Industrial Process Automation Systems

Design and Implementation

1st Edition - November 26, 2014
Authors: B.R. Mehta, Y. Jaganmohan Reddy
Language: English
Paperback ISBN:
9 7 8 - 0 - 1 2 - 8 1 0 2 6 5 - 7
Hardback ISBN:
9 7 8 - 0 - 1 2 - 8 0 0 9 3 9 - 0
eBook ISBN:
9 7 8 - 0 - 1 2 - 8 0 1 0 9 8 - 3

Industrial Process Automation Systems: Design and Implementation is a clear guide to the practicalities of modern industrial automation systems. Bridging the gap between theory… Read more

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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.

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

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).