Introduction to Plant Automation and Controls 1st Edition by Raymond F Gardner ISBN 9780367494209 0367494205

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ISBN 10: 0367494205
ISBN 13: 9780367494209
Author: Raymond F Gardner

Introduction to Plant Automation and Controls 1st Edition Table of contents:

Chapter 1 Measurement fundamentals and instrumentation

INSTRUMENTATION DEFINITIONS

GAGE ACCURACY

GAGE SELECTION

CALIBRATION STANDARDS

CALIBRATION OF INSTRUMENTATION

PRESSURE CONVERSION

PRESSURE GAGES

Pressure measurement

Manometer (U-tube)

Bourdon tube pressure gage

Pressure transducer

Calibrating pressure gages

Temperature measurement

LIQUID-EXPANSION THERMOMETER

FILLED-SYSTEM THERMOMETER

BIMETALLIC-ELEMENT THERMOMETER

ELECTRONIC TEMPERATURE MEASUREMENT DEVICES

Thermocouple

Thermistor

Resistance temperature detector (RTD)

Calibration of a 4-20mA sensor

Verification of the RTD sensor

Calibration of the 4-20mA transmission signal

Calibration of the digital meter

TANK LIQUID-LEVEL MEASUREMENT

Gage glasses, petcocks, and sounding tube

Ultrasonic or radar level transmitters

Pneumercators

Pressure transducers and liquid level measurement

Magnetic float level transmitters

DIFFERENTIAL PRESSURE AND DIFFERENTIAL-PRESSURE TRANSMITTERS

Flow measurement

Positive-displacement totalizing meters

Differential-pressure flow meters

Velocity flow meters

Vortex-shedding flow meter

Turbine flow meter

Non-intrusive flow meters/transmitters

Viscosity measurement

VIBRATION MEASUREMENT

Accelerometer

Notes

Chapter 2 Control terminology, theory, and tuning

OPEN- AND CLOSED-LOOP CONTROL

MODES OF CONTROL

On-off control

Proportional control with feedback

Feedforward control

Proportional control

Gain and proportional band

Offset

Instability and hunting

Integral or reset control

Derivative or rate control

Pneumatic control: nozzle-flapper, pneumatic relays, and PID control

Nozzle-flapper systems

Proportional-only control with open-loop gain

Proportional-only with adjustable closed-loop gain

PI proportional with integral or reset control

PID control—The derivative or rate function

Pneumatic PD control

Pneumatic P, PI, PD, and PID control

TUNING THE PID CONTROLLER

Ziegler-Nichols closed-loop method

Open loop tuning

STABILITY

Chapter 3 Basic electronics

DIODE

FILTERS

VOLTAGE DIVIDER

ZENER DIODE

BIPOLAR JUNCTION TRANSISTOR (BJT)

BIASING

THYRISTOR OR SILICON-CONTROLLED RECTIFIER (SCR)

GATE TURN-OFF THYRISTORS (GTOS)

DIACS AND TRIACS

FIELD-EFFECT TRANSISTOR (FET)

INSULATED-GATE BIPOLAR TRANSISTOR (IGBT)

Notes

Chapter 4 Digital theory, logic, and two-state control

BOOLEAN LOGIC

COMBINATIONAL LOGIC AND BOOLEAN ALGEBRA

The universal NAND gate

INTRODUCTION TO KARNAUGH MAPS

Example 4:

Example 5:

SEQUENTIAL LOGIC AND FLIP-FLOPS

The set-reset (or S-R) flip-flop

The J-K flip-flop

COMBINATIONAL LOGIC USING SWITCHES

SEQUENTIAL LOGIC USING CONTROL RELAYS

DIODES AND TRANSISTOR SWITCHING LOGIC: CONSTRUCTING DIGITAL-CIRCUIT GATES

Diode logic (DL)

Diode-transistor logic (DTL)

Transistor-transistor (TTL)

