ISA MNG INDST CNTRLS-2014 Managing Industrial Controls.pdf

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1、Managing Industrial ControlsBattikha-MIC-2014.book Page i Thursday, September 12, 2013 10:09 PMBattikha-MIC-2014.book Page ii Thursday, September 12, 2013 10:09 PMManaging Industrial ControlsN. E. BattikhaBattikha-MIC-2014.book Page iii Thursday, September 12, 2013 10:09 PMNoticeThe information pres

2、ented in this publication is for the general education of the reader. Because neither the author(s) nor the publisher has any control over the use of the information by the reader, both the author(s) and the publisher disclaim any and all liability of any kind arising out of such use. The reader is

3、expected to exercise sound professional judgment in using any of the information presented in a particular application.Additionally, neither the author(s) nor the publisher has investigated or considered the effect of any patents on the ability of the reader to use any of the information in a partic

4、ular application. The reader is responsible for reviewing any possible patents that may affect any particular use of the information presented.Any references to commercial products in the work are cited as examples only. Neither the author(s) nor the publisher endorses any referenced commercial prod

5、uct. Any trademarks or tradenames referenced belong to the respective owner of the mark or name. Neither the author(s) nor the publisher makes any representation regarding the availability of any referenced commercial product at any time. The manufacturers instructions on use of any commercial produ

6、ct must be followed at all times, even if in conflict with the information in this publication.Copyright 2014 International Society of Automation (ISA)All rights reserved. Printed in the United States of America. 10 9 8 7 6 5 4 3 2ISBN: 978-0-876640-37-1No part of this work may be reproduced, stored

7、 in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or oth-erwise, without the prior written permission of the publisher.ISA67 Alexander DriveP.O. Box 12277Research Triangle Park, NC 27709Library of Congress Cataloging-in-Publication Da

8、taBattikha, N. E.Managing industrial controls / N.E. Battikha.pages cmIncludes bibliographical references and index.ISBN 978-0-87664-037-1 (pbk.)1. Process control. 2. Factory management. I. Title.TS156.8.B383 2014658.5-dc232013037484Battikha-MIC14-front.fm Page iv Wednesday, September 18, 2013 9:30

9、 AMAbout the AuthorN. E. (Bill) Battikha, P.E., has more than 30 years of experience in the field of industrial process control, working mainly in the United States and Can-ada. He holds a Bachelor of Science degree in Engineering and is a member of the Delaware Association of Professional Engineers

10、. Throughout his career, Bill has gained extensive experience in management, engineering and training. He has generated and conducted training courses for many universities and for ISA. He has co-authored a patent and a com-mercial software package. In addition to this book, he has written three oth

11、er books on instrumentation and controls, all published by ISA, with the last of the three an ISA best-seller in its first year of publication. Bill is now the president of Bergotech Inc., an organization specializing in teaching online engineering courses in a variety of disciplines.August 2013Batt

12、ikha-MIC-2014.book Page v Thursday, September 12, 2013 10:09 PMBattikha-MIC-2014.book Page vi Thursday, September 12, 2013 10:09 PMSpecial Thank YouI wish to thank my daughter, Ginette Battikha, a human resource manager at a major law firm, for her contribution in the review of Chapter 1 on Orga-niz

13、ation and the preparation of Chapter 2 on Human Resources. Battikha-MIC-2014.book Page vii Thursday, September 12, 2013 10:09 PMBattikha-MIC-2014.book Page viii Thursday, September 12, 2013 10:09 PMCONTENTS IXContentsAbout the Author vPreface xviiPart 1Managing the Foundation of a Control Systems Or

14、ganizationChapter 1 Organization 3Overview 3Organization of Industrial Control Groups 5Typical Job Titles and Descriptions 11Management and Engineering Job Descriptions 12Maintenance Job Descriptions 19Real-Life Example: The Case for a Flat Organization 23Chapter 2 Human Resources 25Overview 25Recru

15、itment and Selection 25Motivation 31Training 33Reward Systems 36Performance Reviews 39Trade and Labor Unions 43Employment and Human Rights Legislation 45Health and Safety Legislation 46Real-Life Example: Personality vs. Knowledge 50Chapter 3 Industrial Control Systems 51Overview 51Industrial Control

16、 Systems 52Battikha-MIC-2014.book Page ix Thursday, September 12, 2013 10:09 PMX MANAGING INDUSTRIAL CONTROLSDistributed vs. Centralized Control 54Review of the Existing Control Strategy 56Plant Business Strategy 59Steps in the Successful Implementation of Control Systems 61Benefits of Modern Contro

17、l Systems 64Advantages and Disadvantages of Computer-based Control Systems 72System Specification 74Functionality of Control Systems 76Real-Life Example: Control System Selection Without a System Specification 79Chapter 4 Business Development 81Overview 81Managing for Growth and Survival 83The Life

