A Guide to the
Automation
Body
of
Knowledge
2nd Edition
Vernon L. Trevathan, Editor
Table of Contents
Preface, xiii
Basic Continuous Control, 1
1 Process Instrumentation, 3
1.1
Introduction,
1.2
Pressure, 4
1.3
Level,
1.4
Flow,
1.5
Temperature,
5
8
14
1.6 Smart Instruments,
16
1.7 References, 17
About the Author, 17
Analytical Instrumentation, 19
2.1 Introduction, 19
2.2
Sample
Point Selection, 20
2.3 Instrument Selection, 21
2.4
Sample Conditioning Systems, 21
Analytical System Installation,
2.5 Process
22
2.6 Maintenance, 24
2.7 Utilization
2.8
of Results, 27
References,
28
About the Author, 28
3 Continuous Control, 29
3.1 Introduction, 29
3.2 Process
Characteristics,
3.3 Feedback
31
Control, 31
3.4 Controller
Tuning,
3.5 Advanced
Regulatory Control,
36
41
3.6 References, 48
About the Author, 48
4 Control Valves, 49
4.1
Introduction,
4.2 Valve
49
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
Analog Communications, 61
5.1 Introduction, 61
5.2 Pneumatic
Signals,
62
vi
Table of Contents
Signals, 63
Suppression and Elevation of Zero, 65
Other Signals, 66
Analog-to-Digital and Digital-to-Analog Conversion,
5.3 Current
5.4
5.5
5.6
66
5.7 References, 73
About the
Authors,
73
6 Control System Documentation, 75
6.1 Reasons for Documentation, 75
6.2
Types of Documentation, 76
Diagram (PFD), 77
and
Instrument
Piping
Diagrams (P&ID),
6.3 Process Flow
6.4
78
6.5 Instrument Lists, 78
6.6
6.7
6.8
Specification Forms, 78
Logic Diagrams, 81
Location Plans (Instrument
Location
Drawings),
81
6.9 Installation Details, 82
6.10
Loop Diagrams,
6.11 Standards and
83
Regulations,
87
Operating Instructions, 87
About the Author, 88
6.12
Equipment, 89
7 Control
7.1 Introduction and Overview, 90
7.2 Input/Output (I/O), 90
7.3 Control
Network,
93
7.4 Control
Modules,
93
7.5 Human Machine Interface
7.6
7.7
7.8
(HMI),
HMISystem Workstation,
Application Servers, 98
Other Control Systems, 99
96
97
7.9 Future DCS Evolution, 99
7.10
References,
100
About the Author, 100
II Basic Discrete, Sequencing and Manufacturing Control, 101
8 Discrete
8.1
Input & Output Devices and General Manufacturing Measurements, 103
Introduction,
103
8.2 Actuation
8.3
Technologies and Their Control, 104
Sensing Technologies and Interfacing Techniques,
111
8.4 Remote and Networked I/O, 114
8.5 References, 115
About the Author, 115
9 Discrete and
Sequencing Control, 117
9.1 Introduction, 117
9.2
Concepts and Hardware Systems, 117
a Programmable Controller System, 118
User's Control Objectives and Application Requirements, 121
Selecting a PLC System, 124
Software, Programs and Programming Languages, 125
References, 131
Discrete/Sequential
Control
9.3 Basic Functional Structure of
9.4
9.5
9.6
9.7
About the Authors, 132
10 Motor and Drive Control, 133
10.1 Introduction, 133
10.2 DC Motors and Their
10.3 DC Motor
10.4 AC Motors and Their
10.5 AC Motor
Principles
of
Principles
of Operation, 136
Operation,
140
Types,
Choosing the Right Motor, 141
Speed Drives (Electronic DC),
Variable Speed Drives (Electronic AC),
10.6
10.7 Variable
143
10.8
145
10.9. Automation and the Use of VFDs, 150
10.10
References, 152
Author, 152
About the
11 Motion Control, 153
11.1 What is Motion Control?, 153
11.2
Advantages of
11.3
Feedback, 154
Motion Control, 153
11.4 Actuators, 156
11.5 Electric Motors,
Controllers,
11.6
157
158
11.7 Servos, 159
11.8 Feedback Placement, 160
11.9
Multiple Axes,
160
11.10 Leader/Follower, 160
11.11
11.12
11.13
11.14
Interpolation, 160
Performance, 161
Conclusion, 161
References, 161
About the Authors, 161
III Advanced Control Topics, 163
12 Process
12.1
Modeling, 165
Fundamentals,
12.2 Linear
165
Dynamic Estimators,
166
12.3 Multivariate Statistical Process Control, 167
12.4 Artificial Neural Networks, 168
12.5 First
12.6
Principal Models, 169
Capabilities and Limitations,
171
12.7 Costs and Benefits, 174
12.8 References, 174
