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El. knyga: Plant Intelligent Automation and Digital Transformation: Volume I: Process and Factory Automation

(Founder and Chief Executive, Systems and Controls, Kolkata, India)
  • Formatas: EPUB+DRM
  • Išleidimo metai: 28-Oct-2022
  • Leidėjas: Academic Press Inc
  • Kalba: eng
  • ISBN-13: 9780323902472
Kitos knygos pagal šią temą:
Plant Intelligent Automation and Digital Transformation: Volume I: Process and Factory AutomationDidesnis paveikslėlis
  • Formatas: EPUB+DRM
  • Išleidimo metai: 28-Oct-2022
  • Leidėjas: Academic Press Inc
  • Kalba: eng
  • ISBN-13: 9780323902472
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Plant Intelligent Automation and Digital Transformation: Process and Factory Automation is an expansive four volume collection reviewing every major aspect of the intelligent automation and digital transformation of power, process and manufacturing plants, from the specific control and automation systems pertinent to various power process plants through manufacturing and factory automation systems. This volume introduces the foundations of automation control theory, networking practices and communication for power, process and manufacturing plants considered as integrated digital systems. In addition, it discusses Distributed control System (DCS) for Closed loop controls system (CLCS) and PLC based systems for Open loop control systems (OLCS) and factory automation.

This book provides in-depth guidance on functional and design details pertinent to each of the control types referenced above, along with the installation and commissioning of control systems.

  • Introduces the foundations of control systems, networking and industrial data communications for power, process and manufacturing plant automation
  • Reviews core functions, design details and optimized configurations of plant digital control systems
  • Addresses advanced process control for digital control systems (inclusive of software implementations)
  • Provides guidance for installation commissioning of control systems in working plants
Foreword xvii
Preface xix
Acknowledgments xxi
1 General discussions on control systems
1.0 Fundamentals and general discussions on control systems
2(14)
1.0.0 Recapitulations of terms with explanations
2(1)
1.0.1 Requirements for plant automation conceptual discussions
2(4)
1.0.2 Synopsys of issues covered in this volume of the book
6(1)
1.0.3 Microprocessor: microcomputer basics {brief recapitulations)
6(3)
1.0.4 Control implementation issues
9(4)
1.0.5 Mathematical approach for control systems
13(3)
1.1 Control system synthesis and control theory
16(9)
1.1.0 Preliminary discussions
16(1)
1.1.1 Definition of various terms used in control theory
17(1)
1.1.2 Discontinuous (discrete) control system
17(2)
1.1.3 Continuous control system
19(5)
1.1.4 PID implementation in digital control systems
24(1)
1.2 Control loop modes, types and hierarchical control
25(16)
1.2.0 General discussions on modes and types of controls
25(1)
1.2.1 Examples for feed forward control and lag lead controls
25(1)
1.2.2 Cascade control action
25(3)
1.2.3 Ratio control
28(2)
1.2.4 Override control
30(2)
1.2.5 Auctioneering control
32(1)
1.2.6 Split range control
32(2)
1.2.7 Inferential control
34(1)
1.2.8 Adaptive control and gain scheduling
34(3)
1.2.9 Hierarchical control system
37(4)
1.3 Control system models
41(9)
1.3.0 Discussions on control system models
41(1)
1.3.1 Types of systems
42(1)
1.3.2 Model based control (MBC) methodology and structure
42(1)
1.3.3 Various model based control types
43(4)
1.3.4 Control computing and system development
47(1)
1.3.5 Linearization of nonliner systems
47(3)
1.4 State space in control systems
50(2)
1.4.0 Concept of state space and control system
50(1)
