Process software and digital networks : Volume III

INSTRUMENT ENGINEERS’ HANDBOOK

Fourth Edition

Process

Software

and Digital

Networks

VOLUME III

LIPTÁK

ErEn Digital Networks Process Software and FOURTH EDITON

BÉLA G. LIPTÁK, Editor-in-Chief

HALIT ErEn, Volume Editor

ISBN: 978-1-4398-1776-6

9 781439 817766

90000

K10922

K10922_ISBN_Sticker.indd 1 7/13/11 11:50 AM

Process

Software

and Digital

Networks

VOLUME III

I N S T R U M E N T E N G I N E E R S ’ H A N D B O O K

Fourth Edition

I N S T R U M E N T E N G I N E E R S ’ H A N D B O O K

Fourth Edition

Process

Software

and Digital

Networks

VOLUME III

Béla G. liPták, Editor-in-Chief

Halit ErEN, Volume Editor

MATLAB® is a trademark of The MathWorks, Inc. and is used with permission. The MathWorks does not warrant the accuracy of the text or exercises in

this book. This book’s use or discussion of MATLAB® software or related products does not constitute endorsement or sponsorship by The MathWorks

of a particular pedagogical approach or particular use of the MATLAB® software.

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© 2012 by Béla Lipták

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Dedicated to our colleagues and to our profession of automation engineering. It is hoped

that by applying the knowledge found on these pages, we will make our industries more

efficient, safer, and cleaner, and thereby will not only contribute to a happier future for

all mankind, but will also advance the recognition and respectability of our profession.

Béla Lipták (http://belaliptakpe.com/)

