Process Automation Handbook

Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv Biography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi Part I: Technology and Practice 1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2 Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 3 Final Control Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 4 Conventional Control Strategies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 5 Process Control Schemes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 6 Digital Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 7 Control Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377 8 Management of Automation Projects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463 Part II: Theory and Technique 9 Maths and Control Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565 10 Plant and Process Dynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 699 11 Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 771 12 Advanced Process Automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803 13 Advanced Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 963 Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1047 Abbreviations and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1055 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1065 Foreword The process industries are subject to increasing changes. These include globali- tion, increased earning per share expectation, increasing safety and environmental legislation, staff retirement, shortage of engineers and increasingly rapid evolution of technology. To be successful, process manufacturing companies must respond by: Consistently improving safety and environmental performance Becoming more responsive to customers Reducing manufacturing costs Reducing working capital Improving equipment life There are many approaches to achieving these improvements such as improvement of process equipment and ? owsheets, staff training, work process improvement, organizational restructuring and, in particular, process automation.

Technology and Practice. - Summary. - P&I Diagrams. - Block Diagrams. - Signals. - Pneumatics. - Electronics. - Data Typing. - Structured Text. - Microprocessors. - Characteristics. - DP Cells. - Flow: Orifices. - Flow Measurement. - Level Measurement. - Weight Measurement. - Temperature Measurement. - pH Measurement. - Chromatography. - Valves and Actuators. - Valve Sizing. - Valve Positioners. - Feedback Control. - PID Control. - Controller Tuning. - Cascade Control. - Ratio Control. - Feedforward Control. - On-Off Control. - Sequence Control. - Determining Strategy. - Evaporator Control. - Control of Heat Exchangers. - Boiler Control. - Neutralisation Control. - Distillation Control. - Reactor Control. - Batch Process Control. - Systems Architecture. - Systems Hardware. - Communications. - Software Overview. - Operator Interface. - Integrated Alarm Environment. - Analogue Control Loop. - Database Operations and Structure. - Discrete I/O Devices. - Programmable Logic Controllers. - Configuration. - Open Systems. - Fieldbus. - System Layout. - Intrinsic Safety. - Reliability Principles. - Hazard Analysis. - Layers of Safety. - Protection Systems. - Safety Equipment. - Human Factors. - Costs and Benefits Analysis. - User Requirements. - Tendering and Vendor Selection. - Functional Specifications. - Design, Development, Testing and Acceptance. - Installation and Commissioning. - System Management. - Quality Assurance. - Contracts. - Theory and Technique. - Series and Complex Numbers. - First Order Systems. - Laplace Transforms. - Transfer Functions. - Second and Higher Order Systems. - Frequency Response. - Root Locus. - Z Transforms. - Sampled Data Systems. - Z Plane Analysis. - Impulse Compensation. - Matrices and Vectors. - State Space Analysis. - Multivariable Control. - Stochastics. - Linear Regression Analysis. - Linearisation. - Lumped Parameter Systems. - Zero Capacity Systems. - Compressible Flow Systems. - Hydrodynamics. - Multivariable Systems. - Multistage Systems. - Reacting Systems. - Distributed Parameter Systems. - Anti-Surge Systems. - Psychrometric Systems. - Electro-Mechanical Systems. - Numerical Integration. - Procedural Simulation. - Block Orientated Simulation. - Relational Databases. - Management Information Systems. - Principal Components Analysis. - Statistical Process Control. - Linear Programming. - Unconstrained Optimisation. - Constrained Optimisation. - Real Time Optimisers. - Knowledge Based Systems. - Fuzzy Logic Control. - Artificial Neural Networks. - Genetic Algorithms. - Multiloop Systems. - State Feedback Regulators. - Kalman Filtering. - Least Squares Identification. - Recursive Estimation. - Self Tuning Control. - Model Predictive Control. - Non-Linear Control.