Managing Industrial Controls

Industrial control groups exist principally in three business areas: facilities that manufacture industrial control equipment, engineering organisations that implement control systems in plants, and plants that use control systems to operate efficiently. This handy reference book is written as a guide to help train industrial control managers and future managers on how to manage control system projects and industrial control groups. The book is divided into three parts. The first part sets the foundation for managers. It looks at organisations and human resources. It also presents an overview of industrial control systems, followed by tools for business 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 approach to decision making; second, the tools needed by a manager to justify the budgets required to implement industrial 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 covers 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 implementation problems and to measure compliance with plant needs. This book is for people who are: Managers of industrial control groups and who need a handy manual for all matters related to industrial controls from a management point of view Now in industrial controls and are looking to become future managers (or supervisors) of industrial control groups Not now in industrial controls but have been given management responsibilities in that field, such as the manager of an electrical engineering department to whom industrial control responsibilities are now part of the job Interested in learning about the management of industrial controls

Table of Contents:
About the Author v Preface xvii Part 1 Managing the Foundation of a Control Systems Organization Chapter 1 - Organization 3 Overview 3 Organization of Industrial Control Groups 5 Typical Job Titles and Descriptions 11 Management and Engineering Job Descriptions 12 Maintenance Job Descriptions 19 Real-Life Example: The Case for a Flat Organization 23 Chapter 2 - Human Resources 25 Overview 25 Recruitment and Selection 25 Motivation 31 Training 33 Reward Systems 36 Performance Reviews 39 Trade and Labor Unions 43 Employment and Human Rights Legislation 45 Health and Safety Legislation 46 Real-Life Example: Personality vs. Knowledge 50 Chapter 3 - Industrial Control Systems 51 Overview 51 Industrial Control Systems 52 X Managing Industrial Controls Distributed vs. Centralized Control 54 Review of the Existing Control Strategy 56 Plant Business Strategy 59 Steps in the Successful Implementation of Control Systems 61 Benefits of Modern Control Systems 64 Advantages and Disadvantages of Computer-based Control Systems 72 System Specification 74 Functionality of Control Systems 76 Real-Life Example: Control System Selection Without a System Specification 79 Chapter 4 - Business Development 81 Overview 81 Managing for Growth and Survival 83 The Life Cycle of a Service Provider 84 Sizes and Types of Engineering Service Providers 87 Basic Requirements for Business Development 89 Marketing 91 From Inquiry to Purchase Order 96 Fees 101 Maintaining Client Relationships 105 Real-Life Example: How Poor Quality Killed a Thriving Business 106 Chapter 5 - Corporate Standards Development 109 Overview 109 Introduction to Standards Development 110 Purpose of Corporate Standards for Industrial Control 111 Preparing the Preliminary Standards 113 Issuing the Preliminary Standards for Comments 113 Receipt and Handling of Comments 116 Finalizing the Standards 118 Issuing the Standards for Use 120 Standards Maintenance 120 Main Components of Corporate Standards in Industrial Control 122 Philosophy 125 Engineering 130 Installation, Check-out, Commissioning, and Start-up 135 Contents XI Maintenance 137 Real-Life Example: A Team Meeting to Discuss Unresolved Points Prior to Issuing Standards 138 Part 2 Managing Project Implementation of Control Systems Chapter 6 - Plant Needs and Decision Analysis 143 Overview 143 Introduction to the Evaluation of Plant Needs 143 Introduction to Quantified Decision Analysis 153 The Process of Quantified Decision Analysis 155 Real-Life Example: The Analyzer That Started an Evaluation of Plant Needs 160 Chapter 7 - Justification 163 Overview 163 The Need for Justification 