Whitt M.D. Successful instrumentation and control systems design. - 2nd ed. - Research Triangle Park: Intern. soc. of automation, 2012. - xxxviii, 531 p.: ill. + 1 CD-ROM. - (Setting the standard for automation). - Ind.: p.525-531. - Пер. загл.: Успешное проектирование измерительных приборов и систем управления. - ISBN 978-1-936007-45-5  Место хранения:   02 | Отделение ГПНТБ СО РАН | Новосибирск

Оглавление / Contents

List of Figures ............................................... xix Preface ...................................................... xxix List of Acronyms - Part I .................................. xxxvii List of Figures - Part I .................................... xxxix Introduction - Part 1 ........................................... 1 Part I - Chapter 1: The Project ................................. 3 A Introduction ................................................. 3 B Project Planning ............................................. 4 C Contracts and their Effects on Project Structure ............. 8 1 Constraints ............................................... 9 2 Contract Types: The Cost-Pius Contract (CP) .............. 10 3 Contract Types: The Time and Material Contract (T&M) ..... 13 4 Contract Types: The Time and Material/Not-To-Exceed Contract (T&M/NTE) ....................................... 14 5 Contract Types: Lump Sum (Fixed Price) Contract .......... 14 6 Project Structures: The Turnkey Project .................. 16 7 Project Structures: The EPC Project ...................... 16 8 Project Structures: The Retrofit and Green-Field Projects ................................................. 17 9 Project Structures: The Hybrid Project ................... 17 D The Customer/Service Provider Relationship .................. 17 E Project Flow for a Controls Project ......................... 18 1 The Owner's Project ...................................... 21 2 The Control System E/I &C Engineer's Project ............. 30 3 The Control Systems Integrator's Project ................. 40 4 The Control Panel Fabricator's Project ................... 50 Part I - Chapter 2: The Project Team ........................... 55 A The Owner (i.e., Buyer, Customer) ........................... 57 1 Plant Administration ..................................... 58 2 Plant Operations ......................................... 59 3 Plant Engineering/Maintenance ............................ 59 4 Plant Purchasing ......................................... 59 B The Owner's Engineer (OE) ................................... 60 1 The OE as an Individual .................................. 60 2 The OE as an In-House Team ............................... 60 3 The OE as a Consulting Management Firm ................... 61 4 The OE as a Prime Contractor ............................. 61 C The Designer ................................................ 61 1 Project Manager (PM) ..................................... 62 2 Project Engineer (PE) .................................... 63 3 Discipline Lead Engineer (DLE) ........................... 63 4 Discipline Engineer(s) ................................... 63 5 Discipline Design Supervisor (DDS) ....................... 63 6 Discipline Technical Support (Design) Staff .............. 64 D The Control Systems Integrator (CSI) ........................ 64 1 The Process Control Team ................................. 65 2 The Server Setup Team .................................... 66 3 The Network Setup Team ................................... 67 4 The Startup & Commissioning Team ......................... 67 E The Constructor (i.e., Builder) ............................. 67 1 E&I Construction Superintendent .......................... 67 2 E&I Field Engineer & Coordinator ......................... 68 3 E&I General Foreman ...................................... 69 4 Instrument Foreman ....................................... 69 5 Instrument Fitter/Mechanic ............................... 69 6 Pipe Fitter .............................................. 69 7 Instrument Electrical Foreman ............................ 69 8 Electrician .............................................. 69 9 Instrument Electrician/Technician ........................ 70 Part I - Chapter 3: The Managed Project ........................ 71 A Key Project Management Tools ................................ 73 1 The Detailed Scope of Work (SOW) ......................... 74 2 The Estimate ............................................. 76 3 The Schedule ............................................. 78 4 The Proposal ............................................. 79 5 The Project Execution Plan (PEP) ......................... 84 6 The Status Report ........................................ 87 B Project Management Techniques ............................... 90 1 Assessing Project Status ................................. 90 2 Staff Meetings ........................................... 91 3 Management of Change (MOC) ............................... 96 Part I - Summary ........................................... 101 Part I - References ........................................ 103 List of Acronyms - Part II ................................. 109 List of Figures - Part II .................................. 