Instrument Engineers' Handbook, Volume Three : Process Software and Digital Networks

879 Pages·1998·70.518 MB·English

by  Béla G Lipták

I N S T R U M E N T E N G I N E E R S ’ H A N D B O O K
Third Edition
Process
Software
and Digital
Networks
© 2002 by Béla G. Lipták
I N S T R U M E N T E N G I N E E R S ’ H A N D B O O K
Third Edition
Process
Software
and Digital
Networks
Béla G. Lipták
EDITOR-IN-CHIEF
CRC PRESS
Boca Raton London New York Washington, D.C.
© 2002 by Béla G. Lipták
This reference text is published in cooperation with ISA Press, the publishing division of ISA—Instrumentation, Systems, and Automation
Society. ISA is an international, nonprofit, technical organization that fosters advancement in the theory, design, manufacture, and use of
sensors, instruments, computers, and systems for measurement and control in a wide variety of applications. For more information, visit
www.isa.org or call [phone].
Library of Congress Cataloging-in-Publication Data
Instrument engineers’ handbook : process software and digital networks / Béla G. Lipták,
editor-in-chief.—3rd ed.
p. cm.
“The third edition of the IEH was initially planned for three volumes ... to cover the
subjects of process measurement, process control, and process software. Chilton
published the first two volumes in 1995. In October 2000, CRC Press obtained the
rights to publish the third volume.”—Pref.
Includes bibliographical references and index.
ISBN 0-8493-1082-2 (alk. paper)
1. Process control—Handbooks, manuals, etc. 2. Measuring instruments—Handbooks,
manuals, etc. I. Lipták, Béla G. II. Lipták, Béla G. Instrument engineers’ handbook.
Process measurement and analysis III. Lipták, Béla G. Instrument engineers’ handbook.
Process control.

TS156.8 .I56 2002
681′.2—dc21 2002017478

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© 2002 by Béla G. Lipták
No claim to original U.S. Government works
International Standard Book Number 0-8493-1082-2
Library of Congress Card Number 2002017478
Printed in the United States of America 1 2 3 4 5 6 7 8 9 0
Printed on acid-free paper
© 2002 by Béla G. Lipták
Dedicated to you, my colleagues, the instrument and control engineers, hoping
that by applying the knowledge found in these pages, you will make
the world a better, safer, and happier place and thereby will also advance
the recognition and the respectability of the I&C profession
© 2002 by Béla G. Lipták
C O N T E N T S
Contributors ix
Preface xiii
Definitions xix
Abbreviations, Nomenclature, Acronyms, and Symbols xxi
Societies and Organizations xxxi
1 Overall Plant Design 1
1.1 Auditing Existing Plants for Upgrading 5
1.2 Project Management and Documentation 14
1.3 Operator Training, Commissioning, and Start-Up 29
1.4 Flowsheet Symbols and Functional Diagramming for Digitally Implemented Loops 42
1.5 Historical Data Storage and Evaluation 79
1.6 Integration of Process Data with Maintenance Systems 91
1.7 Applications, Standards, and Products for Grounding and Shielding 98
1.8 Concepts of Hierarchical Control 116
1.9 Analog or Discrete Input/Output, Costs and Signal Processing 123
1.10 Estimating the Costs of Control System Packages 142
2 Designing a Safe Plant 151
2.1 Hazardous Area Classification 156
2.2 Intrinsic Safety Rules for Fieldbus Installations 161
2.3 Purging and Inerting Systems 167
2.4 High-Integrity Pressure Protection Systems 173
2.5 Process Safety Management 182
2.6 Redundant or Voting Systems for Increased Reliability 192
2.7 Network Security 198
2.8 Safety Instrumented Systems: Design, Analysis, and Operation 209
2.9 Reliability Engineering Concepts 231
2.10 Intelligent Alarm Management 252
2.11 Safety Instrumentation and Justification of Its Cost 268
