Overview of Industrial Process Automation

Table of Contents

Cover image

Front-matter

Copyright

Dedication

Foreword

About the Author

Preface

Acknowledgments

1. Why Automation?

1.1. Introduction

1.2. Physical Process

1.3. Types of Industrial Processes

1.4. Industry Classification

1.5. Process Automation System

1.6. Needs Met by Automation

1.7. Benefits of Automation

1.8. Automation Steps

1.9. Process Signals

1.10. Summary

2. Automation System Structure

2.1. Introduction

2.2. Subsystems

2.3. Instrumentation Subsystem

2.4. Human Interface Subsystem

2.5. Control Subsystem

2.6. Summary

3. Instrumentation Subsystem

3.1. Introduction

3.2. Structure

3.3. Special Instrumentation Devices

3.4. Interfacing Standards

3.5. Information Reliability

3.6. Isolation and Protection

3.7. Summary

4. Control Subsystem

4.1. Introduction

4.2. Structure

4.3. Interfacing

4.4. Summary

5. Human Interface Subsystem

5.1. Introduction

5.2. Operator Panel

5.3. Construction

5.4. Interfacing with Control Subsystem

5.5. Types of Mimic Panels

5.6. Summary

6. Automation Strategies

6.1. Introduction

6.2. Basic Strategies

6.3. Discrete Control

6.4. Continuous Control

6.5. Hybrid Control

6.6. Summary

7. Programmable Control Subsystem

7.1. Introduction

7.2. Discrete Control

7.3. Continuous Control

7.4. Hybrid Control

7.5. Controller with Additional Features

7.6. Upward Compatibility

7.7. Summary

8. Hardware Structure of Controller

8.1. Introduction

8.2. Major Modules of Controller

8.3. Data Exchange on Bus

8.4. Functional Subsystems

8.5. Controller Capacity Expansion

8.6. Integrated Controller

8.7. Summary

9. Software Structure of Controller

9.1. Introduction

9.2. Types of Software Systems

9.3. Software Structure of Controller

9.4. Scheduling of Tasks

9.5. Scheduling of Tasks in Automation Systems

9.6. Memory Organization

9.7. Summary

10. Programming of Controller

10.1. Introduction

10.2. Higher-level Programming

10.3. Programming Examples

10.4. Summary

11. Advanced Human Interface

11.1. Introduction

11.2. Intelligent Operator Panels

11.3. Operator stations

11.4. Logging stations

11.5. Control Desk

11.6. Summary

12. Types of Automation Systems

12.1. Introduction

12.2. Localized Process

12.3. Distributed Process

12.4. Supervisory Control and Data Acquisition

12.5. Summary

13. Special-Purpose Controllers

13.1. Introduction

13.2. Controller for Localized Processes

13.3. Controller for Distributed Processes

13.4. Other Players

13.5. Summary

14. System Availability

14.1. Introduction

14.2. Standby Schemes

14.3. Distributed Control System

14.4. Network Control System

14.5. I/O Redundancy

14.6. Summary

15. Common Configurations

15.1. Introduction

15.2. Distributed Control System

15.3. Network Control System

15.4. Summary

16. Advanced Input/Output System

16.1. Introduction

16.2. Centralized I/O

16.3. Remote I/O

16.4. Fieldbus I/O

16.5. Summary

17. Concluding Remarks

17.1. Introduction

17.2. Major Functionalities

17.3. Data Availability

17.4. Today’s Automation Systems

17.5. Modern Control Center

17.6. Application Areas of Automation Systems

17.7. Summary

Appendix A. Hardwired Control Subsystem

Appendix B. Processor

Appendix C. Hardware-Software Interfacing

Appendix D. Instruction Set of Processor

Appendix E. Basics of Programming

Appendix F. Advanced Control Strategies

Appendix G. Power Supply System

Appendix H

Front-matter

Overview of Industrial Process Automation

Overview of Industrial Process Automation

KLS Sharma, Senior Professor, International Institute of Information Technology, Bangalore, India

AMSTERDAM • BOSTON • HEIDELBERG • LONDON • NEW YORK • OXFORD • PARIS • SAN DIEGO • SAN FRANCISCO • SINGAPORE • SYDNEY • TOKYO

Copyright

Elsevier

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First edition 2011

Copyright © 2011 Elsevier Inc. All rights reserved

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Notices

Knowledge and best practice in this field are constantly changing. As new research and experience broaden our understanding, changes in research methods, professional practices, or medical treatment may become necessary.

Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any information, methods, compounds, or experiments described herein. In using such information or methods they should be mindful of their own safety and the safety of others, including parties for whom they have a professional responsibility.

To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any liability for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions, or ideas contained in the material herein.

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A catalog record for this book is available from the Library of Congress

ISBN: 978-0-124-15779-8

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Dedication

This book is dedicated to ABB India, where the author learned and practiced automation for over 24 years.

Foreword

Ravi Uppal

President & Chief Executive Officer, Power Business, Director, Group Board, Larson & Toubro, India

This book authored by Dr KLS Sharma, perhaps, should have been titled Automation made easy as he dealt with the subject matter from the very basics to its progressive development to the contemporary practices in a very illustrative manner. Dr Sharma is an academician by mind who has spent his lifetime in industry implementing automation systems in diverse industries and applications. His penchant for academics was so overwhelming that he quit a senior position in the industry to pursue his passion for research in Industrial automation and advocate its application– all across to enable Indian industry achieve global levels of productivity and thus become more competitive.

The book in indeed is a comprehensive treatise on automation covering a wide range of applications in industries ranging from discrete, continuous process to hybrid. It has dealt in detail with both software and hardware related aspects of automation applications. And interestingly, the book has also covers in detail the latest fieldbus configurations and their interfaces with the contemporary Distributed as well as Open control systems.

The world of automation is undergoing a sea change in which automation hardware is no more captive to solution-providers. The world of PLC and DCS are converging, fading away the traditional dividing lines. The application developers are set to lead the industry. All these emerging trends and much more is beautifully captured in the book.

As India, today, develops its infrastructure and industry at an unprecedented pace, it is vital that we adopt the latest and best in class technologies. We have the privilege of choice! Our large demographic size should not compel us to adopt manual or semi automatic processes which may inhibit realisation of global level of productivity and quality. In this pursuit, the scope of automation must be probed and applied. India’s automation market is presently, about US$ One billion compared to China’s US$ 10 Billion market. The Chinese industry is rapidly catching up with the global best in productivity and thus getting acknowledged as the World factory.

Indian industry has to create awareness for automation benefits and also train hundred of thousand automation champions and professionals.

As a representative of Industry, I am very pleased that a book of this quality is being published which would go a long way to make the subject matter popular with the student as well as teaching community and thus give further impetus to automation applications in industry.

About the Author

K.L.S. Sharma graduated from Mysore University and got his masters and doctorate degrees from the Indian Institute of Technology, Delhi.

He has worked for the following organizations:

• Electronics Corporation of India Limited, Hyderabad, India

• ABB Limited, Bangalore, India

• Honeywell Technology Solutions Lab, Bangalore, India

He is currently working in the following positions:

• Senior Professor, International Institute of Information Technology, Bangalore, India

• Professor Emeritus, M S Ramaiah Institute of Technology, Bangalore, India

• Member, Editorial Advisory Board, A&D Magazine on Industrial Automation, India

• Member, Campus Connect Program, Automation Industry Association of India

• Senior Member, International Society of Automation (ISA)

Preface

KLS Sharma (email: kls.sharma@iiitb.ac.in)

During my 33-year career in the computer and automation industry and subsequently my 7 years in academic institutions, I have observed a gap between academia and industry regarding the automation domain. These observations are based on my time spent training new recruits in Indian industry and, later, on my teaching experience in Indian academic institutions. One of the ways this gap can be bridged is by introducing the basics of modern automation technology to those who are beginning careers in automation. This includes students and persons in industry who are switching to the automation domain. Prior knowledge of automation provides these beginners with a better and quicker start.

In many academic institutions, curriculum is being upgraded in instrumentation/control engineering courses to prepare the students for careers in the automation industry. At present, the automation industry spends considerable time and money training and preparing new recruits for the job. The situation is more or less the same for persons switching to the automation domain in industry. This motivated me to write this book introducing the principles of automation in a simple and structured manner.

