International Society of Automation – serie

To run efficiently and cost effectively as well as ensure product quality, manufacturing control systems on the plant floor must be able to communicate with the enterprise systems. Materials must be purchased and delivered on time, personnel must be scheduled, equipment must be available and operating properly, recipes must be precise, processes must be tracked, and product quality must be monitored so that changes can be made--all in real time. The problem is this: each system in the process speaks a different language.The ISA-95 Enterprise Control System Integration series of standards is a guide for creating the interfaces needed to bridge the language gap. It provides consistent terminology for the phases and steps throughout the process control layer and models for implementing the interfaces. The Road to Integration, Second Edition, explains how to use the principles, terminology, and information methods in the standard to integrate enterprise resource planning (ERP) systems, manufacturing execution systems (MES), and manufacturing operations management (MOM) systems.The authors discuss ISA-95 in the broader context of modern information exchange technologies and offer a complete picture for project managers, consultants, programmers, and information architects who want to integrate ERP and MOM/MES systems based on the international standard.

As commercial and residential networks rapidly go the wireless route, will industrial networks soon follow? This fourth edition includes the increasingly popular wireless application Radio Frequency Identification (RFID) and also provides a clear, unbiased view of the emerging wireless communications market. Author Dick Caro explores wireless communications from the factory and process automation viewpoint to help you make clear decisions on the timing and strategy for implementing wireless networks for automation projects. According to Caro, going wireless is more than just plugging in some wireless components to replace the wires. Residential networks are easily justified using today’s inexpensive wireless components to avoid costly or unsightly wire installations. Industrial use is not quite so clear due to privacy and security concerns and the potential for signal loss in plant environments. Industrial use must have secure communications that never fails. However, the cost of industrial wiring is so high, that wireless can usually be justified. This fourth edition includes a general update of events that have occurred since the previous edition. Most importantly, it includes an extensive analysis of new wireless technology intended for process control, such as ISA100 Wireless (ISA100.11a), WirelessHART, WIA-PA, and WiFi, including IEEE 802.11n and 802.11ac.

This book addresses the challenges of the process control effort, recognizing that factory automation systems are no longer isolated entities and that the systems and their functions are indeed merging. Discrete, continuous and batch can be performed together or by the same system used in diverse applications. The book is intended for those readers involved in factory automation systems as well as process, including readers who are already experienced and knowledgeable about distributed processor systems, but may not necessarily be exposed to the technologies and issues discussed in industry. The author looks at past technologies and how their concepts have grown to encompass additional new and exciting nuances of current high technology.

The most comprehensive book on this subject available! A virtual encyclopedia of electrical safety, this latest edition features a new structure. The author rewrote and re-ordered the chapters, either to better reflect today's perspective or to clarify the presentation. Magison expanded his treatment of theory and principles to provide a foundation for addressing some of the questions that arise when no standard or regulation exists. He also added more practical examples of applying principles in real situations. Recognizing the fact that the book's subject matter is truly an international concern, Magison increased the amount of space devoted to work outside North America.

A structured methodology for designing reliable instrumentation and control systems Designing or upgrading instrumentation and control systems requires more than component selection—it demands a structured engineering methodology. Successful Instrumentation and Control Systems Design, now in its Third Edition, provides that framework. Drawing on decades of real‑world experience, it walks readers through design packages, engineering deliverables, documentation practices, and project workflows that support successful outcomes. This updated edition addresses advanced control systems driving automation today, including signal integrity, control architecture, system integration, cybersecurity, and lifecycle maintainability. With billions in legacy systems approaching obsolescence, the book provides critical guidance for modernization efforts. Topics span project planning, integrated controls solutions, project execution plans, estimation methods, and workflows for controls projects. The book also covers: Project flow methodologies and staff coordination strategies that ensure control projects meet scope, schedule, and budget requirements effectively.Technical considerations for signal integrity, control architecture selection, and system integration across distributed and centralized control environments.Cybersecurity frameworks and compliance guidance essential for protecting modern instrumentation systems from evolving digital threats and vulnerabilities.Legacy system migration pathways and modernization strategies for upgrading existing control infrastructure while maintaining operational continuity throughout transitions.Documentation standards and engineering deliverables that form complete design packages meeting industry and regulatory requirements for I&C projects.Consulting design engineers, project managers, control technicians, and maintenance technologists will find this book essential for implementing reliable, scalable control solutions. Whether designing new systems or navigating complex modernization efforts, this reference delivers the methodical approach required for successful I&C projects.

