Process Control Systems Engineering Supply Infrastructure from A to Z von Leon Urbas 1. Auflage Process Control Systems Engineering Urbas schnell und portofrei erhältlich bei beck-shop.de DIE FACHBUCHHANDLUNG Thematische Gliederung: Mess- und Automatisierungstechnik Oldenbourg Industrieverlag 2012 Verlag C.H. Beck im Internet: www.beck.de ISBN 978 3 8356 3198 4
Inhalt Process Control Systems Engineering... 1 Prof. Leon Urbas.... 1 Danksagung... 2 1 Introduction... 3 1.1 Structure... 3 1.2 How to read this book... 4 1.3 References... 7 2 PCS Requirements... 9 2.1 Overview... 9 2.2 Process Industries... 10 2.2.1 Chemicals... 10 2.2.2 Pharmaceuticals... 11 2.2.3 Oil & Gas... 11 2.2.4 Water/Waste Water... 12 2.2.5 Pulp & Paper... 12 2.2.6 Food & Beverage... 12 2.3 Summary... 13 2.4 Cross Domain Concepts... 13 2.4.1 Unit Operations of Chemical Engineering... 13 2.4.2 Batch Processes... 15 2.4.3 Continuous Processes... 16 2.4.4 Risk Reduction by process automation... 16 2.4.5 Human Supervisory Control... 20 2.4.6 Distributed Control System Architectures... 22 2.5 References... 25 3 PCS Engineering... 27 3.1 Overview... 27 3.2 Plant Engineering Projects... 27 3.2.1 Project Management... 28 3.3 Procedural models of PCS Engineering... 30 3.3.1 PPEAM Process Plant Engineering Activity Model... 31 3.3.2 PAS 1059: Processing plant design Procedural model and terminology... 33 3.3.3 NA 35: Handling PCT Projects... 33 3.4 Preliminary Engineering... 36 V
3.4.1 Plant Concept and PCS Concept... 36 4.4.2 Cost Estimation... 37 3.4.3 PCS System Selection... 39 3.5 Basic and Detail PCS Engineering... 41 3.6 Future Directions... 41 3.6.1 Formal models of engineering workflows... 42 3.6.2 Information exchange... 42 3.6.3 Automation of PCS Engineering tasks... 43 3.7 References... 44 4 Modular Engineering Research Plant.... 47 4.1 Process Description... 47 4.1.1 Reactor... 48 4.2 Instrumentation... 50 1.2.1 Piping and Instrumentation Diagram... 50 4.2.2 Identification System... 51 4.2.3 Process Control Requests... 51 4.2.4 PCT Cause and Effect Matrix... 54 4.3 References... 56 5 Process Control System Architecture... 57 5.1 Overview... 57 5.1 Distributed Architecture... 58 5.3 Process Control Station... 59 5.3.1 Cyclic Execution and Process Image... 60 5.4 I/O modules................................................... 62 5.5 Hardware Configuration for the MEAR plant... 63 5.5.1 Step 1: Setting up a PCS 7 project... 65 5.5.2 Configuring the AS... 66 5.5.3 Configuring the remote I/O... 67 5.5.4 Configuring the Operator Station... 68 5.5.5 Check and compile the network... 68 5.6 References... 70 6 Industrial Communications Engineering... 71 6.1 Overview... 71 6.2 Industrial Communication on Field Level... 72 6.2.1 Conventional wiring... 73 6.2.2 Digital fieldbus... 74 6.2.3 Fieldbus Engineering............................................ 75 VI