111 Introduction - Part II ..................................... 115 Part II - Chapter 4: Basic Design Concepts .................... 117 A Scaling and Unit Conversions ............................... 117 1 Definition of Key Terms ................................. 118 2 Accuracy and Repeatability .............................. 120 3 Resolution Effects on Accuracy .......................... 122 4 Instrument Range versus Scale ........................... 123 5 Instrument Calibration .................................. 123 6 Linearization and Unit Conversions ...................... 124 7 Practical Application ................................... 127 B Introduction to Information Management ..................... 129 Part II - Chapter 5: Design Practice .......................... 147 A Basic Wiring Practice ...................................... 148 1 Inter-Cabinet Wiring .................................... 148 2 Intra-Cabinet Wiring .................................... 155 B Failsafe Wiring Practice ................................... 166 C Hazardous Area Classification and Effects on Design ........ 170 1 Hazardous Locations ..................................... 170 2 Explosionproofing ....................................... 174 3 Intrinsic Safety ........................................ 175 4 Purging ................................................. 175 D Connecting to the Control System ........................... 177 1 Discrete (Digital) Wiring ............................... 178 2 Analog Wiring ........................................... 184 E Design Practice Summary .................................... 192 Part II - Chapter 6: The Control System ....................... 193 A Introduction ............................................... 193 B The Cognitive Cycle ........................................ 194 C Control System Overview .................................... 195 1 A Historical Perspective ................................ 195 2 PLC versus DCS .......................................... 197 3 Major Control System Elements ........................... 200 4 Control Modes and Operability ........................... 202 D The Human-Machine Interface ................................ 205 1 The Graphic User Interface (GUI) ........................ 205 2 The HMI Database ........................................ 210 3 The HMI Alarm Manager Utility ........................... 211 4 The Historian ........................................... 212 5 The Trend Utility ....................................... 212 6 Reports ................................................. 213 E Programmable Logic Controller .............................. 214 1 Major PLC Components .................................... 214 2 The PLC Program ......................................... 216 3 The I/O Interface ....................................... 222 F Networking ................................................. 230 1 Optimized/Proprietary Networks .......................... 230 2 Optimized/Non-Proprietary Networks ...................... 232 3 Non-Optimized (Open) Local Area Networks ................ 234 4 Wireless Local Area Networks ............................ 234 5 The Ethernet Client/Server Environment .................. 235 6 The Industrial Enterprise-Wide Network .................. 238 G Working with a Control Systems Integrator (CSI) ............ 241 1 Initial Search .......................................... 241 2 Writing a Control System Specification .................. 242 H Selecting a Control System ................................. 246 References - Part II ....................................... 249 List of Acronyms - Part III ................................ 257 List of Figures - Part III ................................. 259 Introduction - Part III .................................... 267 Part III - Chapter 7: Piping and Instrumentation Diagrams (P&IDs) ....................................................... 271 A General Description ........................................ 271 B Purpose .................................................... 272 C Content .................................................... 272 1 Symbology (ANSI/ISA-5.1-2009) ........................... 273 2 Symbol Identification ................................... 273 D Practical Application ...................................... 276 1 Tank Level: LT-10, LSH-10, LSLL-47 ...................... 276 2 Tank Fill: HV-13, ZSC-13 ................................ 277 3 Tank Discharge: PP-10 ................................... 277 4 Pump Discharge Pressure: PIC-48 ......................... 277 E P&ID Summary ............................................... 278 Part III - Chapter 8: Links to Mechanical and Civil ........... 279 A General Equipment Arrangement Drawing (Civil and Mechanical) ................................................ 279 1 Purpose ................................................. 279 2 Interfaces .............................................. 279 3 Content ................................................. 279 4 Practical Application ................................... 280 5 Equipment Arrangement Summary ........................... 