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PkGdCv6.qxd 09-Aug-07 12:14 PM Page 1 Australia New Zealand West Coast Office 1031 Wellington Street, West Perth, WA 6005 PO Box 1093, West Perth WA 6872 Tel: (08) 9321 1702 Fax: (08) 9321 2891 Parkview Towers, 28 Davies Avenue, Manukau City PO Box 76-142, Manukau City Tel: (09) 263 4759 Fax: (09) 262 2304 East Coast Office PO Box 1750, North Sydney NSW 2059 Tel: (02) 9957 2706 Fax: (02) 9955 4468 ul. 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Introduction.........................................................................................................6 Chapter 2. I&C Drawings and Documentation ....................................................................7 2.1. Introduction to Plant Design .......................................................................................7 2.2. Process diagrams.........................................................................................................7 2.3. Instrumentation documentation ................................................................................11 2.4. Electrical documentation ..........................................................................................15 Chapter 3. Process control ..................................................................................................18 3.1. Basic Control Concepts.............................................................................................18 3.2. Principles of Control Systems...................................................................................19 3.3. Control modes in closed loop control .......................................................................23 3.4. Tuning of Closed Loop Control................................................................................24 3.5. Cascade Control ........................................................................................................27 3.6. Initialization of a cascade system .............................................................................27 3.7. Feed forward Control................................................................................................27 3.8. Manual feedforward control .....................................................................................28 3.9. Automatic feedforward control.................................................................................28 3.10. Time matching as feedforward control .................................................................28 3.11. Overcoming Process dead time.............................................................................29 3.12. First term explanation(disturbance free PV).........................................................30 3.13. Second term explanation(predicted PV) ...............................................................30 Chapter 4. Advanced Process Control................................................................................31 4.1. Introduction...............................................................................................................31 4.2. Overview of Advance Control Methods ...................................................................31 4.3. Internal Model Control .............................................................................................33 Chapter 5. Industrial Data Communications and Wireless.................................................36 5.1. Introduction...............................................................................................................36 5.2. Open Systems Interconnection (OSI) model ............................................................36 5.3. RS-232 interface standard.........................................................................................37 5.4. Fiber Optics...............................................................................................................39 5.5. Modbus .....................................................................................................................40 5.6. Data Highway Plus /DH485......................................................................................44 5.7. HART........................................................................................................................45 5.8. AS-i ...........................................................................................................................46 5.9. DeviceNet .................................................................................................................46 5.10. Profibus .................................................................................................................47 5.11. Foundation Fieldbus..............................................................................................48 5.12. Industrial Ethernet.................................................................................................48 5.13. TCP/IP...................................................................................................................50 5.14. Wireless Fundamentals .........................................................................................52 5.15. Radio/microwave communications.......................................................................53 5.16. Installation & Troubleshooting .............................................................................53 5.17. Industrial network security ...................................................................................59 5.18. Network threats, vulnerabilities and risks.............................................................60 5.19. An approach to network security planning ...........................................................62 5.20. Securing a network by access control...................................................................62 www.PAControl.com 3 Industrial Automation Pocket Book 5.21. Authentication, Authorization, Accounting & encryption....................................63 5.22. Intrusion detection systems...................................................................................65 5.23. VLANs..................................................................................................................65 5.24. VPNs and their security ........................................................................................66 5.25. Wireless networks and their security issues .........................................................67 Chapter 6. HAZOPs Hazard Operations ............................................................................69 6.1. Introduction...............................................................................................................69 6.2. HAZOP Workshop ...................................................................................................70 Chapter 7. Safety Instrumentation and Machinery.............................................................72 7.1. Introduction...............................................................................................................72 7.2. Introduction to IEC 61511 and the safety lifecycle ..................................................80 7.3. SIS configurations for safety and availability targets...............................................84 7.4. Selection of sensors and actuators for safety duties .................................................87 7.5. Selection of safety controllers...................................................................................92 7.6. System integration and application software ............................................................92 7.7. Programming tools....................................................................................................93 7.8. Machinery safety.......................................................................................................94 7.9. Guide to Regulations and Standards.........................................................................95 