Cover Control Systems Engineer (CSE)
Notice from the Publisher
This Reference Manual Covers All Subject Content for the PE/CSE Examination
Plan Your Study Time
Table of Contents
Introduction to This Study Guide
About the Author
People who have contributed to the previous editions of this manual
Tips on How to Use This Study Guide
Using Thumbnails to Navigate
Using Bookmarks to Navigate
Important File Attachments - Open by clicking on the paper clip!
How to Print this Manual
Welcome to Control Systems Engineering
Licensing as Professional Engineer / Control Systems Engineer (CSE)
Why Become a Professional Engineer?
This is the third edition of this study manual
The new and expanded sections include:
Recommended Flow Chart of Study for the CSE
Overview of Recommended Flow Chart of Study for the CSE
Examination General Information
State Licensing Requirements
Eligibility
Exam schedule
Description of Examination
Exam content
I. Measurement
II. Signals, Transmission, and Networking
III. Final Control Elements
IV. Control Systems
V. Safety Systems
VI. Codes, Standards, Regulations
Exam Scoring
Reference Materials for the Exam
Recommended books and materials to take to the exam
Books and Materials for Testing
Books for additional study
Courses for additional study
ISA Control Systems Engineer (CSE) PE Review
Industrial Network Training
Control Systems Engineer (CSE) Supplement Course
Online Process Plant @ Learn Control Systems.com
Process Measurement Standards and Terminology
Overview of process measurement, control and calibration
Process Signal and Calibration Terminology
Definition of the Range of an Instrument
Definition of the Span of an Instrument
Definition of the use of Zero in Instrumentation
Live-Zero
Elevated-Zero
Suppressed-Zero
Illustrations of range and span terminology
Illustrations of measured variable, measured signal, range and span
Applications of Fluid Mechanics in Process Control
Relationship of pressure and flow
Applications of the formulas
Summary of fluid mechanics for process control
Temperature Measurement and Calibration
Temperature measurement devices and calibration
Thermocouple - worked examples (how to read the thermocouple tables)
RTD (Resistance Temperature Detector)
Installing RTDs and Thermocouples into a process stream
Typical RTD and thermocouple applications
Pressure Measurement and Calibration
Pressure measurement and head pressure
Applying pressure measurement and signals - worked examples
Differential pressure and meter calibration
Pressure change in a pipe for a given flow rate
Pressure change across the flow element for a given flow rate
Pressure calibration of transmitter
Level Measurement and Calibration
Applying level measurement and calibration - Worked examples
Level displacer (Buoyancy)
Bubbler level measurement
Density measurement
Interface level measurement
Radar and Ultrasonic level measurement
Time of flight technology
Ultrasonic level measurement
Radar (non-contact)
Guided Wave Radar (GWR)
Capacitance level measurement
Radiometric (gamma) level measurement
Level gauging system in a tank farm
Calculating the volume in tanks
Flow Measurement and Calibration
Applying flow measurement devices
Turndown ratio in a flow meter
ISA Standard flow meter symbols
Flow meter applications chart
Pressure tappings (Impulse Line Taps)
Orifice tap dimensions and impulse line connections
Various Types of Flow Meters
Applying the Bernoulli principle for flow control
Types of Head Pressure based meters
Venturi meter
ISO 5167 Orifice Plate & Orifice plate
Dall tube
Pitot-Static tube
Multi-hole pressure probe
Cone meters
Annubar meters (also reference averaging pitot tubes)
Differential head meter calculations
Classic fluid mechanics model
โKโ value flow coefficients
The beta ratio
Pipe Size Is Important - Remember!