1.4.1 State variable and process
50(1)
1.4.2 System state
50(1)
1.4.3 State equation
51(1)
1.4.4 Output equation
52(1)
1.4.5 Block diagram representation of state space
52(1)
1.5 Optimization of controls and automations
52(5)
1.5.0 Basics of process control and process automation
52(1)
1.5.1 Structural approach for integrated optimization and control
52(1)
1.5.2 Discussions on integrated structure
53(1)
1.5.3 Advanced process controller (APC) and optimization
54(1)
List of abbreviations used
54(1)
References
55(1)
Further reading
56(1)
2 Basics of networking
2.0 Basics of networking
57(2)
2.0.0 Outline discussions on basic networking
57(2)
3 Industrial data communication
3.0 Industrial data communication
59(2)
3.0.0 Outline discussions on industrial data communication
59(2)
4 System diagnostics, security, and safety
4.0 Functional details of system diagnostics, security, and safety
61(5)
4.0.0 Discussions on diagnostics, system security, and safety
61(1)
4.0.1 Basic discussions on diagnostics
61(2)
4.0.2 Control system security and access control
63(2)
4.0.3 Plant safety conceptual discussions
65(1)
4.1 Discussions on diagnostics
66(6)
4.1.0 General discussions on self-diagnostics for devices and systems
66(1)
4.1.1 Self diagnosis at field level
67(1)
4.1.2 Self diagnosis in intelligent devices and systems
68(1)
4.1.3 Process/equipment diagnostic method---ADS
69(1)
4.1.4 Diagnosis types and alarms with example
69(1)
4.1.5 Expert diagnosis systems
69(3)
4.2 Control systems security discussions
72(5)
4.2.0 Basic objectives and recommended strategies
72(1)
4.2.1 Control system security risk management
73(1)
4.2.2 Control system security: policy and deployment
74(1)
4.2.3 Discussions on ISA 99/IEC 62443 standard sets
74(3)
4.3 Plant safety discussions with safety fieldbus outline
77(20)
4.3.0 Plant safety and security discussions
77(1)
4.3.1 Conceptual discussions ON SIF, SIS, and SIL and ALARP
78(3)
4.3.2 Outline of safe fieldbus and IS for fieldbus
81(2)
4.3.3 Electrical area classification
83(3)
4.3.4 Enclosure class
86(1)
4.3.5 Intrinsic safety
87(6)
List of abbreviations
93(1)
References
94(3)
5 Control intelligence and futuristic approach
5.0 Control intelligence and futuristic approach
97(3)
5.0.0 Outline of control intelligence and futuristic approach
97(3)
6 PLC and Open-loop control system (OLCS) functional and design details
6.0 PLC and open-loop control system
100(5)
6.0.0 Requirements of OLCS; hierarchical control and interlock discussions
100(1)
6.0.1 OLCS characteristics and comparison with CLCS
101(1)
6.0.2 OLCS CLCS plant automation
102(1)
6.0.3 Interlock concept and hierarchical interlock issues
103(1)
6.0.4 Hierarchical control---grouping discussions
104(1)
6.1 Basics of PLC with hardware details
105(17)
6.1.0 Basics of PLC system
105(3)
6.1.1 PLC logics and I/O interface
108(2)
6.1.2 Discussions on PLC hardware
110(10)
6.1.3 Brief discussions on PLC selection
120(2)
6.2 PLC software discussions
122(12)
6.2.0 PLC software programming types
122(1)
6.2.1 Programming different languages
123(6)
6.2.2 Discussions on software standards for PLC
129(3)
6.2.3 PLC software issues for considerations
132(2)
6.2.4 PLC programming basics and memory area
134(1)
6.3 Types of PLC
134(4)
6.3.0 Basis for PLC classification
134(1)
6.3.1 PLC types based on mounting
135(1)
6.3.2 Types of PLC according to size
136(1)
6.3.3 PLC classification based on I/O types
137(1)
6.3.4 PLC types on redundancy criteria
137(1)
6.3.5 Miscellaneous issues for PLC classifications
138(1)
6.4 Features and configurations of PLC
138(4)
6.4.0 Required features and configuration
138(1)
6.4.1 Salient features of PLC
138(2)
6.4.2 Feature based PLC configuration changes
140(2)
6.5 Networking interfaces and system integration
142(6)
6.5.0 Basic issues for interfaces and system integration (PLC/DCS)
