Industrial Process Automation Systems

Industrial Process Automation Systems

Design and Implementation

1st Edition - November 26, 2014

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  • Authors: B.R. Mehta, Y. Jaganmohan Reddy
  • Hardcover ISBN: 9780128009390
  • eBook ISBN: 9780128010983

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Industrial Process Automation Systems: Design and Implementation is a clear guide to the practicalities of modern industrial automation systems. Bridging the gap between theory and technician-level coverage, it offers a pragmatic approach to the subject based on industrial experience, taking in the latest technologies and professional practices.Its comprehensive coverage of concepts and applications provides engineers with the knowledge they need before referring to vendor documentation, while clear guidelines for implementing process control options and worked examples of deployments translate theory into practice with ease.This book is an ideal introduction to the subject for junior level professionals as well as being an essential reference for more experienced practitioners.

Key Features

  • Provides knowledge of the different systems available and their applications, enabling engineers to design automation solutions to solve real industry problems
  • Includes case studies and practical information on key items that need to be considered when procuring automation systems
  • Written by an experienced practitioner from a leading technology company


Practicing automation design and maintenance engineers, junior level engineers from instrumentation, electrical, chemical and production, Students at PG level for Control and Instrumentation, Process Automation, Chemical Engineering in chemical, petrochemical, power, metals, mining and pharmaceutical industries

Table of Contents

  • 1: Industrial automation
    1.1. Introduction
    1.2. Innovators
    1.3. Industrial revolutions
    1.4. Evolution of automation from needs perspectives
    1.5. Evolution of automation from technology perspectives
    1.6. Challenges three decades back
    1.7. Current challenges
    1.8. Technology trends
    1.9. Device connectivity
    1.10. Automation system controllers
    1.11. The generic duties of an automation system in hierarchical form
    1.12. Functional requirements of an integrated information and automation systems: A generic list
    1.13. Conceptual/functional topology of an automation system
    2: The programmable logic controller
    2.1. Introduction to the programmable logic controller
    2.2. Hardware
    2.3. Internal architecture
    2.4. I/O devices
    2.5. I/O processing
    2.6. Ladder and function block programming
    2.7. Function blocks
    2.8. IL, SFC, and ST programming methods
    3: Distributed control system
    3.1. Introduction
    3.2. Evolution of traditional control systems
    3.3. Distributed control systems
    3.4. Functional components of DCS
    3.5. Diagnostics in IOs
    3.6. Controllers
    3.7. Workstations
    3.8. Functional Features of DCS
    4: Batch automation systems
    4.1. Introduction
    5: Functional safety and safety instrumented systems
    5.1. Functional safety: an introduction
    5.2. What is functional safety?
    5.3. Safety functions and safety-related systems
    5.4. Example of functional safety
    5.5. Legislation and standards
    5.6. IEC 61508/IEC 61511: an introduction
    5.7. Scope of the standard
    5.8. The overall safety life cycle (SLS)
    5.9. Risk and its analysis and reduction
    5.10. Safety requirements and safety functions
    5.11. Safety integrity levels (SIL)
    5.12. Functional safety management
    5.13. Layers of protection
    5.14. Risk analysis techniques
    5.15. Safety requirement specifications
    5.16. General requirements
    5.17. Response time
    5.18. SIF specification
    5.19. Operator interfaces (HMI)
    5.20. Safety instrumented systems
    5.21. Reliability and diagnostics
    5.22. SIS voting principles and methods
    5.23. SIS SIL level calculation tools
    5.24. SIS communication protocols and field-buses
    5.25. FF-SIS: foundation Fieldbus for safety instrumented systems
    5.26. PROFISafe
    5.27. PROFIsafe protocol
    5.28. Black Channel principle
    5.29. Integrated Safety data communications
    5.30. Selection of safety instrumented system
    6: Fire and gas detection system
    6.1. Introduction to the fire and gas (F&G) detection system
    6.2. Understanding industry safety performance standards
    6.3. Critical components
    6.4. F&G detectors
    6.5. F&G network architecture
    6.6. Integrated approach for F&G
    6.7. Conclusion
    7: SCADA systems
    7.1. Overview of SCADA systems
    7.2. Minicomputers and microprocessors
    7.3. Remote terminal units
    7.4. Communication technologies
    7.5. Program development tools
    7.6. Operator interface
    8: Programmable automation controller
    8.1. Modern industrial application
    9: Serial communications
    9.1. RS232 overview
    9.2. RS232 signal information
    9.3. Limitations of RS232 applications
    9.4. Overview of EIA-485
    9.5. The difference between RS232/RS485/RS422
    9.6. Modbus serial communications
    9.7. Modbus map
    9.8. Error checking methods
    9.9. Modbus exception codes
    10: Industrial networks
    10.1. Introduction to industrial networks
    10.2. The OSI network model
    10.3. TCP/IP
    11: HART communication
    11.1. Introduction
    11.2. Technology
    11.3. HART technology
    11.4. Application environment
    12: PROFIBUS communication
    12.1. Overview
    12.2. Supported topology
    12.3. Data exchange
    12.4. Fail-safe operation
    13: Foundation fieldbus communication
    13.1. Fieldbus technology
    14: Wireless communication
    14.1. Introduction
    14.2. Basic concepts of industrial wireless communication
    14.3. ISA100 standard
    14.4. Networks
    14.5. Network configurations
    14.6. Gateway, system manager, and security manager
    14.7. Applications of wireless instrumentation
    14.8. Designing and engineering a wireless system
    15: OPC communications
    15.1. Introduction
    16: Asset management systems
    16.1. Definition of an asset
    16.2. Asset management system
    16.3. Key goal of asset management system
    16.4. Fault models
    16.5. Calculation model
    16.6. Maintaining work processes
    16.7. Unneeded trips to the field – avoided through remote diagnostics
    16.8. Life cycle work processes
    16.9. Intelligent field devices – data flow
    16.10. Integrated asset management
    16.11. Use of the tools
    16.12. Instrument asset management systems – architecture/subsystems
    16.13. Smart field devices
    16.14. Asset management system: role-based diagnostics
    16.15. Device rendering technologies
    16.16. Limitations of DD technology
    16.17. Enhanced device description language
    16.18. FDT/DTM
    16.19. The DTM
    16.20. Key benefits to the users
    17: Calibration management systems
    17.1. Introduction
    17.2. Need for calibration
    17.3. Traceability
    17.4. Calibration standards
    17.5. Calibration concepts
    17.6. Documentation
    17.7. Calibration of transmitters
    17.8. Calibrating a conventional instrument
    17.9. Calibrating a HART instrument
    17.10. Calibrating fieldbus transmitters
    17.11. Calibration Management System
    17.12. Calibration Software
    17.13. Benefits of using calibration management system
    17.14. Business benefits
    18: System maintenance
    18.1. Overview
    18.2. Distributed control system maintenance
    18.3. Maintenance software
    18.4. Maintenance program implementation and management
    18.5. Software and network maintenance
    18.6. Computer operating environment
    18.7. Network maintenance
    19: Advanced process control systems
    19.1. Introduction and need for advanced process control (APC)
    19.2. History of process control
    19.3. Advanced process control
    19.4. Advantages of APC
    19.5. Architecture and technologies
    20: Training system
    20.1. Introduction to process modeling
    20.2. Training Systems
    20.3. Components of training simulators system
    20.4. Architecture of a Typical training simulators
    21: Alarm management systems
    21.1. Introduction
    21.2. Conventional and advanced alarm systems
    22: Database systems
    22.1. Historian database
    23: Manufacturing execution systems
    23.1. Introduction
    24: Cyber security in industrial automation
    24.1. Plant Control Network
    24.2. Cyber attacks
    24.3. Understanding common PCS vulnerabilities
    24.4. Common PCS software security weaknesses
    24.5. Standards
    25: Mobile and video systems
    25.1. Introduction
    25.2. Mobile process monitoring console
    25.3. Key benefits of wireless process mobile console
    25.4. Handheld mobile device solutions
    25.5. Some of the major benefits of field-based mobility solutions
    25.6. Mobile device based solutions
    25.7. Video system analytics
    25.8. Regions of interest
    25.9. Minimum object size
    25.10. Video system camera server
    25.11. DCS
    25.12. Operator console
    25.13. Video system client

