Loop Checking
Description
In today's competitive markets, manufacturers strive to continually improve manufacturing performance to meet their business needs and goals. As process control loops have a major impact on a plant's financial performance, focusing on loop performance is critical. Loop Checking: A Technician's Guide defines loop checking in the broader scope of control loop performance in addition to the more traditional terms of the plant start-up. It discusses general methods and practices that can be applied across many processes/industries. Featured topics include loop checking basics, factory acceptance testing, wiring and loop checks, performance benchmarking and sustaining performance.
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Person
Harley Jeffery has worked in the field of Industrial Process Controls for over 30 years. Beginning his career with Fisher Controls as a valve application engineer, he spent the last 23 years with Control Southern as a control systems engineer. His experience includes the design, implementation, testing, start-up, and ongoing improvement of analog, distributed, and digital control systems. Harley received a BSIE from Louisiana State University in 1974 and completed Monsanto's Electrical and Instrument Engineering School in 1978. Currently, he is a process control consultant and project manager with Control Southern Inc. He can be reached at harley.jeffery@controlsouthern.com.
Content
PREFACE xiii
Chapter 1 Introduction to Loop Checking 1
1.1 The Opportunity 2
1.2 Loop Checking: Introduction 3
1.3 Process Control Example 10
1.4 Other Loop Checking Considerations 11
1.5 Control Loop Design Guidelines 21
Chapter 2 The Factory Acceptance Test 25
2.1 Documentation 26
2.2 Test Planning 26
2.3 Performing the FAT 27
2.4 Process Simulation 38
2.5 Process Control Example 40
Chapter 3 Start-up 47
3.1 Documentation 47
3.2 Loop Check Plan 48
3.3 Checking the Loop 48
3.4 Process Control Example 51
3.5 Example Forms 54
Chapter 4 Performance Benchmarking 59
4.1 Designing the Test 60
4.2 Performing the Test 62
4.3 Analyzing and Reporting the Test Results 72
4.4 Process Control Example 79
Chapter 5 Sustaining the Performance 89
5.1 Maintenance Strategies 89
5.2 Operator Efficiency 91
5.3 Where to Start? 91
5.4 Selecting the Scope of Your Loop Performance Program 91
5.5 Loop Performance Monitoring/Analyzing 93
5.6 Performance Reporting 104
5.7 Loop Performance Program Architecture 105
5.8 Loop Performance Program Summary 109
References 110
Quiz 111
Acronyms 113
Appendix A Tuning 115
Appendix B Answers 135
Index 139
