Sharma Overview of Industrial Process Automation

1. Auflage 2011
ISBN: 978-0-12-415790-3
Verlag: Elsevier Science & Techn.
Format: EPUB
Kopierschutz: 6 - ePub Watermark

E-Book, Englisch, 320 Seiten

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

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.

Autoren/Hrsg.

Sharma, K. L. S.

Inhaltsverzeichnis

1;Front Cover;1
2;Overview of Industrial Process Automation;4
3;Copyright Page;5
4;Contents;8
5;Foreword;18
6;About the Author;20
7;Preface;22
8;Acknowledgments;26
9;1 Why Automation?;28
9.1;1.1 Introduction;28
9.2;1.2 Physical Process;28
9.2.1;1.2.1 Natural Processes;29
9.2.2;1.2.2 Self-Regulated Processes;29
9.2.3;1.2.3 Man-made or Industrial Processes;29
9.2.3.1;1.2.3.1 Water Tap;29
9.2.3.2;1.2.3.2 Electric Bulb;30
9.2.4;1.2.4 Undesired Behavior;30
9.3;1.3 Types of Industrial Processes;30
9.3.1;1.3.1 Localized Processes;30
9.3.2;1.3.2 Distributed Processes;30
9.4;1.4 Industry Classification;31
9.4.1;1.4.1 Utility Industry;32
9.4.2;1.4.2 Process Industry;33
9.5;1.5 Process Automation System;33
9.5.1;1.5.1 Unattended Processes;34
9.5.2;1.5.2 Manually Attended Processes;35
9.5.3;1.5.3 Automated Processes;36
9.6;1.6 Needs Met by Automation;36
9.7;1.7 Benefits of Automation;37
9.8;1.8 Automation Steps;38
9.8.1;1.8.1 Step 1: Information Acquisition;38
9.8.2;1.8.2 Step 2: Information Analysis and Decision Making;38
9.8.3;1.8.3 Step 3: Control Execution;38
9.9;1.9 Process Signals;39
9.9.1;1.9.1 Classifications;39
9.9.2;1.9.2 Input and Output Signals;39
9.9.2.1;1.9.2.1 Input Signals;39
9.9.2.2;1.9.2.2 Output Signals;40
9.10;1.10 Summary;41
10;2 Automation System Structure;42
10.1;2.1 Introduction;42
10.2;2.2 Subsystems;42
10.2.1;2.2.1 Instrumentation Subsystem;42
10.2.2;2.2.2 Human Interface Subsystem;43
10.2.3;2.2.3 Control Subsystem;43
10.3;2.3 Instrumentation Subsystem;44
10.3.1;2.3.1 Measurement of Information;44
10.3.2;2.3.2 Transfer of Control Command;46
10.4;2.4 Human Interface Subsystem;47
10.4.1;2.4.1 Manual Display and Monitoring;48
10.4.2;2.4.2 Manual Control;48
10.5;2.5 Control Subsystem;48
10.5.1;2.5.1 Information Acquisition;49
10.5.2;2.5.2 Information Analysis and Decision Making;49
10.5.3;2.5.3 Control Execution;49
10.6;2.6 Summary;50
11;3 Instrumentation Subsystem;52
11.1;3.1 Introduction;52
11.2;3.2 Structure;52
11.2.1;3.2.1 Continuous/Analog Instrumentation Devices;52
11.2.1.1;3.2.1.1 Information Acquisition;52
11.2.1.2;3.2.1.2 Control Execution;54
11.2.2;3.2.2 Discrete/Digital Instrumentation Devices;55
11.2.2.1;3.2.2.1 Information Acquisition;55
11.2.2.2;3.2.2.2 Control Execution;57
11.2.3;3.2.3 Fluctuating/Pulse Signals;58
11.3;3.3 Special Instrumentation Devices;58