Product details

  • No. of pages: 668
  • Language: English
  • Copyright: © Butterworth-Heinemann 2014
  • Published: November 26, 2014
  • Imprint: Butterworth-Heinemann
  • Hardcover ISBN: 9780128009390
  • eBook ISBN: 9780128010983

About the Authors

B.R. Mehta

B.R.Mehta is Senior Vice President with Reliance Industries Ltd., Mumbai. He has over 41 years’ experience in the refinery and petrochemicals industry. He has worked on control systems and instrumentation engineering projects for Patalganga, Hazira, and Jamnagar Refinery & Petrochemicals during his 22+ years with Reliance Industries. Prior to joining Reliance, he worked for Agro-Chemical & Food Co., Kenya as Chief Instrumentation Engineer and for Indian Petrochemicals Ltd., Vadodara for 11 years as Instrument Engineer.

He is currently heading the design & engineering department for control systems & instrumentation. During his career he has worked with many overseas licensors, including U.O.P, Foster Wheeler , ICI, Union Carbide , Du Pont , Stork and Stone & Webster. He has also worked with engineering contractors Bechtel, John Brown , Lummus , Jecobs H & G , Lucky Engineering, Chemtex , Worley, and Aker Kvaerne. He has worked on basic engineering, detailed engineering, procurement, inspection, expediting, construction, testing, pre-commissioning & commissioning of various petrochemicals, chemicals, co-generation power & refinery projects from concept to Commissioning.

Affiliations and Expertise

Senior Vice President, Reliance Industries Ltd., Mumbai

Y. Jaganmohan Reddy

Y. Jaganmohan Reddy
Dr. Y. Jaganmohan Reddy, has 18 years of experience in the field of industrial automation and control as a Senior Architect, Systems engineer, Project engineer, Test engineer, Maintenance engineer, and has also worked for Pre and Post sales support in industrial instrumentation, control and automation solutions. He graduated with a degree in Electronics and Instrumentation Engineering in 1997 from Kakatiya Institute of Technology and Sciences, Kakatiya University, Warangal and has a Masters in Software Systems in 2004 from Birla Institute of Technology and Sciences, Pilani, and got his Ph.D. in Electronics and Communication Engineering from JNTUK, Kakinada. Earlier in his career he worked for JOCIL Ltd, a subsidiary of The Andhra Sugars Limited as an engineer (Instrumentation), responsible for maintenance and project activities of the instrumentation and Control Engineering. He is currently working as a senior architect in Natural Gas Measurement and Monitoring Systems in HTS Lab Pvt. Ltd, Hyderabad.

Dr Reddy has published 26 research papers in various International/National journals and conferences and has authored two books on microgrids. He is a member of ISA, IETE and a Certified Automation Professional (CAP) and Systems Engineering Professional, and his research areas include Industrial automation, Power systems, Energy management systems, Instrumentation, and control systems.

Affiliations and Expertise

Senior Architect at Honeywell Technology Solutions Lab, Hyderabad Area, India, and International Society of Automation (ISA) Certified Automation Professional (CAP).

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