Design Patterns for Flexible Manufacturing

5190TSD4c4L......Page 1
Front Matter......Page 2
Acknowledgements......Page 4
Dedication......Page 5
List of Figures......Page 6
Index......Page 0
Table of Contents......Page 12
Preface......Page 15
1.2 Predictability......Page 16
1.3 Project Structure......Page 17
1.3.2 Cost-Plus Project......Page 18
1.3.3 Fixed-Cost (Lump-Sum) Project......Page 20
1.4.1 Preliminary: Identification......Page 21
1.4.2 Phase One: Investigation......Page 25
1.4.3 Phase Two: Execution......Page 28
1.4.4 Phase Three: Construct and Commission......Page 29
1.5 Project Deliverables......Page 31
1.5.5 DCS Selection/Familiarization......Page 32
1.5.12 I/O Configuration......Page 33
1.5.17 Instrument Elementary Wiring Diagrams and Loop Sheets......Page 34
1.5.19 Installation Details......Page 35
1.5.25 Redlines......Page 36
1.5.27 Project Wrap-up......Page 37
2. The Project Team......Page 38
2.1.1 Project Manager......Page 39
2.1.4 Construction Liaison......Page 40
2.2 The Designer......Page 41
2.3.2 E&I Field Engineer and Coordinator......Page 43
2.3.7 Instrument Electrical Foreman......Page 44
3.1 Scope of Work......Page 45
3.1.2 Clarifications......Page 46
3.1.3 Project Description......Page 47
3.1.4 General Execution Strategy......Page 48
3.2 Estimate......Page 50
3.3 Schedule......Page 51
3.4 Status Report......Page 52
4.1 Definition of Key Terms......Page 55
4.2 Accuracy......Page 56
4.3 Resolution Effects on Accuracy......Page 57
4.6 Linearization and Unit Conversions......Page 58
4.7 Practical Application......Page 62
5.1 Introduction to Information Management......Page 63
5.1.2 Database......Page 64
5.2.1 Document Management - Drawing List......Page 65
5.2.2 Device Management......Page 67
5.3.1 Definition of Key Terms......Page 69
5.3.3 Numbering Methods......Page 74
5.3.4 Handling the Numbers......Page 75
5.3.5 Inter-Cabinet Wiring......Page 76
5.3.6 Intra-Cabinet Wiring......Page 78
5.4 Failsafe Wiring Practice......Page 80
5.5.1 Hazardous Locations......Page 82
5.5.3 Intrinsic Safety......Page 85
5.5.4 Purging......Page 86
5.6.1 Discrete (Digital) Wiring......Page 87
5.6.2 Analog Wiring......Page 93
5.7 Design Practice Summary......Page 99
6.2 The Cognitive Cycle......Page 100
6.3 Control System Basics......Page 102
6.4 Process Control System......Page 103
6.4.1 Control Board......Page 104
6.4.2 Human-Machine Interface......Page 105
6.4.3 Process Controller - PLC versus DCS......Page 112
6.5 Programmable Logic Controller......Page 115
6.5.1 Major PLC Components......Page 116
6.5.2 PLC Program......Page 117
6.5.3 I/O Interface......Page 123
6.6.1 Optimized/Proprietary Protocol......Page 127
6.6.2 Optimized/Nonproprietary Protocols......Page 129
6.6.4 Wireless Local Area Network......Page 130
6.7.2 Project Flow......Page 131
6.7.3 Deliverables......Page 133
6.8 Specifying a PLC/HMI System......Page 134
7.2 Purpose......Page 136
7.3.1 Symbology (ISA-5.1-1984 and ISA-5.3-1983)......Page 137
7.3.2 Symbol Identification......Page 138
7.4.2 Tank Fill: HV-13, ZSC-13......Page 139
7.4.3 Tank Discharge: PP-10......Page 140
7.5 P&ID Summary......Page 141
8.1.4 Practical Application......Page 142
8.3 Pump and Equipment Specifications (Mechanical)......Page 144
8.4 Links Summary......Page 145
9.2 Control System Orientation......Page 146
9.3 Project Database Initialization......Page 149
