1、START-UPA TECHNICIANS GUIDESecond EditionSTART-UPA TECHNICIANS GUIDESecond EditionDiane R. BarkinISA TECHNICIAN SERIESCopyright 2012 by International Society of Automation67 Alexander DriveP.O. Box 12277Research Triangle Park, NC 27709All rights reserved.Printed in the United States of America.10 9
2、8 7 6 5 4 3 2 ISBN: 978-1-936007-08-0No part of this work may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise,without the prior written permission of the publisher.NoticeThe information presented in
3、 this publication is for the general education of the reader. Because neither the author nor the publisher has any control over the use of the information by the reader, both the author and the publisher disclaim any and all liability of any kind arising out of such use. The reader is expected to ex
4、ercise sound professional judgment in using any of the information presented in a particular application.Additionally, neither the author nor the publisher have investigated or considered the effect of any patents on the ability of the reader to use any of the information in a par-ticular applicatio
5、n. 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 nor the publisher endorses any referenced commercial product. Any trademark
6、s or tradenames referenced belong to the respective owner of the mark or name. Neither the author 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 product must be followed a
7、t all times, even if in conflict with the information in this publication.Library of Congress Cataloging-in-Publication DataDEDICATIONThis book is dedicated to my mother, Jindra Brumlik, a woman of many talents: artist, teacher and selfless mentor. Through her energy she touched many.“We are a mutua
8、l admiration society.”Table of Contents viiTABLE OF CONTENTSChapter 1 The Role Of The CST In A Start-Up . . . . . . . . . . . . . . . . . . . . . . . .11.1 Job Descriptions 31.2 CST Roles 51.2.1 Training .51.2.2 Safety Inspector 61.2.3 Liaison 71.2.4 Technician Duties .81.2.5 Quality/Inspection .81.
9、2.6 Design And Engineering Assistance . 121.2.7 Leader 121.3 CST Tasks 131.3.1 Baseline Duties . 131.3.2 Pre-Start-Up And Testing Of Safety Systems 141.3.3 Wet And Dry Runs 141.3.4 Initial CST Start-Up Activities . 171.3.5 Planning For The Future: Maintenance . 171.4 Initial Equipment Start-Up Activ
10、ities 191.4.1 Burner Management Systems 201.4.2 Regenerative Systems . 211.4.3 Control Loops 211.4.4 Process Automation Systems . 23Summary 24Quiz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Chapter 2 Applicable Safety Practices and Standards .
11、. . . . . . . . . . . . . . . 272.1 The Fourteen Points Of OSHA PSM . 302.1.1 Point 1 Employee Involvement . 312.1.2 Point 2 Process Safety Information . 312.1.3 Point 3 Process Hazard Analysis (PHA) 322.1.4 Point 4 Operating Procedures 332.1.5 Point 5 Employee Training . 342.1.6 Point 6 Contractors
12、 . 342.1.7 Point 7 Pre-start-up Safety . 352.1.8 Point 8 Mechanical Integrity . 352.1.9 Point 9 Non-routine Work (Hot Work) Authorizations .372.1.10 Point 10 Managing Change 372.1.11 Point 11 Investigation of Incidents 39viii Start Up: A Technicians Guide2.1.12 Point 12 Emergency Preparedness 402.1.
13、13 Point 13 Compliance Audits . 412.1.14 Point 14 Trade Secrets 412.1.15 Summary: The CST and the Fourteen Points 412.2 The Common Types Of Safety Meetings 422.3 The Common Types Of Safety Training . 462.3.1 OSHA Regulatory Safety Training . 462.3.2 Industry- or Plant-specific Training 522.3.3 Safet
14、y Program Evaluation, Leadership, and Job Safety Analysis . 532.4 Lock Out/Tag Out 552.5 Compliance Documentation 572.5.1 Material Safety Data Sheets 582.6 Frequently Encountered Safety Equipment 612.7 Start-Up Safety: Practical Examples 642.8 Safety Instrumented Systems . 66Summary . 69Quiz. . . .
