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Second edition
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KLS Sharma graduated from University of Mysuru, India, and received his masters and doctoral degrees from the Indian Institute of Technology, Delhi, India.
He has worked for the following organizations:
• Technical manager, Electronics Corporation of India, Hyderabad, India
• Assistant vice president, ABB, Bengaluru, India
• Consultant, Honeywell Technology Solutions Lab, Bengaluru, India
• Professor, International Institute of Information Technology, Bengaluru, India
• Professor emeritus, MS Ramaiah Institute of Technology, Bengaluru, India
• Member, Campus Connect Program, Automation Industry Association of India, Delhi, India
• Distinguished visiting professor, National Institute of Technology Karnataka, Surathkal, India
His current positions are:
• Advisor, Automation Education and Training, Bengaluru, India
• Principal consultant, Advanced Engineering Group, Infosys, Bengaluru, India
• Member, Editorial Advisory Board, A&D Magazine on Industrial Automation, Pune, India
• Senior member, International Society of Automation (ISA)
• ISA Celebrating Excellence Member’s Choice Award for Student Mentor of the Year 2015.
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Extract from the article by Jim Pinto
“As the second decade of the 21st century moves forward, technology continues to accelerate and is generating rapid changes in industrial automation & control systems. Industrial automation can and will generate explosive growth in the next decade, with several new inflection points:
• Nanotechnology will bring tiny, low-power, low-cost sensors and nano-scale electromechanical systems. The Internet-of-Things (IoT)—Europeans call it Industry 4.0—will be pervasive and change the face of industrial automation, generating vast productivity gains.
• Wireless sensors and distributed peer-to-peer networks will give rise to major new software applications—tiny operating systems in wireless nodes will allow nodes to communicate with each other in a larger complex adaptive systems.
• Today’s pervasive smart-phone has more power than a super-computer of just a couple of decades ago. The use of WiFi-connected tablets, smartphones and mobile devices with new real-time monitoring software (Apps) will be used widely in industrial plants and process control environments.
• Conventional Real-time control systems will give way to multi-processors and complex adaptive systems
These are the waves of the future. The leaders will not be the traditional automation majors, but new start-ups with innovative ideas that will generate industrial productivity gains to drive significant growth.”
June 28, 2016
Carlsbad, CA, USA
Jim Pinto jim@jimpinto.com
Jim Pinto is an international speaker, technology futurist, automation consultant, and writer (http://JimPinto.com).
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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 students for careers in the automation industry. Currently 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 modern 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
Current automation technology is one of the few engineering domains that use many modern technologies. Among these, information, communication, and networking technologies have become integral parts of today’s automation. Basic subsystems of a modern automation system are instrumentation, control, and the human interface. In all of 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.
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 at IIIT/Bangalore, former professor at IIT/ Kanpur, and a veteran on control systems and power systems.
Prof. H.N. Mahabala, former professor at IIT/Kanpur, IIT/Chennai, and 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 of IIIT/Bangalore, and Mr. Anup Wadhwa, director of 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.
March 1, 2011 Bangalore, India
KLS Sharma
13. System availability enhancements: explains typical standby/redundancy schemes for all types of automation systems to increase their availability.
14. Common configurations: explains configurations that are commonly employed in distributed control systems and network control systems that are need based.
15. Customization: explains the realization of a tailor-made industrial automation system from a common platform.
Chapters 16–21 are added to this edition to take the traditional industrial automation system into the connected world integrated with enterprise and business processes.
16. Data communication and networking: explains the deployment of this technology to manage inter and intra system data exchange in industrial automation systems in a secure way.
17. Fieldbus technology: explains moving from conventional centralized input–output (I/O) to fieldbus I/O to eliminate control and signal cabling and field asset management.
18. Safety systems: explains the management of safety in process plants and machines to avoid or reduce damage to the people, property, and their environment in case of a hazard.
19. Management of industrial processes: explains the different kinds of industrial processes such as manufacturing (process plants and factories) and utility (civic and backbone) and their management.
20. Information technology–operation technology (IT-OT) convergence: explains the integration of OT (plant and automation system) and IT (business systems) to derive operational and business excellence.
21. Concluding remarks: Summarizes basic, extended, and some additional functionalities, and a peek into some emerging trends in industrial automation technology
As mentioned, these are provided for the sake of completeness and to create a base for easy understanding of the relation between hardware and software in DACU.
1. Hardwired control subsystem: explains legacy technologies in the realization of control subsystems to implement all types of automation strategies.
2. Processor: explains the architecture of a hypothetical processor-based DACU with all of its basic and functional modules
3. Hardware-software interfacing: explains how software in a DACU is interfaced to hardware in a DACU to execute the automation strategy.
4. Basics of programming: explains the programming of DACU, starting from machine level to higher level and its conversion into executable code.
I wish to acknowledge that the content in this book is mainly the result of my learning, practicing, teaching, and training experience in industrial automation in ABB India, where I worked for over 24 years followed by teaching and training experience in