11.3.1;3.3.1 Switching Instrumentation Devices;59
11.3.2;3.3.2 Integrating Instrumentation Devices;60
11.4;3.4 Interfacing Standards;61
11.4.1;3.4.1 Analog Input and Output Devices;61
11.4.2;3.4.2 Digital Input and Output Devices;61
11.4.3;3.4.3 Switching and Integrating Devices;62
11.5;3.5 Information Reliability;62
11.5.1;3.5.1 Analog Inputs;63
11.5.2;3.5.2 Digital Inputs;63
11.6;3.6 Isolation and Protection;63
11.6.1;3.6.1 Isolation;64
11.6.2;3.6.2 Protection;64
11.6.3;3.6.3 Solutions;64
11.7;3.7 Summary;66
12;4 Control Subsystem;68
12.1;4.1 Introduction;68
12.2;4.2 Structure;68
12.3;4.3 Interfacing;69
12.3.1;4.3.1 General;69
12.3.2;4.3.2 Instrumentation Subsystem;70
12.3.3;4.3.3 Human Interface Subsystem;71
12.4;4.4 Summary;72
13;5 Human Interface Subsystem;74
13.1;5.1 Introduction;74
13.2;5.2 Operator Panel;74
13.2.1;5.2.1 Active Display Elements;74
13.2.2;5.2.2 Active Control Elements;75
13.2.3;5.2.3 Panel;76
13.3;5.3 Construction;76
13.3.1;5.3.1 Basic Approach;77
13.3.2;5.3.2 Mimic Approach;77
13.4;5.4 Interfacing with Control Subsystem;78
13.5;5.5 Types of Mimic Panels;78
13.6;5.6 Summary;79
14;6 Automation Strategies;80
14.1;6.1 Introduction;80
14.2;6.2 Basic Strategies;80
14.2.1;6.2.1 Open Loop Control;81
14.2.2;6.2.2 Closed Loop Control;81
14.3;6.3 Discrete Control;82
14.3.1;6.3.1 Discrete Control—Open Loop;82
14.3.2;6.3.2 Discrete Control—Sequential Control with Interlocks;83
14.4;6.4 Continuous Control;83
14.4.1;6.4.1 Continuous Control—Open Loop;84
14.4.2;6.4.2 Continuous Control—Closed Loop;84
14.5;6.5 Hybrid Control;85
14.5.1;6.5.1 Hybrid Control—Two-Step;85
14.5.2;6.5.2 Hybrid Control—Two-Step with Dead-Band;87
14.6;6.6 Summary;89
15;7 Programmable Control Subsystem;90
15.1;7.1 Introduction;90
15.2;7.2 Discrete Control;92
15.2.1;7.2.1 Sequential Control with Interlocks;92
15.3;7.3 Continuous Control;96
15.3.1;7.3.1 Closed Loop Control;96
15.3.2;7.3.2 Multi-Input/Multi-Output Control;97
15.4;7.4 Hybrid Control;100
15.4.1;7.4.1 Two-Step Control with Dead-Band;100
15.5;7.5 Controller with Additional Features;101
15.5.1;7.5.1 Communicability;103
15.5.2;7.5.2 Self-Supervision or Watchdog;106
15.6;7.6 Upward Compatibility;106
15.7;7.7 Summary;107
16;8 Hardware Structure of Controller;108
16.1;8.1 Introduction;108
16.2;8.2 Major Modules of Controller;109
16.2.1;8.2.1 Rack;109
16.2.2;8.2.2 Bus;109
16.2.3;8.2.3 Functional Modules;111
16.2.4;8.2.4 System Cable;111
16.3;8.3 Data Exchange on Bus;112
16.4;8.4 Functional Subsystems;113
16.4.1;8.4.1 Power Supply Subsystem;113
16.4.1.1;8.4.1.1 Power Supply Module;113
16.4.2;8.4.2 Processor Subsystem;113
16.4.2.1;8.4.2.1 Processor Module;114
16.4.2.2;8.4.2.2 Memory Module;114
16.4.2.3;8.4.2.3 Watchdog Module;114
