2) Modular controllers are more flexible, offering option for I and O capacity processor memory size input voltage and communication type.
Originally programmable controllers are used to control application where I and O are digital.they were ideal for application that were more sequential and discrete than continuous in nature. Over times,suppliers added analogue and process control capabilities making the programmable controller a more viable solution for batch and process applications (Andreas, 2004).

It was not until micro controllers were introduced, that the programmable could economically meet the demands of smaller machines, i.e equipment that once relied exclusively on relay and single board computers ( SBCs ) micro computers are generally designed to handle 10,32, I and O in a cost efficient package making then a viable and reliable replacement .in addition this low cost and fixed  I and O option has opened the door for many smaller machines original manufacturer (OEMs) to apply automated control in places where it was not feasible in the past For example maintenance could used a micro programmable controllers to power compressor, pump, engine,travelling block, hoist machines,and air conditioner etc,While the technology like the programmable controller has been in the market for more than 25years,there is also the possibility for adequate advancement in this area of technology. There has been also a positive step for the development of Soft control program as an heir to the programmable controller,In essence the soft controller is the act of replacing the traditional controllers with software that allow user to perform programmable controller function in a personnel computer (PC) ..
It is easy band simple to put  the programmable controller in PC clothing, the soft controller is an important development for individual who have control application with a high degree of performance and processing content (somogyl, 2004).
Soft control however is only part of a larger trend of that of PC based control, the PC based control is a concept of applying control functions normally embedded in hardware or software to the control platform. These encompasses not just the control engine,but all aspect of the system including the programming operator interface,operating systems, communication application programming interface (APIs).networking and I and O personal computer (PC) based control.
The soft control system has been adopted by some manufacturer, but must continue to rely on the more rugged programmable controller .This may be true and achievable as new generation programmable controllers incorporating features of PC based control but maintaining their routs in reliability and ruggedness,(Bryan,1997).

THE AUTOMATION SYSTEM

The earliest automated system consisted of an operator turning a switch on which would supply power to output,typically an electric motor.  At some point the operator will turn the switch off, reversing the effect and removing power these were the light switch days of automation . Maintenance soon advanced to relay panels which featured a series of switches that could be activated to bring power to some number of outputs,Relay panels functioned like switches but allow for more complex and precise control of operation with multiple outputs.However bank of relay panels generated significant amount of heat which were difficult to wired and upgrade and also were prone to failure and occupied a lots of space. These deficiencies led to invention of programmable controls. - an electronic device that essentially replaced banks of relay which are used in several forms in millions of today automated operations.In parallel, single  loop and analog controller were replaced by distributed controller system ( DCS) used in majority of contemporary process control applications.These new solid state devices offered greater reliability,required less maintenance and had a longer life than their mechanical counterparts . The programmable language that control the behavior of the programmable controls and distributed control system could be modified without the need to disconnect or reroute single wire.The new automation technology resulted inconsiderable cost saving due to reduced commissioning time and wiring expense, as well as greater flexibility in installation  and trouble shooting . At dawn of programmable controller and digital control systems (DCSs), plant floor operation was isolated from the rest of the enterprise- operating autonomously and out of sight from the company. Those days are almost over as company realized that to excel that they may tap into and analyze and exploit information located on the plant floor. whether the challenge is faster time to market,improve process yield, non stop operation, or a tighter supply chain, getting the right data at the right time is essential.to achieve these , many enterprises turned to contemporary automation controls and networking architecture, computer based control for maintenance,machinery , material handling, systems and related equipment costs can effectively generate wealth of information about productivity, product design, quality and delivery,
Presently automation is more important than ever as company retrieved to fine turn the processes and capture revenue and loyalty from consumers.The thesis will breakdown the major categories of hardware and software that drive industrial automation, define the various layer of automation, detail how to plan, implement, integrate, and maintain a system, to look at what technologies and practice impact maintenance (Andreas,2004)

INDUSTRIAL AUTOMATION SYSTEM.

