A Guide to the Automation Body of Knowledge, 2nd Edition

Table of ContentsPreface, xv Basic Continuous Control, 1 1 Process Instrumentation, 3 1.1 Introduction, 3 1.2 Pressure, 4 1.3 Level, 5 1.4 Flow, 8 1.5 Temperature, 14 1.6 Smart Instruments, 16 1.7 References, 17 About the Author, 17 2 Analytical Instrumentation, 19 2.1 Introduction, 19 2.2 Sample Point Selection, 20 2.3 Instrument Selection, 21 2.4 Sample Conditioning Systems, 21 2.5 Process Analytical System Installation, 22 2.6 Maintenance, 24 2.7 Utilization of Results, 27 2.8 References, 28 About the Author, 28 3 Continuous Control, 29 3.1 Introduction, 29 3.2 Process Characteristics, 31 3.3 Feedback Control, 31 3.4 Controller Tuning, 36 3.5 Advanced Regulatory Control, 41 3.6 References, 48 About the Author, 48 4 Control Valves, 49 4.1 Introduction, 49 4.2 Valve Types, 49 4.3 Standards and Codes, 52 4.4 Valve Selection, 53 4.5 Operation, 55 4.6 Actuators and Accessories, 56 4.7 References, 58 About the Author, 59 5 Analog Communications, 61 5.1 Introduction, 61 5.2 Pneumatic Signals, 62 v 99 7. 66 5. 83 6. 118 9.8 Location Plans (Instrument Location Drawings). 125 9.6 HMI—System Workstation. 78 6.5 Human Machine Interface (HMI).4 Control Modules.2 Types of Documentation.6 Software.5 References. 103 8. Programs and Programming Languages. 82 6. 93 7. 93 7. 117 9. 87 About the Author.4 User's Control Objectives and Application Requirements. 78 6. 114 8. 76 6. 115 About the Author.9 Future DCS Evolution.2 Discrete/Sequential Control Concepts and Hardware Systems.5 Other Signals. 103 8.11 Standards and Regulations. 77 6. 81 6.vi Table of Contents 5.7 Logic Diagrams.10 Loop Diagrams.5 Instrument Lists.1 Introduction.3 Basic Functional Structure of a Programmable Controller System. 89 7.6 Analog-to-Digital and Digital-to-Analog Conversion.12 Operating Instructions. 75 6.5 Selecting a PLC System. 101 8 Discrete Input & Output Devices and General Manufacturing Measurements. 132 . 73 About the Authors.4 Piping and Instrument Diagrams (P&ID). 100 II Basic Discrete.4 Suppression and Elevation of Zero. 117 9.7 References. 104 8.3 Process Flow Diagram (PFD). 100 About the Author. 88 7 Control Equipment. 65 5. 99 7. 97 7. 124 9.1 Introduction and Overview.3 Current Signals.8 Other Control Systems. 63 5.2 Actuation Technologies and Their Control. 121 9.7 Application Servers.10 References. 111 8.9 Installation Details. 90 7. 117 9. 131 About the Authors. 75 6. 73 6 Control System Documentation.6 Specification Forms. 66 5. 115 9 Discrete and Sequencing Control. 78 6. 81 6.4 Remote and Networked I/O.1 Introduction. 87 6. 96 7.1 Reasons for Documentation. 98 7.2 Input/Output (I/O). Sequencing and Manufacturing Control.7 References. 90 7.3 Sensing Technologies and Interfacing Techniques.3 Control Network. 153 11. 175 13.5 AC Motor Types.6 Capabilities and Limitations. 175 13.1 Fundamentals. 174 13 Advanced Process Control. 160 11.5 Real Time Optimization. 179 13.8 References.Table of Contents vii 10 Motor and Drive Control. 154 11. 140 10. 156 11.6 Controllers.4 AC Motors and Their Principles of Operation.7 Costs and Benefits.8 Variable Speed Drives (Electronic AC). 161 About the Authors.5 Electric Motors. 189 13. 161 11.11 Interpolation.1 Introduction.2 Linear Dynamic Estimators.1 Fundamentals.3 DC Motor Types.3 Feedback.6 Capabilities and Limitations. 174 12.7 Variable Speed Drives (Electronic DC). 190 About the Author.7 Costs and Benefits. 160 11. 133 10. 161 11.6 Choosing the Right Motor.3 Adaptive Control. 165 12. 152 About the Author. 165 12. 150 10. 158 11. 135 10. 166 12. 136 10.4 Actuators. 133 10.9.2 Advantages of Motion Control. 174 About the Author. 143 10. 184 13. 159 11. 160 11.14 References. Automation and the Use of VFDs.12 Performance.4 Model Predictive Control. 183 13. 163 12 Process Modeling. 175 13.10 References. 153 11. 133 10. 