Wireless Control Foundation: Continuous and Discrete Control for the Process Industry offers an overview of wireless communication concepts and terminology essential for implementing wireless control in the process industry. The control system interfaces and wireless field devices discussed in this book are based on industrial wireless standards and are suitable for monitoring and control applications. Initially, wireless transmitters were used only for process monitoring, not control. However, over the years, wireless measurements have gained high user confidence, and new control techniques have been developed to address the unique characteristics of wireless operation. Due to the widespread acceptance of wireless transmitters, many manufacturers are now developing and introducing wireless final control elements, such as on/off and throttling valves.
This book details technical innovations that utilize wireless measurements and final control elements for control purposes. It explains how control can be structured to manage the slow, non-periodic measurement update rates from wireless transmitters and how to compensate for communication delays to the final control elements. These innovative control techniques enable the use of wireless measurements and valves in closed-loop control systems, allowing for seamless integration. It also discusses how wireless measurements can be integrated with model predictive control (MPC). Multiple application examples illustrate the requirements for implementing wireless control. Workshops included in this book explore key concepts related to wireless control, with solutions available on the accompanying website.
Designed for process or control engineers, this book assumes familiarity with traditional control methods but limited experience in designing, installing, testing or commissioning control systems that use wireless transmitters and valves. It offers comprehensive coverage of wireless control for both continuous and discrete applications within the process industry, and it provides information on commercially available analog and discrete wireless transmitters, as well as on/off valves.
Some readers may work with existing distributed control systems (DCSs) that lack native support for wireless field devices, guidance is given on integrating wireless networks into control systems using supported serial and Ethernet interfaces. It also explains how to create the necessary proportional-integral-derivative (PID) modifications for wireless control using DCS-supported tools, and one chapter describes how to easily develop a dynamic simulation of the process and wireless field devices within a DCS for checkout and operator training on wireless control.
Table of Contents:
About the Authors ix
Foreword xvii
Chapter 1 INTRODUCTION 1
Chapter 2 HISTORY AND BACKGROUND OF WirelessHART TECHNOLOGY 7
2.1 About WirelessHART, 8
2.2 WirelessHART Architecture, 11
2.3 Case Study, 21
2.4 Comments, 30
2.5 Workshop – Accessing a Gateway, 32
Chapter 3 WIRELESS FIELD DEVICES 35
3.1 Compliance Testing, 35
3.2 Wireless Device Power Requirement, 38
3.3 Wireless Adapters, 38
Chapter 4 COMMISSIONING WIRELESS DEVICES AND DIAGNOSING FIELD OPERATION 43
4.1 Forming a Wireless Network, 44
4.2 Using Wireless Devices with the Host System, 49
4.3 Wireless Monitoring and Diagnosis, 51
4.4 Workshops, 64
Chapter 5 CONTROL USING WIRELESS TRANSMITTERS 67
5.1 Impact of Wireless Measurement on Process Control Implementation, 67
5.2 Control Using Wireless Measurements, 74
5.3 Control Performance Comparison, 82
5.4 Implementing Wireless Control, 84
5.5 Field Results, 86
5.6 Workshop – Control Using Wireless Transmitters, 95
Chapter 6 CONTROL USING WIRELESS THROTTLING VALVES 101
6.1 Background, 102
6.2 PID Enhancement for Wireless Valve, 103
6.3 New WirelessHART Command, 106
6.4 Control Implementation When Using a Wireless Valve, 107
6.5 Field Trial Implementation, 109
6.6 Field Trial of Wireless Control, 114
6.7 Workshop – Control Using Wireless Throttling Valves, 128
Chapter 7 DISCRETE CONTROL USING WIRELESS FIELD DEVICES 133
7.1 Recycle Tank Level Control, 133
7.2 Storage Tank Temperature Control, 136
7.3 Example Discrete Control Installations, 137
7.4 Future of Discrete Control, 140
7.5 Workshop – Discrete Control Using Wireless Field Devices, 142
Chapter 8 MODEL-BASED CONTROL USING WIRELESS TRANSMITTERS 145
8.1 Background – Process Modeling, 146
8.2 Modifications for a Wireless Measurement, 152
8.3 Implementation Considerations, 154
8.4 Test Results, 156
8.5 Guideline on Using Process Model in Wireless Control, 159
8.6 Workshops, 160
8.7 Alternative Approaches for Wireless Control, 162
8.8 Advanced Topics, 164
Chapter 9 WIRELESS MODEL PREDICTIVE CONTROL 171
9.1 Wireless MPC Concept, 171
9.2 Multi-rate MPC control, 176
9.3 Test Results, 177
9.4 Workshop – Wireless Model Predictive Control, 180
9.5 Advanced Topics, 182
Chapter 10 APPLYING WIRELESS IN LEGACY CONTROL SYSTEMS 189
10.1 Providing PIDPlus Capability in a Legacy System, 189
10.2 Interfacing to a Legacy Control System, 196