ix

C O N T E N T S

Preface xiii

Acknowledgments xxiii

Contributors xxv

Definitions xxix

Abbreviations xlix

Organizations lix

1 Process Control and Automation 1

1 Distributed Control Systems and Process Plants 5

Mark Nixon

2 Networks in Process Automation: Hardware Structures and Integration of Process

Variables into Networks 40

Peter G. Berrie and Klaus-Peter Lindner

3 Instrumentation in Processes and Automation 72

Donald Chmielewski and Miguel J. Bagajewicz

4 Programmable Logic Controllers 90

Sujata Agashe and Sudhir D. Agashe

5 SCADA—Supervisory Control and Data Acquisition System and an Example 101

Hiten A. Dalal

6 Intelligent Instruments and Sensors: Architecture, Software, Networks,

Protocols, and Standards 130

Deniz Gurkan and Halit Eren

7 Calibrations in Process Control 141

Halit Eren

8 Standards in Process Control and Automation 150

Halit Eren

9 Automation and Robotics in Processes 158

Arif Sirinterlikci, Arzu Karaman, and Oksan Imamog`lu

2 Process-Control Methods 169

10 Batch-Process Automation 172

Asish Ghosh

x Contents

11 Plant-Wide Controller Performance Monitoring 200

Chris McNabb

12 Plant Optimization 228

Michael Ruel

13 Neural Networks in Process and Automation 254

R. Russell Rhinehart

14 Fuzzy Logic Control in Processes and Automation 265

R. Russell Rhinehart

15 Internet in Automation and Process Control Systems 275

Babu Joseph and Deepak Srinivasagupta

16 Telemetry Systems: Phone, Radio, Cellular, and Satellite 284

Curt W. Wendt

3 Digital Techniques and Data Handling 301

17 Digital Technology Fundamentals, Microcontrollers, Microcomputers,

and FPGAs in Processes 303

Cesar Ortega-Sanchez

18 Signal Processing in Process Control and Automation 313

Emre Deniz Eren and Halit Eren

19 Data Acquisition Fundamentals 330

David Potter and Halit Eren

20 Analog and Digital Signal Transmission in Processes: Protocols and Standards 342

Ian H. Gibson

21 Data Acquisition: Buses, Networks, Software, and Data Handling 351

David Potter

22 Data Reconciliation and Software Methods for Bias Detection 364

Miguel J. Bagajewicz and SR Derrick K. Rollins

4 Software, Programming, and Simulations 383

23 Software Fundamentals 385

Halit Eren

24 Virtual Plants: Process Simulation and Emulation 391

Hironori Hibino

25 Virtual Reality Tools for Testing Control Room Concepts 406

Asgeir Droivoldsmo and Michael Louka

26 Model-Free Adaptive Control Software 415

George S. Cheng and Steven L. Mulkey

27 Operation Optimization with Sequential Empirical Optimization

and Software Implementation 438

Carlos W. Moreno

28 Data Historian 454

Irena Yee and Halit Eren

Contents xi

5 Networks, Security, and Protection 461

29 Computer Networks: LANs, MANs, WANs, and Wireless 465

Hura Gurdeep

30 Internet Fundamentals and Cyber Security Management 484

Hura Gurdeep

31 Network Security, Threats, Authentication, Authorization, and Securing Devices 506

Wenbin Luo

32 VPN, CCN, and IT Support 517

Burhan Basaran and Cengiz Burnaz

33 Fiber-Optic Network Components 525

Jin Wei Tioh, Mani Mina, Robert J. Weber, and Arun K. Somani

34 Fiber-Optic Communications and Networks 546

Martin Maier

35 Network Access Protection 565

Dinesh C. Verma

36 Comments on Cyber Security in Industrial Control Systems and Automation 571

Jacob Brodsky and Joseph Weiss

6 Fieldbus Networks 575

37 Fieldbuses 578

Lucia Seno and Stefano Vitturi

38 HART Networks 587

David S. Nyce

39 Foundation Fieldbus: Features and Software Support 598

Salvatore Cavalieri

40 PROFIBUS Networks 616

Peter G. Berrie and Jochen Müller

41 Industrial Ethernet and TCP/IP-Based Systems 636

Gianluca Cena, Stefano Scanzio, Stefano Vitturi, and Claudio Zunino

42 Niche Fieldbus Networks 654

Lucia Seno and Stefano Vitturi

7 Process Management, Maintenance, Safety,

and Reliability 671

43 Network Security Awareness, Management, and Risk Analysis 674

Helen Armstrong

44 Manufacturing Execution Systems 689

Zameer Patel

45 Auditing and Upgrading Plants, Control Rooms, and Networks 698

Bridget A. Fitzpatrick

46 Hazardous Areas: Classifications, Equipment, Purging, and Management 706

David S. Nyce

xii Contents

47 Safety in Processes: Rules, Standards, Certification, Culture, and Management 716

Asish Ghosh

48 Reliability, Redundancy, and Voting Systems 736

William Goble

49 Computerized Maintenance and Maintenance Management 746

Pete Peter W. Ralph

8 Process Control and Automation Applications 757

50 Manufacturing, Plant, and Production Management: Applied in Automobile

Industry 762

Paulina Golinska and Marek Fertsch

51 Control Systems and Automation in Steel Thixoforming Production 781

Ahmed Rassili and Dirk Fischer

52 Processes and Automation in Dairy Industry 797

Sudhir D. Agashe and Sujata Agashe

53 Software for Pharmaceutical Automation 803

George C. Buckbee

54 Process Automation in the Automotive Industry 809

Vivek Hajarnavis

55 Mine-Wide SCADA System 821

Erik Bartsch

56 Application of Artificial Intelligence and Fuzzy Logic in Mineral Processing:

Hydrocyclones 840

Kok Wai Wong and Halit Eren

57 Computer Control in Mining and Extractive Metallurgy 847

Greg Baiden and Sirkka-Liisa Jämsä-Jounela

58 Telemetry Control and Management of Water Treatment Plants 858

Curt W. Wendt

59 Design and Implementation of a Safe and Reliable Instrumentation

and Control System in Oil and Gas Industry 870

Harvindar S. Gambhir

60 Power Network Security 880

Nian Liu

61 Nuclear Plant Instrumentation and Control System Performance Monitoring 903

Hashem M. Hashemian

62 Alternative Energy I: Control Software Needs of Renewable Energy Processes 919

Béla Lipták

63 Alternative Energy II—SCADA System for Thermal Power Plant 930

Mihai Iacob, Gheorghe-Daniel Andreescu, and Nicolae Muntean

64 Alternative Energy III—Wind Energy 940

Gordon Smith

Appendix 951

A.1 International System of Units 953

A.2 Engineering Conversion Factors 963

Contents xiii

A.3 Chemical Resistance of Materials 985

A.4 Composition of Metallic and Other Materials 993

A.5 Steam and Water Tables 997

A.6 Friction Loss in Pipes 1005

A.7 Tank Volumes 1013

A.8 Partial List of Suppliers 1017

xiii

P R E F A C E

I thank Dr. Halit Eren for his fine work in editing the fourth

edition of the third volume of the Instrument Engineers’

Handbook (IEH). I also thank his daughter, Pelin Eren and

colleague Cesar Ortega-Sanchez, who assisted him in this

major task, as well as the coauthors of this volume for their

valuable contributions.