Standard Flow Measurement Equations
Spink - Flow Measurement Equation
The basic Spink equation derived
The basic Spink equation for liquid
The basic Spink equation for gas and vapor
The basic Spink equation for steam
Applications of the Beta and Spink factors
Table 3 โ The Spink Factor (S)
ISO 5167 - Flow Measurement Equation
The expansibility factor
The discharge coefficient
The ISO 5167 equation explained
Solve for the Reynolds number โReโ
Solve for the coefficient โCโ
Solve for mass flow rate:
Solve for volumetric flow rate
Equation Comparison Summary
Sizing orifice type devices for flow measurement - worked examples
Mass flow measurement and control
Applying mass flow measurement with an orifice - worked example
Turbine meter applications
Turbine flow meter - worked example
Weight Measurement and Calibration
Weight measurement devices and calibration
Load cells
Load cells for (flow, level, force) applications in process
Process Analyzers
Electrical conductivity and ph correction
How are pH and electrical conductivity measured?
Control of pH values in processes
Typical pH correction control scheme
Control of conductivity
Instrument specifications and operating parameters
Common Plant Analyzers
Boiling Point Analyzers
Vacuum Distillation Analyzer
Flash Point Analyzer
Cloud Point Analyzer
Freeze Point Analyzer
Pour Point Analyzer
Color Analyzer
Combustion and Analyzers
Combustion furnace and air-fuel ratio control
Air-Fuel ratio control utilizing CO and O2 concentrations
BMS - Burner Management Safety
OSHA Requirements
Carbon dioxide (CO2) reading
Examples of Process Analyzers
Select the appropriate analyzer and configuration
Typical Analyzer Piping and Control Schematic
Process Control Valves and Actuators
Process control valves
Considerations when sizing a control valve
Flow Coefficient Cv
Specific Gravity
Operating Conditions
ISA standard valve symbols
ISA standard pressure regulating valve symbols
Valve actuators
ISA standard actuator symbols
Limit switches on a valve - ISA standard symbol
Calculating the size of the actuator
Example actuator sizing
Split ranging control valves
Valve positioner applications
ISA standard valve positioner symbols
Summary of positioners
When should a positioner be used?
Electrical positioners
Control valve application comparison chart
Understanding flow with valve characteristics
What is the ฮP for valve sizing?
System piping ฮP pressure drops
Control valve ฮP pressure drop
Graph of the Inherent valve characteristics (off the shelf)
Which valve characteristic trim to use?
Characteristic distortion in valves
Gain and Rangeability (turndown ratio in valves)
Proper control valve sizing
Oversized valves present problems
Experiment and understand Installed valve characteristics
Summary of control valve characteristics
Control Valve Sizing
The Valve Sizing Equations
The Basic equation for liquid flow
The basic equation for gas flow
The basic equation for steam flow
Sizing valves for liquid - worked example
Sizing valves for gas - worked example
Sizing valves for vapor and steam - worked example
Sizing valves for two phase flow - worked example
Two Phase Flow Worked Example
ฮP Valve Limitations - Very Important!
Flowing Quantity (the turndown ratio of a valve)
Flashing
Joule-Thomson Effect (J-T) โ auto refrigeration in valves
Choked Flow
Maximum ฮP and Maximum Flow (qmax) in Valves Applications
Determining qmax (Maximum Flow Rate)
Determining ฮPmax (the Allowable Sizing Pressure Drop)
Cavitation in valves
Check for cavitation and choked flow in a control valves - worked examples
Fluid Velocities through Control Valves
Viscosity Correction for Sizing Valves
Pressure Relief Valves and Rupture Disks
Pressure Relief Valves (PRV) and Pressure Safety Valves (PSV)
Important Note: (Do Not Throttle Pressure Relief Valves)
EPA regulations
