1
DISTRIBUTED CONTROL SYSTEMS AND PROCESS PLANTS
Partial List of Suppliers
Definitions
Summary
Introduction
Plant Structure
Plant Organization
Plant Operators
Plant Maintenance
Laboratories
Evolution of Distributed Control Systems
Control System Classification
Safety Systems
Continuous Processes
Self-Regulating Processes
Integrating Response
Batch Processes
Fed-Batch Processes
Profile Control
Distributed Control System Architecture
Functional Components
Process Control Networks
Operator Console
Control System Configuration
Input/Output Cards
Conventional IO
Diagnostics
Redundancy
Historical Data
Security
Integration
Alarms, Alerts, and Alarm Management
Alert Processing
Alarm Management
Meeting Control Performance Requirements
Control Execution Rates
IO Processing Delays
Anti-Aliasing Filtering
Digital Control System Networks
DCS Topologies
Corporate Network
Plant Network
Process Control Networks
Area Control Networks
Field Networks
Wireless Networks
Network Integration
Division of Network into Process Network and Office Network
IT Security
Office Environment
Plant Environment
Process Control Device Connectivity
Wireless Networks and Devices
Field Instruments
Equipment Packages
Future Trends
Conclusions and Comments
Symbols
Abbreviations
Bibliography
2
NETWORKS IN PROCESS AUTOMATION: HARDWARE STRUCTURES AND INTEGRATION OF PROCESS VARIABLES INTO NETWORKS
Partial List of Suppliers
Introduction
Enterprise Asset Management
Information Requirement and Flow
Control
Plant Management
Enterprise Management
Communication Models
Communication Hierarchy
Network Requirements
OSI Reference Model
OSI Implementation
Control and Fieldbus Protocols
Wireless Networks
Process Network Fundamentals
Transmission Medium
Topologies
Transmission
Logical Link and Media Access Control
Media Access Methods
Communication Relationships
Network Layers
Transport Layer
Application Layer
Industrial Networks
Programmable Logic Controllers
Distributed Control System
SCADA Systems
Network Security
Network Components
Fieldbus Networks
AS-Interface
4–20 mA/HART
PROFIBUS DP/PROFIBUS PA
FOUNDATION Fieldbus
MODBUS
ControlNet
Ethernet
Wireless
Field Instrumentation
Safety Integrity Level
Hazardous Areas
Integration of Process Variables
Device Integration
Interchangeability of Devices
Engineering
OPC Server
Plant Asset Management
Net-Wide Data Exchange
Step
Product Attributes
XML
Conclusions
References
Bibliography
3
INSTRUMENTATION IN PROCESSES AND AUTOMATION
Introduction
Measured and Key Variables
Instrumentation Design Goals
Cost Optimal Accurate Sensor Network
Example
Parameter Estimation
Precision Upgrade
Example
Resource Reallocation
Example
Reliable Sensor Networks
Repairable Sensor Networks
Example
Robust Sensor Networks
Example
Example of Accuracy-Constrained Networks
Design of Economic Value–Optimal Sensor Networks
Example
Design of Sensor Networks for Process Fault Diagnosis
Design of Sensor Networks for Process Fault Resolution
Design of Sensor Networks for Process Fault Diagnosis—Value Perspective
Design of Sensor Networks for Automation
Example of Automation-Based Cost-Optimal Sensor Networks
Conclusions
Nomenclature
References
4
PROGRAMMABLE LOGIC CONTROLLERS
Partial List of Suppliers
Introduction
Types of Processes
Evolution of Automation
Programmable Logic Controllers
Input Modules
Output Modules
Central Processing Unit
Specifications of CPU
Memory
Power Supply
Programming Devices
PLC Programming
Instructions Used in Ladder Programming
Timers
Counters
Recent Trends in PLCs
Abbreviations
Bibliography
5
SCADA—SUPERVISORY CONTROL AND DATA ACQUISITION SYSTEM AND AN EXAMPLE
Partial List of Suppliers
Introduction
Part 1—SCADA HMI Essentials
SCADA Components
Field I/O
Logic Solvers
Networks and Network Components
SCADA Configuration and the Software
Hardware Configuration
Point Loading
I/O Allocation
Logic Development
Compilation and Codes
Connecting to CPU and Downloading the Codes
Logic Simulations and Pretests
HMI Hardware
HMI Software
HMI Concept Development
Color Schemes
Navigation Schemes
Preliminary Configurations
Middleware Tag Definitions and Configurations
Tag Database Loading
Creation of Building Blocks
Creation of Home Screen and Process Screens
Creation of Control Panels or Pop-Ups
Creation of Set-Up Screens
Creation of Alarm Management
Creation of Historical Trends
Creation of Reports
Basic Navigation Test
Connecting with Controllers
Testing Set of Screens
Pre-FAT Test of Hardware and HMI
Engineering Work Stations
Part 2—A Practical Example of SCADA-HMI
System Definition
Master HMI Display Panel Operation
Alarm Log Display Screen
Historical Log
Auxiliary HMI Display Screen
Sequence of Operations
EFSO Sequence of Operation
HMI Screens for EFSO Sequence
Bypass Sequence of Operation
HMI Screens for Bypass Sequence
Communication Failure
Bibliography
6
INTELLIGENT INSTRUMENTS AND SENSORS: ARCHITECTURE, SOFTWARE, NETWORKS, PROTOCOLS, AND STANDARDS
Introduction
Intelligent Instruments
Examples of Intelligent Instruments
Intelligent Sensors
Intelligent Sensor Characteristics and Networking
IEEE 1451 Standard
Transducer Electronic Data Sheet
Network Capable Application Processor
Smart Transducer Interface Module
Communications of Intelligent Sensors
Intelligent Sensor PnP Capability
Management of Intelligent Sensor Networks
Use of SNMP Protocol for Intelligent Sensors in Networks
Basic Encoding Rules
Standardized Reference to Integrated Intelligent Sensors
References
7
CALIBRATIONS IN PROCESS CONTROL
Partial List of Service and Software Providers
Introduction
Definitions
Errors and Uncertainties in Calibrations
Benefits of Calibrations
Calibration Methods and Procedures
Calibration Methods
Calibration Personnel
Calibration Laboratories
Calibration Institutions
Calibration Records
Calibration Software Support
Use of Spreadsheets
Calibration Management Software
Integration of Calibration with CMMS
Cost of Calibration
Measurement Assurance Planning
Literature on Calibration
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