171 12.13 Conclusion.5 First Principal Models.8 Feedback Placement.7 Servos.4 Artificial Neural Networks. 160 11.9 Multiple Axes.3 Multivariate Statistical Process Control. 157 11. 180 13. 145 10. 152 11 Motion Control.1 What is Motion Control?. 153 11.10 Leader/Follower.2 Fuzzy Logic Control. 161 III Advanced Control Topics. 190 . 169 12. 168 12.8 References.2 DC Motors and Their Principles of Operation. 167 12. 141 10. 2 Origins.1 Introduction.2 History of the Evolution to Direct Digital Control or DDC. 201 15 Environmental. 198 14.6 References. 223 17.11 Testing/Certifications. 227 18 Alarm Management.4 Summary.13 Chapter Summary. 226 IV Reliability.5 Future of Web Services in Building Automation. 217 17. 214 16.8 Resources to Learn More.4 How to Specify Building Automation Systems. 191 14.14 References. 229 18. 235 18.10 Writing Contracts.1 Introduction.3 Alarm System Problems. 193 14. 205 15. 203 15.5 References.4 Alarms for Safety.9 Writing a Request for Proposals. 208 16. 205 About the Author. 224 About the Author. 215 About the Author. 203 15.4 Extractive CEMS Hardware. 212 16.12 Maintenance. 235 .3 Economic Incentives.1 Introduction & Overview. 207 16.viii Table of Contents 14 Control of Batch Processes. 212 16.1 Introduction.3 Recipe. 213 16.4 Building Controls. 206 16 Environmental Monitoring. 204 15. 217 17.5 Environmental Control Issues. 200 About the Author. 218 17. 207 16. 203 15.3 Open Protocols used in Building Automation.2 What Is the ANSI/ISA-88 Standard?. 207 16. 222 17. 235 About the Author.5 References.6 Web-Based Facilities Operations Guide. 213 16.7 Summary. 234 18. 191 14.6 DAS/RTU Systems. 212 16.2 Risk Reduction. 220 17. 208 16. 200 14.8 System Design & Integration.7 Chart Recorders. 212 16. 222 17. Quality Assurance/Quality Control.2 Alarm System Practices.3 Affected Companies. 212 16.1 What Is a Batch Process?. 229 18. 215 16.5 Calibrations. 215 17 Building Automation. 203 15. 224 17. Safety and Electrical. 229 18. 264 21. 262 21 Electrical Installations. 251 20.6 Periodic Restoration and Imperfect Testing.4 System Analysis.1 Introduction. 241 19. 243 19. 283 22.1 Introduction. 251 20.2 Protocol Concepts.2 Scope.4 Measurements of Successful Operation—Repairable Systems. 263 21. 297 23 Digital Communications. 302 .5 Ground Loops. 295 About the Author. 283 22. 268 21.1 Introduction.5 Average Unavailability with Periodic Inspection and Test.3 System Technologies.8 Surge Suppressors.7 Equipment Failure Modes. 240 19. 260 20.3 Useful Approximations. 264 21. 257 20. 252 20.12 References. 274 21. 269 21.3 Equipment for Use Where Explosive Concentrations of Gas. 263 21.4 Grounding Systems. Vapor. 284 22.2 Philosophy of General Purpose Requirements.1 Introduction.1 Introduction.9 Power. 248 19. 258 20.5 For More Information.10 Uninterruptible Power Systems (UPS). 280 About the Authors. 272 21. 277 21. 247 19. 261 About the Author.2 Measurements of Successful Operation – No Repair.Table of Contents ix 19 Reliability.9 Redundancy.6 Key Points.3 Grounding and Bonding. 249 20 Process Safety and Safety Instrumented Systems.5 Abnormal Situation Management. 244 19.4 Equipment for Use in Locations Where Combustible Dust May be Present.8 References. 237 19. 299 23. 284 22. 300 23.6 Noise Reduction. 263 21. 296 V Integration and Software.2 Safety Instrumented System Design Life Cycle. 292 22.8 Safety Integrated Function (SIF) Modeling of Failure Modes.7 Electrostatic Noise. 245 19. or Dust Might be Present. 260 20.7 Rules of Thumb. 278 21. 273 21. 237 19. 261 20.11 Electrical Installation Details. 237 19.3 Network Protocols.10 References. 280 22 Safe Use and Application of Electrical Apparatus. 299 23. 249 About the Author. 351 27. 359 27.2 Graphics.2 MES Integration with Business Planning and Logistics. 330 About the Authors.7 Level 3-4 Boundary.8 References.1 Introduction. 313 24.4 Alarms.6 Bibliography.1 Network Classifications. 348 26.7 Data Storage and Retrieval.2 Industrial Network Standards. 