Regulation details
PRD bypass
Pilot operated safety valve
Bellow or balanced bellow and diaphragm
Weight loaded PRV operation
Venting Atmospheric and Low-Pressure Storage Tanks
API Standards for pressure relieving systems
CFR Standards for pressure relief required by federal law
API Standard 2000 โ Venting atmospheric and low-pressure storage tanks
API Standard 2003 โ Protection against ignitions from static, lightning, and stray currents
API Standard 2350 โ Overfill protection for storage tanks in petroleum facilities
API Standard 2510 โ Design and construction of LPG installations
NFPA 30 โ Flammable and combustible liquids code
Important excerpts from NFPA 30 code:
Chapter 4: Tanks Storage
Chapter 5: Piping Systems
Chapter 6: Container and Portable Storage Tanks
Chapter 7: Operations
ASME VIII code for sizing relief valves and rupture disks
Introduction to ASME VIII
Overview Section VIII - Pressure Vessels
ASME VIII โ Pressure relief requirements
ASME VIII - Pressure limits in sizing
Table 5 - ASME standard nozzle orifice data
ISA pressure relief valve and rupture disc symbols
Sizing equations for relief valves and rupture disks
ASME VIII code equations USCS units
A Note about sonic or choked flow
Variables for PRV and PSV sizing equations
Sizing rupture disks - worked examples
Sizing pressure relief valves - worked examples
Review of Feedback Control Fundamentals
Compare Open Loop Control to Closed Loop Control
Open Loop Example โ A Mathematical Analysis
Closed Loop Example โ A Mathematical Analysis
The Transfer Function for the Automobile
Review of Frequency Response Fundamentals
Electrical Application โ A First Order System
Bode Plot of First Order System
Calculate the data for the Bode Plot
Creating a Bode Plot โ First Order System using Frequency
Hydraulic Application โ A First Order System
Process Control Theory and Controller Tuning
Degrees Of Freedom in Process Control Systems
Controllers and control strategies (models-modes)
Process Loop Gain (Gp)
Process Signal Linearization
Signal Filtering in Process Control
Appling Signal Filters
Filter Time Constant and Sample Time
Example of Filter Time Selection
DCS/PLC Sample and Scan Time Consideration
Sampling time
Time per scan cycle
Tuning of Process Controllers
Closed Loop Tuning of the Controller
Example: Tune Using Ultimate Gain (continuous cycling)
Open Loop Tuning of the Controller
Example: Tuning using Process Reaction Curve (Step Response)
Advanced Tuning Methods for Controllers
The Integral Criteria Method
Lambda Tuning Concepts
Example Reactor Ratio Timing
IMC Tuning Method
PID Controller Models
Trial and Error Tuning Method
Dead Time and PID Control
PID Tuning Video - Parameters in Action
Process Characteristics from the transfer function
Poles, Zeros and Dampening from the Transfer Function
Find the Poles from the Function
Find the Damping from the Function
Find the Time Constant
Find the Period
Find the Time Constant from the Period
Find Overshoot and Peak Value
Block Diagram Algebra
Example of Block Diagram Algebra Reduction
Nyquist Stability Criterion
Routh Stability Criterion
Check for Stability using Routh (Example)
Communications and Industrial Control Networks
Overview of Corporate and Plant Networks
Open System Interconnect (OSI) and TCP/IP network layer model
7 Layers of networking in the OSI model
Physical (Layer 1)
Data Link (Layer 2)
Network (Layer 3)
Transport (Layer 4)
Session (Layer 5)
Presentation (Layer 6)
Application (Layer 7)
Cisco Network Certification โ IIOT (Industrial Internet of Things) for IT & OT
The typical network model
The Network Essentials
Overview of Industrial Networks
The most popular industrial networks and their applications are below
HART Networks
Traditional HART Network
A Wired HART Network
A Wireless HART Network
PROFIBUS and AS-I Networks
Reasons for choosing PROFIBUS
