Plant Intelligent Automation and Digital Transformation: Volume I: Process and Factory Automation

Front Cover
Plant Intelligent Automation and Digital Transformation
Plant Intelligent Automation and Digital Transformation
Copyright
Dedication
Contents
Foreword
Preface
Acknowledgment
1 - General discussions on control systems
1.0 Fundamentals and general discussions on control systems
1.0.0 Recapitulations of terms with explanations
1.0.1 Requirements for plant automation conceptual discussions
1.0.2 Synopsys of issues covered in this volume of the book
1.0.3 Microprocessor: microcomputer basics (brief recapitulations)
1.0.4 Control implementation issues
1.0.5 Mathematical approach for control systems
1.1 Control system synthesis and control theory
1.1.0 Preliminary discussions
1.1.1 Definition of various terms used in control theory
1.1.2 Discontinuous (discrete) control system
1.1.3 Continuous control system
1.1.4 PID implementation in digital control systems
1.2 Control loop modes, types and hierarchical control
1.2.0 General discussions on modes and types of controls
1.2.1 Examples for feed forward control and lag lead controls
1.2.2 Cascade control action
1.2.3 Ratio control
1.2.4 Override control
1.2.5 Auctioneering control
1.2.6 Split range control
1.2.7 Inferential control
1.2.8 Adaptive control and gain scheduling
1.2.9 Hierarchical control system
1.3 Control system models
1.3.0 Discussions on control system models
1.3.1 Types of systems
1.3.2 Model based control (MBC) methodology and structure
1.3.3 Various model based control types
1.3.4 Control computing and system development
1.3.5 Linearization of nonliner systems
1.4 State space in control systems
1.4.0 Concept of state space and control system
1.4.1 State variable and process
1.4.2 System state
1.4.3 State equation
1.4.4 Output equation
1.4.5 Block diagram representation of state space
1.5 Optimization of controls and automations
1.5.0 Basics of process control and process automation
1.5.1 Structural approach for integrated optimization and control
1.5.2 Discussions on integrated structure
1.5.3 Advanced process controller (APC) and optimization
List of abbreviations used
References
Further reading
2 - Basics of networking
2.0 Basics of networking
2.0.0 Outline discussions on basic networking
3 - Industrial data communication
3.0 Industrial data communication
3.0.0 Outline discussions on industrial data communication
4 - System diagnostics, security, and safety
4.0 Functional details of system diagnostics, security, and safety
4.0.0 Discussions on diagnostics, system security, and safety
4.0.1 Basic discussions on diagnostics
4.0.2 Control system security and access control
4.0.3 Plant safety conceptual discussions
4.1 Discussions on diagnostics
4.1.0 General discussions on self-diagnostics for devices and systems
4.1.1 Self diagnosis at field level
4.1.2 Self diagnosis in intelligent devices and systems
4.1.3 Process/equipment diagnostic method-ADS
4.1.4 Diagnosis types and alarms with example
4.1.5 Expert diagnosis systems
4.2 Control systems security discussions
4.2.0 Basic objectives and recommended strategies
4.2.1 Control system security risk management
4.2.2 Control system security: policy and deployment
4.2.3 Discussions on ISA 99/IEC 62443 standard sets
4.3 Plant safety discussions with safety fieldbus outline
4.3.0 Plant safety and security discussions
4.3.1 Conceptual discussions ON SIF, SIS, and SIL and ALARP
4.3.2 Outline of safe fieldbus and IS for fieldbus
4.3.3 Electrical area classification
4.3.4 Enclosure class
4.3.5 Intrinsic safety
List of abbreviations
References
5 - Control intelligence and futuristic approach
5.0 Control intelligence and futuristic approach
5.0.0 Outline of control intelligence and futuristic approach
6 - PLC and Open loop control system (OLCS) functional and design details
6.0 PLC and open-loop control system
6.0.0 Requirements of OLCS; hierarchical control and interlock discussions
6.0.1 OLCS characteristics and comparison with CLCS
6.0.2 OLCS CLCS plant automation
6.0.3 Interlock concept and hierarchical interlock issues
6.0.4 Hierarchical control-grouping discussions
6.1 Basics of PLC with hardware details
6.1.0 Basics of PLC system
6.1.1 PLC logics and I/O interface
6.1.2 Discussions on PLC hardware
6.1.3 Brief discussions on PLC selection
6.2 PLC software discussions
6.2.0 PLC software programming types
6.2.1 Programming different languages