280 B Piping Drawing (Mechanical) ................................ 281 1 Purpose ................................................. 282 2 Interfaces .............................................. 282 3 Content (as related to I&C) ............................. 282 C Pump and Equipment Specifications (Mechanical) ............. 282 D Links Summary .............................................. 282 Part III - Chapter 9: Preliminary Engineering ................. 283 A Development of a Detailed Scope of Work .................... 284 1 Purpose (Project Overview) .............................. 284 2 Project Scope—I&C ....................................... 284 3 Safety Concerns ......................................... 284 4 Assumptions ............................................. 284 5 Exclusions .............................................. 284 6 Deliverables ............................................ 284 7 Milestone Schedule ...................................... 285 B Control System Orientation ................................. 285 C Project Database Initialization ............................ 288 1 Initialize Document Control Table ....................... 289 2 Initialize Instrument and I/O List Table ................ 295 3 Database Summary ........................................ 302 D Estimate and Schedule Development .......................... 302 1 Cover Worksheet ......................................... 303 2 Devices Worksheet ....................................... 303 3 Count Worksheet ......................................... 309 4 Labor Worksheet ......................................... 310 5 Summary Worksheet ....................................... 314 6 Schedule Worksheet ...................................... 316 7 Estimate and Schedule Summary ........................... 317 E Preliminary Engineering Summary ............................ 319 Part III - Chapter 10: Control Systems Integration (CSI) ...... 321 A FEL Stage 1 - Business Planning ............................ 321 1 Cost/Benefit Analysis ................................... 322 2 Control System Specification ............................ 323 3 Functional Description .................................. 324 4 Project Estimate ........................................ 325 5 Project Proposal ........................................ 327 B FEL Stage 2 - Project Definition ........................... 327 1 Sequential Function Chart (SFC) ......................... 328 2 Continuous Function Chart (CFC) ......................... 328 3 Control Narrative ....................................... 329 4 Sequence Control Detail Sheets (SCDS) ................... 329 5 Device Control Detail Sheets (DCDS) ..................... 329 6 Functional Logic Diagrams ............................... 329 C Control Narrative .......................................... 329 1 Sequential Function Chart (SFC) ......................... 329 2 Continuous Function Chart (CFC) ......................... 333 3 SFC Control Narrative Fragment .......................... 334 4 Sequence Step Detail Sheet (SSDS) ....................... 337 5 Device Control Detail Sheet (DCDS) ...................... 345 6 Functional Logic Diagram ................................ 350 7 Logic Diagram Standard ISA-5.1 .......................... 362 8 FEL2 Systems Integration Summary ........................ 363 D Operator Interface Specification Development - The HMI ..... 365 1 Animation Plan .......................................... 366 2 Screen Diagrams ......................................... 367 3 Tagname Database, Device Driver, and I/O Mapping ........ 374 4 Finished Graphics Screen ................................ 375 5 Alarm Manager ........................................... 377 6 Historian ............................................... 378 7 HMI Report Generation ................................... 378 E Network Single-Line Diagram Generation ..................... 378 F Other Systems Integration Tasks ............................ 379 1 Control System Cabinetry Design and Delivery ............ 379 2 I/O Address Assignment (Partitioning) ................... 379 3 Factory (or Functional) Acceptance Test (FAT) ........... 381 4 Site Acceptance Test (SAT) .............................. 384 5 Commissioning ........................................... 385 6 Operations and Maintenance (O&M) Manual ................. 385 7 Onsite Training ......................................... 386 G Systems Integration Summary ................................ 387 Part III - Chapter 11: Information Management ................. 389 A Document Control ........................................... 389 B Instrument and I/O List .................................... 390 1 Instrument and I/O List Table ........................... 391 2 Preliminary Design Query ................................ 391 3 Plan Drawing Takeoff Query .............................. 392 4 Plan Dwg Takeoff Query Report ........................... 392 5 X-Ref Document Cross-Reference Query .................... 393 6 X-Ref Document Cross-Reference Report ................... 394 C Database Summary ........................................... 394 Part III - Chapter 12: Instrument Specifications .............. 