18、Cycle of a Service Provider 84Sizes and Types of Engineering Service Providers 87Basic Requirements for Business Development 89Marketing 91From Inquiry to Purchase Order 96Fees 101Maintaining Client Relationships 105Real-Life Example: How Poor Quality Killed a Thriving Business 106Chapter 5 Corporat

19、e Standards Development 109Overview 109Introduction to Standards Development 110Purpose of Corporate Standards for Industrial Control 111Preparing the Preliminary Standards 113Issuing the Preliminary Standards for Comments 113Receipt and Handling of Comments 116Finalizing the Standards 118Issuing th

20、e Standards for Use 120Standards Maintenance 120Main Components of Corporate Standards in Industrial Control 122Philosophy 125Engineering 130Installation, Check-out, Commissioning, and Start-up 135Battikha-MIC-2014.book Page x Thursday, September 12, 2013 10:09 PMCONTENTS XIMaintenance 137Real-Life

21、Example: A Team Meeting to Discuss Unresolved Points Prior to Issuing Standards 138Part 2Managing Project Implementation of Control SystemsChapter 6 Plant Needs and Decision Analysis 143Overview 143Introduction to the Evaluation of Plant Needs 143Introduction to Quantified Decision Analysis 153The P

22、rocess of Quantified Decision Analysis 155Real-Life Example: The Analyzer That Started an Evaluation of Plant Needs 160Chapter 7 Justification 163Overview 163The Need for Justification 163Hurdles in the Justification Process 165Vendor Selection 166Costs The Bottom Line 168Cost Justification 173Justi

23、fication Follow-up 177Recalculation of the Cost Justification 180Real-Life Example: The Case for Selecting a PLC Vendor 185Chapter 8 Project Management - The Basics 187Overview 187Project Definition 188Project Charter 189Managing Projects 190Industrial Control Projects 195Communication 197Standard a

24、nd Code Compliance 199Control Scope Definition and Work Definition for Industrial Controls 200Control Strategy 202Contracts 204Battikha-MIC-2014.book Page xi Thursday, September 12, 2013 10:09 PMXII MANAGING INDUSTRIAL CONTROLSBidders 207Real-Life Example: Defining the Scope of Work 209Chapter 9 Pro

25、ject Implementation Management, Schedule, and Budgets 211Overview 211Assembling the Project Team 212Confidentiality Agreements 213Project Kick-off Meeting 213Training 215Project Manager Key Skills 216Project Performance 216Schedule and Time Management 217Cost Estimates and Budgets 220Document Contro

26、l 223Management of Change 224Real-Life Example: A Saga of Uncontrolled Document Changes 231Chapter 10 Project Implementation Engineering to Project Closing 233Overview 233Engineering 234Front-end Engineering 234Detailed Engineering 238Engineering Contractor Scope of Work 240Packaged Equipment Suppli

27、er Scope of Work 240Quality 240Procurement 241Vendor Documents 243PLC Programming and Documentation 244Graphics, Alarms, Trends and Reports 246Control Rooms 249Equipment Installation, Check-out, Commissioning and Start-up 254Project Closing 255Real-Life Example: The Controls Group Was Ignored When P

28、ackaged Equipment Was Purchased 257Battikha-MIC-2014.book Page xii Thursday, September 12, 2013 10:09 PMCONTENTS XIIIPart 3Managing the Installation, Maintenance and Auditing of Control SystemsChapter 11 Equipment Installation 261Overview 261Scope of Work 263Execution 264Installation and Mounting 26

29、9Process Tubing 276Air Tubing 277Wiring 279Real-Life Example: Are Drawings Required to Be Created for the Installation Details of Each Piece of Control Equipment? 284Chapter 12 Check-out, Commissioning, and Start-up 287Overview 287Organization 287Safety Equipment 288Required Documents 289Lockout and

30、 Tagout (LOTO) Procedures 291Troubleshooting 292Check-out 293Commissioning 298Start-up 299Real-Life Example: Commissioning and Start-up Are Not an 8 to 5 Job 302Chapter 13 Maintenance 305Overview 305Implementation 308Types of Maintenance 308Personnel 309Training 310Records 310Hazards 312Electrical I

31、solation 315Programmable Electronic Systems 316Battikha-MIC-2014.book Page xiii Thursday, September 12, 2013 10:09 PMXIV MANAGING INDUSTRIAL CONTROLSAlarm and Trip Systems 316Calibration 317Calibration Sheets 320Control Equipment Classification 321Real-Life Example: The Case of a Corroded DCS Ground