9.3.1 Initialize Document Control Table......Page 151
9.3.2 Initialize Instrument and I/O List Table......Page 154
9.4.2 Devices Worksheet......Page 161
9.4.3 Count Worksheet......Page 165
9.4.4 Labor Worksheet......Page 168
9.4.5 Summary Worksheet......Page 169
9.4.6 Schedule Worksheet......Page 173
9.5 Preliminary Engineering Summary......Page 176
10.1 Division of Labor......Page 178
10.2 Review......Page 180
10.3 Develop a Control Logic Specification......Page 181
10.3.1 Stage 1: Control Overview......Page 182
10.3.2 Stage 2A: Sequential Function Chart......Page 183
10.3.3 Stage 2B: Continuous Function Chart......Page 186
10.3.4 Stage 2C: Control Narrative......Page 187
10.3.5 Stage 3A: Sequence Step Detail Sheet......Page 188
10.3.6 Stage 3B: Device Logic......Page 195
10.3.7 Stage 4: Logic Diagram......Page 199
10.3.8 SAMA Logic Diagram Standard......Page 208
10.3.9 Control Logic (Programming) Summary......Page 210
10.4 Operator Interface Specification Development - HMI......Page 211
10.6 Other Systems Integration Tasks......Page 223
10.7 Systems Integration Summary......Page 230
11.1 Document Control Table with Related Queries and Reports......Page 231
11.1.2 Order Drawings Query......Page 232
11.1.3 Transmittal Query......Page 233
11.2.1 Instrument and I/O List Table......Page 234
11.2.2 Preliminary Design Query......Page 235
11.2.4 PlanDwgTakeoffQuery Report......Page 236
11.2.5 X-Ref Document Cross-Reference Query......Page 237
11.2.6 X-Ref Document Cross-Reference Report......Page 238
12. Instrument Specifications......Page 240
12.1.2 Instrument Designer......Page 241
12.1.5 Maintenance......Page 242
12.3.1 LT/LSH-10......Page 243
12.3.2 PV-48......Page 244
12.4 Summary......Page 247
13.1.2 Physical Arrangement......Page 248
13.2.1 Environmental Issues......Page 249
13.2.2 Furniture and Equipment Arrangement......Page 250
13.3.1 Why Produce Instrument Location Plan Drawings?......Page 251
13.3.2 Anatomy of an Instrument Location Plan......Page 252
13.3.4 Drawing Production Technique......Page 253
13.3.5 Material Takeoff......Page 267
13.4 Instrument Installation Details......Page 270
13.4.1 Electrical Installation Details......Page 271
13.4.2 Tubing Details......Page 272
13.4.4 Database......Page 273
13.4.5 Material Takeoff......Page 274
13.5 Summary......Page 275
14. Instrument and Control Wiring......Page 276
14.1 Instrument Elementary (Ladder) Diagram......Page 278
14.1.1 Motor Elementaries......Page 281
14.1.2 AC Power Distribution......Page 283
14.1.3 DC Power Distribution......Page 284
14.1.4 PLC Ladder Diagram (Elementary)......Page 285
14.2 Loop Sheet (Ref: ANSI/ISA-5.4-1991)......Page 291
14.3.1 Junction Box JB-TK10-1: Initial Layout......Page 294
14.3.2 Termination Cabinet TC-2......Page 299
14.4 Wiring Summary......Page 307
15.1 Procedure......Page 315
15.2 Junction Box JB-TK10-01 Arrangement Drawing ARR-002......Page 316
15.2.2 Design the Panel......Page 317
15.2.3 Generate a Bill of Materials......Page 319
15.3 Summary......Page 320
16.1 Typical Purchasing Cycle......Page 322
16.3 Bulk Electrical Bill of Materials......Page 324
16.4 Bulk Mechanical Bill of Materials......Page 328
16.5 Procurement Summary......Page 334
17.2 Technical Content - Squad Check......Page 336
17.4 Design Check Summary......Page 337
18.1 Construction Support......Page 339
18.4 Phase III Summary......Page 341