142(1)
6.5.1 Serial link in system integration
142(3)
6.5.2 System integration by fieldbus
145(1)
6.5.3 Ethernet for system integration
146(1)
6.5.4 System integration with OPC
146(1)
6.5.5 Discussions on system integration and interface examples
147(1)
6.6 Brief discussions on HMI and engineering interfaces
148(1)
6.7 System diagnostics and security
149(6)
6.7.0 System diagnostics and security issues
149(2)
6.7.1 Overview of systems (ICS) diagnostics
151(1)
6.7.2 Program diagnostics and tests
151(1)
6.7.3 Process diagnostics and diagnostic analysis for maintenance
152(1)
6.7.4 PLC vulnerability discussions
152(1)
6.7.5 ICS threat, vulnerability and risk factors
153(1)
6.7.6 ICS security program development
154(1)
6.8 PLC performance and application area
155(1)
6.8.0 PLC applications performance and selections
155(1)
6.8.1 Discussions on PLC performance and services
155(1)
6.8.2 PLC application area
156(1)
6.9 Safe PLC discussion
156(15)
6.9.0 General discussions of safe logic solver and safety PLC
157(1)
6.9.1 Requirements for safety PLC system
158(1)
6.9.2 Selection of safe PLC
159(1)
6.9.3 Safe PLC design and implementation issues
160(2)
6.9.4 Factory automation with safe PLC
162(1)
6.9.5 Safe PLC---SIS discussions
163(5)
List of abbreviations used
168(1)
References
169(2)
7 OLCS in process plants andm PLC details
7.0 Open loop controls in process automation and I/O detailing
171(8)
7.0.0 Analog I/O and modulating controls in PLC
172(1)
7.0.1 Distinctive features and evolution of PLC and DCS
172(1)
7.0.2 Technological changes for PLC for process controls
173(1)
7.0.3 Process controls in PLC
174(3)
7.0.4 Discussions on PLC I/Os types and signal processing
177(2)
7.1 Discussions on I/O interfaces types
179(6)
7.1.0 Discussions on PLC I/O categories
179(1)
7.1.1 Discussions on PLC timing issues
180(2)
7.1.2 High speed I/O processing in PLC
182(3)
7.1.3 Special I/O interfaces
185(1)
7.2 Description and design aspect of PLC I/O modules
185(4)
7.2.0 Description and design details I/O modules
185(2)
7.2.1 Discussions on general design issues for I/O
187(1)
7.2.2 Design considerations for I/O modules
188(1)
7.3 Specification of PLC I/O modules
189(1)
7.3.0 Common specification issues
189(1)
7.3.1 Specification for discrete I/O modules
190(1)
7.3.2 Specification for analog I/O modules
190(1)
7.4 Discussions on PLC architecture and redundancy types
190(11)
7.4.0 Broad classification of PLC architecture
191(3)
7.4.1 Discussions on redundant PLC architecture
194(2)
7.4.2 Redundancy and control system connections
196(3)
7.4.3 PLC redundancy types and safety applications
199(2)
7.5 Application programming and analog applications
201(8)
7.5.0 Discussions ON OPP, FB & CM
201(1)
7.5.1 Computation and control in PLC system
202(1)
7.5.2 Computation & control for flow loop
202(2)
7.5.3 Advanced cascade & split range controls in PLC
204(3)
List of abbreviations used
207(1)
References
207(2)
8 Batch process control and automation
8.0 PLC/DCS applications in batch process control
209(7)
8.0.0 General discussions on batch process and PLC/DCS
209(2)
8.0.1 Discussions on batch procedural and control issues
211(2)
8.0.2 Sequential control and programming in batch process
213(3)
8.1 Batch process control standards
216(9)
8.1.0 General discussions of batch control standards
216(3)
8.1.1 Model and recipe in batch process (ISA 88)
219(5)
8.1.2 Recipe composition and structural variations
224(1)
8.2 Batch control system discussions
225(3)
8.2.0 General control and monitoring system
226(1)
8.2.1 Control activity--- batch process management
227(1)
8.2.2 Exception handling
228(1)
8.3 Automation interfaces and control center in batch process
228(5)
8.3.0 General considerations for batch controls
228(1)
8.3.1 Batch process interfaces
229(1)
8.3.2 Network configuration control center and reporting