16.4.3;8.4.3 Input/Output Subsystem;118
16.4.3.1;8.4.3.1 Digital Input Module;118
16.4.3.2;8.4.3.2 Digital Output Module;118
16.4.3.3;8.4.3.3 Analog Input Module;118
16.4.3.4;8.4.3.4 Analog Output Module;119
16.4.3.5;8.4.3.5 Pulse Input Module;119
16.4.3.6;8.4.3.6 Pulse Output Module;119
16.4.3.7;8.4.3.7 Capacity in I/O Modules;121
16.4.4;8.4.4 Communication Subsystem;123
16.4.4.1;8.4.4.1 Communication Module;123
16.4.4.2;8.4.4.2 Communication Cables;124
16.4.5;8.4.5 Integrated Processor Module;124
16.5;8.5 Controller Capacity Expansion;126
16.5.1;8.5.1 Bus Extension (Parallel) Module;126
16.5.2;8.5.2 Bus Extension (Serial) Module;127
16.6;8.6 Integrated Controller;128
16.7;8.7 Summary;129
17;9 Software Structure of Controller;130
17.1;9.1 Introduction;130
17.2;9.2 Types of Software Systems;130
17.2.1;9.2.1 Non-Real-Time System;131
17.2.2;9.2.2 Real-Time System;131
17.3;9.3 Software Structure of Controller;132
17.3.1;9.3.1 Hardware Platform;133
17.3.2;9.3.2 Real-Time Operating System;133
17.3.3;9.3.3 Utility Software;133
17.3.4;9.3.4 Application Software;133
17.4;9.4 Scheduling of Tasks;134
17.4.1;9.4.1 Sequential Scheduling;134
17.4.2;9.4.2 Sequential Scheduling with Time-Slice;134
17.4.3;9.4.3 Real-Time Scheduling;135
17.4.3.1;9.4.3.1 Program Interrupt;135
17.4.3.2;9.4.3.2 Task Execution;135
17.5;9.5 Scheduling of Tasks in Automation Systems;136
17.5.1;9.5.1 Process Data Acquisition;136
17.5.2;9.5.2 Process Data Monitoring;137
17.5.3;9.5.3 Process Control;137
17.6;9.6 Memory Organization;137
17.7;9.7 Summary;138
18;10 Programming of Controller;140
18.1;10.1 Introduction;140
18.2;10.2 Higher-level Programming;140
18.2.1;10.2.1 Ladder Diagram;141
18.2.2;10.2.2 Function Block Diagram;144
18.3;10.3 Programming Examples;147
18.3.1;10.3.1 Sequential Control with Interlocks;147
18.3.2;10.3.2 Loop Control;154
18.3.3;10.3.3 Two-Step Control with Dead-Band;156
18.4;10.4 Summary;160
19;11 Advanced Human Interface;162
19.1;11.1 Introduction;162
19.2;11.2 Intelligent Operator Panels;163
19.3;11.3 Operator stations;165
19.3.1;11.3.1 Display Screen Layout;167
19.3.2;11.3.2 Interaction with the Process;168
19.3.2.1;11.3.2.1 Direct Interaction;168
19.3.2.2;11.3.2.2 Navigated Interaction;168
19.3.2.3;11.3.2.3 Other Features;172
19.3.3;11.3.3 Comparison with Operator Panel;173
19.3.3.1;11.3.3.1 Advantages and Disadvantages of Operator Stations;173
19.3.4;11.3.4 Enhanced Operator Stations;173
19.3.4.1;11.3.4.1 Multiple Monitors;174
19.3.4.2;11.3.4.2 Large Screen Displays;174
19.3.4.3;11.3.4.3 Displays with Embedded Video;175
19.3.4.4;11.3.4.4 Combined Mimic Panel and Operator Station;175
19.3.5;11.3.5 Variants of Operator Stations;176