163 Hurdles in the Justification Process 165 Vendor Selection 166 Costs - The Bottom Line 168 Cost Justification 173 Justification Follow-up 177 Recalculation of the Cost Justification 180 Real-Life Example: The Case for Selecting a PLC Vendor 185 Chapter 8 - Project Management - The Basics 187 Overview 187 Project Definition 188 Project Charter 189 Managing Projects 190 Industrial Control Projects 195 Communication 197 Standard and Code Compliance 199 Control Scope Definition and Work Definition for Industrial Controls 200 Control Strategy 202 Contracts 204 XII Managing Industrial Controls Bidders 207 Real-Life Example: Defining the Scope of Work 209 Chapter 9 - Project Implementation - Management, Schedule, and Budgets 211 Overview 211 Assembling the Project Team 212 Confidentiality Agreements 213 Project Kick-off Meeting 213 Training 215 Project Manager Key Skills 216 Project Performance 216 Schedule and Time Management 217 Cost Estimates and Budgets 220 Document Control 223 Management of Change 224 Real-Life Example: A Saga of Uncontrolled Document Changes 231 Chapter 10 - Project Implementation - Engineering to Project Closing 233 Overview 233 Engineering 234 Front-end Engineering 234 Detailed Engineering 238 Engineering Contractor Scope of Work 240 Packaged Equipment Supplier Scope of Work 240 Quality 240 Procurement 241 Vendor Documents 243 PLC Programming and Documentation 244 Graphics, Alarms, Trends and Reports 246 Control Rooms 249 Equipment Installation, Check-out, Commissioning and Start-up 254 Project Closing 255 Real-Life Example: The Controls Group Was Ignored When Packaged Equipment Was Purchased 257 Contents XIII Part 3Managing the Installation, Maintenance and Auditing of Control Systems Chapter 11 - Equipment Installation 261 Overview 261 Scope of Work 263 Execution 264 Installation and Mounting 269 Process Tubing 276 Air Tubing 277 Wiring 279 Real-Life Example: Are Drawings Required to Be Created for the Installation Details of Each Piece of Control Equipment? 284 Chapter 12 - Check-out, Commissioning, and Start-up 287 Overview 287 Organization 287 Safety Equipment 288 Required Documents 289 Lockout and Tagout (LOTO) Procedures 291 Troubleshooting 292 Check-out 293 Commissioning 298 Start-up 299 Real-Life Example: Commissioning and Start-up Are Nota n 8 to 5 Job 302 Chapter 13 - Maintenance 305 Overview 305 Implementation 308 Types of Maintenance 308 Personnel 309 Training 310 Records 310 Hazards 312 Electrical Isolation 315 Programmable Electronic Systems 316 XIV Managing Industrial Controls Alarm and Trip Systems 316 Calibration 317 Calibration Sheets 320 Control Equipment Classification 321 Real-Life Example: The Case of a Corroded DCS Ground 324 Chapter 14 - Auditing - The Basics 325 Overview 325 Purpose of Auditing 327 The Auditing Function 329 Auditing Existing Controls 330 Scope of Work and Time Required 331 Protocol 333 Auditors 333 Interviews 334 Searching and Reviewing Documents 336 The Audit Report 337 Frequency 339 Real-Life Example: Audit of a Fertilizer Plant with Most of Its Automatic Controllers on Manual 340 Chapter 15 - Auditing - Management, Engineering, Maintenance and Hardware 343 Overview 343 Management 343 Engineering Records 348 Maintenance 349 Control Equipment 351 Control Rooms 356 Programmable Electronic Systems 359 Alarm and Trip Systems 367 Real-Life Example: A Chlorine Plant with Rust Creeping into a Field-mounted PLC Cabinet 376 Appendix A - Control Scope Definition Checklist 379 Appendix B - Scope of Work 385 Appendix C - Engineering Contractor Scope of Work 389 Contents XV Appendix D - Packaged Equipment Supplier Scope of Work 393 Appendix E - Control Panel Specification 397 Appendix F - Audit Protocol 407 Appendix G - Audit Report 415 Bibliography 423 Index 425

About the Author :
N. 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 Canada. He holds a Bachelor of Science degree in Engineering and is a member of the Delaware Association of Professional Engineers. 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 commercial software package. In addition to this book, he has written three other 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 organisation specialising in teaching online engineering courses in a variety of disciplines.