Automation maintenance brings lots of advantages to the company or enterprise,some are for incremental improvement while others are mostly for survival .In all ramification it is mostly the maintenance, instrumentation and electrical industries etc that demands automation, it is because the production output and customers or sometimes the sensitivity of the operating facilities that forced most of the changes,the customers preference is for better products,more variety and lower costs etc (somogy,2009).
-consistency:customer wants the same experience every time they buy a product
-Reliability:today ultra- efficient factories cannot effort a minute down time with an ideal factory consisting thousands of dollars per day in lost revenues.
lower cost:In a well articulated market where product differentiation is limited,minor variation in costs could caused a customer to switch brands. making the product cost effective as possible,without sacrificing quality critical for over all productivity and financial health.
Flexibility:the ability of quick replacement of malfunctioned devices is critical at a time when company strive to reduce their financial goods inventories and respond quickly to customer demands.It will be an advantage to realize how prevalent industrial automation is in our daily lives, Almost everything in our life has been impacted by industrial automation, for example, it is used in bread production industry,gas utilization, control of elevator,and model automotive machines and vehicles.etc
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THE SPECIFICATION OF MATERIALS AND INDUSTRIAL AUTOMATION .SYSTEM

The specification of  automation strategy of maintenance management of industrial plant and and facility shall conform to an approved code of standard which shall envisage four principal areas viz:     Automation of plants and facility
The automation and strategical management systems of maintenance
The human side of automation systems management in maintenance
And total management and industrial control
The areas mentioned above shall also be considered to either of the following codes for standardization and specifications.
Automation systems and networking, ASTM, ASCII., ASME, API,
Industrial automation equipment,calibration,testing and certification, ASTM,ASCH, ASME,API.
Control logic and inventory ASME ,ASCII,AP, NACE
Industrial automation.process control mensuration. ASME, NACE, API, ASTM.

INDUSTRIAL AUTOMATION SYSTEM.
The industrial automation is a vast device discipline that encompasses machinery,electronics software and information system working together towards a common objective, set of objective or goal i.e increased production , improved quality,lower cost and maximum reliability,and flexibility,,increase productivity could results or creates lapses in quality therefore it is not an easy process but may require sufficient monitoring and supervision.
Keeping costs down could lower productivity and improves quality and repeat ability

 often impact flexibility .. It is the ultimate balance of these four goals -productivity,quality, cost and flexibility that allows a company to used automated production,maintenance,and instrumentation as a strategic advantage in a good market or competitive environment, the ultimate is to strike the balance, Although it could be difficult to obtained but where effective training and planning are adequately mapped out,the advantages can be easily detected visually.Most organisation would conduct some forecasting on their production automation effectiveness, to determined the company achievement in billions of dollars,  hence would enable them to  project further investment in other facility for quality and production improvement..  .
The advantages of automation in production processes,maintenance,and instrumentation effectiveness  in production plants can hardly be over emphasized. A myriad of technical advances i.e faster computers and reliable software,better networks,smarter devices,more advance materials and new enterprises solutions contributes to maintenance systems that are more and agile than ever before.

THE METHODS OF MATERIALS AND DESCRIPTION OF THE STUDY;

Every project investigation and the materials are chosen based on the parameters of the study,they are  situated in an area where the instruments or laboratory requirement for the fact finding can be made easily available.The automation system are mostly utilized in oil and gas producing companies, petrochemical .refinery including  other manufacturing and process industry.And their geographical location are normally stated  to enhance accurate data presentation of material, and the division, .institution,And the local government area where it was performed are also sighted for proper data correlation  .The activities of the oil and gas industries in the state includes exploration,production ,transportation,marketing ,storage and distribution of crude oil,manufacturing of petroleum products and their derivatives . Theses have some maintenance impacts on the machinery that are used for reliability and availability and the automation of the product task ,Total exploration and production (Nigeria) limited an oil company in Nigeria, has operated for over thirty years in this particular area in which the project was sited.hence it was chosen as the best facility where the project could be executed.
THE SAMPLING OF MATERIALS:Th criteria that shall be used to select the research location and experimental work area includes the following: the proximity to industrial area,
                                                              the accessibility to good industrial plants.
                                                              the mechanical plant and facility, instrumentation and                                                                       control,
                                                              the automation process loops and network and other                                                                          tooling,laboratory and equipment
                                           including other accessories that could be relevant in the experimentation fact findings.Engineering measuring instrument sensors, scales and  other devices that could be used for effective technical performance of the project were also available.
The maintenance automation strategical management and control of industrial plants and facilities would be an enormous advantage for effective plant operation.

AUTOMATION LIFE CYCLE MANAGEMENT.