19.4;11.4 Logging stations;176
19.4.1;11.4.1 Data Logging;176
19.5;11.5 Control Desk;177
19.6;11.6 Summary;178
20;12 Types of Automation Systems;180
20.1;12.1 Introduction;180
20.2;12.2 Localized Process;180
20.2.1;12.2.1 Centralized Control System;181
20.2.2;12.2.2 Decentralized/Distributed Control System;182
20.3;12.3 Distributed Process;183
20.3.1;12.3.1 Remote Control System;184
20.3.2;12.3.2 Network Control System;184
20.3.3;12.3.3 Front-End Processor;184
20.3.3.1;12.3.3.1 Controller-Based FEP;186
20.3.3.2;12.3.3.2 Computer-Based FEP;187
20.4;12.4 Supervisory Control and Data Acquisition;188
20.4.1;12.4.1 Background;188
20.4.2;12.4.2 Case Study;188
20.4.3;12.4.3 Similarities with DCS and NCS;190
20.4.3.1;12.4.3.1 SCADA in DCS;190
20.4.3.2;12.4.3.2 SCADA in NCS;190
20.5;12.5 Summary;191
21;13 Special-Purpose Controllers;192
21.1;13.1 Introduction;192
21.2;13.2 Controller for Localized Processes;192
21.2.1;13.2.1 Programmable Logic Controller;192
21.2.2;13.2.2 Loop Controller;195
21.2.3;13.2.3 Programmable Controller;196
21.3;13.3 Controller for Distributed Processes;197
21.3.1;13.3.1 Remote Terminal Unit;198
21.4;13.4 Other Players;201
21.4.1;13.4.1 PC-Based Controller;201
21.4.2;13.4.2 Programmable Automation Controller;201
21.5;13.5 Summary;203
22;14 System Availability;204
22.1;14.1 Introduction;204
22.2;14.2 Standby Schemes;204
22.2.1;14.2.1 No Standby;204
22.2.2;14.2.2 Cold Standby;205
22.2.3;14.2.3 Hot Standby;205
22.3;14.3 Distributed Control System;206
22.3.1;14.3.1 Availability Analysis in DCS;206
22.3.1.1;14.3.1.1 Level 1: Instrumentation Subsystems;206
22.3.1.2;14.3.1.2 Level 2: Controllers;207
22.3.1.3;14.3.1.3 Level 3: Local Communication Subsystem;208
22.3.1.4;14.3.1.4 Level 4: Operator Station;208
22.3.2;14.3.2 Availability Enhancement in DCS;209
22.3.2.1;14.3.2.1 Processor in Controller;209
22.3.2.2;14.3.2.2 Ethernet I/F in Controller;209
22.3.2.3;14.3.2.3 LAN;210
22.4;14.4 Network Control System;210
22.4.1;14.4.1 Availability Analysis in NCS;211
22.4.1.1;14.4.1.1 Level 1: Instrumentation Subsystem;212
22.4.1.2;14.4.1.2 Level 2: RTUs;212
22.4.1.3;14.4.1.3 Level 3: Remote Communication Subsystem;213
22.4.1.4;14.4.1.4 Level 4: FEP Subsystem;213
22.4.1.5;14.4.1.5 Level 5: Local Communication Subsystem;213
22.4.1.6;14.4.1.6 Level 6: Operator Station;213
22.4.2;14.4.2 Availability Enhancement in NCS;213
22.4.2.1;14.4.2.1 Serial I/F and Processor in RTU;213
22.4.2.2;14.4.2.2 WAN;213
22.4.2.3;14.4.2.3 Serial I/F, Processor, and Ethernet I/F in FEP;214
22.4.2.4;14.4.2.4 LAN;214
22.5;14.5 I/O Redundancy;215
22.6;14.6 Summary;215
23;15 Common Configurations;216
23.1;15.1 Introduction;216
23.2;15.2 Distributed Control System;216
