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

570 Pages·2022·27.516 MB·English

by  Swapan Basu

Plant Intelligent Automation
and Digital Transformation
Process and Factory Automation
VOLUME I
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Plant Intelligent Automation
and Digital Transformation
Process and Factory Automation
VOLUME I
Swapan Basu
Founder, Systems and Controls, Kolkata, India
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Dedication
In the name of Gurudeb I trust,
I dedicate this volume of the book
to everyone who selflessly sacrificed their lives in the services
of mankind during the global pandemic Covid 19
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Contents
Foreword xvii 1.2.2 Cascade control
Preface xix action 25
1.2.3 Ratio control 28
Acknowledgments xxi
1.2.4 Override control 30
1.2.5 Auctioneering control 32
1. General discussions on control 1.2.6 Split range control 32
systems 1.2.7 Inferential control 34
1.0 Fundamentals and general discussions 1.2.8 Adaptive control and gain
on control systems 2 scheduling 34
1.0.0 Recapitulations of terms 1.2.9 Hierarchicalcontrol
with explanations 2 system 37
1.0.1 Requirements for plant
1.3 Control system models 41
automation conceptual
1.3.0 Discussions on control
discussions 2
system models 41
1.0.2 Synopsys of issues covered
1.3.1 Types of systems 42
in this volume of the
1.3.2 Model based control (MBC)
book 6
methodologyand
1.0.3 Microprocessor:
structure 42
microcomputer basics
1.3.3 Various model based
(brief recapitulations) 6
control types 43
1.0.4 Control implementation
1.3.4 Control computing and
issues 9
system development 47
1.0.5 Mathematical approach for
1.3.5 Linearization of nonliner
control systems 13
systems 47
1.1 Control system synthesis and
1.4 State space in control systems 50
control theory 16
1.4.0 Concept of state space and
1.1.0 Preliminary
control system 50
discussions 16
1.4.1 State variable and
1.1.1 Definition of various terms
process 50
used in control theory 17
1.4.2 System state 50
1.1.2 Discontinuous (discrete)
1.4.3 State equation 51
control system 17
1.4.4 Output equation 52
1.1.3 Continuous control
1.4.5 Block diagram
system 19
representation
1.1.4 PID implementation in
of state space 52
digital control systems 24
1.5 Optimization of controls and
1.2 Control loop modes, types and
automations 52
hierarchical control 25
1.5.0 Basics of process control
1.2.0 General discussions on
and process
modes and types of
automation 52
controls 25
1.5.1 Structural approach for
1.2.1 Examples for feed forward
integrated optimization
control and lag lead
and control 52
controls 25
vii
viii Contents
1.5.2 Discussions on integrated 4.2.2 Control system security: policy
structure 53 and deployment 74
1.5.3 Advanced process controller 4.2.3 Discussions on ISA 99/IEC
(APC) and 62443 standard sets 74
optimization 54 4.3 Plant safetydiscussions with safety
List of abbreviations used 54 fieldbus outline 77
References 55 4.3.0 Plant safetyand security
Further reading 56 discussions 77
4.3.1 Conceptual discussions ON
2. Basics of networking SIF, SIS, and SIL and
ALARP 78
2.0 Basics of networking 57 4.3.2 Outline of safe fieldbus and
2.0.0 Outline discussions on
IS for fieldbus 81
basic networking 57
4.3.3 Electrical area
classification 83
3. Industrial data communication
4.3.4 Enclosure class 86
4.3.5 Intrinsic safety 87
3.0 Industrial data communication 59
3.0.0 Outline discussions on List of abbreviations 93
industrial data References 94
communication 59
5. Control intelligence and futuristic
4. System diagnostics, security, and approach
safety
5.0 Control intelligence and futuristic
4.0 Functional details of system approach 97
5.0.0 Outline of control intelligence
