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Water Environment Federation
Automation of Water Resource Recovery Facilities
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Contents
List of Figures
List of Tables
Preface
Chapter 1 Introduction to
Automation of Water Resource Recovery Facilities
Robert D. Hill, Ph.D, P.E.
1.0 WHAT IS COMPLETE AUTOMATION DESIGN?
2.0 MOTIVATION FOR UPDATING THIS MANUAL
3.0 TECHNOLOGY AS A STRATEGY, NOT A LIMITATION
4.0 WHAT THIS MANUAL DOES AND DOES NOT INCLUDE
5.0 INTENDED AUDIENCE
6.0 MANUAL OF PRACTICE CHAPTER CONTENTS
7.0 REFERENCES
8.0 SUGGESTED READINGS
Chapter 2 The Business Case for Automation David B. Kubel, P.E.
Dave W. Roberts, P.E.
1.0 INTRODUCTION
2.0 BENEFITS OF AUTOMATION
2.1 Tangible Economic Benefits
2.1.1 Labor Savings
2.1.2 Energy Savings
2.1.3 Chemical Savings
2.1.4 Additional Savings
2.2 Intangible Economic Benefits 2.2.1 Compliance Monitoring
2.2.2 Improved Process Performance and Reliability
2.2.3 Improved Responsiveness
2.2.4 Enhanced Decision Making
2.2.5 Reduced Risk
2.2.6 Workforce Morale and Aging
2.2.7 Customer Satisfaction
3.0 AUTOMATION COSTS
3.1 Planning and Engineering
3.2 Equipment Procurement
3.3 Installation, Commissioning, Testing, and Training
3.4 Post Acceptance Support and Maintenance
3.5 Intangible Costs
3.6 Hardware and Software Life Expectancy
4.0 COST–BENEFIT ANALYSIS
4.1 Financial Analysis
4.1.1 Simple Payback Period
4.1.2 Return on Investment
4.1.3 Life Cycle Costs and Net Present Value
4.2 Risk Analysis
4.3 Approaches to Incorporate Intangible Benefits
4.3.1 Asset Management
4.3.2 Triple Bottom Line
4.3.3 Balanced Scorecard
5.0 FORMULATING THE BUSINESS CASE
6.0 REFERENCES
7.0 SUGGESTED READINGS
Chapter 3 Complete Automation Design Peter R. Craan, P.E., CAP
1.0 THE DESIGN PROCESS
1.1 Project Structure
1.2 Predesign Phase
1.3 Detailed Design Phase
1.4 Final Design Phase
2.0 DESIGN DOCUMENTS
2.1 Bid Documents 2.1.1 Specifications
2.1.1.1 General Requirements for Process Automation Systems
2.1.1.2 Factory Testing
2.1.1.3 Panel Enclosure
2.1.1.4 Operator Interface Terminals
2.1.1.5 Panel-Mounted Devices
2.1.1.6 Networking Equipment
2.1.1.7 Input/Output List
2.1.1.8 Instrument List or Index
2.1.1.9 Network Cabling
2.1.1.10 Uninterruptible Power Supplies
2.1.1.11 Process Control Narratives
2.1.1.12 Programming Standards
2.1.1.13 Field Instruments
2.1.2 Drawings 2.1.2.1 Process Flow Diagrams
2.1.2.2 Process and Instrument Diagrams
2.1.2.3 Process Control System Architecture Diagram
2.1.2.4 Elementary Wiring Diagrams
2.1.2.5 Instrumentation and Panel Location Drawings
2.1.2.6 Instrumentation Installation Details
2.2 Automation Design Implementation Documents
2.2.1 Loop Diagrams
2.2.2 Interconnecting Wiring Diagrams
2.2.3 Control Panel Design Drawings
2.2.4 Programmable Logic Controller Program
2.2.5 Distributed Control System Configuration
2.2.6 Instrument Data Sheets
2.2.7 Detailed Process Control Narratives
2.2.8 Logic Diagrams and Detailed Process Control Sequence Flow Charts
2.3 Sources of Technical Design Information 2.3.1 Technical Societies
2.3.2 Vendors
2.3.2.1 Selecting Vendors and Technologies
