A Guide to the Automation Body of Knowledge

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1 A Guide to the Automation Body of Knowledge 2nd Edition Vernon L. Trevathan, Editor

2 Table of Contents Preface, xv Basic Continuous Control, 1 1 Process Instrumentation, Introduction, Pressure, Level, Flow, Temperature, Smart Instruments, References, 17 About the Author, 17 2 Analytical Instrumentation, Introduction, Sample Point Selection, Instrument Selection, Sample Conditioning Systems, Process Analytical System Installation, Maintenance, Utilization of Results, References, 28 About the Author, 28 3 Continuous Control, Introduction, Process Characteristics, Feedback Control, Controller Tuning, Advanced Regulatory Control, References, 48 About the Author, 48 4 Control Valves, Introduction, Valve Types, Standards and Codes, Valve Selection, Operation, Actuators and Accessories, References, 58 About the Author, 59 5 Analog Communications, Introduction, Pneumatic Signals, 62 v

3 vi Table of Contents 5.3 Current Signals, Suppression and Elevation of Zero, Other Signals, Analog-to-Digital and Digital-to-Analog Conversion, References, 73 About the Authors, 73 6 Control System Documentation, Reasons for Documentation, Types of Documentation, Process Flow Diagram (PFD), Piping and Instrument Diagrams (P&ID), Instrument Lists, Specification Forms, Logic Diagrams, Location Plans (Instrument Location Drawings), Installation Details, Loop Diagrams, Standards and Regulations, Operating Instructions, 87 About the Author, 88 7 Control Equipment, Introduction and Overview, Input/Output (I/O), Control Network, Control Modules, Human Machine Interface (HMI), HMI System Workstation, Application Servers, Other Control Systems, Future DCS Evolution, References, 100 About the Author, 100 II Basic Discrete, Sequencing and Manufacturing Control, Discrete Input & Output Devices and General Manufacturing Measurements, Introduction, Actuation Technologies and Their Control, Sensing Technologies and Interfacing Techniques, Remote and Networked I/O, References, 115 About the Author, Discrete and Sequencing Control, Introduction, Discrete/Sequential Control Concepts and Hardware Systems, Basic Functional Structure of a Programmable Controller System, User's Control Objectives and Application Requirements, Selecting a PLC System, Software, Programs and Programming Languages, References, 131 About the Authors, 132

4 Table of Contents vii 10 Motor and Drive Control, Introduction, DC Motors and Their Principles of Operation, DC Motor Types, AC Motors and Their Principles of Operation, AC Motor Types, Choosing the Right Motor, Variable Speed Drives (Electronic DC), Variable Speed Drives (Electronic AC), Automation and the Use of VFDs, References, 152 About the Author, Motion Control, What is Motion Control?, Advantages of Motion Control, Feedback, Actuators, Electric Motors, Controllers, Servos, Feedback Placement, Multiple Axes, Leader/Follower, Interpolation, Performance, Conclusion, References, 161 About the Authors, 161 III Advanced Control Topics, Process Modeling, Fundamentals, Linear Dynamic Estimators, Multivariate Statistical Process Control, Artificial Neural Networks, First Principal Models, Capabilities and Limitations, Costs and Benefits, References, 174 About the Author, Advanced Process Control, Fundamentals, Fuzzy Logic Control, Adaptive Control, Model Predictive Control, Real Time Optimization, Capabilities and Limitations, Costs and Benefits, References, 190 About the Author, 190

5 viii Table of Contents 14 Control of Batch Processes, What Is a Batch Process?, What Is the ANSI/ISA-88 Standard?, Recipe, Summary, References, 200 About the Author, Environmental, Introduction, Risk Reduction, Economic Incentives, Building Controls, Environmental Control Issues, References, 205 About the Author, Environmental Monitoring, Introduction, Origins, Affected Companies, Extractive CEMS Hardware, Calibrations, DAS/RTU Systems, Chart Recorders, System Design & Integration, Writing a Request for Proposals, Writing Contracts, Testing/Certifications, Maintenance, Quality Assurance/Quality Control, Chapter Summary, References, 215 About the Author, Building Automation, Introduction & Overview, History of the Evolution to Direct Digital Control or DDC, Open Protocols used in Building Automation, How to Specify Building Automation Systems, Future of Web Services in Building Automation, Web-Based Facilities Operations Guide, Summary, Resources to Learn More, 224 About the Author, 226 IV Reliability, Safety and Electrical, Alarm Management, Introduction, Alarm System Practices, Alarm System Problems, Alarms for Safety, References, 235 About the Author, 235

