1.1 Introduction 1 1.2 Innovators 4 1.3 Industrial revolutions 10 1.4 Evolution of automation from needs perspectives 11 1.5 Evolution of automation from technology perspectives 11 1.6 Challenges three decades back 12 1.7 Current challenges 13 1.8 Technology trends 13 1.9 Device connectivity 18 1.10 Automation system controllers 22 1.11 The generic duties of an automation system in hierarchical form 27 1.12 Functional requirements of an integrated information and automation systems: A generic list 27 1.13 Conceptual/functional topology of an automation system 33
CHAPTER 2 The Programmable Logic Controller 37
2.1 Introduction to the programmable logic controller 37 2.2 Hardware 38 2.3 Internal architecture 39 2.4 I/O devices 42 2.5 I/O processing 48 2.6 Ladder and function block programming 52 2.7 Function blocks 61 2.8 IL, SFC, and ST programming methods 65
CHAPTER 3 Distributed Control System 75
3.1 Introduction 75 3.2 Evolution of traditional control systems 76 3.3 Distributed control systems 81 3.4 Functional components of DCS 88 3.5 Diagnostics in IOs 99 3.6 Controllers 101 3.7 Workstations 108 3.8 Functional features of DCS 111
CHAPTER 4 Batch Automation Systems 135
4.1 Introduction 135 CHAPTER 5 Functional Safety and Safety Instrumented Systems 157 5.1 Functional safety: an introduction 157 5.2 What is functional safety? 157 5.3 Safety functions and safety-related systems 157 5.4 Example of functional safety 158 5.5 Legislation and standards 159 5.6 IEC 61508/IEC 61511: an introduction 160 5.7 Scope of the standard 162 5.8 The overall safety life cycle (SLS) 164 5.9 Risk and its analysis and reduction 165 5.10 Safety requirements and safety functions 166 5.11 Safety integrity levels (SIL) 167 5.12 Functional safety management 169 5.13 Layers of protection 170 5.14 Risk analysis techniques 171 5.15 Safety requirement specifications 176 5.16 General requirements 178 5.17 Response time 178 5.18 SIF specification 179 5.19 Operator interfaces (HMI) 185 5.20 Safety instrumented systems 186 5.21 Reliability and diagnostics 189 5.22 SIS voting principles and methods 194 5.23 SIS SIL level calculation tools 200 5.24 SIS communication protocols and field-buses 200 5.25 FF-SIS: foundation fieldbus for safety instrumented systems 201 5.26 PROFIsafe 204 5.27 PROFIsafe protocol 207 5.28 Black channel principle 207 5.29 Integrated safety data communications 208 5.30 Selection of safety instrumented system 209
CHAPTER 6 Fire and Gas Detection System 217
6.1 Introduction to the fire and gas (F&G) detection system 217 6.2 Understanding industry safety performance standards 219 6.3 Critical components 220 6.4 F&G detectors 221 6.5 F&G network architecture 226 6.6 Integrated approach for F&G 232 6.7 Conclusion 235
CHAPTER 7 SCADA Systems 237
7.1 Overview of SCADA systems 237 7.2 Minicomputers and microprocessors 241 7.3 Remote terminal units 248 7.4 Communication technologies 264 7.5 Program development tools 275 7.6 Operator interface 278
CHAPTER 8 Programmable Automation Controller 301
8.1 Modern industrial application 301
CHAPTER 9 Serial Communications 307
9.1 RS232 overview 307 9.2 RS232 signal information 307 9.3 Limitations of RS232 applications 320 9.4 Overview of EIA-485 321 9.5 The difference between RS232/RS485/RS422 325 9.6 Modbus serial communications 327 9.7 Modbus map 335 9.8 Error checking methods 336 9.9 Modbus exception codes 337
CHAPTER 10 Industrial Networks 341
10.1 Introduction to industrial networks 341 10.2 The OSI network model 342 10.3 TCP/IP 344
14.1 Introduction 417 14.2 Basic concepts of industrial wireless communication 419 14.3 ISA100 standard 426 14.4 Networks 439 14.5 Network configurations 443 14.6 Gateway, system manager, and security manager 447 14.7 Applications of wireless instrumentation 451 14.8 Designing and engineering a wireless system 455
CHAPTER 15 OPC Communications 459
15.1 Introduction 459
CHAPTER 16 Asset Management Systems 479
16.1 Definition of an asset 479 16.2 Asset management system 479 16.3 Key goal of asset management system 480 16.4 Fault models 482 16.5 Calculation model 483 16.6 Maintaining work processes 486 16.7 Unneeded trips to the field - avoided through remote diagnostics 488 16.8 Life cycle work processes 489 16.9 Intelligent field devices - data flow 491 16.10 Integrated asset management 492 16.11 Use of the tools 493 16.12 Instrument asset management systems - architecture/subsystems 494 16.13 Smart field devices 496 16.14 Asset management system: role-based diagnostics 496 16.15 Device rendering technologies 498 16.16 Limitations of DD technology 501 16.17 Enhanced device description language 501 16.18 FDT/DTM 504 16.19 The DTM 504 16.20 Key benefits to the users 505
CHAPTER 17 Calibration Management Systems 507
17.1 Introduction 507 17.2 Need for calibration 507 17.3 Traceability 508 17.4 Calibration standards 508 17.5 Calibration concepts 510 17.6 Documentation 511 17.7 Calibration of transmitters 511 17.8 Calibrating a conventional instrument 515 17.9 Calibrating a HART instrument 516 17.10 Calibrating fieldbus transmitters 517 17.11 Calibration management system 518 17.12 Calibration software 520 17.13 Benefits of using calibration management system 521 17.14 Business benefits 522 CHAPTER 18 System Maintenance 523 18.1 Overview 523 18.2 Distributed control system maintenance 524 18.3 Maintenance software 526 18.4 Maintenance program implementation and management 526 18.5 Software and network maintenance 532 18.6 Computer operating environment 532 18.7 Network maintenance 539
CHAPTER 19 Advanced Process Control Systems 547
19.1 Introduction and need for advanced process control (APC) 547 19.2 History of process control 547 19.3 Advanced process control 549 19.4 Advantages of APC 553 19.5 Architecture and technologies 553
CHAPTER 20 Training System 559
20.1 Introduction to process modeling 559 20.2 Training systems 562 20.3 Components of training simulators system 563 20.4 Architecture of a typical training simulators 565
CHAPTER 21 Alarm Management Systems 569
21.1 Introduction 569 21.2 Conventional and advanced alarm systems 570
CHAPTER 22 Database Systems 583
22.1 Historian database 583
CHAPTER 23 Manufacturing Execution Systems 593
23.1 Introduction 593
CHAPTER 24 Cyber Security in Industrial Automation
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
CHAPTER 25 Mobile and Video Systems
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