230(3)
8.4 Batch control execution details
233(4)
8.4.0 General batch executions requirements
233(1)
8.4.1 Operator's guide and historian
234(2)
8.4.2 Batch process data analysis
236(1)
8.5 Discussions on batch process management
237(6)
8.5.0 Overview of batch process management
237(1)
8.5.1 Resource management, batch scheduling, dispatching and tracking
238(1)
8.5.2 Batch process optimization
239(1)
List of abbreviations used
240(1)
References
241(1)
Further reading
241(2)
9 Manufacturing and factory automation
9.0 General discussions: manufacturing advancement and 3D printing
243(6)
9.0.0 General considerations for factory automation
243(2)
9.0.1 Advanced integrated factory automation
245(2)
9.0.2 Basics of 3D printing with benefits applications
247(1)
9.0.3 3D scanning for 3D printing
248(1)
9.0.4 3D printing technology types and materials
249(1)
9.1 Requirements manufacturing automation
249(4)
9.1.0 Essential steps for automation in manufacturing
249(2)
9.1.1 General design aspects of factory automation
251(1)
9.1.2 Manufacturing automation design methodology
252(1)
9.2 Various controls types in manufacturing
253(3)
9.2.0 General issues related to I&C for manufacturing industries
253(1)
9.2.1 Discussions on factory automation CNC, CAD-CAM and CIM
254(1)
9.2.2 PC based controls in manufacturing
255(1)
9.3 Programmable automation control (PAC)
256(4)
9.3.0 Basics of programmable automation controller
256(2)
9.3.1 Discussions on PAC system
258(1)
9.3.2 PAC PC PLC in industrial automation
259(1)
9.4 Total factory automation concept
260(3)
9.4.0 Concept of factory automation and automation benefits
261(1)
9.4.1 Issues related to factory automation and SM
262(1)
9.5 Future automation: Industrie 4.0 and smart factory
263(10)
9.5.0 General discussion on Industrie 4.0
263(3)
9.5.1 Controls AI security and edge computing in Industrie 4.0
266(2)
9.5.2 Smart factory and Industrie 4.0
268(3)
List of abbreviations used
271(1)
References
272(1)
10 Building and service sector automation
10.0 Building management system (BMS): areas of applications
273(7)
10.0.0 General discussions on BMS
273(3)
10.0.1 Conceptual discussions on smart building
276(1)
10.0.2 Trends in building automationsystems
277(1)
10.0.3 Integrated smart building: automation issues
278(2)
10.1 Discussions on BACS: HVAC and other systems
280(10)
10.1.0 Fundamentals of BACS
280(2)
10.1.1 BACS architecture: HW, SW and automation levels
282(4)
10.1.2 HVAC controls and automation
286(2)
10.1.3 BACS: HVAC controls
288(2)
10.2 BACS: integrated and smart buildings
290(4)
10.2.0 Fundamentals of integrated BMS for smart building
290(2)
10.2.1 Discussions on EMS in smart building
292(2)
10.3 BMS: fire and access control
294(4)
10.3.0 General discussions on fire and access control
294(3)
10.3.1 Integration: BACS and fire system
297(1)
10.4 Lighting control in BACS
298(4)
10.4.0 Overview of lighting in BACS
298(3)
10.4.1 Integrated lighting control in BACS
301(1)
10.5 Security issues in BACS
302(7)
10.5.0 General discussions on security issues in BACS
302(2)
10.5.1 Discussions on BACS cyber security
304(2)
List of abbreviations
306(1)
References
306(3)
11 PLCopen concept and applications
11.0 Fundamentals of PLC-open
309(7)
11.0.0 Basics of PLCopen concept
309(2)
11.0.1 Brief discussions on PLCopen XML
311(2)
11.0.2 Basics of PLCopen OPC UA
313(3)
11.1 PLCopen motion: features and applications
316(7)
11.1.0 Basics of PLCopen motion control
317(2)
11.1.1 Discussions on PLCopen functional block and application
319(2)
11.1.2 Discussions on PLCopen motion control standard
321(2)
11.2 PLCopen: safety software
323(8)
11.2.0 Overview of PLCopen safety software specification
323(4)
11.2.1 Discussion on PLCopen safety architecture and processing
327(3)
List of abbreviations used
330(1)
References
330(1)
