Dr. Sharma is an industrial automation professional by education, qualification, and practice. He worked in the automation industry for over 33 years (25 years in ABB India) followed by academic institutions promoting automation education and training. He has totally dedicated himself to teach/train people in industry and academic institutions in current philosophy, technology, terminology, and practices in automation. He has several articles to his credit in automation education and training in automation magazines.
Man-made or industrial processes, localised or geographically distributed, need be automated in order to ensure they produce quality, consistent, and cost-effective goods or services. Automation systems for these processes broadly consist of instrumentation, control, human interface, and communication subsystems. This book introduces the basics of philosophy, technology, terminology, and practices of modern automation systems with simple illustrations and examples. - Provides an introduction to automation- Explains the concepts through simple illustrations and examples- Describes how to understand technical documents
Front Cover 1
Overview of Industrial Process Automation 4
Copyright Page 5
Contents 8
Foreword 18
About the Author 20
Preface 22
Acknowledgments 26
1 Why Automation? 28
1.1 Introduction 28
1.2 Physical Process 28
1.2.1 Natural Processes 29
1.2.2 Self-Regulated Processes 29
1.2.3 Man-made or Industrial Processes 29
1.2.3.1 Water Tap 29
1.2.3.2 Electric Bulb 30
1.2.4 Undesired Behavior 30
1.3 Types of Industrial Processes 30
1.3.1 Localized Processes 30
1.3.2 Distributed Processes 30
1.4 Industry Classification 31
1.4.1 Utility Industry 32
1.4.2 Process Industry 33
1.5 Process Automation System 33
1.5.1 Unattended Processes 34
1.5.2 Manually Attended Processes 35
1.5.3 Automated Processes 36
1.6 Needs Met by Automation 36
1.7 Benefits of Automation 37
1.8 Automation Steps 38
1.8.1 Step 1: Information Acquisition 38
1.8.2 Step 2: Information Analysis and Decision Making 38
1.8.3 Step 3: Control Execution 38
1.9 Process Signals 39
1.9.1 Classifications 39
1.9.2 Input and Output Signals 39
1.9.2.1 Input Signals 39
1.9.2.2 Output Signals 40
1.10 Summary 41
2 Automation System Structure 42
2.1 Introduction 42
2.2 Subsystems 42
2.2.1 Instrumentation Subsystem 42
2.2.2 Human Interface Subsystem 43
2.2.3 Control Subsystem 43
2.3 Instrumentation Subsystem 44
2.3.1 Measurement of Information 44
2.3.2 Transfer of Control Command 46
2.4 Human Interface Subsystem 47
2.4.1 Manual Display and Monitoring 48
2.4.2 Manual Control 48
2.5 Control Subsystem 48
2.5.1 Information Acquisition 49
2.5.2 Information Analysis and Decision Making 49
2.5.3 Control Execution 49
2.6 Summary 50
3 Instrumentation Subsystem 52
3.1 Introduction 52
3.2 Structure 52
3.2.1 Continuous/Analog Instrumentation Devices 52
3.2.1.1 Information Acquisition 52
3.2.1.2 Control Execution 54
3.2.2 Discrete/Digital Instrumentation Devices 55
3.2.2.1 Information Acquisition 55
3.2.2.2 Control Execution 57
3.2.3 Fluctuating/Pulse Signals 58
3.3 Special Instrumentation Devices 58
3.3.1 Switching Instrumentation Devices 59
3.3.2 Integrating Instrumentation Devices 60
3.4 Interfacing Standards 61
3.4.1 Analog Input and Output Devices 61
3.4.2 Digital Input and Output Devices 61
3.4.3 Switching and Integrating Devices 62
3.5 Information Reliability 62
3.5.1 Analog Inputs 63
3.5.2 Digital Inputs 63
3.6 Isolation and Protection 63
3.6.1 Isolation 64
3.6.2 Protection 64
3.6.3 Solutions 64
3.7 Summary 66
4 Control Subsystem 68
4.1 Introduction 68
4.2 Structure 68
4.3 Interfacing 69
4.3.1 General 69
4.3.2 Instrumentation Subsystem 70