397 A Purpose .................................................... 398 1 Mechanical Designers .................................... 398 2 Instrument Designers .................................... 399 3 Other Users ............................................. 401 B Interfaces ................................................. 401 C Examples ................................................... 402 1 LT/LSH-10 ............................................... 402 2 PV-48 ................................................... 405 D Summary .................................................... 407 Part III - Chapter 13: Physical Drawings ...................... 409 A Control Room ............................................... 409 1 Environmental Issues .................................... 409 2 Physical Arrangement .................................... 410 3 Control Room Design Summary ............................. 411 B Termination Room ........................................... 411 1 Environmental Issues .................................... 411 2 Furniture and Equipment Arrangement ..................... 413 3 Termination Room Design Summary ......................... 413 C Process Area (Instrument Location Plan) .................... 413 1 Why Produce Instrument Location Plan Drawings? .......... 415 2 Anatomy of an Instrument Location Plan .................. 415 3 Design Considerations ................................... 416 4 Drawing Production Technique ............................ 417 5 Material Takeoff ........................................ 429 D Instrument Installation Details ............................ 433 1 Electrical Installation Details ......................... 434 2 Tubing Details .......................................... 435 3 Mounting Details ........................................ 436 4 Related Database Activities ............................. 436 5 Material Takeoff ........................................ 438 E Summary .................................................... 438 Part III - Chapter 14: Instrument and Control Wiring .......... 441 A Instrument Elementary (Ladder) Diagram ..................... 444 1 Motor Elementaries ...................................... 447 2 AC Power Distribution Schematic ......................... 449 3 DC Power Distribution Schematic ......................... 451 4 PLC Ladder Diagram (Elementary) ......................... 452 B Loop Sheet (Ref: ISA-5.4-1991)14 ........................... 458 C Connection Diagrams ........................................ 462 1 Junction Box JB-TK10-1: Initial Layout .................. 463 2 Termination Cabinet TC-2 ................................ 469 D Wiring Summary ............................................. 479 Part III - Chapter 15: Panel Arrangements ..................... 485 A Procedure .................................................. 486 B Junction Box JB-TK10-01 Arrangement Drawing ARR-002 ........ 487 1 Set Up a Scale .......................................... 488 2 Design the Panel ........................................ 488 3 Generate a Bill of Materials ............................ 491 C Summary .................................................... 492 Part III - Chapter 16: Procurement ............................ 493 A Typical Purchasing Cycle ................................... 494 B Material Classification .................................... 496 C Bulk Bill of Materials ..................................... 496 D Detail Bill of Materials ................................... 501 E Procurement Summary ........................................ 506 Part III - Chapter 17: Quality Control—The Integrated Design Check ......................................................... 509 A Administrative Content - Individual Checks ................. 509 B Technical Content - Squad Check ............................ 510 C Squad-Check Roster ......................................... 511 D Design Check Summary ....................................... 511 Part III - Chapter 18: Phase 3—Deployment ..................... 513 A Construction ............................................... 513 1 Kickoff Meeting ......................................... 513 2 Construction ............................................ 514 B Pre-Commissioning .......................................... 515 C Cold-Commissioning (Site Acceptance) ....................... 516 1 Device Tests ............................................ 516 2 Subsystem Tests ......................................... 517 D Hot-Commissioning (Startup) ................................ 517 E Adjustment of Document Package to Reflect Construction Modifications .............................................. 517 F Issue for Record ........................................... 518 G Phase 3 Summary ............................................ 518 Part III - Chapter 19: Phase 4 - Support ...................... 519 A Warranty Support ........................................... 519 B Continuing Service Support ................................. 519 References - Part III ...................................... 521 Additional Resources ....................................... 523 Index ......................................................... 525