Chapter 11 SIMULATING WIRELESS CONTROL 209
11.1 Process Simulation Techniques, 209
11.2 Developing a Process Simulation from the P&ID, 212
11.3 Simulating Process Non-linearity, 220
11.4 Other Considerations, 220
11.5 Workshop – Simulating Wireless Control, 222
11.6 Theory – Simulation Based on Step Response, 223
APPENDIX A 231
APPENDIX B 239
INDEX 253
About the Author :
Terrence L. "Terry" Blevins has been actively involved in the application and design of process control systems throughout his career. Terry was instrumental in the initial establishment of Emerson Process Management s Advanced Control Program in 1992. From 1998 2005 Terry was the team lead for the development of DeltaV advanced control products. From 1994 2013 he was the Fieldbus Foundation team lead for the development and maintenance of the Function Block Specification and editor of the SIS Architecture and Model Specifications. Terry is the U.S. expert to the IEC SC65E WG7 function block committee that is responsible for the IEC 61804 function block standards. He is a voting member and chairman of the ISA SP104-EDDL (Electronic Device Description Language) committee and is the technical advisor to the United States Technical Advisory Group (USTAG) for the IEC65E subcommittee. He is also a member of the U.S. National Committee (USNC) Technical Advisory Group (TAG) (IEC/SC65 and IEC/TC65). Terry coauthored the ISA bestselling books Advanced Control Unleashed (2002), Control Loop Foundation (2010) and Advanced Control Foundation (2012). He has over 50 patents and has written over 80 papers on process control system design and applications. Terry received a Bachelor of Science in Electrical Engineering from the University of Louisville in 1971 and a Master of Science in Electrical Engineering from Purdue University in 1973. In 2004, he was inducted into Control Magazine's Process Automation Hall of Fame. Terry is an ISA Fellow. At present, Terry is a principal technologist in the applied research team at Emerson Process Management.
Deji Chen recently joined Tongji University as a professor at the Computer Science Department. His research will be focused on Industrial Internet, which is the continuation of his work at Emerson Process Management where he was a member of the DeltaV future architecture team. Deji has been involved in process automation for almost two decades. He was among the first creators of OPC. He has worked on different fieldbuses including Foundation Fieldbus. He coauthored the first definitive book on WirelessHART, WirelessHART: Real-Time Mesh Network for Industrial Automation (2010) and translated the ISA bestselling book Control Loop Foundation – Batch and Continuous Processes into Chinese (2012). In 1999 he received his Ph.D. from the University of Texas at Austin; his thesis was "Real-Time Data Management in the Distributed Environment." Deji is an IEEE senior member and an ISA senior member.
Mark Nixon has been involved in the process industries throughout his career. Mark started his career as a systems engineer working on projects in oil & gas, chemicals and pulp & paper. He moved from Canada to Austin, Texas in 1988, where he has held positions in both research and development. From 1995 through 2005 Mark was lead architect for DeltaV. In 2006 he joined the wireless team, taking an active role in the development of WirelessHART and IEC 62591. Mark's current research includes control, data analytics, wireless, low power, virtualization and operator interfaces. He coauthored WirelessHART: RealTime Mesh Network for Industrial Automation (2010), Control Loop Foundation – Batch and Continuous Processes (2010) and Advanced Control Foundation (2012). He holds more than 85 patents. In 2012 he was inducted into Control Magazine's Process Automation Hall of Fame. Mark is an ISA Fellow. Mark received his Bachelor of Science in Electrical Engineering from the University of Waterloo in 1982. At present, Mark is the director of applied research at Emerson Process Management.
Willy Wojsznis has been involved in the development of advanced control products over the last nearly 25 years, focusing on model predictive control, auto tuning and data analytics. Over the previous 25 years of his career he worked on developing computer control systems and applications. His professional work has resulted in a number of successful and innovative advanced control products, over 40 patents and over 50 technical papers. He received a control engineering degree (EE) from Kiev Technical University in 1964, a Master of Science in Applied Mathematics from Wroclaw University in 1972 and a Ph.D. from Warsaw University of Technology in 1973. He coauthored the ISA bestselling books Advanced Control Unleashed (2002) and Advanced Control Foundation (2012). In 2010, he was inducted into Control Magazine's Process Automation Hall of Fame. Willy is an ISA Fellow and an IEEE senior member. At present, he is a member of the Emerson Process Management applied research team supporting research into optimization, big data and process data analytics.
