Industrial Process

Automation Systems
Design and Implementation

B. R. Mehta
Y. J. Reddy

AMSTERDAM • BOSTON • HEIDELBERG • LONDON

NEW YORK • OXFORD • PARIS • SAN DIEGO
SAN FRANCISCO • SINGAPORE • SYDNRY • TOKYO
Uutterworlh-Heinemann is an Imprinl ot'Hlsevier
Contents

CHAPTER 1 Industrial Automation 1

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:
Ageneric 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
V
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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 IEC61508/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
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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
CHAPTER 11 HART Communication 365
11.1 Introduction 365
11.2 Technology 365
11.3 HART technology 369
11.4 Application environment 370
CHAPTER 12 PROFIBUS Communication 381
12.1 Overview 381
12.2 Supported topology 386
12.3 Data exchange 388
12.4 Fail-safe operation 391
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CHAPTER 13 Foundation Fieldbus Communication 401

13.1 Fieldbus technology 401
CHAPTER 14 Wireless Communication 417
14.1 Introduction 417
14.2 Basic concepts of industrial wireless communication 419
14.3 IS A100 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 TheDTM 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
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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
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CHAPTER 24 Cyber Security in Industrial Automation 609

24.1 Plant control network 609
24.2 Cyber attacks 618
24.3 Understanding common PCS vulnerabilities 621
24.4 Common PCS software security weaknesses 622
24.5 Standards 626
CHAPTER 25 Mobile and Video Systems 631
25.1 Introduction 631
25.2 Mobile process monitoring console 632
25.3 Key benefits of wireless process mobile console 632
25.4 Handheld mobile device solutions 633
25.5 Some of the major benefits of field-based mobility solutions 634
25.6 Mobile device based solutions 634
25.7 Video system analytics 638
25.8 Regions of interest 639
25.9 Minimum object size 639
25.10 Video system camera server 639
25.11 DCS 639
25.12 Operator console 640
25.13 Video system client 640

Index 641