Process Measurement and Analysis
VOLUME II
C O N T E N T S
Contributors xi
Introduction xix
Definitions xxix
Societies and Organizations li
Abbreviations, Nomenclature, Acronyms, and Symbols liii
1 General 1
1.1 Analog vs. Digital Instruments 3
1.2 Computer Configurations of Supervisory Units 15
1.3 Computers — Simulation by Analog and Hybrid Systems 26
1.4 Electronic vs. Pneumatic Instruments 41
1.5 Human Engineering 46
1.6 Process Alarm Management 59
1.7 Speech Synthesis and Voice Recognition 64
1.8 Wiring Practices and Signal Conditioning 71
2 Control Theory 89
2.1 Control Basics 96
2.2 Control Modes — PID Controllers 114
2.3 Control Modes — PID Variations 124
2.4 Control Modes — Digital PID Controllers 130
2.5 Control Modes — Closed-Loop Response 135
2.6 Control Systems — Cascade Loops 148
2.7 Empirical Process Optimization 157
2.8 Expert Systems 162
2.9 Feedback and Feedforward Control 173
2.10 Genetic and Other Evolutionary Algorithms 181
2.11 Hierarchical Control 193
2.12 Interaction and Decoupling 205
2.13 Model-Based Control 209
2.14 Model-Based Predictive Control Patents 214
2.15 Model-Free Adaptive (MFA) Control 224
2.16 Modeling and Simulation of Processes 234
2.17 Model Predictive Control and Optimization 242
2.18 Neural Networks for Process Modeling 253
2.19 Nonlinear and Adaptive Control 265
2.20 Optimizing Control 274
2.21 PID Algorithms and Programming 284
2.22 Process Gains, Time Lags, Reaction Curves 296
2.23 Ratio Control 305
2.24 Real-Time Performance Assessment 311
2.25 Relative Gain Calculations 318
2.26 Robustness: A Guide for Sensitivity and Stability 323
2.27 Sampled Data Control Systems 326
2.28 Selective, Override, and Limit Controls 336
2.29 Self-Tuning Controllers 345
2.30 Sliding Mode Control in Process Industry 351
2.31 Software for Fuzzy Logic Control 360
2.32 Stability Analysis, Transfer Functions 375
2.33 State Space Control 393
2.34 Statistical Process Control 405
2.35 Tuning PID Controllers 414
2.36 Tuning Level Control Loops 432
2.37 Tuning Interacting Loops, Synchronizing Loops 442
2.38 Tuning by Computer 446
3 Transmitters and Local Controllers 457
3.1 Controllers — Pneumatic 460
3.2 Controllers — Electronic 478
3.3 Converters and Dampeners 488
3.4 Relays for Computing and Programmers 493
3.5 Telemetering Systems 507
3.6 Transmitters — Electronic 520
3.7 Transmitters — Fiber-Optic Transmission 535
3.8 Transmitters — Pneumatic 547
3.9 Transmitters: Self-Checking and Self-Validating 559
3.10 Transmitters: Smart, Multivariable, and Fieldbus 567
4 Control Room Equipment 575
4.1 Annunciators and Alarms 580
4.2 Control Centers and Panels — Traditional 598
4.3 Control Center Upgrading 618
4.4 Controllers — Electronic Analog and Digital 633
4.5 CRT Displays 650
4.6 DCS: Basic Trends and Advances 663
4.7 DCS: Control and Simulation Advances 677
4.8 DCS: Installation and Commissioning 687
4.9 DCS: Integration with Buses and Networks 693
4.10 DCS: Integration with Other Systems 700
4.11 DCS: Management of Abnormal Situations 706
4.12 DCS: Modern Control Graphics 720
4.13 DCS: Operator’s Graphics 727
4.14 DCS: System Architecture 739
4.15 Digital Readouts and Graphic Displays 757
4.16 Fieldbuses and Network Protocols 770
4.17 Human–Machine Interface Evolution 790
4.18 Indicators, Analog Displays 805
4.19 Lights 812
4.20 Recorders, Oscillographs, Loggers, Tape Recorders 818
4.21 Switches, Pushbuttons, Keyboards 829
4.22 Touch Screen Displays 845
4.23 Uninterruptible Power and Voltage Supplies (UPS and UVS) 854
4.24 Workstation Designs 868
5 PLCs and Other Logic Devices 877
5.1 Binary Logic Diagrams for Process Operations 880
5.2 Ladder Diagrams 893
5.3 Optimization of Logic Circuits 898
5.4 PLCs: Programmable Logic Controllers 906
5.5 PLC Programming 944
5.6 PLC Software Advances 966
5.7 Practical Logic Design 976
5.8 Programmable Safety Systems 993
5.9 Relays 1006
