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Leon Urbas

Process ControlSystems Engineering

Leon

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OldenbOurg IndustrIeverlag gmbH www.oldenbourg-industrieverlag.de

Process Control Systems Engineering

Process Control Systems (PCS) are distributed control systems (DCS) that are spe-cialized to meet the requirements of the process industries. Many of the processes and plants involved have high safety and availability requirements, are instrumen-ted with a large number of sensors and actuators and show a high degree of auto-mation, 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 con-trol 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 sys-tem. However, others argue that PCS architectures that address all of the distinct requirements of the process industries should be generic enough to render the di-stinction between PCS and, for example, DCS for power generation and distribution a merely marketing or historical issue, not a technical one.

This text book contributes by focussing on PCS engineering basics that are com-mon 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 inte-grated 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.

ISBN 978-3-8356-3198-4

OldenbOurg IndustrIeverlag gmbH www.oldenbourg-industrieverlag.de

Bibliografische Information der Deutschen Nationalbibliothek

Die Deutsche Nationalbibliothek verzeichnet diese Publikation in der Deutschen Nationalbibliografie; detaillierte bibliografische Daten sind im Internet über http://dnb.d-db.de abrufbar.

© 2012 Oldenbourg Industrieverlag GmbHRosenheimer Straße 145, D-81671 MünchenTelefon: (089) 45051-0www.oldenbourg-industrieverlag.de

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 HütterHerstellung: Annika BöningTitelgrafik: Siemens AG [2012]Satz: Schmidt Media Design, MünchenDruck/Bindung: Druckerei Chmielorz GmbH, WiesbadenGedruckt auf säure- und chlorfreiem Papier

ISBN 978-3-8356-3198-4

Process ControlSystems Engineering

Leon Urbas

supported by

Annett Krause Jens Ziegler

OldenbOurg IndustrIeverlag gmbH www.oldenbourg-industrieverlag.de

E20001-F90-P260-V1-7600

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, learn-ing 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.

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Inhalt

Process Control Systems Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.2 How to read this book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61.3 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 PCS Requirements� . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112.2 Process Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.2.1 Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122.2.2 Pharmaceuticals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.2.3 Oil & Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132.2.4 Water/Waste Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.2.5 Pulp & Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.2.6 Food & Beverage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142.3 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.4 Cross Domain Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.4.1 Unit Operations of Chemical Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.4.2 Batch Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172.4.3 Continuous Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182.4.4 Risk Reduction by process automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182.4.5 Human Supervisory Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222.4.6 Distributed Control System Architectures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242.5 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3 PCS Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293.2 Plant Engineering Projects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293.2.1 Project Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303.3 Procedural models of PCS Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323.3.1 PPEAM – Process Plant Engineering Activity Model . . . . . . . . . . . . . . . . . . . 333.3.2 PAS 1059: Processing plant design – Procedural model and terminology . . . . 353.3.3 NA 35: Handling PCT Projects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353.4 Preliminary Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383.4.1 Plant Concept and PCS Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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3.4.2 Cost Estimation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393.4.3 PCS System Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413.5 Basic and Detail PCS Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433.6 Future Directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433.6.1 Formal models of engineering workflows . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433.6.2 Information exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443.6.3 Automation of PCS Engineering tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453.7 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4 Modular Engineering Res�earch Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.1 Process Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494.1.1 Reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504.2 Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524.2.1 Piping and Instrumentation Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524.2.2 Identification System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534.2.3 Process Control Requests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534.2.4 PCT Cause and Effect Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564.3 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5 Proces�s� Control Sys�tem Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

5.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595.2 Distributed Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605.3 Process Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615.3.1 Cyclic Execution and Process Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625.4 I/O modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645.5 Hardware Configuration for the MEAR plant . . . . . . . . . . . . . . . . . . . . . . . . . 655.5.1 Setting up a PCS 7 project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675.5.2 Configuring the AS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 685.5.3 Configuring the remote I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 695.5.4 Configuring the Operator Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705.5.5 Check and compile the network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705.6 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

6 Indus�trial Communications� Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

6.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 736.2 Industrial Communication on Field Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746.2.1 Conventional wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 756.2.2 Digital fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 766.2.3 Fieldbus Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 776.3 Industrial Communications with MES and ERP . . . . . . . . . . . . . . . . . . . . . . . 78