Updated ISA-authorized book covering the ISA Automation Body of Knowledge The newly updated Fourth Edition of A Guide to the Automation Body of Knowledge is the only officially authorized book covering the International Society of Automation's (ISA's) body of knowledge core competencies. This revised guide provides an overview of the most important automation concepts and processes, while also describing the technical skills required to implement them in today's industrial environment. The book enables readers to effectively study for the ISA Certified Automation Professional® (CAP®), ISA Certified Control Systems Technician® (CCST®), and/or Professional Engineer (PE) Control Systems Engineer (CSE) exams. Edited and written by leading experts from all aspects of automation, A Guide to the Automation Body of Knowledge includes information on: Process and analytical instrumentation; discrete, continuous, and batch control; and control valves and final control elementsBasic discrete, sequencing, and manufacturing control, advanced control, process modeling, and digital twins, digital and analog communications, and data management and system softwareNetworking and cybersecurity, safety and reliability, system checkout, testing, start-up, troubleshooting, and project managementManufacturing operations management, automation justification and performance analysis, motors and drives, electrical systems, asset management and maintenance, motion control and vision systems, and control systems including PLCs, DCSs, and SCADAWhether you are an engineer, manager, control systems integrator, student, or educator, A Guide to the Automation Body of Knowledge is the book you will turn to again and again as the ultimate source on what is encompassed by automation.

Transform process data into actionable information using proven design principles Data-to-Information Handbook: Building Effective Display Systems for Refining Processes is a practical guide for designing human-machine interfaces that transform raw data into clear, actionable information. Written by experts with extensive experience in control systems and operator performance, the book is grounded in the IEC 63303 and ISA-101 standards and offers comprehensive guidance on creating effective display systems that enhance operator decision-making and reduce uncertainty in continuous process environments. The handbook explains display design principles and examples from continuous process plants across multiple industries. It specifies the information needed at each hierarchy level for major equipment and sections, with detailed representations for refinery processes. The book delivers three key applications: designing new systems, evaluating existing ones, and generating practical improvement concepts. The book also: Combines guidance from IEC 63303 and ISA-101 standards with practical strategies for building effective HMI displays in continuous process environments.Provides a complete hierarchical display system for an entire refinery with examples for different hierarchy levels.Specifies information requirements at each display level for major equipment and sections in process plants.Offers detailed representations of systems and equipment for major refinery processes with practical display examples.Includes proven concepts and techniques for modifying existing graphics to enhance operator perceptibility and confidence.The Data-to-Information Handbook is essential for project engineers, process automation engineers, display designers, and operators working in continuous process industries. Practitioners will learn to design displays that significantly improve operator confidence, reduce uncertainty, and support better decision-making in control rooms across refining, chemical, and related industries.

In his preface, the editor describes this volume as a road map to the field of flow measurement. It discusses strategies for problem solving and puts the whole array of types of flowmeters at the reader's disposal. Emphasis is placed on the importance of accuracy in measurements and ways of ensuring accuracy and avoiding equipment damage through correct forecast of operating conditions, flowmeter selection, installation, calibration, and maintenance. Fundamental considerations such as mixed-phase flow, piping effects, and flow conditioning are examined at length. The problem of attaining a meaningful flow signal through linearization, compensation, and totalization is discussed.

