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

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 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 Back Cover