Understanding Distributed Processor Systems for Controls explains how modern control systems manage industrial processes. It guides readers through the purpose of control systems, the hardware and software components inside controllers and how operators interact with plants using video displays and human-machine interfaces. It balances explanations of older technologies still in use with the rapidly changing innovations shaping today's systems, emphasizing that the true goal is improved plant productivity, not just impressive features.

This book covers the process of planning, specifying, selecting and implementing a control system, including vendor comparison, testing and project management. It also examines human factors, such as how operators perceive information, design principles for clear screens and alarms, and methods to make interfaces intuitive and safe. Technical ideas are presented clearly so that engineers, managers, technicians, and newcomers (including non-engineers) can ask the right questions and make better decisions about control systems.

Part A. Introduction 1

Chapter 1. Purpose of This Book 3
Chapter 2. Evolution of Plantwide Process Control 11
Chapter 3. The Nuts and Bolts of Computing Devices 33

Part B. Controllers 43

Chapter 4. Controller Hardware Structures 45
Chapter 5. Controller Software Structures 51
Chapter 6. Controller Redundancy 65
Chapter 7. Connections to the Controller 73

Part C. Human Interfaces 89

Chapter 8. Humans in Control 91
Chapter 9. Video for User Interfaces 97
Chapter 10. Adjusting Technology to Fit—Use the Medium 105
Chapter 11. Video Monitor Hardware 111
Chapter 12. Exploring Displays 121
Chapter 13. Trending Data Through Video 131
Chapter 14. Communication of Information 143
Chapter 15. Video Screen Animation 149
Chapter 16. Screen Navigation 159
Chapter 17. Human Information Processing 175

Part D. Plant Upsets 197

Chapter 18. Working With Alarms 199
Chapter 19. Alarm Choices 205
Chapter 20. Alarm Structures and Hierarchies 209
Chapter 21. Overall System Display Structures 217

Part E. Networks 225

Chapter 22. More Nuts and Bolts 227
Chapter 23. Physical Structures 235
Chapter 24. Logical Structures 245
Chapter 25. Open Communications Standards 263
Chapter 26. Digital Field Communications 285
Chapter 27. Architectural Issues 299

Part F. Connecting the Enterprise 307

Chapter 28. Succeeding in the Business 309
Chapter 29. Plant Information 327

Part G. The Process 337

Chapter 30. Continuous Processing 339
Chapter 31. Discontinuous Processing 351
Chapter 32. Toward Standardizing Configuration 361

Part H. System Security 377

Chapter 33. Risk of Failure 379
Chapter 34. Measuring Deficiency 389
Chapter 35. Nature of Failures 395
Chapter 36. Finding Fault 403
Chapter 37. Operational Security 415
Chapter 38. Systems For Process Safety 419

Part I. Typical Vendor Architectures 427

Chapter 39. Older Examples 429
Chapter 40. Justification 451
Chapter 41. Preparation and Definition 455
Chapter 42. Specification 469
Chapter 43. Selection Process 479
Chapter 44. The System has been Bought! 515

Part K. Why Distribute My Control? 525

Chapter 45. Selling Change 527

Part L. Future Trends 531

Chapter 46. Distributed Ain't Dead!! 533
Chapter 47. Market Domains 537

Bibliography 543
Glossary, Acronyms, and Abbreviations: Beyond Distributed Process Control 545
Vendor-Specific Acronyms: DCS 699
Index 715