5.10 Solid-State Logic Elements 1015
5.11 System Integration: Computers with PLCs 1023
5.12 Time Delay Relays 1030
5.13 Timers and Programming Timers 1036
6 Control Valve Selection and Sizing 1045
6.1 Application and Selection of Control Valves 1050
6.2 Accessories and Positioners 1087
6.3 Actuators: Digital, Electric, Hydraulic, Solenoid 1105
6.4 Actuators: Pneumatic 1124
6.5 Advanced Stem Packing Designs 1144
6.6 Capacity Testing 1150
6.7 Characteristics and Rangeability 1154
6.8 Diagnostics and Predictive Valve Maintenance 1161
6.9 Dynamic Performance of Control Valves 1165
6.10 Emergency Partial-Stroke Testing of Block Valves 1172
6.11 Fieldbus and Smart Valves 1182
6.12 Intelligent Valves, Positioners, Accessories 1193
6.13 Miscellaneous Valve and Trim Designs 1199
6.14 Valves: Noise Calculation, Prediction, and Reduction 1213
6.15 Sizing 1234
6.16 Valve Types: Ball Valves 1262
6.17 Valve Types: Butterfly Valves 1273
6.18 Valve Types: Digital Valves 1284
6.19 Valve Types: Globe Valves 1290
6.20 Valve Types: Pinch Valves 1323
6.21 Valve Types: Plug Valves 1341
6.22 Valve Types: Saunders Diaphragm Valves 1348
6.23 Valve Types: Sliding Gate Valves 1353
7 Regulators and Final Control Elements 1359
7.1 Dampers and Louvers 1362
7.2 Electric Energy Modulation 1368
7.3 Linear and Angular Positioning of Machinery 1375
7.4 Pumps as Control Elements 1382
7.5 Regulators — Flow 1397
7.6 Regulators — Level 1405
7.7 Regulators — Pressure 1412
7.8 Regulators — Temperature 1426
7.9 Thermostats and Humidistats 1440
7.10 Variable-Speed Drives 1454
8 Control and Optimization of Unit Operations 1473
8.1 Aeration and DO Controls 1484
8.2 Airhandler and Building Conditioning Controls 1507
8.3 Batch Control Description, Terminology, and Standard S88 1528
8.4 Batch Processes and their Automation 1544
8.5 Blending and Ratio Controls 1558
8.6 Boiler Control and Optimization 1572
8.7 Centrifuge Controls 1632
8.8 Chemical Reactors: Batch Sequencing 1640
8.9 Chemical Reactors: Basic Control Strategies 1664
8.10 Chemical Reactors: Control and Optimization 1697
8.11 Chemical Reactors: Simulation and Modeling 1711
8.12 Chiller Control 1720
8.13 Chiller Optimization 1729
8.14 Clean-Room Controls and Optimization 1753
8.15 Compressor Control and Optimization 1763
8.16 Cooling Tower Control 1794
8.17 Cooling Tower Optimization 1805
8.18 Crystallizer Controls 1811
8.19 Distillation: Basic Controls 1820
8.20 Distillation: Calculations of Relative Gains 1855
8.21 Distillation: Optimization and Advanced Controls 1866
8.22 Dryer Controls 1904
8.23 Evaporator Controls 1914
8.24 Extruder Controls 1932
8.25 Fan Controls 1946
8.26 Fuel Cell Controls 1952
8.27 Furnace and Reformer Controls 1966
8.28 Header-Supplied Distribution Control 1993
8.29 Heat Exchanger Control and Optimization 2004
8.30 Inert Gas Blanketing Controls 2025
8.31 ORP Controls 2032
8.32 pH Control 2044
8.33 Power Plant Controls: Cogeneration and Combined Cycle 2057
8.34 Pump Controls 2084
8.35 Pump Optimization 2110
8.36 Rolling Mill Controls 2116
8.37 Separation Controls, Air 2123
8.38 Steam Turbine Controls 2137
8.39 Wastewater Treatment Controls 2152
8.40 Water Supply Plant Controls 2172
8.41 Well-Supplied Underground Gas Storage Controls 2194
Appendix 2209
A.1 International System of Units 2210
A.2 Engineering Conversion Factors 2220
A.3 Chemical Resistance of Materials (Table A.3) 2242
A.4 Composition of Metallic and Other Materials (Table A.4) 2251
A.5 Steam and Water Tables 2254
A.6 Friction Loss in Pipes 2262
A.7 Tank Volumes 2266
A.8 Partial List of Suppliers 2269
A.9 Directory of “Lost” Companies (Revised 6/2004) 2295
A.10 ISA Standards 2302
© 2006 by Béla Lipták
Related:
INSTRUMENT ENGINEERS' HANDBOOK-VOLUME I
Measurement and Instrumentation Principles
WIKA-Handbook · Pressure and Temperature Measurement U.S. Edition
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