Chapter 8. Hazardous Areas and Intrinsic Safety...............................................................98 8.1. Introduction...............................................................................................................98 8.2. Zonal Classification ................................................................................................100 8.3. Area classification...................................................................................................101 8.4. Methods of explosion protection ............................................................................103 8.5. Flameproof concept Ex d........................................................................................104 8.6. Intrinsic safety.........................................................................................................105 8.7. Increased safety.......................................................................................................107 8.8. Certification (components) .....................................................................................108 8.9. Principles of testing ................................................................................................108 8.10. Non Sparking concept.........................................................................................109 8.11. Concept Ex p.......................................................................................................110 8.12. Other protection concepts ...................................................................................112 8.13. Earthing & Bonding............................................................................................114 8.14. Standards and codes of practice..........................................................................115 8.15. Fault finding and repairs .....................................................................................115 Chapter 9. SCADA...........................................................................................................118 9.1. Introduction and Brief History of SCADA.............................................................118 9.2. SCADA Systems Software .....................................................................................121 9.3. Distributed control system (DCS)...........................................................................129 9.4. Introduction to the PLC ..........................................................................................132 9.5. Considerations and benefits of SCADA system .....................................................134 9.6. An alarm system .....................................................................................................135 Chapter 10. Project Management of I&C Projects.............................................................140 10.1. Fundamentals of project management ................................................................140 10.2. Time management...............................................................................................142 10.3. Cost Management ...............................................................................................143 10.4. Integrated cost and time management ................................................................144 www.PAControl.com 4 Industrial Automation Pocket Book 10.5. 10.6. 10.7. Chapter 11. 11.1. 11.2. 11.3. 11.4. 11.5. 11.6. 11.7. 11.8. 11.9. 11.10. 11.11. 11.12. 11.13. 11.14. Chapter 12. 12.1. 12.2. 12.3. Management of project team ..............................................................................144 Risk Management ...............................................................................................145 Contract law ........................................................................................................146 Latest Instrumentation and Valve Developments ...........................................150 Basic Measurement performance terms and Specifications ...............................150 Advanced Measurement Performance terms and Specifications........................151 Pressure Measurement ........................................................................................152 Level Measurement.............................................................................................156 Temperature Measurement .................................................................................158 Thermocouples....................................................................................................158 Resistance Temperature Detectors (RTD’s) .......................................................159 Thermistors .........................................................................................................159 Infrared Pyrometers ............................................................................................160 Acoustic Pyrometers ...........................................................................................160 Flow Measurement..............................................................................................160 Differential Pressure Flowmeters .......................................................................162 Magnetic Flowmeters..........................................................................................164 Control Valves ....................................................................................................166 Forecasts and Predictions................................................................................168 Main Technology Trends....................................................................................168 The China Challenge...........................................................................................169 Market Predictions ..............................................................................................170 www.PAControl.com 5 Industrial Automation Pocket Book Preface Industrial Automation is a discipline that includes knowledge and expertise from various branches of engineering including electrical, electronics, chemical, mechanical, communications and more recently computer and software engineering. Automation & Control by its very nature demands a cross fertilization of these faculties. Industrial Automation Engineers have always drawn new technologies and implemented original or enhanced versions to meet their requirements. As the range of technology diversifies the demand on the innovative ability of these Engineers has increased. IDC Technologies has been in the business of bringing together the domain gurus and the practicing engineers under an umbrella called training. The sum of the knowledge that IDC Technologies has acquired over many years has now given it an opportunity to compile this comprehensive hand book for the reference of every automation engineer. The breadth and depth of Industrial Automation is enormous and justice cannot be expected from a book of a few hundred pages. This book comprises over 1200 pages of useful, hard hitting information from the trenches on industrial automation. This book delivers a critical blend of knowledge and skills, covering technology in control and instrumentation, industry analysis and forecasts, leadership and management - everything that is relevant to a modern control and instrumentation engineer. Good management, financial and business skills are also provided in these chapters. These highly practical materials provide you with solid skills in this often neglected area for control and instrumentation engineers. This book was originally written for UK and other European users and contains many references to the products and standards in those countries. We have made an effort to include IEEE/ANSI/NEMA references wherever possible. The general protection approach and theoretical principles are however universally applicable. The terms ‘earth’ as well as ‘ground’ have both been