No technical library is complete without this comprehensive dictionary covering the entire vocabulary of instrumentation, systems, and automation. Now in its 4th edition, this authoritative ISA dictionary has been completely revised and expanded to reflect the latest trends in industrial instrumentation and automation. References to all relevant ISA and IEC standards are now included throughout, along with illustrations to enhance the definitions of more difficult terms. This reference encompasses not only specialized vocabulary unique to instruments and control systems, but many terms from other engineering disciplines as well. Ideal for engineers, technicians, students, and technical writers, this volume is packed with practical information. Clear in presentation, easy to use either in the office or on the shop floor, the Automation, Systems, and Instrumentation Dictionary is the only resource you'll need for a concise and thorough understanding of your professional language.

This book is designed to help practicing engineers avoid costs associated with misapplication of flowmeters. The text reviews the important concepts of flow measurement and provides explanations, practical considerations, illustrations, and examples of existing flowmeter technology. A rational procedure for flowmeter selection is presented to help decision makers evaluate appropriate criteria.(Volume in RMC Series).

This comprehensive review of calibration provides an excellent foundation for understanding principles and applications of the most frequently performed tasks of a technician. Topics addressed include terminology, bench vs. field calibration, loop vs. individual instrument calibration, instrument classification systems, documentation, and specific calibration techniques for temperature, pressure, level, flow, final control, and analytical instrumentation. The book is designed as a structured learning tool with questions and answers in each chapter. An extensive appendix containing sample P&IDs, loop diagrams, spec sheets, sample calibration procedures, and conversion and reference tables serves as very useful reference. If you calibrate instruments or supervise someone that does, then you need this book.

The authors of the best-selling book ""PID Controllers: Theory, Design, and Tuning"" once again combine their extensive knowledge in the PID arena to bring you an in-depth look at the world of PID control. A new book, ""Advanced PID Control"" builds on the basics learned in ""PID Controllers"" but augments it through use of advanced control techniques. Design of PID controllers are brought into the mainstream of control system design by focusing on requirements that capture effects of load disturbances, measurement noise, robustness to process variations and maintaining set points. In this way it is possible to make a smooth transition from PID control to more advanced model based controllers. It is also possible to get insight into fundamental limitations and to determine the information needed to design good controllers.The book provides a solid foundation for understanding, operating and implementing the more advanced features of PID controllers, including auto-tuning, gain scheduling and adaptation. Particular attention is given to specific challenges such as reset windup, long process dead times, and oscillatory systems. As in their other book, modeling methods, implementation details, and problem-solving techniques are also presented.

Troubleshooting loops and systems is something all technicians must do, but that few truly master. This newly revised edition draws on the author's long experience as an instrument and electrical engineer and his maintenance expertise to provide a detailed look at the skills and knowledge required for troubleshooting. Interspersed with a wealth of practical detail and real-world examples are Mostia's no-nonsense discussions of what a good troubleshooter needs to know. He provides an in-depth discussion of the basic logical framework that underlies all troubleshooting as well as advanced troubleshooting techniques.

This up-to-date work on final control elements presents theoretical and practical information in an easy, conversational style, which makes it an excellent reference for experienced instrument and process engineers as well as students who are new to the field.The book begins with a basic explanation of the function and purpose of control valves, explaining the various types of valves that are available along with their features and limitations. It also provides:Directions for selecting the best valve for a given service and the right flow characteristicsSimplified equations for sizing control valves for liquids and gases under normal and special conditions, such as flashing and laminar flowDirections for minimizing environmental problems, such as noise produced by turbulent or cavitating fluids and aerodynamic noiseSolutions to dynamic instability problemsMethods for improving control loop stabilityDiscussion on related safety issues such as “fail-safe” action and cybersecurityMany reference tables provide information that will be invaluable in valve selection, such as valve materials, temperature ratings, and valve dimensions. Also, for the benefit of international readers, examples and equations are presented in metric as well as U.S. customary terms and measurements.