PROFIBUS DP
PROFIBUS PA
PROFINET
AS-I
PROFIBUS Fieldbus Message Specification (FMS)
PROFIBUS
PROFISafe
PROFIDrive
Use of the OSI Networking Layers
PROFIBUS/AS-I/PROFINET Certifications:
FOUNDATION FIELDBUS
Reasons for choosing FOUNDATION FIELDBUS
H2 or HSE (High Speed Ethernet)
FOUNDATION H1
Typical FOUNDATION Segments
Use of the OSI Networking Layers
Rockwell and ODVA (CIP) Networks
ControlNet
DeviceNet
EtherNet/IP
CompoNet
DH485, DH+, RIO
Modbus Networks
Traditional Modbus Networks
Communication and Devices
Protocols
EtherCAT
SERCOS
Summary - Automation and Process Control Networks
Plant Facility Monitoring & Control System (FMCS)
BACnet
LonWorks
Typical Building Automation Network
Networked intelligent and smart devices
PID control in intelligent networked devices
PROFIBUS Control Blocks
The Rosemount 333 Tri-Loop to split multiple variable signals
The Application of Digital Logic in Control Systems
Overview of Digital Logic
Digital Logic Gate Symbols
Digital Logic Gate Truth Tables
ISA Binary Logic
Relay Ladder Logic
Standard RLL Symbols
Sealing Circuits
Control System Architectures
DCS Plant Wide Control System Architecture - Networked
PLC Control System Architecture
PLC (Programmable Logic Controller) vs PAC (Process Automation Controller)
Controller Application Function Comparison Chart
SCADA Control System Architecture
PLC Programming Languages
PLC Programming (LD) ladder diagram or (RLL) relay ladder logic
PLC Programming (ST) structured text
PLC Programming (FBD) functional block diagram
PLC Programming (SFC) sequential function chart
Writing a Program and Developing a HMI for a Small Systems
RSLogix 5000, ControlLogix PIDE (PID Enhanced) Function Block Diagram
Motor Control and Logic Functions
Plant Electrical System
Motor Control Center (MCC)
Typical MCC Design
Typical Motor Controller
How to Control a Motor
Starter Auxiliary Contacts
Overload and Fault
The basic NEMA stop-start station
Typical Motor Control Schematic
NEMA and IEC Terminal Designations
NEMA Standards Publication ICS 19-2002 (R2007)
Relays and Contacts
Coil Lettering and Relay Socket Numbers (NEMA & IEC Numbers)
Standard Symbols
Standard Symbols (Continued)
NEMA and IEC Comparisons
Stop-Start Station Control Circuit Schematic
Starter Control Circuit Schematic
Relay Ladder Logic (RLL) and Function Blocks
RLL and Their Boolean Functions
Putting Ladder Logic into the PLC
Example of a Safety System in a PLC
Safety Logic in the PLC
Alarming on Sensor Input Failure
The PLC Logic for Valve and Alarm Monitoring
Schematic to Programming Languages
The Application of Analog Circuits in Control Systems
Overview of Analog Signals
Typical Analog Loop Wiring Diagram
Simplified signal transmitters that maintain constant flow rate for measurement variable
Constant Current Loops and Ohmโs Law
Current Loop Fundamentals
The 4-20 mA Current Loop
Using Current to Transmit Transducer Data
Current Loop Components
Current Loop System
Designing a Current Loop System
Choosing a Power Supply
Adding More Transducers and Instruments
Devices in Series
A typical Current Loop Repeater
Active and Passive Current Loops
Sinking and Sourcing Devices
What is the difference between PNP and NPN?
PNP Sensor verses NPN Sensor
Overview of Motion Controller Applications
Motion Control Systems
The basic architecture of a motion control system contains:
Stepper Motor
Closed-Loop Stepper Motor
Stepper motor advantages
Linear motion control
Series vs. parallel connection
Servo motor systems
Advanced motion controls
Position plus velocity system
Electro-hydraulic Servo System
Position and pressure/force control
Position transducers
Fieldbus interfaces
Applications of servo systems
Soft Starter Applications
How does a soft starter work?
Benefits of choosing a soft starter
Variable Frequency Drive
How does a variable frequency drive work?