12 PC-based control, MTP, FDT, EDD, and OPC
12.0 General discussions on PC based systems
331(5)
12.0.0 Overview of PC based system
331(2)
12.0.1 Favorable issues for selecting PC based controls
333(1)
12.0.2 Types and details of industrial PC
334(1)
12.0.3 Open PC technology
335(1)
12.1 PC based PLC/OLCS and motion control
336(7)
12.1.0 PC based factory automation
336(3)
12.1.1 IPC in machine building and motion controls
339(2)
12.1.2 IPC in smart factory Industrie 4.0 approach
341(2)
12.2 PC based process controls & MTP
343(7)
12.2.0 PC based process control and automation---MTP
343(2)
12.2.1 Modular process controls concept
345(3)
12.2.2 Safe and integrated process solution
348(2)
12.3 Other production line issue, FDT, EDD and OPC
350(11)
12.3.0 Discussions on FDT --- DTM, EDDL and OPC integration
351(6)
12.3.1 Discussions on IPC IIoT and Industrie 4.0
357(1)
List of abbreviations used
358(1)
References
358(3)
13 CLCS---an approach to DCS-MIS
13.0 Requirements, functional, and design details of CLCS
361(10)
13.0.0 CLCS conceptual discussions
362(1)
13.0.1 Discussions on continuous signal and block diagram (S plane)
363(3)
13.0.2 Discussions on discrete signal and block diagram (z plane)
366(3)
13.0.3 Discussions on discrete signal analysis---Z transform
369(2)
13.1 CLCS and supervisory system design aspects and configuration
371(12)
13.1.0 Functional details of CLCS and supervisory systems
371(5)
13.1.1 Elements and features of CLCS/DCS
376(3)
13.1.2 Conceptual discussions on industrial IT
379(4)
13.2 CLCS behavior and time response
383(7)
13.2.0 Time response of different order systems
383(2)
13.2.1 Discussions on CLCS response
385(2)
13.2.2 State space analysis in CLCS
387(3)
13.3 Basics of modeling and simulation in CLCS
390(7)
13.3.0 Conceptual discussion on functional modeling
391(2)
13.3.1 Mathematical modeling
393(2)
13.3.2 Simulation in control system---basics
395(2)
13.4 CLCS performance and selection discussions
397(9)
13.4.0 Advanced process control issues
397(2)
13.4.1 Control loop performance monitoring (CLPM)
399(3)
13.4.2 Performance and selection issues for CLCS
402(4)
13.5 Various important CLCS issues
406(11)
13.5.0 CLCS networking and allied issues
406(2)
13.5.1 Advanced closed loop control tuning methods
408(3)
13.5.2 Discussions on diagnostics and security issues in DCS
411(1)
13.5.3 Miscellaneous DCS utilities and functions
412(3)
List of abbreviations
415(1)
References
415(2)
14 Stand-alone controller in process automation
14.0 Stand-alone controller features
417(1)
14.0.0 Requirements for selecting stand-alone controller
417(1)
14.0.1 Features and benefits of stand-alone controller
418(1)
14.1 Stand-alone controller functional details
418(2)
14.1.0 Stand-alone controller block diagram
418(1)
14.1.1 Functionalities of stand-alone controller
419(1)
14.2 Stand-alone controller description
420(1)
14.3 Interface and integration of stand-alone controller
421(1)
14.4 Stand-alone controller application areas
422(1)
14.5 Stand-alone controller specification
423(2)
List of abbreviations used
424(1)
References
424(1)
15 DCS features, elements and HW details
15.0 Discussions on features of DCS
425(7)
15.0.0 General DCS features
426(2)
15.0.1 Detailed discussions on some important feature
428(2)
15.0.2 Selection Issues for open DCS
430(2)
15.1 DCS elements: functional details and applications
432(5)
15.1.0 Major functional elements
432(2)
15.1.1 Miscellaneous information and application services
434(2)
15.1.2 Device management
436(1)
15.2 HW details of DCS
437(10)
15.2.0 Processors and servers hardware details
437(2)
15.2.1 Discussions on I/O system
439(1)
15.2.2 Discussions on HMI system
440(4)
15.2.3 Data and information management
444(3)
15.3 DCS design and simulation units
447(7)
15.3.0 Basic functional details of CLCS OLCS MIS
448(3)