About the Author, 174
13 Advanced Process Control, 175
13.1 Fundamentals, 175
13.2
13.3
Fuzzy Logic Control, 175
Adaptive Control, 179
13.4 Model Predictive Control, 180
13.5 Real Time
13.6
133
Types, 135
Optimization,
Capabilities
183
and Limitations,
13.7 Costs and Benefits, 189
13.8 References, 190
About the Author, 190
184
viii
Table of Contents
14 Control of Batch Processes, 191
14.1 What Is
Batch Process?, 191
14.2 What Is the ANSI/ISA-88 Standard?, 193
14.3 Recipe, 198
14.4
Summary,
14.5
References,
200
200
About the Author, 201
15 Environmental, 203
Introduction,
15.1
15.2 Risk
15.3 Economic
15.4
203
Reduction, 203
Incentives, 203
Building Controls,
204
15.5 Environmental Control Issues, 205
15.6 References, 205
About the Author, 206
16 Environmental
207
Monitoring,
16.1 Introduction, 207
16.2
207
Origins,
16.3 Affected
Companies,
16.4 Extractive CEMS
16.5
Calibrations,
208
Hardware,
208
212
16.6 DAS/RTU
16.7 Chart
Systems, 212
Recorders, 212
16.8
System Design & Integration, 212
Writing a Request for Proposals, 212
16.10 Writing Contracts, 213
16.9
16.11
Testing/Certifications,
16.12 Maintenance,
213
Quality Assurance/Quality Control,
16.13
Chapter Summary,
16.14
References,
214
215
215
About the Author, 215
17
Building Automation, 217
17.1 Introduction &
Overview,
217
of the Evolution to Direct
History
17.3
Open Protocols used in Building Automation,
17.4 How to
Automation
17.7
Summary,
224
17.8 Resources to Learn More, 224
About the Author, 226
IV Reliability, Safety and Electrical, 227
18 Alarm
18.1
Management, 229
Introduction,
229
18.2 Alarm
System Practices,
18.3 Alarm
System Problems,
18.4 Alarms for
Safety,
18.5 References, 235
About the Author, 235
or
DDC, 218
220
Systems, 222
Building Automation, 222
Operations Guide, 223
Specify Building
17.5 Future of Web Services in
17.6 Web-Based Facilities
Digital
Control
17.2
235
229
234
Table of Contents
19 Reliability, 237
237
19.2 Measurements of Successful
19.3 Useful
Approximations,
Operation
Introduction,
19.1
No
Repair,
237
240
19.4 Measurements of Successful
19.5
Average Unavailability
19.6 Periodic Restoration and
19.7
OperationRepairable Systems, 241
Inspection and Test, 243
Imperfect Testing, 244
with Periodic
19.8
Equipment Failure Modes, 245
Safety Integrated Function (SIF) Modeling
19.9
Redundancy,
19.10
of Failure Modes, 247
248
References, 249
About the Author, 249
20 Process
Safety
and
Instrumented
Safety
20.1
Introduction,
20.2
Safety
20.3
System Technologies,
20.4
System Analysis,
Systems,
251
251
Instrumented System Design Life
Cycle,
252
257
258
20.5 Abnormal Situation Management, 260
20.6
Key Points,
260
20.7 Rules of Thumb, 261
20.8 References, 261
About the Author, 262
21 Electrical Installations, 263
21.1 Introduction, 263
21.2
21.3
21.4
21.5
Scope, 263
Grounding and Bonding,
Grounding Systems, 264
Ground Loops, 268
21.6 Noise
Reduction,
264
269
21.7 Electrostatic Noise, 272
21.8
Surge Suppressors,
273
21.9 Power, 274
21.10
Uninterruptible
Power
21.11 Electrical Installation
21.12
References,
Systems (UPS),
Details,
277
278
280
About the Authors, 280
22 Safe Use and
Application of Electrical Apparatus, 283
22.1
Introduction, 283
22.2
Philosophy of General Purpose Requirements, 284
Equipment for Use Where Explosive Concentrations
Might be Present, 284
Equipment for Use in Locations Where Combustible
22.3
22.4
22.5 For More Information, 295
About the Author, 296
V Integration and Software, 297
23
Digital Communications, 299
23.1
Introduction,
299
23.2 Protocol Concepts, 300
23.3 Network Protocols, 302
of Gas,
Dust
Vapor,
May
or
Dust
be Present, 292
ix
Table of Contents
23.4 Network
Topology,
307
23.5 Wireless
Networks,
311
23.6
Bibliography,
312
About the Authors, 312
24 Industrial Networks, 313
24.1 Network Classifications, 313
24.2
Industrial Network Standards, 315
24.3
Bibliography,
330
About the Authors, 331