This book teaches beginners the basics of automation, and it is also intended as a guide to teachers and trainers who are introducing the subject. It addresses the current philosophy, technology, terminology, and practices within the automation industry using simple examples and illustrations.

The present automation system is built out of a combination of technologies, which include the following:

• Sensor and control

• Electronics

• Electrical drives

• Information (computer science and engineering)

• Communication and networking

• Embedded

• Digital signal processing

• Control engineering, and many more

Present automation technology is one of the few engineering domains that use many modern technologies. Among these, information, communication, and networking technologies have become integral part of today’s automation. Basic subsystems of modern automation system are instrumentation, control, and human interface. In all the subsystems, the influence of various technologies is visible. By and large, the major providers of automation use similar philosophies in forming their products, systems, and solutions.

As of now, most of the information on modern automation exists in the form of technical documents prepared by automation companies. These documents are usually specific to their products, systems, solutions, and training. This knowledge has not yet been widely disseminated to the general public, and the books that are available deal with specific products and systems. Most of this industry material is somewhat difficult for beginners to understand. It is good for next-level reading after some exposure to the basics.

Automation of the industrial process calls for industrial process automation systems. These involve designing, developing, manufacturing, installing, commissioning, and maintaining of automation systems, which calls for the services of qualified and trained automation engineers. In addressing the basic concepts of automation, this book provides a starting point for the necessary education and training process.

Over the years, considerable advances have taken place in hardware technologies (mainly in electronics and communication). However, in computer-based automation systems, hardware interfaces have remained virtually the same—except that control has become more powerful due to availability of large memory and increased processor speeds. In other words, the memory and speed constraints present in earlier systems are not an issue today. In view of this, many aspects of hardware interface and function have been taken over by software, which does not need special interface electronics. Today, complete operation and control of industrial processes are by software-driven automation systems. Further, this software provides maximum support to the user. The user is now only required to configure and customize the automation system for a particular process. Therefore, the emphasis in this book is placed on hardware, engineering, and application programming.

This book is intended for:

• Students beginning automation careers

• Teachers of automation and related subjects

• Engineers switching to automation careers

• Trainers of automation

How to read the book:

• Follow the book from beginning to end, as its sequence is structured as a guided tour of the subject.

• Skip appendixes if you already have the background knowledge. They are provided for the sake of completeness and to create a base for easy understanding of the book.

Benefits the book provides for readers:

• Does not call for any prior knowledge of automation

• Presents a guided tour of automation

• Explains the concepts through simple illustrations and examples

• Makes further study easy

• Prepares understand technical documents in the automation industry

Based on my experience in training, teaching, and interacting with trainees and students, I have specially formulated and simplified the illustrations and discussions in this book to facilitate easy understanding.

The book is organized as follows:

Chapter 1: Why Automation?—Industrial process, Undesired behavior of process, Types and classifications of process, Unattended, manually attended, and fully automated processes, Needs and benefits of automation, Process signals

Chapter 2: Automation System Structure—Functions of automation subsystems, Instrumentation, control, and human interface, Individual roles

Chapter 3: Instrumentation Subsystem—Structure and functions, Types of instrumentation devices, Interface to control subsystem, Interfacing standards, Isolation and protection

Chapter 4: Control Subsystem—Functions and structure, Interfaces to instrumentation and human interface subsystems

Chapter 5: Human Interface Subsystem—Construction, Active display and control elements, Types of panels, Interface to control subsystem

Chapter 6: Automation Strategies—Basic strategies, Open and closed loop, Discrete, continuous, and Hybrid

Chapter 7: Programmable Control Subsystem—Processor-based subsystem, Controller, Input/output structure, Special features—communicability and self-supervisability

Chapter 8: Hardware Structure of Controller—Construction of controller, Major functional modules, Data transfer on the bus, Structure and working of functional modules, Integration

Chapter 9: Software Structure of Controller—Difference between general-purpose computing and real-time computing, Real-time operating system, Scheduling and execution of tasks, Program interrupt

Chapter 10: Programming of Controller—Programming of automation strategies, higher-level languages, IEC 61131-3 standard, Ladder logic diagram, Function block diagram