Conversion from AC to DC to AC PWM
Volts to Hertz Relationship
Important Note about Low Frequency in VFDs
VFDs put Noise into the Electrical System
PID Control with VFD or DC Drive
Closed loop control with drive electronics
Block diagram of PID control with feedback operation available on some VFDs
Drive with built-in PID tension control of web or winding reel operation
Electrical Systems and Power Quality
Filtering Power and Harmonics
Harmonic Neutralizing Transformers
Filtering of a Harmonics in Power Systems
Passive Filter
Active Filter
Proper Grounding Procedures
Emergency Standby Systems
Article 700 โ Emergency Systems
Article 701 โ Legally Required Standby Systems
Article 702 โ Optional Standby Systems
UPS (uninterruptible power supply)
UPS and Battery Bank Sizing
Load Profile Calculation
Battery Sizing Calculation
Worked Example โ Sizing the Battery Bank
Backup Generator
BMCS Implementation (Building Monitoring and Controls System)
Hydraulics and Pneumatics
Fluid Power Systems
Hydraulic Systems
Pneumatic Systems
Typical Pneumatic System (this type may be found in a manufacturing or chemical plant)
Mechanical Flow Diagram of a Large Compressor
Instrumentation Air Header (Fluid Distribution Header or Manifold)
Pneumatic Schematic of Valve Controller
I/P Current to Pneumatic Positioner
Instrument Air Cost - Engineering Economics
Assumption
Peak air demand
Vendor data
Include Total Demand
Instrument Air Piping and Cost
Pipe sizing is just like sizing electrical lines
Caution Using Charts and Graphs
Interconnects and headers
The Target Objectives
Eliminate the pressure drop
Air Velocity
Crunching the Numbers
Recover Wasted Heat to Save Money
Fluid Power Schematic Symbols
Overview of Conveying Technologies
Some common types of conveying systems are as follows:
Heavy Duty Roller Conveyors
Flexible Conveyors
Vertical Conveyors and Spiral Conveyors
Spiral Conveyors
Vertical conveyor with forks
Vibrating Conveyors
Pneumatic and Vacuum Conveyors
Pneumatic Tube Conveyor Systems
Large Complex Pneumatic Conveying Systems
Typical Plant Pneumatic Conveying System
HMI for Pneumatic Conveying System
Dilute Phase Systems
Dense Phase Systems
Conveying Phase Diagram
Pressure Distance Relationships
Vacuum Conveying
A typical vacuum product transportation system
Vacuum conveying systems and HMI display
Vacuum conveying system HMI display
Blower operating cost of pneumatic systems
Screw conveying systems
Screw conveyor instruments
Mass or bulk flow measurement
Radiometric measurement for mass flow rate
Load cell measurement for mass flow rate
Mass flow control of conveying system
Radiometric measurement for mass flow rate
Load Cell (Strain Gauge) measurement for mass flow rate
Typical scale systems used on manufacturing lines and in plants
Chemical Process Technology and Equipment
Process Technologies
Separation Processes
A Typical Horizontal 3-Phase Separator
Industrial Distillation
A Typical Industrial Distillation Process
A Typical Distillation Unit
Industrial Furnaces (Fired Heaters)
Industrial Furnaces
Fired Heater Control Scheme
Expansion Tanks and Heat Transfer Fluid
Vapor Pressure, Boiling and Cavitation in Equipment
Vaporization in Equipment
Control Valve Applications
Pumping Applications
Video of Vaporization and Cavitation Phenomenon
Heat Exchangers
Flow Arrangement
Shell and Tube Heat exchanger
Dynamic scraped surface heat exchanger
Phase-change heat exchangers
Reboiler as seen on a distillation column
Heat Exchanger BTU Calculation and Control
Example of how to control the heat exchanger:
Condenser (heat transfer)
Evaporation Processes
What is evaporation?
What is latent heat?
What is the boiling point?
Various types of evaporators and their working principle
Vertical Falling Film Evaporator
Horizontal film evaporator
Low Temperature Vacuum Evaporator
Using the Psychrometric Chart
Cooling Towers
Cooling tower calculations
Cooling tower water loss and make-up
Cooling tower control scheme and operating cost
Typical pH correction system
Chemical Reactors and Control
What is a reactor?