Chapter 5 Motor controllers

SWITCHES AND ELECTRICAL DEVICES

MOTOR CONTROLLER /COMBINATION STARTER CONSTRUCTION

MOTOR CONTACTORS

CONTROL RELAYS

SOLID-STATE RELAYS AND CONTACTORS

SPECIALTY RELAYS

Timing relays

Latching relays

Alternating relays

INTERPOSING RELAYS

LEAD-LAG CONTROLLERS

ONE-SHOT, WATCHDOG, AND OTHER TIMERS

NEMA RATINGS

MOTOR CONTROLLER DIAGRAMS

LOW-VOLTAGE PROTECTION/LOW-VOLTAGE RELEASE

REVERSING MOTORS

JOGGING MOTORS

REDUCED-VOLTAGE STARTING

Multi-speed motors

Wound-rotor induction motor—Multiple speed and reduced-current starting

Wye-delta reduced-voltage starting

Part-winding reduced current starters

Primary resistor/primary reactor/autotransformer

Primary-resistor starting

Primary-reactor starting

Autotransformers

Example 1

Electronic solid-state soft start

Variable-frequency drives

Notes

Chapter 6 Variable-frequency drives and harmonics

VARIABLE-FREQUENCY DRIVES (VFDS)

VFD DESIGN

Voltage-source inverters (VSI)

Phase-controlled current-source inverters (CSI)

Load-commuted inverters (LCI)

Cycloconverters (CCV)

Pulse-width modulation (PWM)

Flux-vector drives

VFD voltage control

Soft starters

HARMONICS

Harmonics in the time and frequency domains

CAUSES OF HARMONICS

Linear loads

Non-linear loads

CLASSIFICATION OF HARMONIC TYPES

Positive-, negative-, and zero-sequence harmonics

Triplens

Intraharmonics and subharmonics

Third harmonic

Harmonics from the front-end rectifier section

Percent total harmonic distortion

Reflected waves

Notching

HARMONICS MITIGATION TECHNIQUES

Dc link choke

Ac line reactor

Tuned harmonic filters

Multi-pulse transformers

Delta-to-delta-wye multi-phase transformer

Multi-tap, multiphase transformer

Active front ends

dv/dt filters

HARMONICS AND POWER QUALITY ANALYZERS

Quantifying harmonics severity

Example

Solution method 1

Solution method 2

Power-quality measurement

CONCLUSION

Notes

Chapter 7 Boiler controls

BURNER-MANAGEMENT SYSTEM AND FLAME SAFEGUARD SYSTEM (FSS)

Check permissives and interlocks

Boiler pre-purge

Ignition attempt

Flame detection

Release to modulate

Burner normal cycling

Boiler operation during load changes

Burner management permissives

Burner safety shutdown

Boiler trips

COMBUSTION-CONTROL SYSTEM

Control symbols

Single-element and two-element combustion control systems

Boiler control schemes

Series versus parallel combustion-control systems

Parallel positioning using single-point positioning

Metered series combustion-control systems

Fully metered parallel positioning

Fully metered parallel positioning with cross-limiting

Two-element combustion-control system (parallel positioning with cross-limiting)

Two-element combustion-control system parallel positioning with cross-limiting and O2 trim