This edition covers the software and the digital networks

that are used to monitor, control, and automate the vari￾ous industrial and nonindustrial processes. As to the other

volumes of the three-volume IEH set, the fourth edition of

Volume 1 covered measurement and analysis, while Volume

2 dealt with control and optimization. Now, when the fourth

updating edition of all three volumes is completed and is

available in both printed and electronic forms, we will start

working on the fifth edition of IEH.

Each updated edition of the three IEH volumes requires

about a decade to prepare, so the fifth edition is expected to

be completed only by 2020. We will start that effort by first

updating Volume 1, which should be completed in about 3

years (in 2014). If you or one of your colleagues is knowl￾edgeable about a sensor or an analyzer and would like to con￾tribute to this fifth edition of Volume 1 by either updating

an existing chapter or by preparing a new one that would

describe an instrument that did not exist 10 years ago, please

contact me at [email protected], http://belaliptakpe.com//.

After some comments by the volume editor, Dr. Halit

Eren, I will tell you about the birth of IEH and will share

with you some observations concerning the present state of

our profession and its future goals.

NOTES BY THE EDITOR OF THIS VOLUME

This volume provides an in-depth, state-of-the-art review of

control software packages that are used in plant optimization,

control, maintenance, and safety. Automation and control

systems are evolving rapidly with more and more applica￾tions of intelligent instruments, enhanced networks, use of

the Internet, virtual private networks, and integration of con￾trol systems with the main networks used by management,

all of which operate in a global environment. This holistic

approach is convenient and efficient, but it also introduces

cyber and local network security problems that need to be

addressed by effective technical solutions and proper man￾agement policies and practices.

Conventional control networks, such as fieldbuses, do not

operate as stand-alone and isolated entities. They are—or if

not already can be made—a part of a larger network through

the use of virtual networks. If given permission or access,

they can be controlled and operated by anyone anywhere in

the world. This volume highlights the technological, man￾agement, and cultural aspects of network security.

Nowadays, almost every device is software driven. Some

single chips comply with international standards, contain

memory and intelligence, and are often embedded in the

manufactured products. This introduces network security

problems.

This volume is organized in eight parts, each containing

a number of related chapters. Part I discusses SCADA and

PLC systems that are still at the heart of industrial control.

Process automation–related national and international stan￾dards are also discussed together with topics like calibration.

Part II covers software used in the automation and optimiza￾tion of batch and continuous processes. It also covers arti￾ficial intelligence, the Internet, and telemetric operations.

Part III focuses on digital systems and describes the funda￾mentals of signal processing, data acquisition, data handling,

signal transmission, data reconciliation, and bias detec￾tion techniques used in digital hardware. Part IV explains

the fundamentals of software used in process simulations,

control room design, and virtual reality. In addition, model￾free adaptive control and optimization are also discussed.

Part V discusses networks and network security as part of

the World Wide Web. It also covers virtual networks and

the fundamentals of Internet access protection and security

from a technological, organizational, and cyber attack point

of view. Part VI focuses on fieldbuses and on wireless tech￾nology used in the form of LAN, WAN, or satellite systems.

In addition to HART, Foundation Fieldbus, Profibus, and the

industrial Ethernet are also discussed. Part VII covers the

xiv Preface

use of networks as used by managers to make economic and

financial decisions as well as production planning, mainte￾nance, etc. It also covers network security from a managerial

point of view and discusses MES, CMMS, reliability, redun￾dancy, and voting systems. Part VIII gives 15 examples of

software applications from a number of industries, including

automobile, mining, renewable energy, steel, dairy, pharma￾ceutical, mineral processing, oil, gas, electric power, utility,

and nuclear industries.

HISTORY OF IEH

In 1956, as a 20-year-old university student in Hungary, I was

one of the freedom fighters who tried to end Soviet occupation.