15、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Chapter 3 Documenting the Start-up Process . . . . . . . . . . . . . . . . . . . . . . 733.1 Types Of Documents 743.2 Hardcopy And Electronic Documents . 753.2.1 Original (Hardcopy) Drawings 753.2.2 Electroni
16、c Drawings 763.3 Document Location . 823.4 Start-Up Drawings And Documents . 833.4.1 Gantt Charts . 833.4.2 Functional Specifications 843.4.3 Process Flow Diagrams 853.4.4 Piping And Instrumentation Drawing . 883.4.5 General Arrangement (Location) Drawing . 913.4.6 Specfication (“Spec”) Sheets . 933
17、.4.7 Loop Diagrams (Loop Sheets) 953.4.8 Loop-Check Log Sheet 963.4.9 Calibration Data Sheet 973.4.10 Installation Detail . 983.4.11 Other Documents And Drawings 993.5 Documentation Needed During Start-Up . 1063.6 Maintenance, Upkeep, And Control Of Start-Up Documents 107Summary 111Quiz . 112Table o
18、f Contents ixChapter 4 Working with Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1134.1 Start-Up Team Organization: CST Interaction 1164.1.1 Operations Department 1164.1.2 Control Systems Engineer . 1174.1.3 Project Engineering Department . 1174.1.4 Process Engineering (T
19、echnical Representative) 1184.1.5 The Project Manager And Other Management Personnel . 1194.1.6 Maintenance Department . 1204.1.7 Environmental Department . 1214.1.8 Purchasing Department 1244.1.9 Human Resources . 1244.1.10 Information Technology (IT) Department 1254.2 CST Interaction With Other Pe
20、rsonnel 1274.2.1 Contractors . 1284.2.2 Third-Party Packaged Systems (TPPS) Representatives . 1284.2.3 PAS Vendors And System Integrators 1294.2.4 Personnel From Other Plants 1304.3 Chain Of Command 130Summary 132Quiz . 133Chapter 5 Verifying and Managing Changes . . . . . . . . . . . . . . . . . .
21、. . . . 1355.1 Documentation Used By The CST . 1375.1.1 The Punch List 1375.1.2 Loop Folders 1375.1.3 Red-Lines And Management Of Change 1405.2 Testing Documentation 1425.2.1 Factory Acceptance Testing 1425.2.2 Site Integration Testing . 1445.2.3 Site Acceptance Testing . 1445.2.4 Process Validation
22、 . 1455.2.5 Availability And Performance Testing . 1475.3 Completion Order Of Loops . 1485.4 Calibration And Loop Checking: Verification Of Completion . 1515.4.1 Calibration 1515.4.2 Quality Inspection 1545.4.3 Loop Check . 155Summary 157Quiz . 158x Start Up: A Technicians GuideChapter 6 Start-up Pl
23、an for the CST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1596.1 Required Number Of Personnel 1596.1.1 Division Of Responsibility 1596.1.2 Job Tasks 1606.1.3 Coverage During Different Start-Up Phases 1616.1.4 Start-Up Length And Project Phases 1626.1.5 Environmental Problems . 1626.
24、1.6 Processing Problems 1626.1.7 Equipment Problems 1636.2 Staffing And Overtime 1636.2.1 Scheduling . 1646.2.2 Workload And Priorities 1666.3 Cross-Training . 1676.3.1 Installation Training 1686.3.2 Configuration Training . 1686.3.3 Maintenance Training 1696.3.4 Other Training And Equipment 1706.4
25、Task Assignments And Responsibilities 1726.5 Tasks Prior To Start-Up 1736.6 Moc And Red-Lining 1756.7 Emergency Contacts . 175Summary 176Quiz . 177Chapter 7 Assisting Operations and Other Site Personnel . . . . . . . . . . . 1797.1 Identify And Resolve Problems . 1807.2 Calibration Changes 1867.3 Fa
26、ulty LoopsA Typical Scenario 1877.4 Troubleshooting . 1907.5 CST Tools, Test Equipment And Technology 1927.6 Working With Vendor Reps And Specialists 194Summary 194Quiz . 195Chapter 8 Tuning Control Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1978.1 Types Of Loops 1998.2
27、Types Of Signals . 2028.3 Types Of Control . 2088.3.1 Closed-Loop Or Feedback Control 2088.3.2 Open-Loop Control 2128.3.3 Discrete Control . 212Table of Contents xi8.3.4 Continuous Control 2128.3.5 Batch Control . 2128.4 PID Parameters . 2138.4.1 Algorithm 2138.4.2 Gain . 2158.4.3 Integral 2158.4.4
28、Derivative 2158.4.5 Dead Time 2158.4.6 Overshoot 2168.5 Control Action . 2178.5.1 On-Off Action . 2178.5.2 Proportional-Only Control 2188.5.3 Proportional-Integral Control 2198.5.4 ProPortional-Derivative Control 2198.5.5 Proportional-Integral-Derivative Control . 2208.6 How To Tune A Loop 2208.6.1
29、Trial And Error 2208.6.2 Analytical (Software Solutions) 2208.6.3 Ziegler-Nichols Methods . . . . . . . . . . . . . . . . . . . . 2228.6.4 Other Methods 2238.7 Advanced Process Control . 2238.8 Other Types Of Process Control . 2238.8.1 Fuzzy Logic . 2238.8.2 Gain Scheduling . 2238.8.2 Neural Network
30、s . 2248.9 Who Is Responsible For Implementing Changes? . 2248.10 Making The Changes . 2248.11 Whom To Notify Of Changes 2268.12 Documenting Changes . 226Summary 227Postscript ISA Cap 229Quiz . 230References/Bibliography 231Appendix A Sample Job Descriptions . . . . . . . . . . . . . . . . . . . 233
31、Appendix B Sample Material Safety Data Sheets (MSDS) . . . 237Appendix C Vendor Document: Factory Acceptance Test (FAT) . . . . . . . . . . . . . . . . . . . . . . 245Appendix D Answers to Exercises and Quizzes . . . . . . . . . . . 257Appendix E ISA Form 20 .50 . . . . . . . . . . . . . . . . . . .