Types of reactors
Basic control scheme for a reactor
CSTR (Constant Stirred Tank Reactor)
Hydrocracking reactor controls
Chemical Scrubbers
Wet exhaust gas cleaning
Wet gas scrubber
Dry scrubbing
Scrubber waste products
Bacteria spread
Dehydration Processes
Absorption
Joule-Thompson effect
Crystallization Technology
Static Crystallization
Falling Film Crystallization
Suspension Crystallization
Process flow diagram suspension crystallization
Freeze Concentration
Overview of a small crystallization plant to control
Flare and Vent Disposal Systems
Types of flares
Flare Control Systems
Quality Control Standards for Production of Products
ISA Standards for Documentation
ISA Instrument or Function Symbol
ISA Line Type Symbols
Standard line types:
ISA Identification Letters
ISA P&ID Identification (Controllers & Readouts)
ISA P&ID Identification (Transmitters, Switches & Alarms)
ISA P&ID Identification (Compute, Relay & Elements)
Piping and Equipment Symbols
Standard P&ID (Piping and Instrumentation Diagram)
P&ID Sample 1 (Functions)
P&ID Sample 2 (Alarms)
P&ID Sample 3 (Separator)
EM (equipment modules) as in ISA S88 standard
Cross limiting control of furnace
Simplified P&ID Sample 1
Simplified P&ID Sample 2
ISA Standard PFD (Piping Flow Diagram) or MFD (Mechanical Flow Diagram)
PFD (Piping Flow Diagram) Sample 1
BFD (Block Flow Diagram)
BFD Sample 1
BFD Sample 2
ISA Standard Loop Diagram
Instrument Location and Elevation Plan Drawing
Instrument Index Sheet
DCS or PLC I/O List (a list of inputs and outputs with tags and calibration data)
ISA Standard (HMI) Graphical Display Symbols & Designations
HMI Sample 1
HMI Sample 2
NFPA 79 Colors for Graphical Displays (Industrial Machinery)
Battery Limits of the Plant
Overview of Safety Instrumented Systems
Overview of process safety and shutdown
SIS (Safety Instrumented Systems)
Complying with IEC 61511 / ISA 84
Other codes related to SIS systems
ISA and OSHA letter defining the requirements of the implementation of SIS systems
Initiating Events of Safety Instrumented Systems
The difference between BPCS and SIS systems
IEC 61508 mandatory and guidelines
SIF and SIL
Risk analysis and protection layers
Designing a SIS System
SIL (Safety Integrity Level) โ Unit for Functional Safety
SFF โ Safe Failure Fraction
Probability of Failures on Demand (PFD)
Probability of Failures per Hour (PFH)
SIL Capability and Safety System
SIF (Safety Instrumented Function)
A typical P&ID of the (SIF) Instrumentation
Voting or (Polling of the System)
A typical voting system and its instrumentation for the above P&ID
Types of Voting (X out of X)
Voting Probabilities
The SIS calculations
Quantification of Reliability in almost absolute terms
Failure Models โ The Bathtub Curve
Reliability Laws
Improving the reliability of a measurement system
Safety Integrity Level (SIL) and Availability
Sample of SIL Evaluation
Acronyms
Metrics used in the reliability engineering field involving SIS
2. MTTR = Mean Time to Repair
3. MTBF โ Mean Time Between Failures
4. Availability A(t) and Unavailability U(t)
5. Probability of Failure on Demand (PFDavg) and Periodic Test and inspection
SIS Calculations - worked example
Calculating PFD (Probability of Failure on Demand)
Calculating MTTF (Mean Time to Failure) based on failure ratesโฆ
Calculating MTBF based on failures
SIS & SIL โ worked examples
Recommended SIS Study Material
Excerpts from Process Safebook 1 โ Rockwell Automation
Overview of NEC / NFPA and Other Codes
CFR (Federal Government) Public Safety Standards of the United States
List of NFPA codes (be familiar with these codes)
NFPA 70 โ NEC (National Electrical Code)
Voltage Drop Calculations
Substitute specific resistance (k) for resistance (R) of wire
Wire and cable sizing formulas for voltage drop
Voltage drop calculations โ worked examples
NEC Article 500 Explosion Proof Installations
Class I Hazardous Location NEC Article 501
Class I Location Definition
Class I Division Definitions
Class I Group Definitions
Class I Temperature Definition
Class II Hazardous Location NEC Article 502
Class II Location Definition
Class II Division Definitions
Class II Group Definitions
Class II Temperature Class
Class III Hazardous Location NEC Article 503
Class III Location Definition
Class III Division Definitions
Class III Group Definitions
Use of Zone Classifications
Classification Comparison (Zone/Division) for a Class I Location
Group Comparison (Zone/ Division) for a Class I Location
Protection Methods Comparison Class
Designation of NEC/CEC Classification
Hazardous Location Classification
Summary the various hazardous (classified) locations.