Our efforts were similar to the fight to liberate America in the

war between 1775 and 1781. The difference was that George

Washington won, while Imre Nagy was hanged and 3% of

the Hungarians—mostly well-educated young people—were

either killed or became refugees. I was one of them.

My first job in America was to work for Sam Russel, who,

during World War II, led the effort to develop a synthetic rub￾ber industry after the Japanese cut off our natural rubber sup￾ply from Indonesia. By the end of the war, American trucks

were rolling on synthetic rubber tires and Sam was already

thinking about starting an engineering design firm (C&R)

with the goal of developing a plastics industry. In the late

1950s, he hired me to work for him as an instrument engineer

in a department that, at that time, had only three engineers.

I tried to learn all that was available in this new profes￾sion of automation. I read all there was to read, attended

every conference, and in a couple of years knew a lot about

stuff like frequency domain analysis. As to practical knowl￾edge of measurement and control, I had to learn on my own

or from people like Greg Shinsky and Donald Eckman.

One day, Sam Russel asked me if I would take over our

fast-growing instrument department. I said that at the age of

25 and with my thick Hungarian accent I would not be able

to lead experienced engineers twice my age. I volunteered

instead to accept his offer only if I could hire the best grad￾uates from the best universities and if Sam allowed me to

teach them. This I proposed to do by taking every Friday and

instead of working on the jobs, I would teach them the pro￾fession and bring them “up to speed” that way. He said OK.

Later in the early 1960s, Nick Groonewelt—a Dutch

American who still parted his hair in the middle and was run￾ning a publishing company—visited my office and noted the

tall piles of paper on my desk. “What are these?” he asked.

“My Friday notes, which I teach from,” I replied. “Why don’t

you use a handbook of your profession?” he asked. “Because

there is none that is any good!” was my reply. “Well, let’s

publish these Friday notes then!” And this is how the IEH

was born.

In preparing the first edition that was published in 1969,

I asked the Nobel laurate Edward Teller to write a preface for

it. “Why should I? I know nothing about your profession!” he

replied. “Because everybody knows that you are Hungarian

and I want the readers to know that the IEH is a Hungarian

contribution to American science!” I said. Ede bácsi (uncle

Edward) went to the library, spent a whole weekend there, and

wrote a preface that turned out to be much better than this one.

AUTOMATION AND CONTROL ENGINEERING

Ours is a very young profession. Compared to other fields

of engineering, we were way behind. When the first edition

of the IEH was published, Marks’ Mechanical Engineers’

Handbook was in its fifth edition and Perry’s Chemical

Engineers’ Handbook was in its sixth edition! It is partially

for this reason that people are more aware of what a mechani￾cal engineer or a chemical engineer does, whereas they have

no idea what we do. When I say that my field is process con￾trol or instrumentation, all I get is a blank stare.

It is time for us to change that. The first step would be to

use a name for our profession that people understand, such as

“automation.” It is also time for our profession to develop a

distinct identity.

When I was teaching at Yale University, my course was

offered under the chemical engineering department. This

was not because Yale had anything against our profession,

but because they did not even know that it exists. Even this

handbook provides an example as to the confusion about our

identity, because CRC/Taylor & Francis Group will be pub￾lishing this handbook in their electrical engineering series.

Once again, this is not due to any bias against our profession,

but rather it reflects our failure to develop a distinct identity!

“Automation” is a term that the wider public understands,

and I am glad that ISA changed its name to International

Society of Automation (ISA).

DEVELOPMENTS OVER THE LAST DECADES

These days, computers are our main tools of control, and it

is the software that makes computers useful. The chapters

of this volume describe how computers are being used in

optimizing our processes, providing self-diagnostics, and

displaying status information in operator-friendly formats.

Today, we can fully automate the safety of our processes, we

can eliminate the need for manual actions by panicked opera￾tors following the instructions of greedy management, and

thereby we can prevent oil spills, nuclear accidents, and the

use of our air and waters as garbage dumps.

During the last decade, the artificial separation between

the plant’s control, logic, and business needs has disappeared

and have gradually been integrated. The operating software

of the future will support all needs of a process; not only will

digital networks become wireless, digital bus protocols will

also become the same around the world, eliminating the need

for interfacing and the associated risk of mix-up, not to men￾tion the creation of captive markets. This situation is being