Overview of Industrial Process Automation

K.L.S. Sharma

• Publisher: Elsevier
• Year: 2016
• eBook ISBN: 9780128093030
• Edition: 2
• Topic: Technology & Engineering
• Subtopic: Automation in Engineering
• Index: Technology & Engineering

Overview of Industrial Process Automation, Second Edition, introduces the basics of philosophy, technology, terminology, and practices of modern automation systems through the presentation of updated examples, illustrations, case studies, and images. This updated edition adds new developments in the automation domain, and its reorganization of chapters and appendixes provides better continuity and seamless knowledge transfer. Manufacturing and chemical engineers involved in factory and process automation, and students studying industrial automation will find this book to be a great, comprehensive resource for further explanation and study. - Presents a ready made reference that introduces all aspects of automation technology in a single place with day-to-day examples - Provides a basic platform for the understanding of industry literature on automation products, systems, and solutions - Contains a guided tour of the subject without the requirement of any previous knowledge on automation - Includes new topics, such as factory and process automation, IT/OT Integration, ISA 95, Industry 4.0, IoT, etc., along with safety systems in process plants and machines

1

Why Automation?

Abstract

This chapter provides a brief introduction to industrial processes, classifications, physical structure, application, and behavior. The chapter further explains the automation system along with its basic functions and its role in managing industrial processes to achieve desired results. The chapter ends with the needs met by automation and the benefits of automation.

Keywords

Industrial processes; Localized and distributed processes; Manufacturing and utility processes; Process behavior; Process management; Automation steps; Process signals

Chapter Outline

1.1 Introduction

1.2 Physical Processes

1.2.1 Natural

1.2.2 Self-regulated

1.2.3 Industrial

1.2.3.1 Application

1.2.3.2 Operational

1.2.3.3 Physical

1.3 Localized and Distributed Processes

1.4 Process Behavior

1.4.1 Water Tap

1.4.2 Electric Bulb

1.5 Process Management

1.5.1 Unattended

1.5.2 Attended

1.5.3 Automated

1.6 Process Signals

1.6.1 Input Signals

1.6.2 Output Signals

1.7 Automation Steps

1.7.1 Data Acquisition

1.7.2 Data Analysis, Monitoring, and Decision Making

1.7.3 Control Execution

1.8 Needs met by Automation

1.9 Benefits of Automation

1.9.1 Manufacturing Processes

1.9.2 Utility Processes

1.10 Summary

1.1. Introduction

Over the past few decades, the emphasis in industry worldwide has been to produce goods or deliver services which are of quality, consistency, and cost-effective, to stay in the market. Quality, consistency, and competitiveness cannot be achieved without automating the process of manufacturing goods and of delivering services. In line with this trend, the application of automation today is omnipresent in almost all applications, from deep water sea to space, and has gained the confidence of the world for achieving desired results. Over the years, automation technology has advanced along with various other technologies. The main driving and enabling technologies are information, communication, networking, and electronics.

This list below shows the evolution of automation technology over the past decades:

• 1940–1960: Pneumatic

• 1960–2000: Analog: Electrical, mechanical, and hydraulic

• 1980–1990: Digital: Proprietary

• 2000 onward: Digital: Open.

The technology has already moved to an open network of embedded systems.¹ This chapter gives a brief introduction to automation and explains why it is necessary to automate the production of goods and delivery of services to achieve the required quality, consistency, and cost-competitiveness for today’s marketplace. Apart from these tangible requirements, there are many more complex requirements that cannot be achieved without automation.

1.2. Physical Processes

Physical process² is a series of actions, operations, changes, or functions that takes place within, bringing about changes or producing an output or a result. It is also a sequence of interdependent operations or actions which, at every stage, consumes one or more inputs or resources to convert them into outputs or results to reach a known goal or the desired end result.

Whatever we see and work within reality are all physical processes. Physical processes can be broadly divided into three categories:

• Natural processes,

• Self-regulated processes, and

• Industrial processes.

1.2.1. Natural

Natural processes³ are presented by or produced by nature. The best example is a human body that generally does not need external assistance to regulate its body parameters (e.g., body temperature) irrespective of the effects of surrounding environmental conditions. The human body maintains or regulates all of its parameters. Typically, in natural processes no abnormal behavior is present in most of the conditions.

1.2.2. Self-regulated

Self-regulated processes⁴ are not natural but do not need external assistance for regulation. The best example is a domestic geyser that is designed such that th...

Table of contents

• Cover image
• Title page
• Table of Contents
• Copyright
• Dedication
• About the Author
• Foreword
• Preface to the First Edition
• Preface to the Second Edition
• Acknowledgments
• 1. Why Automation?
• 2. Automation System Structure
• 3. Instrumentation Subsystems
• 4. Human Interface Subsystem
• 5. Control Subsystem
• 6. Automation Strategies
• 7. Programmable Control Subsystems
• 8. Data Acquisition and Control Unit: Hardware
• 9. Data Acquisition and Control Unit: Software
• 10. Advanced Human Interface
• 11. Types of Automation Systems
• 12. Special-Purpose Data Acquisition and Control Units
• 13. System Availability Enhancements
• 14. Common Configurations
• 15. Customization
• 16. Data Communication and Networking
• 17. Fieldbus Technology
• 18. Safety Systems
• 19. Management of Industrial Processes
• 20. Information Technology–Operation Technology Convergence
• 21. Concluding Remarks
• Appendix A. Hardwired Control Subsystem
• Appendix B. Processor
• Appendix C. Hardware–Software Interfacing
• Appendix D. Basics of Programming
• Index