2.12 International Safety Standards and Certification
(ANSI/ISA-S84, IEC 61511/61508/62061, ISO 13849) 278
3 Control Center, Workstation, and Logic Design 285
3.1 Operator Interface Evolution 288
3.2 Virtual Reality Tools for Testing Control Room Concepts 299
3.3 Upgrading the Control Room 307
vii
© 2002 by Béla G. Lipták
viii Contents
3.4 Manufacturing Platforms and Workstations 323
3.5 Workstation Hosts: Design Concepts and Classification 327
3.6 Integration of DCS, PLC, HMI, and SCADA Systems 334
3.7 Integration with RTUs, Multiplexers, Fieldbuses, and Data Highways 341
3.8 Hybrid Systems with Discrete and Analog Capability 351
3.9 SCADA—Supervisory Control and Data Acquisition 357
3.10 PLC Programming 368
3.11 Fault-Tolerant Programming and Real-Time Operating Systems 387
3.12 Practical Logic Design 396
4 Buses and Networks 423
4.1 An Introduction to Networks in Process Automation 430
4.2 PLC Proprietary and Open Networks 442
4.3 Hardware Selection for Fieldbus Systems 465
4.4 Sorting Out the Protocols 478
4.5 Overall Fieldbus Trends 495
4.6 Fieldbus Advantages and Disadvantages 505
4.7 Fieldbus Design, Installation, Economics, and Documentation 513
4.8 Instrumentation Network Design and Upgrade 522
4.9 Global System Architectures 534
4.10 Advantages and Limitations of Open Networks 540
4.11 HART Networks 547
4.12 Foundation Fieldbus Network 564
4.13 PROFIBUS-PA 578
4.14 Designing PROFIBUS-PA and Foundation Fieldbus Segments 588
4.15 Ethernet and TCP/IP-Based Systems 601
4.16 Fieldbus Networks Catering to Specific Niches of Industry 612
4.17 Proprietary Networks 627
4.18 Fiber-Optic Networks 638
4.19 Satellite, Infrared, Radio, and Wireless LAN Networks 649
5 Software Packages 669
5.1 Control Loop Optimization 672
5.2 Data Reconciliation 687
5.3 Sequence of Event Recorders and Post-Trip Reviews 703
5.4 OPC Software Architecture 708
5.5 Batch Control State of the Art 714
5.6 Plantwide Control Loop Optimization 728
5.7 Plantwide Controller Performance Monitoring 749
5.8 The ‘‘Virtual Plant,’’ A Tool for Better Understanding 761
Appendix 773
A.1 International System of Units 774
A.2 Engineering Conversion Factors 784
A.3 Chemical Resistance of Materials 807
A.4 Composition of Metallic and Other Materials 813
A.5 Steam and Water Tables 816
A.6 Friction Loss in Pipes 824
A.7 Tank Volumes 828
A.8 Partial List of Suppliers 831
© 2002 by Béla G. Lipták
C O N T R I B U T O R S
The name of the author is given at the beginning of each section. Here, all the contributors of this volume are listed in
alphabetical order, giving their academic degrees and affiliations they held at the time of publication.
MIGUEL J. BAGAJEWICZ PhD, AIChe, Professor, University of Oklahoma, Norman, Oklahoma, U.S.A.
CHET S. BARTON PE, BSEE, Senior Process Automation Engineer, Jacobs Engineering, Baton Rouge,
Louisiana, U.S.A.
JONAS BERGE Engineer, Smar, Singapore
PETER GRAHAM BERRIE BScE, PhD, AIChe, Marketing Communications, Endress+Hauser Process Solutions
AG, Reinach, Switzerland
VIPUL A. BHAVSAR BE (I&C), Diploma in Management, Consultant–Control Systems Engineer, Canada
STUART A. BOYER PE, BSc, EE, President, Iliad Engineering, Inc., Canada
GEORGE C. BUCKBEE PE, BSChE, MSChE, Control Engineer, Top Control, Clarks Summit, Pennsylvania,
U.S.A.
ERIC J. BYRES PE, Research Faculty, British Columbia Institute of Technology, Canada
DANIEL E. CAPANO President, Diversified Technical Services, Inc., Stamford, Connecticut, U.S.A.
RICHARD H. CARO BchE, MS, MBA, CMC Associates, Acton, Massachusetts, U.S.A.
HARRY L. CHEDDIE PE, BSc, Principal Engineer, Exida.com, Sarnia, Ontario, Canada
SCOTT C. CLARK BS, ChE, Project Engineer, Merck & Co., Inc., Elkton, Virginia, U.S.A.