6.2.2 Discussions on software standards for PLC
6.2.3 PLC software issues for considerations
6.2.4 PLC programming basics and memory area
6.3 Types of PLC
6.3.0 Basis for PLC classification
6.3.1 PLC types based on mounting
6.3.2 Types of PLC according to size
6.3.3 PLC classification based on I/O types
6.3.4 PLC types on redundancy criteria
6.3.5 Miscellaneous issues for PLC classifications
6.4 Features and configurations of PLC
6.4.0 Required features and configuration
6.4.1 Salient features of PLC
6.4.2 Feature based PLC configuration changes
6.5 Networking interfaces and system integration
6.5.0 Basic issues for interfaces and system integration (PLC/DCS)
6.5.1 Serial link in system integration
6.5.2 System integration by fieldbus
6.5.3 Ethernet for system integration
6.5.4 System integration with OPC
6.5.5 Discussions on system integration and interface examples
6.6 Brief discussions on HMI and engineering interfaces
6.7 System diagnostics and security
6.7.0 System diagnostics and security issues
6.7.1 Overview of systems (ICS) diagnostics
6.7.2 Program diagnostics and tests
6.7.3 Process diagnostics and diagnostic analysis for maintenance
6.7.4 PLC vulnerability discussions
6.7.5 ICS threat, vulnerability and risk factors
6.7.6 ICS security program development
6.8 PLC performance and application area
6.8.0 PLC applications performance and selections
6.8.1 Discussions on PLC performance and services
6.8.2 PLC application area
6.9 Safe PLC discussion
6.9.0 General discussions of safe logic solver and safety PLC
6.9.1 Requirements for safety PLC system
6.9.2 Selection of safe PLC
6.9.3 Safe PLC design and implementation issues
6.9.4 Factory automation with safe PLC
6.9.5 Safe PLC-SIS discussions
List of abbreviations used
References
7 - OLCS in process plants and PLC details
7.0 Open loop controls in process automation and I/O detailing
7.0.0 Analog I/O and modulating controls in PLC
7.0.1 Distinctive features and evolution of PLC and DCS
7.0.2 Technological changes for PLC for process controls
7.0.3 Process controls in PLC
7.0.4 Discussions on PLC I/Os types and signal processing
7.1 Discussions on I/O interfaces types
7.1.0 Discussions on PLC I/O categories
7.1.1 Discussions on PLC timing issues
7.1.2 High speed I/O processing in PLC
7.1.3 Special I/O interfaces
7.2 Description and design aspect of PLC I/O modules
7.2.0 Description and design details I/O modules
7.2.1 Discussions on general design issues for I/O
7.2.2 Design considerations for I/O modules
7.3 Specification of PLC I/O modules
7.3.0 Common specification issues
7.3.1 Specification for discrete I/O modules
7.3.2 Specification for analog I/O modules
7.4 Discussions on PLC architecture and redundancy types
7.4.0 Broad classification of PLC architecture
7.4.1 Discussions on redundant PLC architecture
7.4.2 Redundancy and control system connections
7.4.3 PLC redundancy types and safety applications
7.5 Application programming and analog applications
7.5.0 Discussions ON OPP, FB & CM
7.5.1 Computation and control in PLC system
7.5.2 Computation & control for flow loop
7.5.3 Advanced cascade & split range controls in PLC
List of abbreviations used
References
8 - Batch process control and automation
8.0 PLC/DCS applications in batch process control
8.0.0 General discussions on batch process and PLC/DCS
8.0.1 Discussions on batch procedural and control issues
8.0.2 Sequential control and programming in batch process
8.1 Batch process control standards
8.1.0 General discussions of batch control standards
8.1.1 Model and recipe in batch process (ISA 88) [1]
8.1.2 Recipe composition and structural variations [1]
8.2 Batch control system discussions
8.2.0 General control and monitoring system
8.2.1 Control activity--- batch process management
8.2.2 Exception handling
8.3 Automation interfaces and control center in batch process
8.3.0 General considerations for batch controls
8.3.1 Batch process interfaces
8.3.2 Network configuration control center and reporting
8.4 Batch control execution details
8.4.0 General batch executions requirements
8.4.1 Operator's guide and historian
8.4.2 Batch process data analysis
8.5 Discussions on batch process management
8.5.0 Overview of batch process management
8.5.1 Resource management, batch scheduling, dispatching and tracking
8.5.2 Batch process optimization
List of abbreviations used
References
Further reading
9 - Manufacturing and factory automation
9.0 General discussions: manufacturing advancement and 3D printing