Shanghai,(2009), highlighted that they were satisfied with honey well life cycle management solution which enabled them controllable and predictive future costs, this life management guarantees how their system could be kept running in good working condition .Also their future systems upgrades could be done as part of their strategical plan hence would avoid complicated negotiation process.As one the largest modern petrochemical enterprise in China, shanghai petrochemical maintains the industry leadership by driving technology to suites it needs., in order to find the most cost effective way to manage assets and maintain its technological innovation . Shanghai petrochemical implemented the life cycle management LCM program from honey well solution, a pheonex based process automation vendor. The LCM had proven to a comprehensive cost effective solution,to manage and export shanghai petrochemical existing asset as it undergoes a three years technology migration and expansion project, prior to using the honey-well LCM solution. Shanghai petrochemical faced major challenges in managing assets,keeping technology current, avoiding obsolescence, and controlling maintenance and support costs.the benefit expected with the new LCM solution includes numerous cost saving and performance improvement,such as :
upgrading all global solution(GUS) and application measuring platform,
processing platform (APP) stations resulting in improved performance reliability and risk avoidance .
Controlling predictive cost for maintenance upgrading and expanding the system for the next three years.
planning work scope to suit plant schedules in a more flexible manner.
Mitigating the risk of obsolescence and enhancing safety of plant operation.
Increasing deficiency and costs saving by having a single contract to cover all upgrades and expansion to avoid complicated contract negotiations, The petrochemical is located in Sinshannwei in the Jinshan District of shanghai, SINOPEC Shanghai petrochemical company Ltd. It maintains highly integrated production and operations of petroleum products, petrochemical synthetic fibres and plastics.The Shanghai petrochemical has more than 60 production plants with operation including oil refining petrochemical processes and manufacturing of plastics and synthetic fibres. The company has total assets of approximately US $5 Billion with a work force of more than 23,000.the modern large scale complex has its own utilities to supply waters,electricity,steam and gas,and environmental protection system, ocean and inland water way, rail road and road transportation facilities.The shanghai petrochemical need to upgrade its existing distributed control systems ( DCS ) to the latest technology,and to maintain the leadership as one of the premier petrochemical plant in China. The shanghai petrochemical was looking for an asset management system that will help it remain current in technological changes while maintaining the investment of its legacy systems. It also needed a cost effective solution that will looked at their systems throughout the expected life span.Though prior to using honey well LCM solution, They had a major challenges to manage the asset and more importantly to prevent the system from becoming obsolete. In so doing however,it realized that it has  to look at the impact that the upgrading the technology would have on maintenance and support costs (Shanghai , 2009) .
Shanghai petrochemical turned to honey well to help managed such asset as GUS and APP node computers,history module, advanced process manager (APM), controller and plant cape servers and stations.In view of the impact of the upgrading effects on the Plant maintenance and support of the hardware and software assets, Shanghai petrochemical implemented the Honeywell LCM, and with the life cycle management (LCM) implementation shanghai petrochemical could now manage cost to guarantee continue system operations and ensure that the upgrades are completed according to the company strategical plans (shanghai, 2009) .

OBSOLESCENCE MANAGEMENT AND HIDDEN COST OF AGING COMPONENTS.

Micheal (2005) ,commented that, organisation whose operation rely on long life span equipment cannot effort to hide their heads in the sand over the growing problem of component obsolescence, special interest forum set up to tackle the issue has warned that the components obsolescent group  (COG ), said that the research carried out for the ministry of defense outlined the likely cost, which the British Ministry could avoid in obsolescence management. This ranges from more than 300,000 thousand pounds for a major components for solution involving using existing stockpiled parts. These are non recurring engineering cost and do not include any other associated costs.,such a down time of equipment , any additional engineering to integrate the part , new training procedure which may be required, or storage cost.
Trenchard , (2005) ; emphasised that the costs metrics outligned in the research could be applied across many industrial sectors instances of vulnerable equipment which include military and commercial air craft, trains, transport signaling systems, automotive vehicles, equipment in power plant or special medical devices. According to COG, although the issue of how equipment could be maintained on when parts are no longer available is becoming necessarily widely recognized ,too many organizations are still not taken a proactive approach to managing the potential risk. He continued that by identifying an obsolescence problems early the more expensive problem could be   avoided .Once a component is obsolete, the cost of replacement part could be many times the original cost  not there could also be the additional expense of the equipment being out of service and the man hour it could also take to sources, is difficult to find components or reengineer a suitable replacement. There may not even be any replacement available ;where an equipment cost million of pounds and is intended to decays, managing components obsolescence proactive is very essential, if it is to last its full life expectancy and minimize unneccessary maintenance. The cause implication to an organisation reputation and cost relationships could also be significant, organization are therefore are therefore advised to take step to predict where potential problems might arise and to monitor the availability of components that have a high wish of becoming obsolete. They could work closely with others in the supply chain using well based obsolescence management tools. This will enable them to plan whether and when to increase their stocks and or update equipment , It could also help them to avoid  accidental buying counterfeit or substandard product.