Process Automation Handbook - A Guide to Theory and Practice

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.

List of contents

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.

About the author

Jonathan Love has been a lecturer in the School of Chemical Engineering and Advanced Materials at the University of Newcastle since 2002 where he is Director of Integrated Graduate Development Scheme (IGDS) in Process Automation. Over his career he has also lectured at the universities of Sheffield, Leeds and Huddersfield. Mr Love's industrial experience includes working as a Control Engineer at Honeywell Hi-Spec and as a Commissioning Engineer at Courtaulds Ltd.
His research interests include: dynamics of mass transfer processes, design of pH control systems for effluent treatment plants, structure of application software for batch process control, use of genetic algorithms for scheduling batch plants and, control and operability studies. Mr Love has published around 60 articles in journals, conference proceedings and industrial reports.

Summary

This book distils into a single coherent handbook all the essentials of process automation at a depth sufficient for most practical purposes. No other book covers the gap between the theory and practice of control systems so comprehensively and at a level suitable for practicing engineers.

Additional text

From the reviews:

"Jonathan Love's tour-de-force single volume Process Automation Handbook is a necessary reference, right beside Liptak's Instrument Engineer's Handbook, and if I can be pardoned, my own Instrumentation Reference Book, that should be on every process automation professional's desk or bookshelf.

"In the other two works, Liptak and I concentrate on the automation components, systems and devices that make automation work, while Love concentrates on the processes and systems that those devices make up.

"This book cannot be rated too highly. Dr. Love is a remarkably good writer, too, and his book is anything but dry and scholarly. Scholarship is there, yes, and exceptionally good, too, but the book is written in an extremely accessible voice.

"Since we are seeing people entering the profession who haven't any experience and don't have a clue how to make these systems work, it is essential for books like this to be written simply, yet deeply, because it is books like the Process Automation Handbook that will be the substitute for the experience and expertise that is retiring and walking away from the process industries daily as our work force ages.

"If you are in the field of process automation, suck it up and buy this book! It is one of the best investments in your career you can make." (Walt Boyes, Editor, ControlGlobal.com, April 2010)

"The objective of Process Automation Handbook has been to distill into a single coherent handbook all the essentials of process automation at a depth sufficient for most practical purposes. … will be of value to any engineer actively concerned with process control and automation in the chemical and process industries and final-year undergraduate and postgraduate students studying process control. Written for: Control engineers in bulk chemicals, speciality chemicals, biochemicals, pharmaceuticals, petrochemicals, oil and gas, power water treatment, mineralsprocessing, food and drink … ." (Automatisierungstechnische Praxis, Vol. 50 (2), 2008)

"The book opens with basic process control … . A practical, sound basis is given for each topic, making the material accessible to the practitioner. … An excellent handbook and a rich sourcebook for the practicing engineer, it includes most topics pertinent to modern process control. The book is well referenced and indexed and includes an excellent acronym table. Summing Up: Recommended. Upper-division undergraduates through professionals." (K. I. Mumme, CHOICE, Vol. 45 (9), 2008)

"… the Handbook of process automation deserves a 'must-buy' place on the bookshelves of anyone involved in applying process automation for profit in the process industries." (Paul Sawyer, secretary of IChemE's Process Management and Control Subject Group, TCE Today, July 2008)

Report

From the reviews:

"Jonathan Love's tour-de-force single volume Process Automation Handbook is a necessary reference, right beside Liptak's Instrument Engineer's Handbook, and if I can be pardoned, my own Instrumentation Reference Book, that should be on every process automation professional's desk or bookshelf.
"In the other two works, Liptak and I concentrate on the automation components, systems and devices that make automation work, while Love concentrates on the processes and systems that those devices make up.
"This book cannot be rated too highly. Dr. Love is a remarkably good writer, too, and his book is anything but dry and scholarly. Scholarship is there, yes, and exceptionally good, too, but the book is written in an extremely accessible voice.
"Since we are seeing people entering the profession who haven't any experience and don't have a clue how to make these systems work, it is essential for books like this to be written simply, yet deeply, because it is books like the Process Automation Handbook that will be the substitute for the experience and expertise that is retiring and walking away from the process industries daily as our work force ages.
"If you are in the field of process automation, suck it up and buy this book! It is one of the best investments in your career you can make." (Walt Boyes, Editor, ControlGlobal.com, April 2010)
"The objective of Process Automation Handbook has been to distill into a single coherent handbook all the essentials of process automation at a depth sufficient for most practical purposes. ... will be of value to any engineer actively concerned with process control and automation in the chemical and process industries and final-year undergraduate and postgraduate students studying process control. Written for: Control engineers in bulk chemicals, speciality chemicals, biochemicals, pharmaceuticals, petrochemicals, oil and gas, power water treatment, mineralsprocessing, food and drink ... ." (Automatisierungstechnische Praxis, Vol. 50 (2), 2008)
"The book opens with basic process control ... . A practical, sound basis is given for each topic, making the material accessible to the practitioner. ... An excellent handbook and a rich sourcebook for the practicing engineer, it includes most topics pertinent to modern process control. The book is well referenced and indexed and includes an excellent acronym table. Summing Up: Recommended. Upper-division undergraduates through professionals." (K. I. Mumme, CHOICE, Vol. 45 (9), 2008)
"... the Handbook of process automation deserves a 'must-buy' place on the bookshelves of anyone involved in applying process automation for profit in the process industries." (Paul Sawyer, secretary of IChemE's Process Management and Control Subject Group, TCE Today, July 2008)

Product details

• Authors: Jonathan Love
• Publisher: Springer, Berlin
• Languages: English
• Product format: Hardback
• Released: 27.08.2007
• EAN: 9781846282812
• ISBN: 978-1-84628-281-2
• No. of pages: 1093
• Dimensions: 199 mm x 267 mm x 68 mm
• Weight: 2564 g
• Illustrations: XLVIII, 1093 p.
• Subjects: Natural sciences, medicine, IT, technology > Technology > Mechanical engineering, production engineering; Technik, Berufsbildung, Maschinenbau, Chemische Industrie, Elektrogerät, Elektronische Geräte und Materialien, Regelungstechnik, Ingenieurswesen, Maschinenbau allgemein, Fertigungsindustrie, Elektronik - Elektroniker, Ingenieurwissenschaft - Ingenieurwissenschaftler, Industrie / Chemische Industrie, Chemie / Technik, Werkstoffe, Berufe, Industrie, Industrielle Chemie und Chemietechnologie, Technisches Handwerk, Mess- und Automatisierungstechnik, Automation - Automatisierung, Elektronik / Gerät, Bildung / Berufsbildung