ASGEIR DRØIVOLDSMO MS, Research Scientist, OECD Halden Reactor Project, Halden, Norway
SHIBI EMMANUEL MTech, BTech, Head of I&C, Dar Al Riyadh Consultants, Al Khobar, Saudi Arabia
HALIT EREN BSc, MEng, PhD, MBA, Senior Lecturer, Curtin University of Technology, Perth,
Australia
LUDGER FÜCHTLER Dipl. Eng., Marketing Manager, Endress+Hauser Process Solutions AG, Reinach,
Switzerland
ix
© 2002 by Béla G. Lipták
x Contributors
BRUCE J. GEDDES PE, BSME, Framatome ANP DE&S, Charlotte, North Carolina, U.S.A.
JOHN PETER GERRY PE, BSChE, MSChE, President, ExperTune, Inc., Hubertus, Wisconsin, U.S.A.
ASISH GHOSH CE, MIEE, Independent Consultant, Wrentham, Massachusetts, U.S.A.
IAN H. GIBSON BSc, Dipl. ChE, Dipl. Inst.Tech., Principal Technical Specialist-Process & Control
Systems, Fluor Australia Pty Ltd, Melbourne, Australia
HASHEM MEHRDAD HASHEMIAN MSNE, ISA Fellow, President, Analysis and Measurement Services Corp., Knoxville,
Tennessee, U.S.A.
HEROLD I. HERTANU PE, MSEE, President, HLP Associates, New York, U.S.A.
KARLENE A. HOO BS, MS, PhD, AIChe, Associate Professor, Texas Tech University, Lubbock, Texas, U.S.A.
MICHAEL FRANK HORDESKI PE, BSEE, MSEE, Consultant, Jablon Computer, Atascadero, California, U.S.A.
JAMES E. JAMISON PE, BScChE, Senior Lead Instrument and Process Control Engineer, Bantrel, Inc.,
Calgary, Canada
KLAUS H. KORSTEN Dipl. Eng., Marketing Manager, Endress+Hauser Process Solutions AG, Reinach,
Switzerland
KLAUS-PETER LINDNER Dipl. Info., New Technology Specialist, Endress+Hauser Process Solutions AG,
Reinach, Switzerland
BÉLA G. LIPTÁK PE, MME, Consultant, ISA Fellow and recipient of Process Automation Hall of Fame
award for 2001, Stamford, Connecticut, U.S.A.
MICHAEL N. LOUKA BS, Section Head, IFE Halden Virtual Reality Centre, Halden, Norway
M. SAM MANNAN PE, CSP, PhD, AIChe, Professor of Chemical Engineering, Texas A&M University,
College Station, Texas, U.S.A.
EDWARD M. MARSZAL PE, BSChE, Principal Engineer, Exida, Columbus, Ohio, U.S.A.
GREGORY K. McMILLAN BSEngPhy, MSEE, Adjunct Professor, Washington University, St. Louis, Missouri, U.S.A.
DANIEL MIKLOVIC BSEE, MSSM, CMFgE, Vice President and Research Director, Gartner, Sammamish,
Washington, U.S.A.
DOUG MORGAN BSChE, Project Engineer, Control Systems International, Irvine, California, U.S.A.
MICHAEL J. PIOVOSO PE, BSEE, MSEE, PhD, Associate Professor, Pennsylvania State University, Malvern,
Pennsylvania, U.S.A.
WALLACE A. PRATT, JR. BSEE, Chief Engineer, HART Communication Foundation, Austin, Texas, U.S.A.
ALBERTO ROHR EE, Dr. Ing., Consultant, Vedrano al Lambro (MI), Italy
DERRICK KEITH ROLLINS, SR. BS, MS, PhD, AIChe, Associate Professor, Iowa State University, Ames, Iowa, U.S.A.
MICHEL RUEL PE, BScA, President, TOP Control, Inc., Hubertus, Wisconsin, U.S.A.
© 2002 by Béla G. Lipták
Contributors xi
GURBINDER B. SINGH BE, MBA, MCSE, Consultant—Control Systems Engineer, Chicago, Illinois, U.S.A
ROBERT J. SMITH II BSEET, Electrical & Instrumentation Engineer/Information Technology Manager,
Associated Professional Engineering Consultants, Inc., Cincinnati, Ohio, U.S.A.
DAVID A. STROBHAR PE, BSHFE, President, Beville Engineering, Inc., Dayton, Ohio, U.S.A.
ANGELA ELAINE SUMMERS PE, PhD, AIChe, President, SIS-TECH Solutions, LLC, Houston, Texas, U.S.A.