4.3.3 Human Interface Subsystem 71
4.4 Summary 72
5 Human Interface Subsystem 74
5.1 Introduction 74
5.2 Operator Panel 74
5.2.1 Active Display Elements 74
5.2.2 Active Control Elements 75
5.2.3 Panel 76
5.3 Construction 76
5.3.1 Basic Approach 77
5.3.2 Mimic Approach 77
5.4 Interfacing with Control Subsystem 78
5.5 Types of Mimic Panels 78
5.6 Summary 79
6 Automation Strategies 80
6.1 Introduction 80
6.2 Basic Strategies 80
6.2.1 Open Loop Control 81
6.2.2 Closed Loop Control 81
6.3 Discrete Control 82
6.3.1 Discrete Control—Open Loop 82
6.3.2 Discrete Control—Sequential Control with Interlocks 83
6.4 Continuous Control 83
6.4.1 Continuous Control—Open Loop 84
6.4.2 Continuous Control—Closed Loop 84
6.5 Hybrid Control 85
6.5.1 Hybrid Control—Two-Step 85
6.5.2 Hybrid Control—Two-Step with Dead-Band 87
6.6 Summary 89
7 Programmable Control Subsystem 90
7.1 Introduction 90
7.2 Discrete Control 92
7.2.1 Sequential Control with Interlocks 92
7.3 Continuous Control 96
7.3.1 Closed Loop Control 96
7.3.2 Multi-Input/Multi-Output Control 97
7.4 Hybrid Control 100
7.4.1 Two-Step Control with Dead-Band 100
7.5 Controller with Additional Features 101
7.5.1 Communicability 103
7.5.2 Self-Supervision or Watchdog 106
7.6 Upward Compatibility 106
7.7 Summary 107
8 Hardware Structure of Controller 108
8.1 Introduction 108
8.2 Major Modules of Controller 109
8.2.1 Rack 109
8.2.2 Bus 109
8.2.3 Functional Modules 111
8.2.4 System Cable 111
8.3 Data Exchange on Bus 112
8.4 Functional Subsystems 113
8.4.1 Power Supply Subsystem 113
8.4.1.1 Power Supply Module 113
8.4.2 Processor Subsystem 113
8.4.2.1 Processor Module 114
8.4.2.2 Memory Module 114
8.4.2.3 Watchdog Module 114
8.4.3 Input/Output Subsystem 118
8.4.3.1 Digital Input Module 118
8.4.3.2 Digital Output Module 118
8.4.3.3 Analog Input Module 118
8.4.3.4 Analog Output Module 119
8.4.3.5 Pulse Input Module 119
8.4.3.6 Pulse Output Module 119
8.4.3.7 Capacity in I/O Modules 121
8.4.4 Communication Subsystem 123
8.4.4.1 Communication Module 123
8.4.4.2 Communication Cables 124
8.4.5 Integrated Processor Module 124
8.5 Controller Capacity Expansion 126
8.5.1 Bus Extension (Parallel) Module 126
8.5.2 Bus Extension (Serial) Module 127
8.6 Integrated Controller 128
8.7 Summary 129
9 Software Structure of Controller 130
9.1 Introduction 130
9.2 Types of Software Systems 130
9.2.1 Non-Real-Time System 131
9.2.2 Real-Time System 131
9.3 Software Structure of Controller 132
9.3.1 Hardware Platform 133
9.3.2 Real-Time Operating System 133
9.3.3 Utility Software 133
9.3.4 Application Software 133
9.4 Scheduling of Tasks 134
9.4.1 Sequential Scheduling 134
9.4.2 Sequential Scheduling with Time-Slice 134
9.4.3 Real-Time Scheduling 135
9.4.3.1 Program Interrupt 135
9.4.3.2 Task Execution 135
9.5 Scheduling of Tasks in Automation Systems 136
9.5.1 Process Data Acquisition 136
9.5.2 Process Data Monitoring 137
9.5.3 Process Control 137
9.6 Memory Organization 137
9.7 Summary 138
10 Programming of Controller 140
10.1 Introduction 140
10.2 Higher-level Programming 140
10.2.1 Ladder Diagram 141
10.2.2 Function Block Diagram 144
10.3 Programming Examples 147
10.3.1 Sequential Control with Interlocks 147
10.3.2 Loop Control 154
10.3.3 Two-Step Control with Dead-Band 156
10.4 Summary 160
11 Advanced Human Interface 162
11.1 Introduction 162
11.2 Intelligent Operator Panels 163
11.3 Operator stations 165
11.3.1 Display Screen Layout 167
11.3.2 Interaction with the Process 168
11.3.2.1 Direct Interaction 168
11.3.2.2 Navigated Interaction 168
11.3.2.3 Other Features 172
11.3.3 Comparison with Operator Panel 173
11.3.3.1 Advantages and Disadvantages of Operator Stations 173