23.2.1;15.2.1 Operator Stations;216
23.2.2;15.2.2 Supervisory Stations;216
23.2.3;15.2.3 Application Stations;217
23.3;15.3 Network Control System;218
23.4;15.4 Summary;219
24;16 Advanced Input/Output System;220
24.1;16.1 Introduction;220
24.2;16.2 Centralized I/O;220
24.2.1;16.2.1 Intelligent CIO;221
24.2.2;16.2.2 Advantages and Disadvantages;222
24.3;16.3 Remote I/O;223
24.3.1;16.3.1 Advantages and Disadvantages;225
24.4;16.4 Fieldbus I/O;226
24.4.1;16.4.1 Advantages and Disadvantages;227
24.4.2;16.4.2 Fieldbus I/F Module;229
24.4.3;16.4.3 Intelligent Serial I/F;231
24.4.4;16.4.4 Protocol Standards;231
24.5;16.5 Summary;232
25;17 Concluding Remarks;234
25.1;17.1 Introduction;234
25.2;17.2 Major Functionalities;234
25.2.1;17.2.1 Data Acquisition;234
25.2.2;17.2.2 Data Supervision or Monitoring;234
25.2.3;17.2.3 Process Survey;234
25.2.4;17.2.4 Process Control;235
25.2.5;17.2.5 Process Studies;235
25.2.6;17.2.6 Human Interaction;235
25.2.7;17.2.7 Data Logging and History Generation;235
25.2.8;17.2.8 Data Exchange;235
25.3;17.3 Data Availability;235
25.4;17.4 Today’s Automation Systems;236
25.5;17.5 Modern Control Center;237
25.6;17.6 Application Areas of Automation Systems;237
25.6.1;17.6.1 Discrete Process Automation;238
25.6.2;17.6.2 Continuous Process Automation;238
25.6.3;17.6.3 Batch Process Automation;238
25.7;17.7 Summary;239
26;A. Hardwired Control Subsystem;240
26.1;A.1 Introduction;240
26.2;A.2 Discrete Control;240
26.2.1;A.2.1 Relay Technology;240
26.2.1.1;A.2.1.1 Control Strategy Implementation;244
26.2.1.2;A.2.1.2 Open Loop Control—Discrete;247
26.2.1.3;A.2.1.3 Sequential Control with Interlocks—Discrete;248
26.2.1.4;A.2.1.4 Advantages and Disadvantages;250
26.2.2;A.2.2 Solid State Technology;250
26.2.2.1;A.2.2.1 Control Strategy Implementation;251
26.2.2.2;A.2.2.2 Open Loop Control—Discrete;251
26.2.2.3;A.2.2.3 Sequential Control with Interlocks—Discrete;252
26.2.2.4;A.2.2.4 Advantages and Disadvantages;254
26.3;A.3 Continuous Control;255
26.3.1;A.3.1 Solid State Technology;255
26.3.1.1;A.3.1.1 Control Strategy Implementation;256
26.3.1.2;A.3.1.2 Open Loop Control—Continuous;256
26.3.1.3;A.3.1.3 Closed Loop Control—Continuous;257
26.4;A.4 Hybrid Control;258
26.4.1;A.4.1 Solid State Technology;258
26.4.1.1;A.4.1.1 Control Strategy Implementation;258
26.4.1.2;A.4.1.2 Two-Step Control;258
26.4.1.3;A.4.1.3 Two-Step Control with Dead-Band;259
26.5;A.5 FPGA- and FPAA-Based Controllers;261
27;B. Processor;262
27.1;B.1 Introduction;262
27.2;B.2 Hardware structure;262
27.2.1;B.2.1 Bus;262
27.2.2;B.2.2 Address Space and Distribution;263
27.2.3;B.2.3 Interfacing of Modules with Bus;264
27.2.3.1;B.2.3.1 Power Supply Module;264
27.2.3.2;B.2.3.2 Processor Module;264