G. KEVIN TOTHEROW BSEE, President, Sylution Consulting, Jesup, Georgia, U.S.A.
ANN TUCK BSME, Control Systems Assistant Chief Engineer, Bechtel Corporation, Frederick,
Maryland, U.S.A.
IAN VERHAPPEN PE, BScE, Engineering Associate, Syncrude Canada Ltd, Fort McMurray, Alberta,
Canada
STEFANO VITTURI Dr. Eng., Researcher, CNR-LADSEB, Padova, Italy
HARRY H. WEST PE, CSP, PhD, AIChe, Adjunct Professor of Chemical Engineering, Texas A&M
University, College Station, Texas, U.S.A.
© 2002 by Béla G. Lipták
P R E F A C E
THE MATURING OF THE I&C PROFESSION degrees in I&C engineering. Some do not even have an I&C
department. Even those that do often tend to treat control as
The first volume of the Instrument Engineers’ Handbook if it were a subfield of mathematics. At such universities control
(ΙΕΗ) described the devices and methods used in performing issues are often discussed in the “frequency domain,” and
automatic industrial process measurement and analysis. The control problems are analyzed by using partial differential
second volume of the IEH dealt with automatic process con- equations and Laplace transfer functions. Under such condi-
trol devices and systems used in our various industries. This tions, the engineering students, when first exposed to the field
third volume of the IEH provides an in-depth, state-of-the- of process control, often receive the wrong impression of
art review of all the existing and evolving digital communi- what the I&C profession is all about.
cation and control systems. Although the transportation of Our engineering societies could also do a better job to
digital information by buses and networks is a major topic improve our professional image. The main goal of such engi-
in this volume, the total coverage of the volume includes neering societies as ASME or AIChE is to serve the profes-
much more. This volume also describes a variety of process sional development of their members. These societies focus on
control software packages, which are used in plant optimi- preparing scientific publications, on generating high-quality
zation, maintenance, and safety-related applications. A full engineering standards, or on organizing courses aimed at assist-
chapter is assigned to plant design and updating, while safety ing the professional advancement of their members. In contrast
and operations-related logic systems and the design of inte- to that, the leadership of some I&C societies is dominated
grated workstations and control centers are also emphasized. not by the users, but by the manufacturers, and focuses not on
The volume concludes with a substantial appendix, providing the professional advancement of their members, but on serv-
such practical information as bidders’ lists and addresses, ing the commercial interests of the vendors.
steam tables, materials selection for corrosive services, and The differences between the professional standings of
much more. I&C and other engineering disciplines are also visible in most
It is hoped that the publication of this third volume of the operating plants, where one has no difficulty in finding a
IEH will contribute to increasing the safety and efficiency of resident ME or ChE, but when one asks for the resident I&C
all control systems. Although in the previous editions of the engineer, the answer often is, “We have only instrument
IEH we have advocated the use of intelligent self-monitoring maintenance technicians, the vendors take care of our instru-
and self-diagnosing instrumentation, now it seems that the time ment engineering.” This shows an elementary lack of under-
has come to take the next step and aim for unattended and self- standing of the most basic requirement of good control. It is
optimizing industrial control systems. It is time to proceed from that in order to properly control a process, one must fully
the level of self-monitoring and self-diagnosing packages to understand its unique personality, and vendors can sel-
self-healing systems requiring a minimum of maintenance. dom, if ever, do that.
Ours is a relatively young profession. I do hope that this Another observable difference is demonstrated by the
third volume of the IEH will also improve the respectability bookshelves of the members of the different engineering
and professional standing of the instrumentation and control disciplines. If one walks into the office of an ME, it is likely
(I&C) profession, which is still evolving. Yet, if we compare that one will see one or more editions of Marks’ Handbook
the professional standing and the self-image of instrumentation on the bookshelf. The same holds true for the offices of ChEs,
and control engineers to those of, for example, mechanical except that there it will be Perry’s Handbook on the book-
or chemical engineers, we find ourselves at a disadvantage. shelves. In contrast, the bookshelves of most I&C engineers
The list of disadvantages starts at the universities, which are likely to be flooded by vendors’ catalogs but few profes-
offer ME or ChE degrees, but not too many of them offer sional handbooks are likely to be seen there.
xiii
© 2002 by Béla G. Lipták