6 Table of Contents ix 19 Reliability, Introduction, Measurements of Successful Operation No Repair, Useful Approximations, Measurements of Successful Operation Repairable Systems, Average Unavailability with Periodic Inspection and Test, Periodic Restoration and Imperfect Testing, Equipment Failure Modes, Safety Integrated Function (SIF) Modeling of Failure Modes, Redundancy, References, 249 About the Author, Process Safety and Safety Instrumented Systems, Introduction, Safety Instrumented System Design Life Cycle, System Technologies, System Analysis, Abnormal Situation Management, Key Points, Rules of Thumb, References, 261 About the Author, Electrical Installations, Introduction, Scope, Grounding and Bonding, Grounding Systems, Ground Loops, Noise Reduction, Electrostatic Noise, Surge Suppressors, Power, Uninterruptible Power Systems (UPS), Electrical Installation Details, References, 280 About the Authors, Safe Use and Application of Electrical Apparatus, Introduction, Philosophy of General Purpose Requirements, Equipment for Use Where Explosive Concentrations of Gas, Vapor, or Dust Might be Present, Equipment for Use in Locations Where Combustible Dust May be Present, For More Information, 295 About the Author, 296 V Integration and Software, Digital Communications, Introduction, Protocol Concepts, Network Protocols, 302

7 x Table of Contents 23.4 Network Topology, Wireless Networks, Bibliography, 312 About the Authors, Industrial Networks, Network Classifications, Industrial Network Standards, Bibliography, 330 About the Authors, Manufacturing Execution Systems & Business Integration, Introduction, MES Integration with Business Planning and Logistics, Level 3 Equipment Hierarchy, MES and Production Operations Management, Detailed Production Scheduling, Other Manufacturing Activities, Level 3-4 Boundary, References, 340 About the Author, System and Network Security, Essential Concepts, Security Programs, Plans, and Policies, Basic System and Network Security Techniques, Conclusions on Automation System and Network Security, References, 350 About the Author, Operator Interface, Introduction, Graphics, Components & Controls, Trend, Alarms, Reports, Scripts, Human Engineering, References, 361 About the Author, Data Management, Introduction, Database Structure, Data Relationships, Database Types, Basics of Database Design, Queries and Reports, Data Storage and Retrieval, Database Operations, Special Requirements of Real-Time Process Databases, Data Quality Issues, Database Software, Data Documentation, Database Maintenance, 372

8 Table of Contents xi Data Security, References, 372 About the Author, Software, Introduction & Overview, Benefits, Savings & Doubts, Setup, Configuration, System Integration & Migration, Troubleshooting, Operation & Applications, Availability & Compliance, References, 382 About the Author, Custom Software, Introduction, Specification, Programming, Revision Control, Sourcing, Testing, References, 387 About the Author, 387 VI Deployment and Maintenance, Operator Training, Introduction, Training Process, Preparation, Training Styles, Evaluation and Improvement, References, 396 About the Author, Checkout, System Testing, and Startup, Introduction, Instrumentation Commissioning, Software Testing, System Level Testing, Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), Safety Considerations, References, 408 About the Author, Troubleshooting, Introduction, Logical/Analytical Troubleshooting Framework, The Seven-Step Troubleshooting Procedure, Vendor Assistance: Advantages and Pitfalls, Other Troubleshooting Methods, 416

9 xii Table of Contents 33.6 Summary, References, 419 About the Author, Maintenance, Long-Term Support and System Management, Maintenance Is Big Business, Service Technicians, Big Picture View, Production Losses from Equipment Malfunction, Performance Metrics and Benchmarks, References, 437 About the Author, 438 VII Work Structure, Automation Benefits and Project Justifications, Background, Capital Projects, Return on Investment, Lifecycle Costs, Barriers to Success, Real-Time Cost Accounting, References, 453 About the Author, Project Management and Execution, Introduction, Contracts, Project Lifecycle, Project Management Tools, Project Management Techniques, References, 472 About the Author, Interpersonal Skills, Introduction, Communication, People, Leadership, Conclusion, References, 481 About the Author, 482 Appendix A: Control Equipment Structure, 483 Index, 497

Practical Programmable Logic Controllers (PLCs) for Automation and Process Control. Contents

Practical Programmable Logic Controllers (PLCs) for Automation and Process Control Contents 1 Introduction to the PLC 1 1.1 Introduction 1 1.2 Basic Block Diagram of the PLC 2 1.3 Size of the PLC System