15.3.1 HMI functional design issues
451(2)
15.3.2 Miscellaneous design issue for DCS
453(1)
15.4 DCS control and automation implementation
454(9)
15.4.0 Advanced automation systems
454(1)
15.4.1 Advanced managements functions
455(1)
15.4.2 DCS diagnostic structure and issues
456(3)
15.4.3 Asset management system (AMS)
459(1)
List of abbreviations
460(1)
References
460(1)
Further reading
461(2)
16 General description and configurations for DCS
16.0 DCS configuration: functional details
463(7)
16.0.0 Basic network architectural issues
463(2)
16.0.1 System configuration aspects
465(3)
16.0.2 Control network structure
468(2)
16.1 Discussions on factors for DCS configuration
470(5)
16.1.0 System configuration design issues
470(4)
16.1.1 Features and implementation in DCS configuration
474(1)
16.2 DCS configuration examples and usage
475(6)
16.2.0 DCS configuration planning
476(1)
16.2.1 Client server based DCS configuration with application
477(2)
16.2.2 Nonclient server network with safety system
479(2)
16.3 Future network configurations
481(8)
16.3.0 Future architectural requirements
482(2)
16.3.1 Discussions on open systems
484(2)
List of abbreviations used
486(1)
References
486(3)
17 DCS SW aspects, APC and MIS discussions
17.0 Discussions on SW aspects, APC and MIS
489(7)
17.0.0 Discussions DCS software
490(2)
17.0.1 Discussions on integrated---central engineering
492(2)
17.0.2 Discussions on multivariable controls and APC matric
494(2)
17.0.3 MIS conceptual discussions
496(1)
17.1 DCS control and safety software solutions
496(3)
17.1.0 Discussions on control software aspects
496(1)
17.1.1 Discussions on safety and security controls
497(2)
17.2 Advance process control discussions
499(3)
17.2.0 Discussions on APC concept
499(2)
17.2.1 APC in industrial facilities
501(1)
17.3 DCS monitoring software
502(4)
17.3.0 Work station software functions
502(3)
17.3.1 Miscellaneous monitoring software issues
505(1)
17.4 DCS networking and miscellaneous software issues
506(2)
17.4.0 Device and system integration software issues
507(1)
17.4.1 System management and miscellaneous software issues
507(1)
17.5 DCS and management information system
508(5)
17.5.0 DCS---MIS characteristics
509(1)
17.5.1 DCS supervisory information system and MIS
509(1)
List of abbreviations used
510(1)
References
511(1)
Further reading
511(2)
18 DCS in electrical controls and SCADA
18.0 DCS application in electrical controls and SCADA
513(12)
18.0.0 Intelligent controls power systems
514(1)
18.0.1 Intelligent controls for solar power generation
515(6)
18.0.2 Intelligent controls in other renewal power applications
521(4)
18.1 DCS in excitation and voltage regulation
525(4)
18.1.0 Fundamentals of excitation and AVR systems
525(1)
18.1.1 Digital and intelligent controls in ECS -- AVR
526(3)
18.2 DCS AC drive and motor control (PMCC)
529(4)
18.2.0 Discussions on intelligent drive systems
529(2)
18.2.1 Discussions on intelligent MCC (IMCC) and DCS
531(2)
18.3 DCS and SCADA applications
533(6)
18.3.0 Fundamentals of network intelligent SCADA
533(4)
List of abbreviations
537(1)
References
538(1)
Further reading
538(1)
Index 539
Swapan Basu is the founding member and retired Chief Executive of Systems & Controls Kolkata India. Basu is a senior member of Institute of Electrical and Electronics Engineers (IEEE- USA) and Instrumentation and measurement society and also Senior member of International society of Automation (ISA USA). He brings over 45 years of international professional engineering experience in instrumentation and controls systems for subcritical, super critical thermal power plants Off shore installations and other process plants. Since 1979, he has been leading teams of engineers in India, Jordan, Singapore, South Korea, Syria, and USA
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