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6.3.1 OPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 796.3.2 Configuring the PCS 7 OPC-server . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 836.4 Future Directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 836.4.1 Preliminary Fieldbus Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 836.5 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

7 Bulk Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

7.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 897.2 General structuring principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907.3 Plant Hierarchy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 917.3.1 Structuring Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 927.3.2 Functional structure of the MEAR plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 937.4 PCS Plant Hierarchy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 937.4.1 HMI generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947.4.2 AS-OS Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947.4.3 Batch recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 957.5 Bulk Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 957.5.1 Process tag types and models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 967.5.2 Process tag type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 977.5.3 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 987.5.4 Parameters and Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 997.5.5 Process Object View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1007.6 MEAR plant example for a process tag type . . . . . . . . . . . . . . . . . . . . . . . . . 1017.7 MEAR plant example for a model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1037.8 Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

8 Individual Drive Functions� . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

8.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1058.2 IDF Basic Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1068.2.1 Function Block Types in PCS 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1068.2.2 Safety Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1068.2.3 Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1088.3 Predefined IDF for Field Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1088.4 Channel Functions (Drivers)� . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1118.5 An IDF template from the library . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1118.5.1 Excercise: Define Process Tag Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1128.6 Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

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9 Continuous� Feedback Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

9.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1179.2 Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1189.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1189.2.2 Industrial Suitability of Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1199.2.3 Expanded Control Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1209.2.4 Connecting to the Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1229.3 Exercise: Implementing a continuous control loop . . . . . . . . . . . . . . . . . . . . 1249.4 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

10 Sequential Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

10.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12710.1.1 Continuous and sequential control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12810.1.2 Structure of Step Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12810.1.4 Design of Sequence Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13210.1.5 Interaction of Sequence Controls and

Logic Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13310.1.6 Protection Functions and Operating Modes in Sequence Controls . . . . . . . 13310.1.7 Sequence Controls in PCS 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13410.2 Excersize: Filling of a reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13610.3 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

11 Batch Control with Recipes� . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

11.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14111.2 Recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14211.3 Hierarchical Modelling of procedures, processes and plants . . . . . . . . . . . . 14411.4 Process Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14511.5 Procedural Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14511.6 Physical Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14811.7 Monitoring, Archiving and Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15211.8 Recipe Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15211.9 Batch control with PCS 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15411.9.1 Instanciation of Software Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15411.9.2 Modeling activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15411.9.3 Definition of a master recipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15811.9.4 Creation and Starting of a batch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15911.10 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Inhalt

IX

12 Human Machine Interaction with Proces�s� Dis�plays� . . . . . . . . . . . . . . . . . . 163

12.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16312.2 Objectives of Process Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16412.3 Task and Information Decomposition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16512.4 HMI design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16612.4.1 Concepts of Representation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16712.4.2 Representation Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16912.4.3 Trend Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17112.5 HMI Generation in PCS 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17412.5.1 Configuring the Service Interface in PCS 7 . . . . . . . . . . . . . . . . . . . . . . . . . . 17512.5.2 Configuring the Process Displays in PCS 7 . . . . . . . . . . . . . . . . . . . . . . . . . . 17512.6 Setting up the elementary HMI displays for the MEAR plant . . . . . . . . . . . . 17612.6.1 Engineering System set up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17612.6.2 Preparation for OS generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17612.6.3 OS Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17712.6.4 OS Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17812.6.5 Integrated Faceplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18012.7 Future Directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18212.7.1 Model Driven HMI Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18212.7.2 autoHMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18412.8 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

13 Alarm Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

13.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18713.2 Signalling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18813.2.1 Alarms and Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19013.2.2 Alarm Processing by the Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19113.3 Alarm Management in PCS 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19413.4 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

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1

Proces�s� Control Sys�tems� Engineering

Proces�s� Control Sys�tems� 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 model-ling, usability engineering and systems and workflows for integrated process control systems engineering.

After studying information and automation systems engineeringand obtain-ing 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 cog-nitive 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 human-machine-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 work-ing 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 – Automa-tisierungstechnische Praxis.

3

Acknowledgments�

Acknowledgements�

Over the past decade, I have had the privilege of access to several research net-works 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, instru-mentation 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 seman-tic web computer science, to name only the most visible ones. All these areas of expertise contribute to effective and efficient engineering of process control sys-tems. 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 sup-ported 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.