Hazardous Location Wiring Methods
Purged and pressurized systems
Intrinsically safe systems
Zener diode barrier (configurations)
Conventional passive IS Zener barriers
Active (powered) IS isolation barriers
NEC Article 409 and UL 508A
What is NEC 409 and UL 508A?
SCCR (Short-circuit current rating) of industrial control panels
Components in the power circuit
SCCR calculations โ worked examples
NEC Articles for Remote Control and Signaling
Article Categories
Cabling Installations and Applications (Types and Ratings)
Cables Selection for Installation per NEC Code
Article 725 - Class 1, Class 2, Class 3, Remote-control Circuits
Power sources
Class 1 methods and materials
Class 2 and Class 3 methods and materials
Article 800 - Communications Circuits
Examples of Article 725, 727 and 800 in instrumentation and controls
NEMA Electrical Enclosures Types and Uses
Non-hazardous location NEMA enclosure types
Table 10 โ Indoor Nonhazardous Locations
Table 11 - Outdoor Nonhazardous Locations
Table 12 - Hazardous Locations
Temperature Rise Calculation
NFPA 70E Standard for Electrical Safety
What is NFPA 70E?
What is Arc Flash
Approach / Protection Boundaries
Arc Flash Analysis
Required Arc Flash Warning Label
NFPA 77 Static Electricity
1.2 Purpose
8.1 General overview
8.3.1 Charge generation
G.1 Grounding diagrams
NFPA 780 Lightning Protection (formerly NFPA 78)
NFPA 780 and NFPA 70 (NEC)
Strike-termination devices
Connecting conductors to electrodes
Routing down conductors
Conductor and electrode connection
Earth-grounding electrodes
Summary of lightning protection components
Air terminal height
Conductor bends
Conductor size and material
Transient Protection from Lightning Strikes
NFPA 79 Industrial Machinery
Conductor sizing
Conductor colors
Pushbutton functions for color
Colors for Machine Indicator Lights and Icons Table 10.3.2
NFPA 496 Purged and Pressurized Systems
Overview of the NFPA 496 articles
Factors to consider (NFPA 496, Sec. 5-3)
Location of the control room (NFPA 496, Secs. 5-3.1(c) and 5-3.2)
Positive pressure air systems (NFPA 496, Sec. 5-4.1)
Type X equipment (NFPA 496, Sec. 5-4.4)
Type Y equipment (NFPA 496, Sec. 5-4.5)
Type Z equipment (NFPA 496, Sec. 5-4.5)
Examples of Purged and Pressurized Systems
Basic design of purged enclosures
Basic design of purged buildings
40 CFR & EPA - LDAR
The Clean Air Act (CAA)
What the Law Requires
Putting It All Together
Define the Scope of the Plant
Define the Control Systems Architecture
Some Typical Large DCS Architectures
More on DCS Cabinets and I/O Distribution
Distributing the Power and Control
Routing the Cable Trays
Choose the Wiring Method
Field Distribution Systems
Class I, Division 2 Installations
Class I, Division 1 Installations
Modular Wiring Distribution Systems
Instrument Air Supply and Pneumatic Tubing
Instrument Air Consumption
Compressor Types
Piping System and Manifold
Air Pipe Header
Pneumatic Tubing
Air Distribution Manifold (Header)
Routing of Pneumatic Tubing
Heat Tracing Systems
Electric Heat Tracing
Steam Heat Tracing
Free Heat Tracing Software
Determine Scope of Design
Electrical Scope
Instrumentation and Mechanical Scope
Design of Electrical Plans
Sample of a possible design for the control network and communications in plant
Sample of a possible plan for routing of cable tray and conduit in plant
Sample of a possible layout for a MCC building with medium voltage switchgear installed
Sample of a possible one line electrical diagram for the low voltage in the MCC building
Sample of a possible ladder diagram for the control of an Allen Bradley frequency drive
Sample of a possible electrical field wiring diagram for the frequency drive
Sample of a possible electrical field wiring diagram for routing the analog instruments to the DCS
Locations of Instruments and Piping Design
Finding the location of an instrument in a plant
Useful Equations for Pumping, Piping and Sizing Valves
Find pipe diameter with velocity of flow known
Find flow velocity with pipe diameter known
Find pipe diameter with temperature and pressure correction
Find flow velocity with temperature and pressure correction
Find the Reynolds Number for the flow
Calculate the Piping Head Losses to Size a Control Valve
Find the pump motor size (break horsepower)
Calculating the Hydraulic Horsepower of pumps
Calculating the Brake Horsepower of pumps
Correct Pump Head and Flow Rate for Fluid Viscosity
Piping Absolute Roughness Values
Applications of Pumping Systems
Pump Basics
Static Head
Applying variable frequency drives to pumps to realize savings
Pumps with variable frequency drive (VFD)
When can you save with a VFD?
