Process industry integrated automation technology

Author: Chu Jian
Publisher:
Publish Date: 2004-07-01
Features: This book is one of the training materials in the series of the Informatization Engineering for Manufacturing. It introduces the various technologies required for the comprehensive automation in process industries. Starting from the Production Control System (PCS), with a focus on the Manufacturing Execution System (MES), and integrating the Enterprise Resource Planning (ERP), it comprehensively explains the principles, methods, and industrial applications of each component of the automation system in process industries. The book consists of 12 chapters. Process industries, represented by sectors such as petrochemicals, steel, chemicals, metallurgy, pharmaceuticals, building materials, and light industry, are a very large industry that occupies a significant position in the industrial sector and serve as a crucial pillar for national economic development. According to the China Statistical Yearbook, in 2001, by industry classification, process industries accounted for 60.47% of the total industrial output value and 65.59% of the industrial added value among all state-owned and large-scale non-state-owned industrial enterprises. Process industries in China exhibit varying degrees of characteristics such as high energy consumption, high costs, low labor productivity, and low resource utilization. Energy consumption is generally 30% higher than that of advanced international levels, and labor productivity is only about 20%–30% of that of foreign countries, with production costs being 1–2 times higher than those abroad. Utilizing comprehensive automation technology to modernize process industry enterprises and achieve internationally advanced levels in various technical and economic indicators such as cost, quality, variety, and environmental protection is crucial for enhancing the competitiveness of process industry enterprises. The comprehensive automation system in process industries is a dynamic and broad concept, continuously expanding and deepening with scientific and technological progress and industrial development. In modern industrial production, the comprehensive automation system (hardware and software) not only includes familiar simple and complex automatic control systems, sequential logic control systems, automatic batch processing control systems, interlock protection systems, etc., but also encompasses advanced control for production units, real-time production data integration, process flow simulation and optimization, production equipment fault diagnosis and maintenance, production planning and scheduling systems based on market and production equipment status, production management systems centered on product quality and cost, marketing management systems, and financial management systems. It involves all processes in the product logistics value chain and product lifecycle, providing enterprises with a comprehensive solution (Total Solution). Currently, the integrated solution composed of the Enterprise Resource Planning (ERP), Manufacturing Execution System (MES), and Process Control System (PCS) has become the de facto standard for comprehensive automation systems in process industries. Both domestically and internationally, great attention is paid to this, with new technologies and products constantly emerging, and it has been fully applied in large-scale process industries such as petrochemicals and steel. This book starts from the Production Control System (PCS), focuses on the Manufacturing Execution System (MES), and integrates the Enterprise Resource Planning (ERP) to provide a relatively comprehensive introduction to the principles, methods, and industrial applications of each component of the automation system in process industries. The book consists of 12 chapters, written by professionals engaged in scientific research, development, and engineering applications. Chu Jian and Rong Gang served as the general editors, and Professor Wang Wei reviewed the entire text. Feng Yiping was responsible for the unified layout of the book. The specific content and contributors to the writing work are as follows:
Chapter 1: Comprehensive Automation Integrated Solution – Chu Jian, Rong Gang
Chapter 2: Process Computer Control System – Feng Yiping
Chapter 3: Open Field Control System – Feng Dongqin
Chapter 4: Fault Diagnosis Technology – Li Rongyu
Chapter 5: Real-time Database System – Wu Jianqiang
Chapter 6: Advanced Control and Optimization – Gu Yong, Rong Gang
Chapter 7: Data Correction – Lü Pinjing, Rong Gang
Chapter 8: Production Planning and Scheduling – Liu Chuanwen, Rong Gang
Chapter 9: Production Management System – Zhang Qiran
Chapter 10: Enterprise Resource Management (ERP) – Zhao Xiaoqiang
Chapter 11: Comprehensive Automation Application in Steel Enterprises – Bi Yingjie
Chapter 12: Comprehensive Automation Application in Petrochemical Enterprises – Shen Qianli, Rong Gang
Due to the urgency of the writing schedule, any errors in the book are kindly requested to be pointed out by experts and readers.