32、 324Chapter 14 Auditing The Basics 325Overview 325Purpose of Auditing 327The Auditing Function 329Auditing Existing Controls 330Scope of Work and Time Required 331Protocol 333Auditors 333Interviews 334Searching and Reviewing Documents 336The Audit Report 337Frequency 339Real-Life Example: Audit of a

33、 Fertilizer Plant with Most of Its Automatic Controllers on Manual 340Chapter 15 Auditing Management, Engineering, Maintenance and Hardware 343Overview 343Management 343Engineering Records 348Maintenance 349Control Equipment 351Control Rooms 356Programmable Electronic Systems 359Alarm and Trip Syste

34、ms 367Real-Life Example: A Chlorine Plant with Rust Creeping into a Field-mounted PLC Cabinet 376Appendix A Control Scope Definition Checklist 379Appendix B Scope of Work 385Appendix C Engineering Contractor Scope of Work 389Battikha-MIC-2014.book Page xiv Thursday, September 12, 2013 10:09 PMCONTEN

35、TS XVAppendix D Packaged Equipment Supplier Scope of Work 393Appendix E Control Panel Specification 397Appendix F Audit Protocol 407Appendix G Audit Report 415Bibliography 423Index 425Battikha-MIC-2014.book Page xv Thursday, September 12, 2013 10:09 PMBattikha-MIC-2014.book Page xvi Thursday, Septem

36、ber 12, 2013 10:09 PMXVIIPrefaceIndustrial control groups exist principally in three business areas: facili-ties that manufacture industrial control equipment, engineering organi-zations that implement control systems in plants, and plants that use control systems to operate efficiently.This book is

37、 for people who are: Managers of industrial control groups and who need a handy manual for all matters related to industrial controls from a man-agement point of view, Now in industrial controls and are looking to become future man-agers (or supervisors) of industrial control groups, Not now in indu

38、strial controls but have been given management responsibilities in that field such as the manager of an Electri-cal Engineering department to whom industrial control responsi-bilities are now part of the job, Or just interested in learning about the management of industrial controls.I wrote this boo

39、k because I felt that there is a need to train managers and future managers in industrial control management. There are doz-ens of books on the market on the technical part of industrial controls and books on how to manage engineers. However, I couldnt find any book about how to manage control syste

40、m projects and industrial control groups hence, the writing of this book.In real life, many of the activities described in this book would happen in parallel or even in a different order. However, for the purpose of writing this book, I had to present the topics sequentially. I hope the reader will

41、understand my dilemma.The book is divided into three parts. The first sets the foundation for managers. It looks at organizations and human resources. It also pres-ents an overview of industrial control systems followed by tools for busi-Battikha-MIC-2014.book Page xvii Thursday, September 12, 2013

42、10:09 PMXVIII MANAGING INDUSTRIAL CONTROLSness development and the establishment of corporate standards to guide the work of industrial control groups in the implementation of industrial control systems.The second part covers three basic topics: first, the assessment of plant needs and a quantified

43、approach to decision making; second, the tools needed by a manager to justify the budgets required to implement indus-trial control systems; and third, the actual management of industrial control projects from project definition and scheduling to front-end and detailed engineering.The third part cov

44、ers the post-engineering phases, including equipment installation, check-out, commissioning, and start-up, followed by ongoing maintenance activities. The last two chapters in this part cover auditing, which is a tool that a manager needs to identify control system imple-mentation problems and to me

45、asure compliance with plant needs.Each chapter in the above three parts is followed by a real-life example I encountered in my career.As an aid to managers, I have included a few appendices to facilitate the generation of some key documents. They are to be used as a guide only, since every project h

46、as different requirements.N. E. BattikhaAugust 2013Battikha-MIC-2014.book Page xviii Thursday, September 12, 2013 10:09 PMPart 1Managing the Foundationof a Control SystemsOrganizationBattikha-MIC-2014.book Page 1 Thursday, September 12, 2013 10:09 PMBattikha-MIC-2014.book Page 2 Thursday, September

47、12, 2013 10:09 PM3CHAPTER 1OrganizationThis chapter covers the following topics: Organization of industrial control groups Typical job titles and descriptions Management and engineering job descriptions Maintenance job descriptionsOverviewIndividuals need to be organized when they are put together t

48、o perform certain functions, such as engineering a new plant or maintaining an existing plant. These assembled individuals could form a permanent group in an industrial control department, all of whom are dedicated to that discipline, or could be part of a team assembled for a limited time to implem

49、ent a project with individuals coming from different disciplines. Unorganized permanent groups or temporary teams are prone to misun-derstandings and chaos because personalities may clash and egos may get bruised, all leading to poor performance. Defining the organization is vital for its efficient and productive operation. This is an activity that is performed by a manager and needs to be done before the individuals are assembled and start working together. Therefore, a group or team ready to implement and maintain in