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
