Process Control Systems Engineering

Transcription

1 This text book contributes by focussing on PCS engineering basics that are common to the different domains of the process industries. The examples and exercises are related to an experimental research plant used to investigate the interaction between process modularization and process automation methods in the process industries. This makes it possible to capture features of highly specialized and integrated mono-product plants (e.g. chemicals) as well as application areas which are dominated by locally standardized general-purpose apparatus and multi-product schemes (bio-chemistry, pharma). While the theory we present is applicable for all of the PCS of the different established vendors, the examples as well as most of the screen shots refer to PCS 7, Siemens control system for the process industries. Focusing on a single PCS makes it possible to use this text book not only in basic lectures on PCS Engineering but also in computer lab courses that offer students hands-on experience. Leon Urbas Process Control Systems (PCS) are distributed control systems (DCS) that are specialized to meet the requirements of the process industries. Many of the processes and plants involved have high safety and availability requirements, are instrumented with a large number of sensors and actuators and show a high degree of automation, at least in standard operation regimes. There are remarkable differences and cross-discipline interdependencies between chemical-physical properties of the substances, procedures, unit operations, equipment, instrumentation and control strategies, so that hardly any two plants are identical, even if the products are interchangeable. As a consequence, it is argued that each domain of the process industries, namely chemicals, pharma, pulp & paper, oil & gas, food & beverages and water/waste water treatment should have its own specialized automation system. However, others argue that PCS architectures that address all of the distinct requirements of the process industries should be generic enough to render the distinction between PCS and, for example, DCS for power generation and distribution a merely marketing or historical issue, not a technical one. Leon Urbas Process Control Systems Engineering Process Control Systems Engineering Process Control Systems Engineering ISBN Oldenbourg Industrieverlag GmbH Oldenbourg Industrieverlag GmbH

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3 Bibliografische Information der Deutschen Nationalbibliothek Die Deutsche Nationalbibliothek verzeichnet diese Publikation in der Deutschen Nationalbibliografie; detaillierte bibliografische Daten sind im Internet über abrufbar Oldenbourg Industrieverlag GmbH Rosenheimer Straße 145, D München Telefon: (089) Das Werk ist urheberrechtlich geschützt. Jede Verwertung außerhalb der Grenzen des Urheberrechtsgesetzes ist ohne Zustimmung des Verlages unzulässig und strafbar. Das gilt insbesondere für Vervielfältigungen, Übersetzungen, Mikroverfilmungen und die Einspeicherung und Bearbeitung in elektronischen Systemen. Projektleitung: Anne Hütter Herstellung: Annika Böning Titelgrafik: Siemens AG [2012] Satz: Schmidt Media Design, München Druck/Bindung: Druckerei Chmielorz GmbH, Wiesbaden Gedruckt auf säure- und chlorfreiem Papier ISBN

4 Process Control Systems Engineering Leon Urbas supported by Annett Krause Jens Ziegler Oldenbourg Industrieverlag GmbH

5 E20001-F90-P260-V Applicable practical know-how Comprehensive teaching support for educational institutions Siemens Automation Cooperates with Education Siemens Automation Cooperates with Education (SCE) focuses on the needs of the students by providing educators the tools and training to build confidence and applied expertise. The SCE program delivers value to learning institutions with instructor training, learning curriculum and exceptional hardware and software Trainer Packages. Through partnerships we are driven to share knowledge, resources and tools for teaching automation and drive system technologies. Scan the QR code for further information. siemens.com/sce

6 Inhalt Inhalt Process Control Systems Engineering... 1 Acknowledgments Introduction Structure How to read this book References PCS Requirements Overview Process Industries Chemicals Pharmaceuticals Oil & Gas Water/Waste Water Pulp & Paper Food & Beverage Summary Cross Domain Concepts Unit Operations of Chemical Engineering Batch Processes Continuous Processes Risk Reduction by process automation Human Supervisory Control Distributed Control System Architectures References PCS Engineering Overview Plant Engineering Projects Project Management Procedural models of PCS Engineering PPEAM Process Plant Engineering Activity Model PAS 1059: Processing plant design Procedural model and terminology NA 35: Handling PCT Projects Preliminary Engineering Plant Concept and PCS Concept V

7 Inhalt Cost Estimation PCS System Selection Basic and Detail PCS Engineering Future Directions Formal models of engineering workflows Information exchange Automation of PCS Engineering tasks References Modular Engineering Research Plant Process Description Reactor Instrumentation Piping and Instrumentation Diagram Identification System Process Control Requests PCT Cause and Effect Matrix References Process Control System Architecture Overview Distributed Architecture Process Control Station Cyclic Execution and Process Image I/O modules Hardware Configuration for the MEAR plant Setting up a PCS 7 project Configuring the AS Configuring the remote I/O Configuring the Operator Station Check and compile the network References Industrial Communications Engineering Overview Industrial Communication on Field Level Conventional wiring Digital fieldbus Fieldbus Engineering Industrial Communications with MES and ERP VI

8 Inhalt OPC Configuring the PCS 7 OPC-server Future Directions Preliminary Fieldbus Engineering References Bulk Engineering Overview General structuring principles Plant Hierarchy Structuring Rules Functional structure of the MEAR plant PCS Plant Hierarchy HMI generation AS-OS Assignment Batch recipes Bulk Engineering Process tag types and models Process tag type Model Parameters and Signals Process Object View MEAR plant example for a process tag type MEAR plant example for a model Literature Individual Drive Functions Overview IDF Basic Concepts Function Block Types in PCS Safety Provisions Operating Modes Predefined IDF for Field Devices Channel Functions (Drivers) An IDF template from the library Excercise: Define Process Tag Type Literature VII