27.2.3.3;B.2.3.3 Memory Module;265
27.2.3.4;B.2.3.4 Functional Module;266
27.2.3.5;B.2.3.5 Bus Extension (Parallel) Module;267
27.2.3.6;B.2.3.6 Bus Extension (Serial) Module;267
27.2.3.7;B.2.3.7 Operations on the Bus;268
27.2.3.8;B.2.3.8 Memory Module;268
27.2.3.9;B.2.3.9 I/O Module;268
27.2.3.10;B.2.3.10 Communication Module;268
27.2.3.11;B.2.3.11 Watchdog Module;270
28;C. Hardware-Software Interfacing;272
28.1;C.1 Introduction;272
28.2;C.2 Architectural Aspects;272
28.2.1;C.2.1 Address Distribution;272
28.2.2;C.2.2 Processor Registers;272
28.2.3;C.2.3 Data Range in Memory/Registers;273
28.2.4;C.2.4 Instruction Formats;274
28.2.4.1;C.2.4.1 Data Movement Operations;274
28.2.4.2;C.2.4.2 Logical Operations;274
28.2.4.3;C.2.4.3 Arithmetic Operations;275
28.2.4.4;C.2.4.4 Control Operations;275
28.2.5;C.2.5 Program Interfacing with Functional Modules;276
28.2.5.1;C.2.5.1 Status Register;276
28.2.5.2;C.2.5.2 Data Registers;277
28.2.6;C.2.6 Interfacing of Functional Modules with Software;277
28.2.6.1;C.2.6.1 Digital Input;277
28.2.6.2;C.2.6.2 Digital Output;278
28.2.6.3;C.2.6.3 Analog Input;278
28.2.6.4;C.2.6.4 Analog Output;278
28.2.6.5;C.2.6.5 Pulse Input;279
28.2.6.6;C.2.6.6 Pulse Output;279
28.2.6.7;C.2.6.7 Communication;280
28.2.6.8;C.2.6.8 Watchdog;281
29;D. Instruction Set of Processor;282
29.1;D.1 Introduction;282
29.2;D.2 Data Movement Operations;282
29.3;D.3 Logical Operations;282
29.4;D.4 Arithmetic Operations;283
29.5;D.5 Control Operations;283
30;E. Basics of Programming;284
30.1;E.1 Introduction;284
30.2;E.2 Lower-Level Programming;284
30.2.1;E.2.1 Machine Level;284
30.2.2;E.2.2 Assembly Level;284
30.3;E.3 Programming Examples;285
30.3.1;E.3.1 Programming with Digital I/O;286
30.3.2;E.3.2 Programming with Analog I/O;288
30.3.3;E.3.3 Programming with Pulse I/O;290
30.3.4;E.3.4 Programming with Communication;291
30.3.5;E.3.5 Programming with Interrupt;293
30.3.6;E.3.6 Assembling of Program;295
30.3.7;E.3.7 Higher-Level Programming;298
31;F. Advanced Control Strategies;300
31.1;F.1 Introduction;300
31.2;F.2 Closed Loop Control;300
31.2.1;F.2.1 Controller Response to Control Input;300
31.2.2;F.2.2 Proportional Control;302
31.2.3;F.2.3 Proportional and Integral Control;302
31.2.4;F.2.4 Proportional, Integral, and Derivative Control;303
31.2.5;F.2.5 Summary of Control Schemes;305
31.3;F.3 Feed-Forward Control;305
31.4;F.4 Cascade Control;306
31.5;F.5 Ratio Control;307
31.6;F.6 Multi-Step Control;308
32;G. Power Supply System;312
32.1;G.1 Introduction;312
32.2;G.2 Float-cum-Boost Charger with Battery Backup;312
32.3;G.3 Uninterrupted Power Supply System;313
32.4;G.4 Battery Bank;315
32.5;G.5 Power Distribution;315
33;H. Further Reading;318