2.3.2.2 Incorporating Selected Technologies to Design
2.3.3 Books and Periodicals
2.3.4 The Internet 2.3.4.1 Web Sites
2.3.4.2 Social Media
2.3.5 Training
2.3.6 Previous Design Experience
3.0 POSTDESIGN PHASE 3.1 Design Services During Construction
3.1.1 Submittals
3.1.2 Change Orders 3.1.2.1 Change Order Management
3.1.2.2 Common Risk Areas for Change Orders
3.1.3 Responding to Requests for Information and Request for Clarifications
3.1.4 Meetings with Contractors and Suppliers
3.1.5 Site Visits
3.1.6 Factory Acceptance Tests
3.1.6.1 System Performance
3.1.6.2 Hardware Testing
3.1.6.3 Software Testing
3.1.6.4 Simulation Software
3.1.6.5 Operator Interface Terminals and Operator Workstations
3.2 Construction Management
3.2.1 Installation Inspections
3.2.2 Instrument Calibrations
3.2.3 Field Tests
3.2.4 Wiring Tests
3.2.5 Loop Testing
3.2.6 Integrated System Testing
3.2.7 Commissioning and Final Acceptance
3.2.8 As-Built Drawings and Final Control System Documentation
4.0 REFERENCES
5.0 SUGGESTED READINGS
Chapter 4 Process and Instrumentation Diagram Peter R. Craan, P.E., CAP
1.0 INTRODUCTION
2.0 HOW TO CREATE A PROCESS AND INSTRUMENTATION DIAGRAM
2.1. Process Flow Diagrams
2.1.1 Symbols
2.1.2 Computer-Aided Design Software
2.2 Instrument List
2.3 Input/Output List
2.4 Panel List
2.5 Cable and Conduit List
2.6 Process Control Narratives
2.7 Panel and Field Instrument Specifications
2.8 Electrical Schematics
2.9 Instrument Loop Diagrams
2.10 Equipment Location Drawings
2.11 Control System Architecture Diagram
3.0 PROCESS AND INSTRUMENTATION DIAGRAMS AS COMMUNICATION TOOLS 3.1 Contract Bid Documents
3.2 End User and Owner Feedback
3.3 Operator Training
3.4 Operator-Interface Graphics Development
3.5 As-Built Documentation
3.6 Coordination with Other Design Disciplines
4.0 INTELLIGENT PROCESS AND INSTRUMENTATION DIAGRAMS
4.1 Streamlined Diagram Development
4.1.1 Object-Based Schematics
4.1.2 Modular System
4.1.3 Integration with External Data Sources
4.1.4 Interoperability
4.1.5 Symbol Management Tools
4.1.6 Review and Navigation Tools
4.1.7 Component Management Tools
4.2 Automatically Generated Lists
4.3 Design History for As-Built Drawings
4.4 Construction, Startup, Operation, Maintenance, and Asset Management Uses
5.0 PROCESS AND INSTRUMENTATION DIAGRAMS FOR NONPROCESS SYSTEMS
6.0 REFERENCES
7.0 SUGGESTED READINGS
Chapter 5 Process Control Narratives Jeff Coulson, P. Eng, PMP
Jack Geisenhoff, P.E., PMP
1.0 PURPOSE OF PROCESS CONTROL NARRATIVES
2.0 TYPICAL PROCESS CONTROL NARRATIVE COMPONENTS
2.1 Equipment and Tag Numbers
2.2 Process and Instrumentation Diagrams
2.3 System Components
2.4 Flow Charts
2.5 Control Hierarchy
2.5.1 Local Controls
2.5.2 Motor Control Center Functions
2.5.3 Controller Functions
2.5.4 Remote Manual Controls
2.5.5 Remote Automatic Controls
2.6 Alarms
2.7 Setpoints
2.8 Performance Reporting Data
3.0 OTHER METHODS OF CONVEYING PROCESS DESCRIPTIONS
3.1 Animations
3.2 Static Process Models
3.3 Interactive Process Models
4.0 DEVELOPMENT, UPDATES, AND PRESENTATION
4.1 Document Development and Updates
4.2 Document Storage and Presentation
5.0 REFERENCE
Chapter 6 Specifications Thomas H. Powell, P.E., C.C.S.
