Control Systems Engineering: Designing Automation Systems for Mechanical Equipment, Study Guides, Projects, Research of Control Systems

Download Control Systems Engineering: Designing Automation Systems for Mechanical Equipment and more Study Guides, Projects, Research Control Systems in PDF only on Docsity! Control Systems Engineer Alternate Titles: Controls Engineer, Process Control Engineer, Instrument & Controls Engineer, Systems Engineer, Automation Systems Engineer, Manufacturing Automation Engineer, Instrumentation & Electrical Engineer. Description: Control Systems Engineers analyze user requirements and the design of process and/or mechanical equipment to design automation systems that will cause the equipment to function in the desired manner. They analyze user requirements, procedures, and problems to identify the system components and develop the design and functional specifications for the automation systems. They are responsible for the interface between the hardware and software development for the automation system. Sources of Material: Certified Automation Professional (CAP) Body of Knowledge, Control Systems Engineer (CSE) Examination Specification, Automation Competency Model. Performance Domains: Domain I: Measurement and Control Element Devices; Device Signals, and Transmission Media Domain II: System Design Domain III: Development Domain I: Measurement and Control Element Devices; Device Signals and Transmission Media Task 1: Select, specify, and design the installation of measurement devices to measure and analyze physical and chemical properties. Knowledge of: Sensor technologies applicable to the desired type of measurement (e.g., flow, pressure, level, temperature, analytical, counters, position, motion, vision, etc.) Sensor characteristics (e.g., rangeability, accuracy and precision, temperature effects, response times, reliability, repeatability, etc.) Material compatibility Safety Instrumented System [SIS] model validation calculations (e.g., Safety Integrity Level [SIL], reliability, availability, etc.) Skill in: Calculations involved in: Pressure drop Flow element sizing Differential pressure Hydraulic head pressure Control Systems Engineer 1 Velocity, area, volumetric, density, and mass relationships Velocity, acceleration, mass, work energy Unit conversions Linearization Task 2: Select, specify, and design the installation of control element devices to manipulate flows, energy, positions, speeds, and other variables. Knowledge of: Control Element devices Pressure Relieving Devices Types (e.g., conventional spring, balanced bellows, pilot operated, etc.) Characteristics (e.g., modulating, pop action, etc.) Calculations (e.g., sizing considering inlet pressure drop, back pressure, multiple valves, etc.) Material selection based on process characteristics Installation practices (e.g., linking valves, sparing the valves, accessibility for testing, car sealing inlet valves, piping installation, etc.) Rupture discs (types, characteristics, application, calculations, etc.) Control Valves Types (e.g., globe, ball, butterfly, etc.) Characteristics (e.g., pneumatic or electric actuation, on/off, modulating, linear, low noise, equal percentage, shutoff class, etc.) Calculation (e.g., body and trim sizing, split range, noise, actuator sizing, speed, pressure drop, air/gas consumption, etc.) Applications of fluid dynamics (e.g., cavitation, flashing, choked flow, Joule-Thompson effects, two-phase flow, etc.) Material selection based on process characteristics (e.g., erosion, corrosion, plugged, extreme pressure, temperature, etc.) Accessories (e.g., limit switches, solenoid valves, positioners, transducers, air regulators, etc.) Environmental constraints (e.g., fugitive emissions, packing, special sealing, etc.) Installation practices (e.g., vertical, horizontal, bypasses, troubleshooting, etc.) Motor Driven Control Elements Types of Motors (e.g. Single and Polyphase Alternating Current (AC) Motors, Direct Current (DC) Motors, Stepper Motors, Servo Motors, linear, etc) Types of Motor Controllers or Drives (e.g. full voltage, reduced voltage, reversing, variable frequency, adjustable DC, servo, stepper, etc.) Control Systems Engineer 2 Safety system design (e.g., Safety Instrumented System [SIS], Safety Requirements Specification [SRS], application of OSHA 1910, etc.) Skill in: Participating in a Hazard Operability Review Analyzing safety integrity levels Analyzing hazards Analyzing risks Assessing security requirements or relevant security issues Applying regulations to design Task 2: Establish standards, templates, and guidelines as applied to the automation system using the information gathered in the definition stage and considering human-factor effects in order to satisfy customer design criteria and preferences. Knowledge of: Process Industry Practices (PIP) (Construction Industry Institute) IEC 61131 programming languages Customer standards Vendor standards Template development methodology Measurement and control element devices Electrical standards and codes Instrument selection and sizing tools ISA standards (e.g., S5, S88) Etc. Skill in: Developing programming standards Selecting and sizing instrument equipment Designing instrument installations. Designing low-voltage electrical systems Preparing drawing using AutoCAD software Task 3: Create detailed equipment specifications and instrument data sheets based on vendor selection criteria, characteristics and conditions of the physical environment, regulations, and performance requirements in order to purchase equipment and support system design and development. Knowledge of: Measurement and control element devices. Electrical standards and codes Instrument selection and sizing tools Vendors' offerings Motor and drive selection sizing tools Electronic control system hardware (e.g. controller, power supplies, input/output cards and chassis, communication hardware, etc.) Human Machine Interface (HMI) (e.g., graphics, alarm management, trending, historical data, etc.) Ergonomics (e.g., human factors engineering, physical control room arrangement, panel layout) Skill in: Selecting and sizing motors and drives Control Systems Engineer 5 Selecting and sizing instrument equipment Designing low-voltage electrical systems Selecting and sizing computers