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.

In this third edition, the authors' aim has been to simplify and demystify the procedure of tuning control systems based on their successful tuning work in oil refineries.A new chapter has been added on the use of auto-tuning software currently available in most current computer control systems. The authors have used this software whenever possible to carry out the dynamic testing of the process as it is less disruptive of operations than doing the tests manually. They have also used the tuning results to guide them but always using the principles presented in the book to evaluate them.All of the example responses have been generated using simulation software to illustrate the tuning and show the differences betweentuning controllable versus dead-time dominated loopsaveraging versus tight level controlcascade control versus simple feedback control of a jacketed chemical reactorfeed forward control versus simple feedback controldecoupler control versus simple feedback control of a blender

Written from a practical perspective, Advances in Reactor Measurement and Control underscores how control system design can address the different process responses and fundamental characteristics of the major types of reactors in the process industry.This book enables the reader to learn what measurements, control strategies, controller features and tuning parameters will achieve process objectives for a given type of reactor. No prior education or experience in process engineering or control theory is needed. This book starts with the fundamentals and principles needed to become proficient in getting the best reactor and control system performance. The practitioner will be able to design, implement and support straightforward configurations based on the type of process and equipment.McMillan—the author of more than 20 books, including several ISA best sellers, Process Automation Hall of Fame Inductee and the recipient of the ISA Life Achievement Award—educates through a practitioner’s experience and perspective, outlining the general concepts and details, from the field to the control room, for the control and optimization of batch and continuous reactors.“Taking a practitioner’s approach, I believe, is unique,” McMillan says. “The concepts in this book are developed to help the reader understand the fundamental differences in reactor applications and improve the performance of nearly all types of reactors. This book is unique in providing readily configurable practical solutions for batch and fluidized bed reactors besides the more traditional continuous stirred tank reactors.According to McMillan, the book’s practical value is reinforced through its:Simple presentation of the characteristics and implications of each of the dynamic responses needed to achieve the necessary efficiency, capacity, quality, and safety in operation. Clear explanation of the PID features and tuning and control loops needed for addressing the lack of smoothing in dead time dominant processes and the lack of negative feedback in integrating and runaway processes. The material in this book represents knowledge from leading participants in the ISA Mentor program, Brian Hrankowsky and Héctor Torres, reflecting decades of experience in the pharmaceutical and chemical industry, respectively.

As automation becomes more thoroughly networked with advances in speed, connectivity, and security; this fifth edition of an ISA best seller is still designed to give technical professionals with little or no background in data communications the knowledge they need to succeed. Additionally, even those with nominal knowledge will find information to enhance troubleshooting and to understand both legacy systems and the more advanced systems now being installed throughout automated facilities.As before, the text emphasizes the practical aspects of commonly used systems rather than design criteria. It contains a complete description of the relevant terminology, standards, and protocols including EIA/TIA-232/485, IEEE 802.3, IEEE 802.11, and IEEE 802.15. New material in this edition includes information on updated Ethernet and router technologies; a more detailed description of VPNs; and expanded information on cybersecurity (including ANSI/ISA/IEC 62443). A complete glossary and index allows the book to be used as a handy reference. SCADA, DCS, and fieldbus systems are all explained, as well as operating system considerations from a communications perspective. This is a book for newcomers to automation data communications, as well as a reference for those who are currently working in the field.

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.

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 (HMIs) 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 the 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.

Written for programmable logic controller programmers, this book describes how to create a functional machine control program for industrial equipment that is sequential in nature.The programming methodology starts by breaking the machine into its basic elements. These small and manageable elements allow the programmer to focus on large concerns before dealing with specifics. The methodology then shows how to program each element and how to assemble the elements together into a complete machine control program. The book is intended to provide programmers with the confidence they need to reach decisions, and move forward with the certainty that the program is performing as intended without odd combinations of logic causing unintentional actions. The sequential nature of events will also help operators and maintenance personnel troubleshoot and maintain the equipment after it is put into operation. Ladder logic illustrations demonstrate each part of the text. Although the ladder logic examples use the instruction set for the Allen Bradley SLC 500 programmable logic controller, the concepts and techniques can be used with any brand of programmable logic controller.

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 time- and course-tested book is designed to familiarize readers with the concepts of electricity and electronics as they pertain to industrial measurement and control. And this new fourth edition is accompanied by a lab workbook containing exercises that are designed to approximate "real-life" applications found in vocational, industrial, and occupational areas.As a student-centered resource, this book emphasizes practical application. Where mathematics and algebraic concepts are covered, clear explanations are provided so readers can comprehend processes and solutions without having to perform any complex operations or mathematics. However, an understanding of basic math is required to fully absorb the material found in this book.Particular attention is given to ensuring safe and successful measurement of electrical quantities and a solid understanding of digital and analog meters, bridges, power supplies, solid state circuitry, oscilloscopes, and analog-to-digital convertors. Illustrations and exercises are utilized to better explain concepts and applications and to support the readers' understanding.

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.

This is an instructional introduction to modern-day industrial process control. The content is both practical and theoretical, with an emphasis on the basic principles and concepts of process control and how they are used in industrial applications.The book is designed to be a self-study course for 2- or 3-year technical or degree students or individuals wishing to expand their knowledge of process control. Each chapter builds on the content of the previous chapter, expanding the reader's understanding of the subject. Example problems are used to illustrate specific concepts, and most chapters contain exercises to test and solidify the reader's understanding of the material. However, each chapter can be considered as a discussion of a specific process control topic. For those who have prior knowledge of process control, each chapter can be read and studied independently or used as a reference of the topic covered. This modular construction also enables educators who wish to incorporate the information into course materials to select specific topics and arrange them in an appropriate sequence to tailor their course material.