Chapter 11: Advanced Human Interface—Migration of hardwired operator panel to software-based operator station, Layout and features, Enhanced configurations, Logging station, Control desk

Chapter 12: Types of Automation Systems—Structure for localized and distributed process, Centralized system, Decentralized/distributed system, Remote/networked system, Multiple operator stations, Supervisory control and data acquisition

Chapter 13: Special Purpose Controllers—Customization of controller, Programmable logic controller, Loop controller, Controller, Remote terminal unit, PC-based controller, Programmable automation controller

Chapter 14: System Availability—Availability issues, Improvement of system availability, Cold and hot standby, Standby/redundancy for critical components

Chapter 15: Common Configurations—Configurations with operator stations, Supervisor stations, Application stations

Chapter 16: Advanced Input/Output System—Centralized I/O, Remote I/O, and Fieldbus I/O, Data communication and networking, Communication protocol

Chapter 17: Concluding Remarks—Summary, Application-wise classification of automation systems, Data handling, Future trends

Appendixes: Hardwired Control Subsystems, Processor, Hardware–Software Interfacing, Basics of Programming, Advanced Control Strategies, Power Supply System, Further Reading

I wish to emphasize that the content in this book is mainly a result of my learning, practicing, teaching, and training experience in automation areas in ABB India, where I worked for over 24 years. I would also like to mention the following organizations, where I gained valuable automation teaching and training experience:

International Institute of Information Technology, Bangalore, India (http://www.iiitb.ac.in)

National Institute of Technology Karnataka, Surathkal, India (http://www.nitk.ac.in)

Axcend Automation and Software Solutions, Bangalore, India (http://www.axcend.com)

Honeywell Technology Solutions Lab, Bangalore, India (http://www.honeywell.com)

Emerson Process Management, Mumbai, India (http://www.emerson.com)

M S Ramaiah Institute of Technology, Bangalore, India (http://www.msrit.edu)

For their help with this book, I respectfully and gratefully acknowledge the kind guidance and support of my senior colleagues

Prof. S.S. Prabhu, Senior Professor, IIIT/Bangalore; former Professor, IIT/Kanpur; and a veteran on control systems and power systems

Prof. H.N. Mahabala, former Professor, IIT/Kanpur, IIT/Chennai, IIIT/Bangalore; a veteran on information technology; and a founder of computer education in India

I also acknowledge the help of my student, Mrs. Celina Madhavan, who developed the automation program examples for the book and reviewed the manuscript.

In addition, the following professionals supported me at every stage of preparation of the manuscript with their valuable suggestions and input:

Prof. R Chandrashekar, IIIT/Bangalore, India

Mr. Hemal Desai, Emerson Process Management, Mumbai, India

Mr. Shreesha Chandra, Yokogawa, Bangalore, India

I also gratefully acknowledge the support and encouragement of Prof. S. Sadagopan, Director, IIIT/Bangalore, and Mr. Anup Wadhwa, Director, Automation Industry Association of India (AIA).

Finally, I would like to thank my wife, Mrs. Sumitra Sharma, for her kind encouragement and support through it all.

1st Mach, 2011

Bangalore, India

Acknowledgments

KLS Sharma

I would like to gratefully acknowledge the support from the following organizations for kindly providing the information on their products, systems, and solutions for inclusion in the book:

*Under processing

I have also consulted extensively www.wikipedia.com and many industry and education websites for the information, definitions, and images for explaining some of the concepts in automation.

1. Why Automation?

Starts with an introduction to the processes (man-made or industrial) which need to be automated for making them produce quality, consistent, and cost-effective goods and services. Classification of different kinds of processes by their nature and by their application is discussed. Automation systems are different for different processes. The chapter ends with a discussion on process signals. Input signals facilitate the automation system understand the behavior of the process while the output signals facilitates process control.

Keywords: Process; Physical; Natural; Self-regulated; Man-made; Industrial; Localized; Distributed; Geographically distributed; Utility industry; Process industry; Automation; Information; Acquisition; Analysis; Control; Signals; Input; Output; Discrete; Digital; Continuous; Analog; Fluctuating; Pulse.

1.1. Introduction

Over the past few decades, the industry