Selecting and sizing control equipment Evaluating vendor alternatives Selecting or sizing of input/output signal devices and/or conditioners Task 4: Define the data structure layout and data flow model considering the volume and type of data involved in order to provide specifications for hardware selection and software development. Knowledge of: Data requirements of system to be automated (e.g. data sampling frequency, storage duration, archival requirements, security, integrity, etc.) Data structures of control systems (e.g. distribution and access to data, storage redundancies, distribution, archiving, etc.) Data flow of controls systems (e.g. data buffering, time base stamp, location of active and archive data files) Data analysis tools Entity relationship diagrams Skill in: Modeling data Tuning and normalizing databases Task 5: Select the physical communication media, network architecture, and protocols based on data requirements in order to complete system design and support system development. Knowledge of: Vendor protocols Ethernet and other open networks Physical requirements for networks/media Physical topology rules/limitations Network design Security requirements Redundancies, failure modes, and disaster recovery. Grounding and shielding practices Skill in: Designing networks based on chosen media, architecture and protocols Task 6: Develop a functional description of the automation solution (e.g., control scheme, alarms, HMI, reports) using rules established in the definition stage in order to guide development and programming. Knowledge of: Control theory Basic processes (e.g., compression, combustion, distillation, hydraulics, motion control, etc.) Process dynamics (e.g., loop response, P-V-T relationships, simulations, cycle times, throughput, etc.) Basic control (e.g., regulatory control, feedback, feed forward, cascade, ratio, PID, split-range, etc.) Discrete control (e.g., relay logic, Boolean algebra, state logic, Control Systems Engineer 6 function block/combinational logic, etc.) Sequential control (e.g., batch, sequential function charts, logic sequences, etc.) Visualization, alarming, database/reporting techniques Documentation standards Vendors' capabilities for their hardware and software products General control strategies used within the industry Process/equipment to be automated Operating philosophy Skill in: Writing functional descriptions Interpreting design specifications and user requirements Communicating the functional description to stakeholders Task 7: Design the test plan using chosen methodologies in order to execute appropriate testing relative to functional requirements. Knowledge of: Relevant test standards Simulation tools Process Industry Practices (PIP) (Construction Industry Institute) General software testing procedures Functional description of the system/equipment to be automated Skill in: Writing test plans Developing tests that validate that the system works as specified Task 8: Perform the detailed design for the project by converting the engineering and system design into purchase requisitions, drawings, panel designs, and installation details consistent with the specification and functional descriptions in order to provide detailed information for development and deployment. Knowledge of: Field devices, control devices, visualization devices, computers, and networks Installation standards and recommended practices Electrical and wiring practices Specific customer requirements Functional requirements of the system/equipment to be automated Applicable construction codes and standards Documentation standards Productivity tools (e.g. InTools, AutoCAD, Microstation, etc.) Typical industry standard drawings (e.g., PFD, P&ID, Loop Diagrams, Ladder Diagrams, Logic Drawings, Cause & Effects Drawings, SAFE Charts, etc.) Skill in: Performing detailed design work Documenting the design Task 9: Prepare comprehensive construction work packages by organizing the detailed design information and documents in order to release project for construction. Knowledge of: Applicable construction practices Documentation standards Control Systems Engineer 7 Industry standards (e.g., ISA) Skill in: Documenting security configuration Configuring/programming of security system Implementing security features Task 6: Review configuration and programming using defined practices in order to establish compliance with functional requirements. Knowledge of: Specific control software products Specific HMI software products Specific database software products Specific reporting products Programming structure techniques Network communication Alarming schemes I/O structure Memory addressing schemes Hardware configurations Computer operating systems Defined practices Functional requirements of system/equipment to be automated Skill in: Programming and/or configuration capabilities Documenting configuration and programs Reviewing programming/configuration for compliance with design Requirements Task 7: Test the automation system using the test plan in order to determine compliance with functional requirements. Knowledge of: Testing and simulation techniques Specific simulation products and software. Specific control software products Specific HMI software products Specific database software products Specific reporting products Network communications Alarming schemes I/O structure Memory addressing schemes Hardware configurations Computer operating systems Functional requirements of system/equipment to be automated Skill in: Writing test plans Executing test plans Documenting test results Programming and/or configuration capabilities Implementing connections to remote devices Control Systems Engineer 10 Interpreting functional requirements of system/equipment to be automated Interpreting P&IDs Task 8: Assemble all required documentation and user manuals created during the development process in order to transfer essential knowledge to customers and end users. Knowledge of: General understanding of automation systems Computer operating systems Documentation practices Operations procedures Functional requirements of system/equipment to be automated Skill in: Documenting technical information for non-technical audience Using documentation tools Organizing material for readability - field ins Control Systems Engineer 11