9.0.0 General considerations for factory automation
9.0.1 Advanced integrated factory automation
9.0.2 Basics of 3D printing with benefits applications
9.0.3 3D scanning for 3D printing
9.0.4 3D printing technology types and materials
9.1 Requirements manufacturing automation
9.1.0 Essential steps for automation in manufacturing
9.1.1 General design aspects of factory automation
9.1.2 Manufacturing automation design methodology
9.2 Various controls types in manufacturing
9.2.0 General issues related to I&C for manufacturing industries
9.2.1 Discussions on factory automation CNC, CAD-CAM and CIM
9.2.2 PC based controls in manufacturing
9.3 Programmable automation control (PAC)
9.3.0 Basics of programmable automation controller
9.3.1 Discussions on PAC system
9.3.2 PAC PC PLC in industrial automation
9.4 Total factory automation concept
9.4.0 Concept of factory automation and automation benefits
9.4.1 Issues related to factory automation and SM
9.5 Future automation: Industrie 4.0 and smart factory
9.5.0 General discussion on Industrie 4.0
9.5.1 Controls AI security and edge computing in Industrie 4.0
9.5.2 Smart factory and Industrie 4.0
List of abbreviations used
References
10 - Building and service sector automation
10.0 Building management system (BMS): areas of applications
10.0.0 General discussions on BMS
10.0.1 Conceptual discussions on smart building
10.0.2 Trends in building automation systems
10.0.3 Integrated smart building: automation issues
10.1 Discussions on BACS: HVAC and other systems
10.1.0 Fundamentals of BACS
10.1.1 BACS architecture: HW, SW and automation levels
10.1.2 HVAC controls and automation
10.1.3 BACS: HVAC controls
10.2 BACS: integrated and smart buildings
10.2.0 Fundamentals of integrated BMS for smart building
10.2.1 Discussions on EMS in smart building
10.3 BMS: fire and access control
10.3.0 General discussions on fire and access control
10.3.1 Integration: BACS and fire system
10.4 Lighting control in BACS
10.4.0 Overview of lighting in BACS
10.4.1 Integrated lighting control in BACS
10.5 Security issues in BACS
10.5.0 General discussions on security issues in BACS
10.5.1 Discussions on BACS cyber security
List of abbreviations
References
11 - PLCopen concept and applications
11.0 Fundamentals of PLC-open
11.0.0 Basics of PLCopen concept
11.0.1 Brief discussions on PLCopen XML
11.0.2 Basics of PLCopen OPC UA
11.1 PLCopen motion: features and applications
11.1.0 Basics of PLCopen motion control
11.1.1 Discussions on PLCopen functional block and application
11.1.2 Discussions on PLCopen motion control standard [10]
11.2 PLCopen: safety software
11.2.0 Overview of PLCopen safety software specification
11.2.1 Discussion on PLCopen safety architecture and processing
List of abbreviations used
References
12 - PC-based control, MTP, FDT, EDD, and OPC
12.0 General discussions on PC based systems
12.0.0 Overview of PC based system
12.0.1 Favorable issues for selecting PC based controls
12.0.2 Types and details of industrial PC
12.0.3 Open PC technology
12.1 PC based PLC/OLCS and motion control
12.1.0 PC based factory automation
12.1.1 IPC in machine building and motion controls
12.1.2 IPC in smart factory Industrie 4.0 approach
12.2 PC based process controls & MTP
12.2.0 PC based process control and automation-MTP
12.2.1 Modular process controls concept
12.2.2 Safe and integrated process solution
12.3 Other production line issue, FDT, EDD and OPC
12.3.0 Discussions on FDT - DTM, EDDL and OPC integration
12.3.1 Discussions on IPC IIoT and Industrie 4.0
List of abbreviations used
References
13 - CLCS-an approach to DCS-MIS
13.0 Requirements, functional, and design details of CLCS
13.0.0 CLCS conceptual discussions
13.0.1 Discussions on continuous signal and block diagram (S plane)
13.0.2 Discussions on discrete signal and block diagram (z plane)
13.0.3 Discussions on discrete signal analysis-Z transform
13.1 CLCS and supervisory system design aspects and configuration
13.1.0 Functional details of CLCS and supervisory systems
13.1.1 Elements and features of CLCS/DCS
13.1.2 Conceptual discussions on industrial IT
13.2 CLCS behavior and time response
13.2.0 Time response of different order systems
13.2.1 Discussions on CLCS response
13.2.2 State space analysis in CLCS
13.3 Basics of modeling and simulation in CLCS
13.3.0 Conceptual discussion on functional modeling
13.3.1 Mathematical modeling
13.3.2 Simulation in control system-basics