11.3.4 Enhanced Operator Stations 173
11.3.4.1 Multiple Monitors 174
11.3.4.2 Large Screen Displays 174
11.3.4.3 Displays with Embedded Video 175
11.3.4.4 Combined Mimic Panel and Operator Station 175
11.3.5 Variants of Operator Stations 176
11.4 Logging stations 176
11.4.1 Data Logging 176
11.5 Control Desk 177
11.6 Summary 178
12 Types of Automation Systems 180
12.1 Introduction 180
12.2 Localized Process 180
12.2.1 Centralized Control System 181
12.2.2 Decentralized/Distributed Control System 182
12.3 Distributed Process 183
12.3.1 Remote Control System 184
12.3.2 Network Control System 184
12.3.3 Front-End Processor 184
12.3.3.1 Controller-Based FEP 186
12.3.3.2 Computer-Based FEP 187
12.4 Supervisory Control and Data Acquisition 188
12.4.1 Background 188
12.4.2 Case Study 188
12.4.3 Similarities with DCS and NCS 190
12.4.3.1 SCADA in DCS 190
12.4.3.2 SCADA in NCS 190
12.5 Summary 191
13 Special-Purpose Controllers 192
13.1 Introduction 192
13.2 Controller for Localized Processes 192
13.2.1 Programmable Logic Controller 192
13.2.2 Loop Controller 195
13.2.3 Programmable Controller 196
13.3 Controller for Distributed Processes 197
13.3.1 Remote Terminal Unit 198
13.4 Other Players 201
13.4.1 PC-Based Controller 201
13.4.2 Programmable Automation Controller 201
13.5 Summary 203
14 System Availability 204
14.1 Introduction 204
14.2 Standby Schemes 204
14.2.1 No Standby 204
14.2.2 Cold Standby 205
14.2.3 Hot Standby 205
14.3 Distributed Control System 206
14.3.1 Availability Analysis in DCS 206
14.3.1.1 Level 1: Instrumentation Subsystems 206
14.3.1.2 Level 2: Controllers 207
14.3.1.3 Level 3: Local Communication Subsystem 208
14.3.1.4 Level 4: Operator Station 208
14.3.2 Availability Enhancement in DCS 209
14.3.2.1 Processor in Controller 209
14.3.2.2 Ethernet I/F in Controller 209
14.3.2.3 LAN 210
14.4 Network Control System 210
14.4.1 Availability Analysis in NCS 211
14.4.1.1 Level 1: Instrumentation Subsystem 212
14.4.1.2 Level 2: RTUs 212
14.4.1.3 Level 3: Remote Communication Subsystem 213
14.4.1.4 Level 4: FEP Subsystem 213
14.4.1.5 Level 5: Local Communication Subsystem 213
14.4.1.6 Level 6: Operator Station 213
14.4.2 Availability Enhancement in NCS 213
14.4.2.1 Serial I/F and Processor in RTU 213
14.4.2.2 WAN 213
14.4.2.3 Serial I/F, Processor, and Ethernet I/F in FEP 214
14.4.2.4 LAN 214
14.5 I/O Redundancy 215
14.6 Summary 215
15 Common Configurations 216
15.1 Introduction 216
15.2 Distributed Control System 216
15.2.1 Operator Stations 216
15.2.2 Supervisory Stations 216
15.2.3 Application Stations 217
15.3 Network Control System 218
15.4 Summary 219
16 Advanced Input/Output System 220
16.1 Introduction 220
16.2 Centralized I/O 220
16.2.1 Intelligent CIO 221
16.2.2 Advantages and Disadvantages 222
16.3 Remote I/O 223
16.3.1 Advantages and Disadvantages 225
16.4 Fieldbus I/O 226
16.4.1 Advantages and Disadvantages 227
16.4.2 Fieldbus I/F Module 229
16.4.3 Intelligent Serial I/F 231
16.4.4 Protocol Standards 231
16.5 Summary 232
17 Concluding Remarks 234
17.1 Introduction 234
17.2 Major Functionalities 234
17.2.1 Data Acquisition 234
17.2.2 Data Supervision or Monitoring 234
17.2.3 Process Survey 234
17.2.4 Process Control 235
17.2.5 Process Studies 235
17.2.6 Human Interaction 235
17.2.7 Data Logging and History Generation 235
17.2.8 Data Exchange 235
17.3 Data Availability 235
17.4 Today’s Automation Systems 236
17.5 Modern Control Center 237
17.6 Application Areas of Automation Systems 237
17.6.1 Discrete Process Automation 238
17.6.2 Continuous Process Automation 238
17.6.3 Batch Process Automation 238
17.7 Summary 239
A. Hardwired Control Subsystem 240
A.1 Introduction 240
A.2 Discrete Control 240