7.3 BOILER FEEDWATER SYSTEMS AND CONTROL

Single-element feedwater regulators

Problems with intemittent single-element control

Multi-element feedwater regulation systems

Interactions affecting drum water level and combustion-control systems

Feed pump pressure control

FORCED DRAFT, INDUCED DRAFT, AND FURNACE DRAFT CONTROL

SUPERHEATER TEMPERATURE CONTROL AND DESUPERHEATED STEAM

FUEL SELECTION AND POLLUTION MITGATION

Notes

Chapter 8 Pump and fan controls

PUMP CURVES

CONDENSATE CONTROL SYSTEMS

POSITIVE-DISPLACEMENT PUMPS

FANS, FAN CURVES, AND FAN CONTROL

FAN CONTROL

Notes

Chapter 9 Control valves

SELF-CONTAINED PRESSURE REDUCING VALVES

SELF-CONTAINED TEMPERATURE REGULATING VALVES

PNEUMATIC PILOT-ACTUATED CONTROL VALVES

PNEUMATIC PILOT CONTROLLER

PNEUMATIC ACTUATORS AND POSITIONERS

DIRECT ACTING/REVERSE ACTING AND FAIL-SAFE POSITION

LEVEL CONTROL

VALVE RESPONSE—HYSTERESIS AND DEADBAND

CONSTRUCTION TECHNIQUES TO IMPROVE PERFORMANCE

SIZING CONTROL VALVES FOR LIQUID APPLICATIONS

INSTALLATION CURVE

SIZING CONTROL VALVES FOR COMPRESSIBLE-FLOW APPLICATIONS

FLASHING AND CAVITATION

RECOVERY COEFFICIENT

CHOKED FLOW: COMPRESSIBLE AND INCOMPRESSIBLE FLUIDS

SELECTING THE VALVE Cv USING MANUFACTURER PRODUCT DATA

Example problem

ANSI VALVE CLASS

MOTOR ACTUATORS

CONTROL VALVE SELECTION GUIDELINES

Notes

Chapter 10 Speed, load, and alternator control

SPEED-LIMITING GOVERNORS

Speed-limiting protection

Low-lube-oil-pressure protection

Low-lube-oil pressure adjustment

Speed-limiting governor adjustment

CONSTANT-SPEED GOVERNORS

Mechanical-hydraulic governors

Governor droop and deadband

Equation 1a

Equation 1b

Governor compensation and isochronous control

Two-element governor

Load-sensing element

Flyweight speed-sensing element

Electronic constant speed governor

Governor linkage

Parallel operation of alternators

Paralleled alternators, both with drooping governors

Paralleled alternators, one isochronous and the other with a drooping governor

Other alternator controls

OVERSPEED TRIP DEVICES

Mechanical overspeed trip

Electronic overspeed trip

Other safety shutdown devices

Notes

Chapter 11 Programmable-logic controllers and operation

PLC HISTORY

MODERN PLCS

PLCS IN POWER PLANT CONTROL

PARTS OF THE PLC

Power supply

Central processing unit (CPU)

Memory

ROM

RAM

EPROM

EEPROM

Nonvolative RAM

Input devices

Digital input devices

Analog input devices

Output devices

Cabling and interfaces

Human-machine interface (HMI)

Control signals and signal isolation

GENERAL PLC TROUBLESHOOTING

NETWORKING THE PLC

PROGRAMMING THE PLC

PROGRAM EXECUTION

Relay logic

FUNCTIONS WITHIN PLCS

USING ALLEN-BRADLEY/ROCKWELL AUTOMATION RSLOGIX 500 SOFTWARE

UPLOADING/DOWNLOADING THE PROGRAM

ADDRESSING THE PLC DEVICES

Chapter 12 Wiring PLCs and I/O devices

PLC POWER-SUPPLY SYSTEMS

PLC INPUT AND OUTPUT DEVICES

Solid-state digital input and digital output devices

Sourcing and sinking

Flexible, polarity-independent transistor-based digital I/O devices

Other PLC output-module options

Mechanical relay outputs

High-power DC outputs

AC solid-state relay output

Note

Chapter 13 Allen-Bradley RSLogix software and ladder-diagram programming

ROCKWELL/ALLEN-BRADLEY PLC SOFTWARE

FUNCTIONS WITHIN PLCS

Discrete control/combinational logic

Sequential control

Continuous control

RSLINX, BOOT-DHCP TOOL, AND ESTABLISHING COMMUNICATIONS

RSLinx

BOOTP-DHCP

UPLOADING/DOWNLOADING THE PROGRAM

RS LOGIX PROGRAMMING

TERMS USED WITH PLC LADDER LOGIC PROGRAMMING:

Rack

Rung

Instruction

Bit

Bits, bytes, and words

Hardwired inputs and outputs

Line-smart/page smart numbering

Address

Bitbox

Internal contacts and internal coils

INTERNAL CONTACTS—EXAMINE IF CLOSED (XIC)

INTERNAL CONTACTS—EXAMINE IF OPEN (XIO)

INTERNAL COILS—OUTPUT ENERGIZE (OTE)

OUTPUT LATCH (OTL)/ OUTPUT UNLATCH (OTU)

ONE-SHOT (ONS)/ONE-SHOT RISING (OSR)/ONE-SHOT FALLING (OSF)

TIMERS—ON-TIME DELAY (TON) and OFF-TIME DELAY (TOF)

COUNTERS—COUNT UP (CTU) AND (CTD)

SWITCH BOUNCE AND COUNTERS

ARITHMETIC FUNCTIONS AND STATUS FILE (S2)

