Industrial Process Automation Systems
Design and Implementation
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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
Readership
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
Abstract
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
Abstract
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
Abstract
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
Abstract
4.1. Introduction
5: Functional safety and safety instrumented systems
Abstract
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
Abstract
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
Abstract
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
Abstract
8.1. Modern industrial application
9: Serial communications
Abstract
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
Abstract
10.1. Introduction to industrial networks
10.2. The OSI network model
10.3. TCP/IP
11: HART communication
Abstract
11.1. Introduction
11.2. Technology
11.3. HART technology
11.4. Application environment
12: PROFIBUS communication
Abstract
12.1. Overview
12.2. Supported topology
12.3. Data exchange
12.4. Fail-safe operation
Acknowledgments
13: Foundation fieldbus communication
Abstract
13.1. Fieldbus technology
14: Wireless communication
Abstract
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
Abstract
15.1. Introduction
16: Asset management systems
Abstract
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
Abstract
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
Abstract
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
Abstract
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
Abstract
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
Abstract
21.1. Introduction
21.2. Conventional and advanced alarm systems
22: Database systems
Abstract
22.1. Historian database
23: Manufacturing execution systems
Abstract
23.1. Introduction
24: Cyber security in industrial automation
Abstract
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
Abstract
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
Index
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
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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