Mohamad Bassidgi, P. Eng
1.0 RELATIONSHIP OF SPECIFICATIONS AND DRAWINGS
2.0 SPECIFICATIONS 2.1 Standard Specifications
2.2 Project-Specific Specifications
2.3 Vendor-Supplied and -Suggested Specifications
2.4 Master Specification Guidelines
2.5 MasterFormat 1995
2.6 MasterFormat 2004
2.7 Whole Building Design Guide
3.0 REVISIONS TO TECHNICAL CONTENT 3.1 Notes to Specifiers
3.2 Installation Lessons Learned
4.0 INSTRUMENT DATA SHEETS
5.0 CONSTRUCTION SPECIFICATIONS INSTITUTE 5.1 Performance-Based Specifications
5.2 Descriptive Specifications
6.0 OWNER-DEVELOPED SPECIFICATIONS
7.0 COORDINATION WITH OTHER DISCIPLINES
8.0 REFERENCES
9.0 SUGGESTED READINGS
Chapter 7 Process Control Strategies Jack Geisenhoff, P.E., PMP
Mike Abbott, P.E.
Jeff Coulson, P. Eng, PMP
Richard S. Haugh, P.E.
Robert D. Hill, Ph.D, P.E.
1.0 OBJECTIVE OF AUTOMATIC PROCESS CONTROL
2.0 CONTROL THEORY
3.0 MISTAKE PROOFING
4.0 CONTROL CONCEPTS
4.1 On–Off Control Versus Modulating Control
4.2 Open-Loop Versus Closed-Loop Control
4.3 Feed Forward Versus Feedback Control
4.4 Step Control
4.5 Proportional–Integral–Derivative Control
4.6 Cascade Control
4.7 Rules-Based Control
4.8 Model Predictive Control
4.9 Artificial Neural Networks
4.9.1 Artificial Neural Network Models
4.9.2 Artificial Neural Network Models Used for Process Modeling
4.9.3 Artificial Neural Network Models Used for Process Control
4.10 Control Strategies
4.10.1 Lead–Lag Control
4.10.2 Most-Open Valve Control
5.0 PUMPING AND FLOW CONTROL STRATEGIES 5.1 Process Description
5.1.1 Well Pumping
5.1.2 Flow Pumping
5.1.3 Flow Splitting
5.2 Process Variables
5.3 Controlled Variables
5.4 Control Strategies 5.4.1 Well Pumping—Constant-Speed Pumps
5.4.2 Well Pumping—Variable-Speed Pumps
5.4.3 Flow Pumping
5.4.4 Flow Splitting with Valves or Gates
6.0 SCREENING, GRIT REMOVAL, AND CONVEYANCE CONTROL STRATEGIES 6.1 Process Description
6.1.1 Bar Screens
6.1.2 Grit Removal
6.1.3 Conveyance Systems
6.2 Process Variables
6.3 Controlled Variables
6.4 Control Strategies 6.4.1 Bar Screen Velocity Control
6.4.2 Bar Screen Cleaning Control
6.4.3 Grit Settling Velocity Control
6.4.4 Grit Removal Control
6.4.5 Conveyance System Control
7.0 PRIMARY SLUDGE AND SCUM CONTROL STRATEGIES 7.1 Process Description
7.1.1 Sludge Removal
7.1.2 Scum Removal
7.2 Process Variables
7.3 Controlled Variables
7.4 Control Strategies 7.4.1 Sludge Removal Control—Dedicated Pump
7.4.2 Sludge Removal Control—Valve to Common Pump
7.4.3 Scum Trough Operation Control
7.4.4 Scum Pit Level Control
8.0 ACTIVATED SLUDGE SYSTEM CONTROL STRATEGIES 8.1 Dissolved Oxygen Control 8.1.1 Process Description
8.1.2 Process Variables
8.1.3 Controlled Variables
8.1.4 Control Strategies
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