A.2.1 Relay Technology 240
A.2.1.1 Control Strategy Implementation 244
A.2.1.2 Open Loop Control—Discrete 247
A.2.1.3 Sequential Control with Interlocks—Discrete 248
A.2.1.4 Advantages and Disadvantages 250
A.2.2 Solid State Technology 250
A.2.2.1 Control Strategy Implementation 251
A.2.2.2 Open Loop Control—Discrete 251
A.2.2.3 Sequential Control with Interlocks—Discrete 252
A.2.2.4 Advantages and Disadvantages 254
A.3 Continuous Control 255
A.3.1 Solid State Technology 255
A.3.1.1 Control Strategy Implementation 256
A.3.1.2 Open Loop Control—Continuous 256
A.3.1.3 Closed Loop Control—Continuous 257
A.4 Hybrid Control 258
A.4.1 Solid State Technology 258
A.4.1.1 Control Strategy Implementation 258
A.4.1.2 Two-Step Control 258
A.4.1.3 Two-Step Control with Dead-Band 259
A.5 FPGA- and FPAA-Based Controllers 261
B. Processor 262
B.1 Introduction 262
B.2 Hardware structure 262
B.2.1 Bus 262
B.2.2 Address Space and Distribution 263
B.2.3 Interfacing of Modules with Bus 264
B.2.3.1 Power Supply Module 264
B.2.3.2 Processor Module 264
B.2.3.3 Memory Module 265
B.2.3.4 Functional Module 266
B.2.3.5 Bus Extension (Parallel) Module 267
B.2.3.6 Bus Extension (Serial) Module 267
B.2.3.7 Operations on the Bus 268
B.2.3.8 Memory Module 268
B.2.3.9 I/O Module 268
B.2.3.10 Communication Module 268
B.2.3.11 Watchdog Module 270
C. Hardware-Software Interfacing 272
C.1 Introduction 272
C.2 Architectural Aspects 272
C.2.1 Address Distribution 272
C.2.2 Processor Registers 272
C.2.3 Data Range in Memory/Registers 273
C.2.4 Instruction Formats 274
C.2.4.1 Data Movement Operations 274
C.2.4.2 Logical Operations 274
C.2.4.3 Arithmetic Operations 275
C.2.4.4 Control Operations 275
C.2.5 Program Interfacing with Functional Modules 276
C.2.5.1 Status Register 276
C.2.5.2 Data Registers 277
C.2.6 Interfacing of Functional Modules with Software 277
C.2.6.1 Digital Input 277
C.2.6.2 Digital Output 278
C.2.6.3 Analog Input 278
C.2.6.4 Analog Output 278
C.2.6.5 Pulse Input 279
C.2.6.6 Pulse Output 279
C.2.6.7 Communication 280
C.2.6.8 Watchdog 281
D. Instruction Set of Processor 282
D.1 Introduction 282
D.2 Data Movement Operations 282
D.3 Logical Operations 282
D.4 Arithmetic Operations 283
D.5 Control Operations 283
E. Basics of Programming 284
E.1 Introduction 284
E.2 Lower-Level Programming 284
E.2.1 Machine Level 284
E.2.2 Assembly Level 284
E.3 Programming Examples 285
E.3.1 Programming with Digital I/O 286
E.3.2 Programming with Analog I/O 288
E.3.3 Programming with Pulse I/O 290
E.3.4 Programming with Communication 291
E.3.5 Programming with Interrupt 293
E.3.6 Assembling of Program 295
E.3.7 Higher-Level Programming 298
F. Advanced Control Strategies 300
F.1 Introduction 300
F.2 Closed Loop Control 300
F.2.1 Controller Response to Control Input 300
F.2.2 Proportional Control 302
F.2.3 Proportional and Integral Control 302
F.2.4 Proportional, Integral, and Derivative Control 303
F.2.5 Summary of Control Schemes 305
F.3 Feed-Forward Control 305
F.4 Cascade Control 306
F.5 Ratio Control 307
F.6 Multi-Step Control 308
G. Power Supply System 312
G.1 Introduction 312
G.2 Float-cum-Boost Charger with Battery Backup 312
G.3 Uninterrupted Power Supply System 313
G.4 Battery Bank 315
G.5 Power Distribution 315
H. Further Reading 318
| Erscheint lt. Verlag | 19.8.2011 |
|---|---|
| Sprache | englisch |
| Themenwelt | Technik ► Bauwesen |
| Technik ► Maschinenbau | |
| Wirtschaft ► Betriebswirtschaft / Management ► Logistik / Produktion | |
| ISBN-10 | 0-12-415790-4 / 0124157904 |
| ISBN-13 | 978-0-12-415790-3 / 9780124157903 |
| Haben Sie eine Frage zum Produkt? |
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