HANDBOOK OF PROCESS DYNAMICS, CONTROL AND AUTOMATION: Fundamentals, Tuning Methods, and Safety Systems for Modern Industrial Plants

When an industrial control loop oscillates, a valve sticks, or a process responds too slowly, knowing the theory is only half the challenge. Understanding what causes the problem and how engineering principles translate into real plant performance—is what truly matters.

Process control brings together mathematical modelling, system dynamics, instrumentation, controller tuning, automation, and functional safety. Yet connecting these subjects can be difficult, especially when theoretical calculations must be translated into practical engineering decisions.

HANDBOOK OF PROCESS DYNAMICS, CONTROL AND AUTOMATION by Robert E. Thornton bridges the gap between fundamental control theory and industrial implementation. Through 16 carefully organized chapters, mathematical derivations, worked examples, and practice problems with answers, this technical handbook develops a systematic understanding of modern industrial control systems.

Inside, you will learn how to:

• Understand industrial control architecture through feedback loops, process variables, control objectives, and P&ID instrumentation symbols.

• Develop mathematical process models using conservation equations, linearisation, empirical identification, and dead-time representations.

• Analyse dynamic system responses using Laplace transforms, transfer functions, and first- and second-order models.

• Master essential PID control principles and compare Ziegler–Nichols, Cohen–Coon, and Internal Model Control tuning methods.

• Evaluate system stability through root locus, Bode plots, Nyquist criteria, and stability margins.

• Explore advanced control strategies, including feedforward, cascade, ratio, override, split-range, and dead-time compensation.

• Understand multivariable and predictive control using Relative Gain Array analysis, decoupling, and Model Predictive Control.

• Examine industrial instrumentation and automation, including sensors, control valves, actuators, DCS, PLCs, and alarm management.

• Explore functional safety principles, including Safety Integrity Levels, protective layers, proof testing, and the IEC 61511 safety lifecycle.

• Strengthen engineering problem-solving skills through worked numerical examples, practice exercises, and technical reference equations.

Designed for engineering students and practicing professionals, this handbook is particularly relevant to chemical engineers, process control engineers, instrumentation specialists, automation professionals, and technical personnel working with industrial processing systems.

Whether studying controller stability, comparing tuning methods, investigating process interactions, or exploring modern automation and protective systems, this handbook offers a substantial technical resource for building knowledge and approaching engineering problems with greater clarity.

Move beyond memorizing control equations and develop a deeper understanding of how industrial systems actually behave.

Add this handbook to your engineering reference library and strengthen the connection between control theory, numerical analysis, and industrial practice.