diagnostics, security, and safety 61
4.0.0 Discussions on diagnostics, and futuristic approach 97
system security, and
safety 61 6. PLC and Open-loop control
4.0.1 Basic discussions on system (OLCS) functional and
diagnostics 61 design details
4.0.2 Control system securityand
access control 63 6.0 PLC and open-loop control
4.0.3 Plant safety conceptual system 100
6.0.0 Requirements of OLCS;
discussions 65
hierarchical control and
4.1 Discussions on diagnostics 66
interlock discussions 100
4.1.0 General discussions on
6.0.1 OLCS characteristics and
self-diagnostics for devices
comparison with CLCS 101
and systems 66
6.0.2 OLCS CLCS plant
4.1.1 Selfdiagnosisatfieldlevel 67
automation 102
4.1.2 Self diagnosis in intelligent
6.0.3 Interlock concept and
devices and systems 68
hierarchical interlock
4.1.3 Process/equipment diagnostic
issues 103
methoddADS 69
6.0.4 Hierarchical controld
4.1.4 Diagnosis types and alarms
grouping discussions 104
with example 69
4.1.5 Expert diagnosis systems 69 6.1 Basics of PLC with hardware
details 105
4.2 Control systems security
6.1.0 Basics of PLC system 105
discussions 72
6.1.1 PLC logics and I/O
4.2.0 Basic objectivesand
interface 108
recommended strategies 72
6.1.2 Discussions on PLC
4.2.1 Control system security risk
hardware 110
management 73
Contents ix
6.1.3 Brief discussions on PLC 6.7.0 System diagnostics and
selection 120 security issues 149
6.2 PLC software discussions 122 6.7.1 Overviewof systems (ICS)
6.2.0 PLC software programming diagnostics 151
types 122 6.7.2 Program diagnostics and
6.2.1 Programming different tests 151
languages 123 6.7.3 Process diagnostics and
6.2.2 Discussions on software diagnostic analysis for
standards for PLC 129 maintenance 152
6.2.3 PLC software issues for 6.7.4 PLC vulnerability
considerations 132 discussions 152
6.2.4 PLC programming basics 6.7.5 ICS threat, vulnerability
and memoryarea 134 and risk factors 153
6.3 Types of PLC 134 6.7.6 ICS security program
6.3.0 Basis for PLC development 154
classification 134 6.8 PLC performance and application
6.3.1 PLC types based on area 155
mounting 135 6.8.0 PLC applications performance
6.3.2 Types of PLC according to and selections 155
size 136 6.8.1 Discussions on PLC
6.3.3 PLC classification based performance and
on I/O types 137 services 155
6.3.4 PLC types on redundancy 6.8.2 PLC application area 156
criteria 137 6.9 Safe PLC discussion 156
6.3.5 Miscellaneous issues for 6.9.0 Generaldiscussionsofsafe
PLC classifications 138 logicsolverandsafety
6.4 Features and configurations of PLC 157
PLC 138 6.9.1 Requirements for safety PLC
6.4.0 Required features and system 158
configuration 138 6.9.2 Selection of safe PLC 159
6.4.1 Salient features of PLC 138 6.9.3 Safe PLC design and
6.4.2 Feature based PLC implementation issues 160
configuration changes 140 6.9.4 Factoryautomation with
6.5 Networking interfaces and system safe PLC 162
integration 142 6.9.5 Safe PLCdSIS
6.5.0 Basic issues for interfaces discussions 163
and system integration List of abbreviations
(PLC/DCS) 142 used 168
6.5.1 Serial link in system References 169
integration 142
6.5.2 System integration by 7. OLCS in process plants and
fieldbus 145 PLC details
6.5.3 Ethernet for system
integration 146 7.0 Open loop controls in process
6.5.4 System integration with automation and I/O detailing 171
7.0.0 Analog I/O and modulating
OPC 146
controls in PLC 172
6.5.5 Discussions on system
7.0.1 Distinctive features and
integration and interface
evolution of PLC and
examples 147
DCS 172
6.6 Brief discussions on HMI and
7.0.2 Technologicalchangesfor
engineering interfaces 148
PLCforprocesscontrols 173
6.7 System diagnostics and
7.0.3 ProcesscontrolsinPLC 174
security 149