13.4 CLCS performance and selection discussions
13.4.0 Advanced process control issues
13.4.1 Control loop performance monitoring (CLPM)
13.4.2 Performance and selection issues for CLCS
13.5 Various important CLCS issues
13.5.0 CLCS networking and allied issues
13.5.1 Advanced closed loop control tuning methods
13.5.2 Discussions on diagnostics and security issues in DCS
13.5.3 Miscellaneous DCS utilities and functions
List of abbreviations
References
14 - Stand-alone controller in process automation
14.0 Stand-alone controller features
14.0.0 Requirements for selecting stand-alone controller
14.0.1 Features and benefits of stand-alone controller
14.1 Stand-alone controller functional details
14.1.0 Stand-alone controller block diagram [1]
14.1.1 Functionalities of stand-alone controller
14.2 Stand-alone controller description
14.3 Interface and integration of stand-alone controller
14.4 Stand-alone controller application areas
14.5 Stand-alone controller specification
List of abbreviations used
References
15 - DCS features, elements and HW details
15.0 Discussions on features of DCS
15.0.0 General DCS features
15.0.1 Detailed discussions on some important feature
15.0.2 selection issues for open DCS
15.1 DCS elements: functional details and applications
15.1.0 Major functional elements
15.1.1 Miscellaneous information and application services
15.1.2 Device management
15.2 HW details of DCS
15.2.0 Processors and servers hardware details
15.2.1 Discussions on I/O system
15.2.2 Discussions on HMI system
15.2.3 Data and information management
15.3 DCS design and simulation units
15.3.0 Basic functional details of CLCS OLCS MIS
15.3.1 HMI functional design issues
15.3.2 Miscellaneous design issue for DCS
15.4 DCS control and automation implementation
15.4.0 Advanced automation systems
15.4.1 Advanced managements functions
15.4.2 DCS diagnostic structure and issues
15.4.3 Asset management system (AMS)
List of abbreviations
References
Further reading
16 - General description and configurations for DCS
16.0 DCS configuration: functional details
16.0.0 Basic network architectural issues
16.0.1 System configuration aspects
16.0.2 Control network structure
16.1 Discussions on factors for DCS configuration
16.1.0 System configuration design issues
16.1.1 Features and implementation in DCS configuration
16.2 DCS configuration examples and usage
16.2.0 DCS configuration planning
16.2.1 Client server based DCS configuration with application
16.2.2 Nonclient server network with safety system
16.3 Future network configurations
16.3.0 Future architectural requirements
16.3.1 Discussions on open systems
List of abbreviations used
References
17 - DCS SW aspects, APC and MIS discussions
17.0 Discussions on SW aspects, APC and MIS
17.0.0 Discussions DCS software
17.0.1 Discussions on integrated-central engineering
17.0.2 Discussions on multivariable controls and APC matric
17.0.3 MIS conceptual discussions
17.1 DCS control and safety software solutions
17.1.0 Discussions on control software aspects
17.1.1 Discussions on safety and security controls
17.2 Advance process control discussions
17.2.0 Discussions on APC concept
17.2.1 APC in industrial facilities
17.3 DCS monitoring software
17.3.0 Work station software functions
17.3.1 Miscellaneous monitoring software issues
17.4 DCS networking and miscellaneous software issues
17.4.0 Device and system integration software issues
17.4.1 System management and miscellaneous software issues
17.5 DCS and management information system
17.5.0 DCS-MIS characteristics
17.5.1 DCS supervisory information system and MIS [17]
List of abbreviations used
References
Further reading
18 - DCS in electrical controls and SCADA
18.0 DCS application in electrical controls and SCADA
18.0.0 Intelligent controls power systems
18.0.1 Intelligent controls for solar power generation
18.0.2 Intelligent controls in other renewal power applications
18.1 DCS in excitation and voltage regulation
18.1.0 Fundamentals of excitation and AVR systems
18.1.1 Digital and intelligent controls in ECS - AVR
18.2 DCS AC drive and motor control (PMCC)
18.2.0 Discussions on intelligent drive systems
18.2.1 Discussions on intelligent MCC (IMCC) and DCS
18.3 DCS and SCADA applications
18.3.0 Fundamentals of network intelligent SCADA
List of abbreviations
References
Further reading
Index
A
B
C
D
E
F
G
H
I
K
L
M
N
O
P
R
S
T
V
W
X
Z
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