This practical guide developed by Dave Polka, an industry veteran with more than 30 years of experience, is an invaluable resource for design engineers, automation and control specialists, maintenance technicians, and students. The basic theories of AC and DC drives haven’t changed but the technology certainly has, and this new edition takes a fresh look at how market demands have advanced motor and drive technology to lead the industry in new directions.The second edition incorporates significant new material, including discussions on: AC drives and machine safetyApplication-specific drives and soft-startersEnhanced programmability for AC drives including adaptive, function block, sequential, and IEC-61131-3 programmingMaster(leader)-follower, Ethernet, fiber-optic, and PLC communicationsThe principles of DC and variable frequency AC drive technologyAn overview of drive components and types of drives, with special emphasis given to common applications and energy savingsDC and AC motor and drive operation, as well as AC vector, servo, and permanent magnet motorsInside you will also find easy to understand explanations, summaries, review questions, glossaries, reference tables for formulas and conversions. Great for a tutorial or desk reference!

This book provides practical, comprehensive knowledge on how to use the advances in analytical measurements and basic and advanced control to improve batch profiles and endpoint consistency. The consequential integration of measurements, models, and controls into a digital twin with recently developed blocks to provide profiles and predict endpoints enables:Developing dynamic models from trend charts that are used for experiment design, diagnosing the sources of limitations and inconsistences, and developing and testing solutions 500 times real time without interfering with existing plant operation.Comprehensive views of basic process control with the possibilities of model predictive control to control and optimize batch profiles by non-intrusive development and confirmation.The ability to determine how to maximize the performance of bioreactors, which are often the bottleneck and the key to product quality and consistency, without tests or trials in the actual plant.The resulting improvements in batch cycle time and consistency can be designed, tested, quantified, and confirmed; and operators can be trained independently of actual plant operation. The benefit from the elimination of a bad batch—particularly for new biologics—is potentially worth ten or more million dollars.

Process control is essential in modern manufacturing. The control system is the eyes, ears, and nervous system of the plant. It senses, decides, and directs the activities of the pumps, valves, motors, and other equipment. The control system handles many routine tasks, freeing up the operator to oversee the operation and handle new situations that arise. Without process control, it would be nearly impossible to efficiently produce commodities like pulp and paper, gasoline, plastic, and pharmaceuticals.Most people learn process control through hands-on plant experience, accompanied by a healthy dose of self-study. This is because textbooks generally address the mathematics of process dynamics and control, but often miss the practical aspects. This easy-to-read book fills the gap by focusing on practical real-world knowledge of process control systems, providing clear and concise examples, and providing practical advice for handling day-to-day maintenance and documentation. The author begins by discussing control terminology, principles, and applications, the information one needs to form a basic understanding of process control. He then explains the differences between discrete, continuous, and batch control, as well as the different control systems, programming languages, and documentation needed for each. To complete the foundation, the author addresses the management of control systems including discussions about maintenance, change management, communications, and documentation. Finally, one chapter introduces advanced control topics such as advanced regulatory control, multivariable control, and neural networks.Whether you are a student of process control, a technician or engineer expanding their skills, or someone in operations, maintenance, sales, support, or management who wants to develop a basic understanding of process control, this book is for you.

Are you having trouble demonstrating to management what a manufacturing execution system (MES) is and what it can do for you? Or do you simply need to justify why you even need a MES? Perhaps you are the executive decision maker and just need some answers. Bianca Scholten, the author of the best-selling book, The Road to Integration: Applying ISA-95 in Manufacturing, shares her expertise on the topic in her latest easy-to-read guide to MES.In recent decades, says Scholten, industrial companies have invested much time and money in not only machine and production line automation but also in ERP (Enterprise Resource Planning) systems. The MES falls between these two layers. Many of the preparatory activities (e.g., detailed production scheduling and recipe management), but also retrospective activities (e.g., data collection, reporting, and analysis) are primitive at best.Ideal for CEOs, CFOs, and managers, Scholten sheds some light on how to get out of this outdated situation using real-world examples and the knowledge gleaned from IT, production managers, and other colleagues who have been through the MES experience. She covers MES selection, company expectations during implementation and initial use of the MES, advice on developing and maintaining a multi-site MES template, and return on investment. She also adds a birdÂ's-eye view of the ISA-95 standard for better communication between systems and their applications.