Pocket Guide on Industrial Automation For Engineers and Technicians

PkGdCv6.qxd 09-Aug-07 12:14 PM Page 1 IDC Technologies Worldwide Offices Australia New Zealand West Coast Office Parkview Towers, 28 Davies Avenue, 1031 Wellington Street, Manukau City West Perth, WA 6005 PO Box 76-142, Manukau City PO Box 1093, West Perth WA 6872 Tel: (09) 263 4759 Fax: (09) 262 2304 Tel: (08) 9321 1702 Fax: (08) 9321 2891 Poland East Coast Office ul. Krakowska 50, 30-083 Balice, Krakow PO Box 1750, Tel: +48 12 6304 746 Fax: +48 6304 750 North Sydney NSW 2059 Singapore Tel: (02) 9957 2706 Fax: (02) 9955 4468 100 Eu Tong Sen Street, #04-11 Pearl`s Centre, Canada Singapore 059812 Suite 402, 814 Richards Street, Tel: (65) 6224 6298 Fax: (65) 6224 7922 Vancouver BC V6B 3A7 South Africa Tel: (604) 244 9221 Fax: (604) 682 3139 68 Pretorius Street, President Park, Midrand Toll Free Tel: 1800 324 4244 PO Box 389, Halfway House 1685 Toll Free Fax: 1800 434 4045 Tel: (011) 805 3904 Fax: (011) 312 2150 India Toll Free Tel: 0800 114 160 133 4th Street, United Arab Emirates Kumaran Colony, M1 Floor, Khalifa Street, Vadapalani, Chennai 600026 Al Za’abi Building, Abu Dhabi, UAE Tel: +91 444 208 9353 Tel: +971 2 676 4470 Fax: +971 2 676 4490 Ireland United Kingdom PO Box 8069, Shankill, Co Dublin Suite 18, Fitzroy House, Lynwood Drive, Tel: (01) 473 3190 Fax: (01) 473 3191 Worcester Park, Surrey KT4 7AT Malaysia Tel: (020) 8335 4014 Fax: (020) 8335 4120 26 Jalan Kota Raja E27/E, United States Hicom Town Center, 7101 Highway 71 West #200, Austin TX 78735 Seksyen 27, 40400 Tel: (512) 288 8525 Fax: (512) 288 8521 Shah Alam, Selangor Toll Free Tel: 1800 324 4244 Tel: (03) 5192 3800 Fax: (03) 5192 3801 Toll Free Fax: 1800 434 4045 E-mail: idc@idc-online.com Web Site: www.idc-online.com 6 AUTOMATION IDC Engineering Pocket Guide 1st Edition VOLUME 6 Best Practice in Industrial Data Communications Advanced Process Control Automatic Safety Systems Financial Management www.PAControl.com _________________________________ Pocket Guide on Industrial Automation For Engineers and Technicians Rev 1.04 Edited by Srinivas Medida Technology Training that Works www.PAControl.com 2 Industrial Automation Pocket Book Chapter 1. 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. Management of project team ..............................................................................144 10.6. Risk Management ...............................................................................................145 10.7. Contract law........................................................................................................146 Chapter 11. Latest Instrumentation and Valve Developments...........................................150 11.1. Basic Measurement performance terms and Specifications...............................150 11.2. Advanced Measurement Performance terms and Specifications........................151 11.3. Pressure Measurement........................................................................................152 11.4. Level Measurement.............................................................................................156 11.5. Temperature Measurement.................................................................................158 11.6. Thermocouples....................................................................................................158 11.7. Resistance Temperature Detectors (RTD’s).......................................................159 11.8. Thermistors.........................................................................................................159 11.9. Infrared Pyrometers ............................................................................................160 11.10. Acoustic Pyrometers...........................................................................................160 11.11. Flow Measurement..............................................................................................160 11.12. Differential Pressure Flowmeters .......................................................................162 11.13. Magnetic Flowmeters..........................................................................................164 11.14. Control Valves....................................................................................................166 Chapter 12. Forecasts and Predictions................................................................................168 12.1. Main Technology Trends....................................................................................168 12.2. The China Challenge...........................................................................................169 12.3. Market Predictions..............................................................................................170 www.PAControl.com ... - tailieumienphi.vn