9 Inhalt 9 Continuous Feedback Control Overview Theory Introduction Industrial Suitability of Controllers Expanded Control Structures Connecting to the Process Exercise: Implementing a continuous control loop References Sequential Control Overview Continuous and sequential control Structure of Step Sequences Design of Sequence Controls Interaction of Sequence Controls and Logic Control Systems Protection Functions and Operating Modes in Sequence Controls Sequence Controls in PCS Excersize: Filling of a reactor References Batch Control with Recipes Overview Recipes Hierarchical Modelling of procedures, processes and plants Process Model Procedural Model Physical Model Monitoring, Archiving and Reporting Recipe Engineering Batch control with PCS Instanciation of Software Components Modeling activities Definition of a master recipe Creation and Starting of a batch References VIII

10 Inhalt 12 Human Machine Interaction with Process Displays Overview Objectives of Process Management Task and Information Decomposition HMI design Concepts of Representation Representation Techniques Trend Displays HMI Generation in PCS Configuring the Service Interface in PCS Configuring the Process Displays in PCS Setting up the elementary HMI displays for the MEAR plant Engineering System set up Preparation for OS generation OS Generation OS Editing Integrated Faceplates Future Directions Model Driven HMI Engineering autohmi References Alarm Engineering Overview Signalling Systems Alarms and Indications Alarm Processing by the Operator Alarm Management in PCS References IX

11 E20001-F223-P280-X-7600 Performance you trust SIMATIC PCS 7: the process control system where operational excellence is the standard Process Automation Harmonious interaction between expertise and automation is a fundamental prerequisite for the efficient operation of every industrial plant. Another key prerequisite? A process control system offering performance that leaves nothing to be desired. This is an area where SIMATIC PCS 7 excels, offering tremendous opportunities to optimize the potential of your plant over the entire life cycle: with everything from transparent process control to product quality monitoring, performance figures and consistent process optimization. The advantage? Greater process flexibility as well as higher plant availability and investment confidence. Don t leave things to chance when it comes to efficiency, throughput and yield. Trust in performance that helps you get the maximum out of your plant SIMATIC PCS 7. siemens.com/simatic-pcs7

12 Process Control Systems Engineering Process Control Systems Engineering Prof. Leon Urbas Prof. Leon Urbas (VDI/VDE GMA, NAMUR, VDI-GVC DECHEMA Process- Net, GI, GK) holds the Chair for Distributed Control Systems Engineering at Technische Universität Dresden. His research interests include process control system architectures, human-centred automation, human-machine-interaction in the control room and on the shop floor, applied human performance modelling, usability engineering and systems and workflows for integrated process control systems engineering. After studying information and automation systems engineeringand obtaining a PhD in operator training simulation, he gained three years professional experience in engineering automation and process information systems at a leading fine chemicals company. He then returned to university to set up a cognitive user modelling group which successfully developed tools and methods for lowering the barriers to performing solid cognitive user modelling. From 2004 until 2006 he was spokesman of the prometei PhD Research Training Group prometei which investigates new methods for the prospective design of humanmachine-systems. Since 2006, Prof. Urbas and his team have been transferring basic research results in the areas of human factors and information modelling into industrial process automation. Leon Urbas is spokesman of the GMA working group FA 5.16 Middleware in Industrial Automation, member of the board of the ProcessNet working group process, plant and apparatus technologies (PAAT) and editor-in-chief of the scientific journal atp edition Automatisierungstechnische Praxis. 1

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14 Acknowledgments Acknowledgements Over the past decade, I have had the privilege of access to several research networks and industrial experts alike. The fields with which I have affiliation as a result include chemical process design, optimization and operation, chemical process modelling, process and control engineering, automation theory, instrumentation and control, cognitive science, human factors, human performance modelling, usability engineering, industrial process communications, computer aided engineering, functional safety, computer architectures, middleware in industrial automation, information and business process modelling and semantic web computer science, to name only the most visible ones. All these areas of expertise contribute to effective and efficient engineering of process control systems. Instead of providing a lengthy and incomplete list of thanks to all the people in those international networks I have worked with and from whom I have learnt, I hope that a collective word of thanks will be accepted and the list of references works to provide recognition. This book would not have been written without the initiative of Roland Scheuerer, Siemens SCE, who convinced me of the value of another text book on PCS engineering education. The unique concept of the book which combines both system independent theory and system specific practice is the result of intensive discussions and applied research projects on teaching and training concepts for PCS engineering. I am also grateful to his assistant Sabine Stengel for her support in last minute administrative issues. Furthermore, I want to express my thanks to Anne Hütter, Oldenbourg Industrie Verlag, who supported me to get things done almost in time. The following persons were of invaluable assistance by discussing concepts and reviewing one or more of the chapters of the text book: Falk Doherr, Markus Graube, Richard Holmes, Annett Krause, Wolfgang Morr, Michael Obst, and Jens Ziegler. Many thanks to the members of the Chair for Process Control Systems Engineering who contributed significantly to this text book by editing my lectures at TU Dresden for the SCE project PCS 7 Training Modules for Universities. "" Chapter 8 Individual Drive Functions Jens Ziegler "" Chapter 9 Continous Control Loops Annett Krause "" Chapter 10 Sequential Control Loops Jens Ziegler "" Chapter 13 Alarm Engineering Jens Ziegler Last, but not least, I wish to thank my wife, Petra, for her love and all the support she has given through all of these years. 3

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