32、 . . . . . . . . . 275Appendix F Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283xii Start Up: A Technicians Guide1THE ROLE OF THE CSTIN A START-UPIn this book a start-u
33、p refers to the start-up of a newly built, sub-stantially changed manufacturing facility, or the start-up of a portion of a manufacturing facility which has had a process change requiring new equipment or controls.The responsibilities of the Control Systems Technician (CST) include installation, tro
34、ubleshooting, repair, and routine maintenance of instru-ments. A large portion of this work includes troubleshooting and coor-dinating repairs to control loops throughout the plant. The CST follows company and craft standards and specifications and coordinates his or her activities with Operations a
35、nd with other crafts and departments. A CST may be a direct or contract employee.As a CST this may be the first time you have been asked to participate in a start-up; or perhaps youre very experienced and have participated in many start-ups during your career. In any event, as part of the start-up t
36、eam, you should know what your roles and responsibilities are during this critical period. The chapters of this book cover the major aspects of a CSTs involvement in a plant start-up:Defining the role of the CST during start-up Applicable safety practices and standards Documenting the start-up proce
37、ss Working with others Verifying and managing changes Personnel requirements and responsibilities How a CST assists Operations and other site personnel Tuning control loops Job DescriptionsCST RolesCST TasksInitial Equipment Start-up Activities2 Start Up: A Technicians GuideSometimes start-ups must
38、be accomplished with limited personnel resources and under extreme time pressure. An effective start-up plan, which well discuss in Chapter 3, depends on knowing what technicians should do and how many will be requiredand availableto do it. Man-agement will take personnel limitations into account, b
39、ut CSTs must also understand the roles of the personnel involved in the start-up. Sometimes this information gets communicated verbally, sometimes in formal job descriptions. This chapter will discuss the importance of job descriptions, and the different roles you may be asked to play throughout the
40、 start-up.The role of the CST varies from plant to plant. For example, plant size may determine the roles a CST will play. Where the CST is part of a small group, or possibly working alone, the job will be different than that of a CST working with a larger department. In a larger organization, the C
41、ST may have less independence, with specific jobs he or she has to perform during start-up, and will not necessarily be involved in every function described in this book.The information in this book is intended to apply to many differ-ent types of industries that might employ a CST. Obviously, the t
42、ype of industry and its management will determine exactly how the CST will function within the organization and during start-up.Finally, the start-up is one of the last activities to occur in an overall project which again may be for a newly built, substantially changed or position of a manufacturin
43、g facility undergoing process or equipment changes. Therefore, much of the information in this book pertains to proj-ect execution and control, that is, the steps and deliverables necessary to complete the work to start-up the new and modified facility. Some of the work the CST is responsible for ac
44、tually occurs in preparation of the start-up (e.g., installation, programming, loop check). The Role of the CST in a Start-Up 3DEFINITIONSProject Execution and Control (Project Management): Planning, organizing, securing, and managing resources is about the successful completion of specific project
45、goals and objectives. Resources, may be people, materials and money. Project goals may include but not be limited to a set of agreed upon Deliverables.Deliverables:Plans - Construction, procedures, objectives Drawings - “as built”, loop sheets, documents, loop folders Calculations studies, material
46、and energy balances Purchased Equipment Installation Services - installation, programming, training, SAT, FAT Project: a temporary endeavor, with a defined beginning and end. This is in contrast to the normal operations of a plant, which the com-pleted start-up is expected to achieve.1.1 JOB DESCRIP
47、TIONSThe job description not only defines work responsibilities for the per-son doing the job, it also helps the employer explain what the position re-quires when hiring and during performance evaluations. As a CST, your job description will cover your essential job functions, including those requir
48、ed during a plant start-up. Management can use the job description when hiring to review the position with a potential employee, to orient new employees to their position, and to evaluate current employees job performance. Some job descriptions are very specific while others are more general to allo
49、w for flexibility in work assignment. Job descriptions include the following elements:Job summary statement Basic functions of the position Responsibilities of the position (identifying those tasks that are considered essential)Supervisory responsibilities (if applicable) Skills necessary for the position (e.g., an understanding of math as it pertains to electrical and instrument equipment. Additional skill, knowledge or experience includes but m