341 26. 350 About the Author.11 Database Software. 353 27.5 Basics of Database Design. 361 About the Author. 339 25. 351 27. Components & Controls. 363 28.13 Database Maintenance. 350 27 Operator Interface. and Policies. 366 28.8 References.5 Detailed Production Scheduling.2 Security Programs. Plans.4 Conclusions on Automation System and Network Security. 340 26 System and Network Security.7 Human Engineering.5 References. 355 27. 339 25. 350 26.5 Wireless Networks. 365 28. 336 25.4 MES and Production Operations Management. 337 25.1 Introduction. 341 26. 370 28. 363 28. 369 28.x Table of Contents 23.1 Introduction. 307 23. 351 27. 363 28.5 Reports.3 Trend. 312 24 Industrial Networks.4 Database Types.1 Essential Concepts. 358 27.8 Database Operations. 370 28. 315 24.3 Level 3 Equipment Hierarchy. 336 25. 371 28. 333 25. 365 28.3 Bibliography. 363 28.10 Data Quality Issues. 335 25.3 Basic System and Network Security Techniques. 367 28.6 Scripts.12 Data Documentation. 333 25. 311 23. 364 28.3 Data Relationships. 312 About the Authors.4 Network Topology. 361 28 Data Management. 331 25 Manufacturing Execution Systems & Business Integration. 340 About the Author. 357 27. 344 26. 313 24.2 Database Structure.9 Special Requirements of Real-Time Process Databases.6 Queries and Reports.6 Other Manufacturing Activities. 372 . 9 References.1 Introduction & Overview.7 References. 397 32. 373 29. 408 33 Troubleshooting.2 Training Process. 385 30.3 Setup. 396 32 Checkout. 375 29. 382 About the Author.Table of Contents xi 28. 379 29.7 Operation & Applications. 397 32.5 Evaluation and Improvement.4 System Level Testing.5 Sourcing.14 Data Security.6 Site Acceptance Testing (SAT). 391 31. 387 30. 409 33. 416 .1 Introduction. 382 30.7 Safety Considerations. 386 30.8 Availability & Compliance.6 Troubleshooting.3 Preparation. 378 29.4 Revision Control. 396 31.2 Instrumentation Commissioning. 405 32. 407 32. 416 33.4 Configuration.3 Software Testing. 391 31. 404 32.1 Introduction. 399 32. 384 30. 408 About the Author. 411 33. 383 30. 387 About the Author. 380 29.4 Training Styles. 373 29.2 Benefits. 396 About the Author. 393 31. 409 33.1 Introduction. 387 30 Custom Software.3 The Seven-Step Troubleshooting Procedure.2 Logical/Analytical Troubleshooting Framework. 376 29.4 Vendor Assistance: Advantages and Pitfalls. 372 29 Software. 407 32.6 Testing.5 System Integration & Migration.5 Factory Acceptance Testing (FAT). 409 33.1 Introduction. 389 31 Operator Training. 392 31.8 References. 379 29.15 References. 377 29. Savings & Doubts. and Startup.6 References.2 Specification.5 Other Troubleshooting Methods. 372 28. 394 31.3 Programming. 404 32. 383 VI Deployment and Maintenance. System Testing. 372 About the Author. 383 30. 439 35 Automation Benefits and Project Justifications. 455 36.2 Service Technicians.5 Conclusion. 460 36.6 Summary. 453 About the Author. 442 35. 497 . 453 36 Project Management and Execution. 482 Appendix A: Control Equipment Structure.3 People.4 Leadership.5 Performance Metrics and Benchmarks. 431 34.2 Communication. 421 34. 475 37. 438 VII Work Structure. 445 35.3 Return on Investment. 437 About the Author.1 Background.5 Project Management Techniques.6 References. 474 37.6 Real-Time Cost Accounting. 419 34 Maintenance.7 References. 473 37.4 Lifecycle Costs. 470 36. 421 34.2 Contracts.7 References.1 Introduction.3 Project Lifecycle. Long-Term Support and System Management. 422 34.xii Table of Contents 33. 472 37 Interpersonal Skills. 481 37. 481 About the Author. 473 37.4 Project Management Tools . 419 About the Author. 478 37. 455 36. 423 34. 441 35. 483 Index. 450 35. 441 35.2 Capital Projects. 419 33.6 References.1 Maintenance Is Big Business. 450 35. 443 35. 456 36. 467 36. 472 About the Author.5 Barriers to Success.1 Introduction.4 Production Losses from Equipment Malfunction.6 References. 428 34.3 Big Picture View.