25 Manufacturing Execution Systems & Business
25.1
Introduction,
25.2
MES
Integration
25.3 Level 3
with Business
Equipment Hierarchy,
25.4 MES and Production
Planning and Logistics,
335
336
Operations Management,
25.5 Detailed Production
337
25.6 Other
339
25.7 Level
Integration, 333
333
Scheduling,
Manufacturing Activities,
3-4 Boundary, 339
336
25.8 References, 340
About the Author, 340
26
System and Network Security, 341
26.1 Essential Concepts, 341
26.2 Security Programs, Plans, and Policies, 344
26.3 Basic System and Network Security Techniques, 348
26.4 Conclusions on Automation System and Network Security,
References,
26.5
350
About the Author, 350
27
Operator Interface, 351
27.1
Introduction,
27.2
Graphics, Components
351
&
Controls,
351
27.3 Trend, 353
27.4 Alarms, 355
27.5
Reports, 357
Scripts, 358
27.7 Human Engineering,
27.8 References, 361
About the Author, 361
27.6
28 Data
359
Management, 363
28.1 Introduction, 363
28.2 Database Structure, 363
28.3 Data
Relationships,
28.4 Database
Types,
363
364
28.5 Basics of Database
Design,
365
28.6 Queries and Reports, 365
28.7 Data
Storage and Retrieval, 366
Operations, 367
28.9 Special Requirements of Real-Time
28.10 Data Quality Issues, 370
28.8 Database
28.11 Database Software, 370
28.12 Data
28.13
Documentation, 371
Database Maintenance, 372
Process
Databases,
369
350
28.14 Data
Security,
372
28.15 References, 372
About the Author, 372
29 Software, 373
29.1 Introduction & Overview, 373
29.2 Benefits,
Savings
& Doubts, 375
29.3
Setup,
29.4
Configuration,
29.5
System Integration
29.6
Troubleshooting,
Operation & Applications, 379
Availability & Compliance, 380
29.7
29.8
376
377
&
Migration,
378
379
29.9 References, 382
About the Author, 382
30 Custom Software, 383
30.1 Introduction, 383
30.2
30.3
Specification, 383
Programming, 384
30.4 Revision Control, 385
30.5
Sourcing, 386
Testing, 387
30.7 References, 387
About the Author, 387
30.6
VI Deployment and Maintenance, 389
31
Operator Training, 391
31.1
Introduction,
31.2
Training
31.3
Preparation, 393
Training Styles, 394
31.4
391
Process, 392
31.5 Evaluation and Improvement, 396
31.6 References, 396
About the Author, 396
32 Checkout,
System Testing, and Startup, 397
32.1 Introduction, 397
32.2 Instrumentation
Commissioning,
32.3 Software
32.6
Testing,
System Level Testing, 404
Factory Acceptance Testing (FAT), 405
Site Acceptance Testing (SAT), 407
32.7
Safety Considerations,
32.8
References,
Author,
32.4
32.5
407
408
About the
33
399
404
408
Troubleshooting, 409
33.1 Introduction, 409
33.4
Logical/Analytical Troubleshooting Framework, 409
Seven-Step Troubleshooting Procedure, 411
Vendor Assistance: Advantages and Pitfalls, 416
33.5
Other
33.2
33.3 The
Troubleshooting Methods,
416
xii
Table
of Contents
33.6
Summary,
33.7
References,
419
419
About the Author, 419
34 Maintenance,
Long-Term Support and System Management, 421
34.1 Maintenance Is
Big Business,
421
34.2 Service Technicians, 422
34.3
Big
Picture View, 423
34.4 Production Losses from
Equipment Malfunction,
Benchmarks, 431
428
34.5 Performance Metrics and
34.6 References, 437
About the Author,
438
VII Work Structure, 439
35 Automation Benefits and
35.1
35.2
35.3 Return
35.4
Project Justifications, 441
Background, 441
Capital Projects, 442
on
Investment, 443
Lifecycle Costs,
445
35.5 Barriers to Success, 450
35.6 Real-Time Cost
Accounting,
450
35.7 References, 453
About the Author, 453
36
Project Management and Execution, 455
36.1
Introduction,
455
36.2 Contracts, 456
36.3
36.4
36.5
36.6
Project Lifecycle, 460
Project Management Tools, 467
Project Management Techniques,
References, 472
About the Author, 472
37 Interpersonal Skills, 473
37.1 Introduction, 473
37.2 Communication, 474
37.3
People,
37.4
475
Leadership,
478
37.5 Conclusion, 481
37.6
References,
481
About the Author, 482
Appendix A: Control Equipment Structure, 483
Index, 497
470