Sizing pump head with specific gravity of the pumped fluid
How a Piping System Works
Calculating Volume in Tanks
Cylindrical Tanks Upright
Cylindrical Tanks on Side
Spherical Tanks
Bullet Tanks
Examination Sample Questions
Sample Questions
Answers to Examination Sample Questions
Explanations and Proofs of Examination Sample Questions
Preparing this Guide for the Exam
An Avery tab template is included with this guide
Suggested tabbing the guide
Guide to Using the Fisher Control Valve Handbook
Important Sections to Review
Important Pages to Tab
Valve and materials Selection
Actuator Sizing Methods
Valve Sizing Methods
Electrical Apparatus
Engineering Data
Piping System Applications
Conversions and Equivalents
Appendix and Data Tables
Table A1 - Thermocouple Table (Type J)
Table A2 - Thermocouple Table (Type K)
Table A3 - Thermocouple Table (Type E)
Table A4 - Thermocouple Table (Type T)
Table A5 - Platinum 100 Ohm RTD Table in ohms
Table A6 - Properties of Water Specific Gravity and LBs/HR to GPM
Table A7 - Properties of Water Specific Volume and Density
Table A8 - Properties of Water Kinematic Viscosity centistokes
Table A9 - Properties of Saturated Steam
Table A10 โ Valve Selection โ Materials and Applications
Valve Terms
Selecting your Valve
Valve Types and Descriptions
Valve Selection Overview - Service Application Chart
Valve Selection Detailed - Service Application Chart
Valve Types - Advantages and Disadvantages
Standard Control Valve Body Materials
Valve Seat Leakage Bubbles per Minute
Valve Trim Material Temperature Limits
Valve Service Temperature Limits for Non-Metallic Materials
Valve Stem Packing Friction Values (Typical)
Valve Stem Packing Temperature โ Pressure
Valve Seating Shutoff Pressure
Abbreviations and Terminology
Table A11 โ Properties and Sizing Cv Coefficients for Fisher ED Globe Valves
Table A12 โ Properties and Sizing Cv Coefficients for Fisher Rotary Valves
Table A13 - Numerical Constants for Control Valve Sizing Formulas
Table A14 โ Critical Pressure & Temperature of Elements
Table A15 โ Pipe Standard Dimensions and Data
Table A16 โ NEC Wire Ampacity Table 310.16
Table A17 โ NEC Conductor Properties and Impedance
Table A18 โ NEC Full Load Motor Currents
Table A19 โ NEC Grounding and Bonding Conductors
Table A20 - Specific Gravity and Gas Constants for Some Common Gases
Table A21 - Specific Gravity Common Fluids
Table A22 - The kinematic viscosity common fluids
Table A23 - The absolute viscosity common liquids
Table A24 - The absolute viscosity common gases
Table A25 - Density of Elements in English and Metric Units
Table A26 - Metric Conversion Tables
Table A27 โ Standard Conditions and Gas Laws
Table A28 โ Head Loss in Piping Systems
Table A29 โ Maximal flow velocity in pipes
Table A30 โ Pressure Vapor Chart of Common Liquids
References