Status file

ADDRESSING AND PLC OPERATION

PLC INPUT/OUTPUT DATA LINKS

THE PROGRAM SCAN

FLOW CHARTS AND PSEUDOCODE

ANTICIPATING PROBLEMS WITH PROGRAM LOGIC

DOCUMENTING THE RSLOGIX PROGRAM

SAFETY CONSIDERATIONS DURING PROGRAMMING

Notes

Chapter 14 Electronic 4–20mA analog signals

TWO-WIRE 4–20MA CURRENT LOOP TRANSMITTERS

DETERMINING THE POWER SUPPLY VOLTAGE

CREATING THE 4-20MA TRANSMITTER SIGNAL

GROUND LOOPS: GROUNDING AND ISOLATED INSTRUMENTS

HART COMMUNICATION PROTOCOL

SUMMARY

Chapter 15 Analog functions using Allen-Bradley’s RSLogix software

ANALOG INPUT AND OUTPUT

Signal input and transmission

Signal conversion to machine language

Signal processing

Output signal and transmission

GETTING THE SIGNAL INTO THE PLC

USING THE PLC’S ANALOG SIGNAL

SCALING THE ANALOG SIGNAL

PROBLEM 1: ANALOG-INPUT FOR A PRESSURE TRANSMITTER

PROBLEM 2: ANALOG-OUTPUT FOR A CONTROL VALVE

PROBLEM 3: ANALOG-OUTPUT FOR A VARIABLE FREQUENCY DRIVE (VFD)

PROGRAMMING ANALOG PROPORTIONAL-INTEGRAL-DERIVATIVE APPLICATIONS

SUBROUTINES: LADDER LOGIC RELATED TO COMPUTER PROGRAMMING

SUMMARY

Notes

Chapter 16 IEC 61131-3 PLC programming languages (LD, FBD, SFC, ST, and IF)

THE PROGRAM STRUCTURE

LADDER DIAGRAM (LD)

FUNCTION BLOCK DIAGRAM (FBD)

SEQUENTIAL FUNCTION CHART (SFC)

Program operation

STRUCTURED TEXT (ST)

INSTRUCTION LIST (IL)

Syntax

SUMMARY

Note

Chapter 17 Centralized control systems, DCS, and SCADA

PLANT CONTROL ARCHITECTURES

CENTRALIZED CONTROL AND MONITORING SYSTEM

CENTRALIZED CONTROL SYSTEM

DCS AND SCADA SYSTEMS

SCADA system components

Remote communications

Designing the automation and controls systems

Panel layout drawings

I&C plan & elevation drawings

Instrumentation & controls wiring diagrams

Instrumentation & controls schedules (I&C)

DCS and SCADA communications architecture

PLC wiring diagrams (Figures 17.17, 17.18, and 17.19)

SCADA system screens

Programming the HMI device

Security

Define:

Chapter 18 PLC cabling, data transmission, and networking

SENSOR/TRANSDUCER CABLING—SIGNAL, POWER, EMI/RFI, SHIELDING, AND GROUNDING

SCADA AND DCS CABLING AND DATA TRANSMISSION

CATEGORY 5 AND CATEGORY 6 ETHERNET TCP/IP CABLE

FIBER-OPTIC DATA-TRANSMISSION CABLING

NETWORKING ARRANGEMENTS

INDUSTRIAL NETWORK STANDARDS

Modbus, Profibus, Ethernet/IP

Modbus

Profibus

Notes

Chapter 19 Industrial control system security

SCADA SYSTEM

ICS NETWORKING ARCHITECTURE SECURITY

THREAT TYPES

THREAT-MITIGATION STRATEGIES

Physical access

Hardware

Computer, SCADA, and internet access practices

General PLC programming and operation practices

Chapter 20 PLC terms and definitions

PROGRAMMABLE LOGIC CONTROLLERS AND COMPUTERS

Address

Binary coded decimal (BCD)

Bit

Byte

Central processing unit (CPU)

Electrically erasable programmable read-only memory (EEPROM)

Erasable programmable read-only memory (EPROM)

Image register/image table

Index register

Millisecond

Operator interface

Random-access memory (RAM)

Read-only memory (ROM)

Register

Shift register

Word

PLC INPUT/OUTPUT

Analog input (A/I)

Analog output (A/O)

Analog-to-digital converter (A/D)

Digital-to-analog converter (D/A)

Distributed control system (DCS)

Input module

I/O points

Output module

SCADA (supervisory control and data acquisition)

Transducer

PLC PROGRAMMING

Expression

Function

Instruction

Procedure

Program

Programming device

Routine

Software

Statement

Subroutine

Syntax

PLC DATA TRANSFER

Bandwidth

Baud rate

Collision detection

Ethernet

Master-slave protocol (client-server)

Media-access control (MAC)

Modbus protocol

Modem

Network

Nodes

Packet

Parallel communication

Peer-to-peer network

Polling/Query

Port

Profibus DP

Protocol

RS485 (or TIA-485)

Serial communication

Socket

Supervisory control and data acquisition (SCADA)

Switch or switching hub

Token ring

Transmission control protocol/Internet protocol (TCP/IP)

Index

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Tags: Raymond F Gardner, Plant Automation, Controls