6.3 Industrial Communications with MES and ERP... 76 6.3.1 OLE... 77 6.3.2 Configuring the PCS 7 OPC-server... 81 6.4 Future Directions... 82 6.4.1 Preliminary Fieldbus Engineering... 82 6.5 References... 82 7 Bulk Engineering... 87 7.1 Overview... 87 7.2 General structuring principles... 88 7.3 Plant Hierarchy... 89 7.3.1 Structuring Rules... 90 7.3.2 Functional structure of the MEAR plant... 91 7.4 PCS Plant Hierarchy... 91 7.4.1 HMI generation... 92 7.4.2 AS-OS Assignment... 92 7.4.3 Batch recipes... 93 7.5 Bulk Engineering... 93 7.5.1 Process tag types and models... 94 7.5.2 Process tag type... 95 7.5.3 Model... 96 7.5.4 Parameters and Signals... 97 7.5.5 Process Object View... 98 7.6 MEAR plant example for a process tag type... 99 7.7 MEAR plant example for a model... 101 7.8 Literature... 102 8 Individual Drive Functions... 103 8.1 Overview... 103 8.2 IDF Basic Concepts... 104 8.2.1 Function Block Types in PCS 7... 104 8.2.2 Safety Provisions... 104 8.2.3 Operating Modes... 106 8.3 Predefined IDF for Field Devices... 106 8.4 Channel Functions (Drivers)..................................... 109 8.5 An IDF template from the library... 109 8.5.1 Excercise: Define Process Tag Type... 110 8.6 Literature... 113 VII
9 Continuous Feedback Control... 115 9.1 Introduction... 115 9.2 Theory... 116 9.2.1 Introduction... 116 9.2.2 Industrial Suitability of Controllers... 117 9.2.3 Expanded Control Structures... 118 9.2.4 Connecting to the Process... 120 9.3 Exercise: Implementing a continuous control loop... 122 9.4 References... 124 10 Sequential Control... 125 10.1 Overview... 125 10.1.1 Continuous and sequential control... 126 10.1.2 Structure of Step Sequences... 126 10.1.4 Design of Sequence Controls..................................... 129 10.1.5 Interaction of Sequence Controls and Logic Control Systems... 131 10.1.6 Protection Functions and Operating Modes in Sequence Controls... 131 10.1.7 Sequence Controls in PCS 7... 132 10.2 Excersize: Filling of a reactor... 134 10.3 References... 137 11 Batch Control with Recipes... 139 11.1 Overview... 139 11.2 Recipes...................................................... 140 11.3 Hierarchical Modelling of procedures, processes and plants... 142 11.4 Process Model... 143 11.5 Procedural Model... 143 11.6 Physical Model... 146 11.7 Monitoring, Archiving and Reporting... 150 11.8 Recipe Engineering... 150 11.9 Batch control with PCS 7... 152 11.9.1 Instanciation of Software Components... 152 11.9.2 Modeling activities... 152 11.9.3 Definition of a master recipe... 155 11.9.4 Creation and Starting of a batch... 156 11.10 References... 158 VIII
12 Human Machine Interaction with Process Displays... 161 12.1 Overview... 161 12.2 Objectives of Process Management... 162 12.3 Task and Information Decomposition... 163 12.4 HMI design... 164 12.4.1 Concepts of Representation... 165 12.4.2 Representation Techniques... 167 12.4.3 Trend Displays... 169 12.5 HMI Generation in PCS 7... 172 12.5.1 Configuring the Service Interface in PCS 7... 173 12.5.2 Configuring the Process Displays in PCS 7... 173 12.6 Setting up the elementary HMI displays for the MEAR plant... 174 12.6.1 Engineering System set up... 174 12.6.2 Preparation for OS generation... 174 12.6.3 OS Generation... 175 12.6.4 OS Editing... 176 12.6.5 Integrated Faceplates... 178 12.7 Future Directions... 178 12.7.1 Model Driven HMI Engineering... 180 12.7.2 autohmi... 181 12.8 References... 182 13 Alarm Engineering.... 185 13.1 Overview... 185 13.2 Signalling Systems... 186 13.2.1 Alarms and Indications... 188 13.2.2 Alarm Processing by the Operator... 189 13.3 Alarm Management in PCS 7... 192 13.4 References... 194 IX