in general use to describe the common power/signal reference point interchangeably around the world in the Electro-technical terminology. While the USA and other North American countries favor the use of the term ‘ground’, European countries including the UK and many other Eastern countries prefer the term ‘earth’. In this book, we chose to adopt the term ‘ground’ to denote the common electrical reference point. Our sincere apologies to those readers who would have preferred the use of the term ‘earth’. www.PAControl.com 6 Industrial Automation Pocket Book Chapter 1. Introduction Society in its daily endeavours has become so dependent on automation that it is difficult to imagine life without automation engineering. In addition to the industrial production with which it is popularly associated, it now covers a number of unexpected areas. Trade, environmental protection engineering, traffic engineering, agriculture, building engineering, and medical engineering are but some of the areas where automation is playing a prominent role. Automation engineering is a cross sectional discipline that requires proportional knowledge in hardware and software development and their applications. In the past, automation engineering was mainly understood as control engineering dealing with a number of electrical and electronic components. This picture has changed since computers and software have made their way into every component and element of communications and automation. Industrial automation engineers carry a lot of responsibility in their profession. No other domain demands so much quality from so many perspectives of the function, yet with significant restrictions on the budget. The project managers of industrial automation projects have significant resource constraint, considering the ever changing demands of its management, trying to adopt the rapid acceleration of the technological changes and simultaneously trying to maintain the reliability and unbreakable security of the plant and its instruments. This book is structured to walk you through a précised life cycle of the various automation activities of a plant. There are a number of books that cover different aspects of automation but this is all encompassing. www.PAControl.com 7 Industrial Automation Pocket Book Chapter 2. I&C Drawings and Documentation 2.1. Introduction to Plant Design Plant design (process plant design, power plant design, etc.) refers to the automation technologies, work practices and business rules supporting the design and engineering of process and power plants. Such plants can be built for chemical, petroleum, utility, shipbuilding, and other facilities. Plant design is used to designate a general market area by the many vendors offering technologies to support plant design work. 2.2. Process diagrams The ‘process’ is an idea or concept that is developed to a certain level in order to determine the feasibility of the project. ‘Feasibility’ study is the name given to a small design project that is conducted to determine the scope and cost of implementing the project from concept to operation. To keep things simple, for example, design an imaginary coffee bottling plant to produce bottled coffee for distribution. Start by creating a basic flow diagram that illustrates the objective for the proposed plant; this diagram is called a “Process Block Diagram”. 2.2.1. Process block diagram The block diagram shown in Figure 2. 1 is where it all starts. It is here that the basic components are looked at and the basic requirements determined. This is a diagram of the concept, giving a very broad view of the process. The example below has all ingredients listed and shows that milk, sugar and black coffee make up different permutations of the final product. With this philosophy diagram complete, there is a need to determine the technical requirements. This is done by simultaneously developing two documents; the ‘Process Flow Diagram’ and the ‘Process Description Manual’. www.PAControl.com 8 Industrial Automation Pocket Book Figure 2. 1 Basic flow diagram of Coffee bottling plant 2.2.2. Process flow diagram or piping flow diagram (PFD) The PFD is where we start to define the process by adding equipment and the piping that joins the various items of equipment together. The idea behind the PFD is to show the entire process (the big picture) on as few drawing sheets as possible, as this document is used to develop the process plant and therefore the process engineer wants to see as much of the process as possible. This document is used to determine details like the tank sizes and pipe sizes. Those familiar with mimic panels and SCADA flow screens will notice that these resemble the PFD more than the piping and instrumentation diagram (P&ID) with the addition of the instruments, but not the instrument function. Mass balance: In its most simple form, what goes in must come out. The totals at the end of the process must equal the totals fed into the system. 2.2.3. Process description The process description details the function / purpose of each item of equipment in the plant. This description should contain the following information: • Installation operation – The installation produces bottled coffee • Operating principles – Each part of the process is described • Water supply – Filtered water at ambient temperature is supplied to the water holding tank, the capacity of the tank should be sufficient for all recipes • Coffee supply – Due to the viscosity of the coffee syrup, the syrup is fed from a pressurized vessel to the autoclave, this line should be cleaned frequently with warm water. There will be batches of caffeinated and decaffeinated coffee, the coffee tanks and pipelines must be thoroughly cleaned between batches • Milk supply – There will be an option for low fat or full cream milk, the milk supply should be sufficient for three days operation and should be kept as close to freezing as possible to ensure longevity of the milk • Sugar supply – Sugar will be supplied in a syrup form, we will offer the coffee with no sugar, 1 teaspoon (5 ml of syrup) or two teaspoons (10 ml of syrup). Syrup lines must be cleaned on a regular basis • Circuit draining/make-up – How to start-up or shutdown the facility, cleaning and flushing www.PAControl.com 9 Industrial Automation Pocket Book • • • • • Liquid characteristics – A detailed description on analysis of each liquid type in the system. Includes specific gravity, viscosity, temperature, pressure, composition etc. Specific operating conditions linked to the process – The installation operates 24 hours a day, 365 days a year. As the installation deals with foodstuff, all piping and vessels are to be manufactured from stainless steel Specific maintenance conditions linked to the process – Hygiene levels to be observed Specific safety conditions linked to the process – Hygiene, contamination of product Performance requirements – This section describes the amount of product the plant must be able to produce in a given time frame. PFD now starts to look something like the Figure 2. 2 shown below. Figure 2. 2 Process flow diagram 2.2.4. Piping and Instrumentation Diagram (P&ID) The Piping & Instrumentation Diagram, which may also be referred to as the Process & Instrumentation Diagram, gives a graphical representation of the process including hardware (Piping, Equipment) and software (Control systems); this information is used for the design construction and operation of the facility. The PFD defines “The flow of the process” The PFD covers batching, quantities, output, and composition. The P&ID also provides important information needed by the constructor and manufacturer to develop the other construction input documents (the isometric drawings, or orthographic physical layout drawings, etc.). The P&ID provides direct input to the field for the physical design and installation of field-run piping. For clarity, it is usual to use the same general layout of flow paths on the P&ID as used in the flow diagram. www.PAControl.com