Instrument Engineers' Handbook, Volume 3

Process Software and Digital Networks, Fourth Edition

Bela G. Liptak, Halit Eren, Bela G. Liptak, Halit Eren

• Publisher: CRC Press
• Year: 2018
• ISBN:
  9781351832984
• Edition: 4
• Topic: Technology & Engineering
• Subtopic: Electrical Engineering & Telecommunications
• Index: Technology & Engineering

Instrument Engineers' Handbook – Volume 3: Process Software and Digital Networks, Fourth Edition is the latest addition to an enduring collection that industrial automation (AT) professionals often refer to as the "bible." First published in 1970, the entire handbook is approximately 5, 000 pages, designed as standalone volumes that cover the measurement (Volume 1), control (Volume 2), and software (Volume 3) aspects of automation.

This fourth edition of the third volume provides an in-depth, state-of-the-art review of control software packages used in plant optimization, control, maintenance, and safety. Each updated volume of this renowned reference requires about ten years to prepare, so revised installments have been issued every decade, taking into account the numerous developments that occur from one publication to the next.

Assessing the rapid evolution of automation and optimization in control systems used in all types of industrial plants, this book details the wired/wireless communications and software used. This includes the ever-increasing number of applications for intelligent instruments, enhanced networks, Internet use, virtual private networks, and integration of control systems with the main networks used by management, all of which operate in a linked global environment.

Topics covered include:

• 
  
  

• Advances in new displays, which help operators to more quickly assess and respond to plant conditions

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• Software and networks that help monitor, control, and optimize industrial processes, to determine the efficiency, energy consumption, and profitability of operations

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• Strategies to counteract changes in market conditions and energy and raw material costs

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• Techniques to fortify the safety of plant operations and the security of digital communications systems

This volume explores why the holistic approach to integrating process and enterprise networks is convenient and efficient, despite associated problems involving cyber and local network security, energy conservation, and other issues. It shows how firewalls must separate the business (IT) and the operation (automation technology, or AT) domains to guarantee the safe function of all industrial plants. This book illustrates how these concerns must be addressed using effective technical solutions and proper management policies and practices. Reinforcing the fact that all industrial control systems are, in general, critically interdependent, this handbook provides a wide range of software application examples from industries including: automotive, mining, renewable energy, steel, dairy, pharmaceutical, mineral processing, oil, gas, electric power, utility, and nuclear power.

Process Control and Automation

1

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

...

Table of contents

• Cover
• Half Title
• Title Page
• Copyright Page
• Dedication
• Table of Contents
• Preface
• Acknowledgments
• Contributors
• Definitions
• Abbreviations
• Organizations
• 1 Process Control and Automation
• 2 Process-Control Methods
• 3 Digital Techniques and Data Handling
• 4 Software, Programming, and Simulations
• 5 Networks, Security, and Protection
• 6 Fieldbus Networks
• 7 Process Management, Maintenance, Safety, and Reliability
• 8 Process Control and Automation Applications
• Appendix
• Index