CSE Review

Control Systems
Engineering Exam
Reference Manual:
A Practical Study Guide
Second Edition

For the NCEES Professional Engineering (PE)

Licensing Examination

Bryon Lewis, CSE, PE

Table of Contents
Preface ..................................................................................................................................................... 1
About The Author .................................................................................................................................... 1
General Information ..................................................................................................................................... 3
State Licensing Requirements .................................................................................................................. 3
Eligibility ................................................................................................................................................... 3
Exam Schedule ......................................................................................................................................... 3
Exam Format ............................................................................................................................................ 4
Exam Content ........................................................................................................................................... 4
Reference Materials for the Exam ................................................................................................................ 7
Recommended Books and Materials for Testing ..................................................................................... 7
Books and Courses for Additional Study .................................................................................................. 8
Review of Process Control Subjects ............................................................................................................. 9
Overview of Process Measurement, Control and Calibration ................................................................. 9
Process Signal and Calibration Terminology ..........................................................................................10
Definition of the Range of an Instrument ..............................................................................................10
Definition of the Span of an Instrument ................................................................................................11
Definition of the use of Zero in Instrumentation ...................................................................................12
Live-Zero ............................................................................................................................................12
Elevated-Zero .....................................................................................................................................12
Suppressed-Zero ................................................................................................................................12
Illustrations of range and span terminology ..........................................................................................13
Illustrations of measured variable, measured signal, range and span ..................................................14
Temperature Measurement and Calibration .............................................................................................15
Temperature Measurement Devices and Calibration ............................................................................15
Thermocouple Worked Examples (how to read the thermocouple tables) ..........................................17
RTD (Resistance Temperature Detector) ...............................................................................................18
RTD Worked Examples ...........................................................................................................................18
Pressure Measurement and Calibration ....................................................................................................21
Pressure Measurement and Head Pressure ..........................................................................................21
Applying Pressure Measurement and Signals Worked Examples .........................................................22
Differential Pressure and Meter Calibration ..........................................................................................22
Pressure Change across Pipe for a given Flow Rate ...............................................................................23
Pressure Change across the Flow Element for a given Flow Rate .........................................................23
Pressure Calibration of Transmitter .......................................................................................................24
Level Measurement and Calibration ..........................................................................................................25
Applying Level Measurement and Calibration Worked Examples .........................................................25
Level Displacer (Buoyancy) ....................................................................................................................27
Bubbler Level Measurement ..................................................................................................................29
Density Measurement ............................................................................................................................30
Calculating the Volume in Tanks ............................................................................................................30

Flow Measurement and Calibration ..........................................................................................................31

Applying Flow Measurement Devices ...................................................................................................31
Turndown Ratio in a Flow Meter ..........................................................................................................31
ISA Standard Flow Meter Symbols .........................................................................................................31
Flow Meter Applications Chart ..............................................................................................................32
Orifice Tap Dimensions and Impulse Line Connections .........................................................................33
Applying the Bernoulli Principal for Flow Control ..................................................................................34
Orifice Type Meters ................................................................................................................................35
Orifice Sizing Factors (The Spink Factor) ................................................................................................38
Sizing Orifice Type Devices for Flow Measurement Worked Examples .................................................39
Mass Flow Measurement and Control ...................................................................................................41
Applying Mass Flow Measurement with an Orifice Worked Example ...................................................44
Turbine Flow Meter Worked Example ...................................................................................................46
Weight Measurement and Calibration........................................................................................................49
Weight Measurement Devices and Calibration ......................................................................................49
Sizing Process Control Valves .....................................................................................................................51
Process Control Valves ...........................................................................................................................51
Turndown Ratio in Valves ......................................................................................................................51
ISA Standard Valve Symbols ...................................................................................................................52
ISA Standard Pressure Regulating Valve Symbols ..................................................................................52
Valve Actuators ......................................................................................................................................53
ISA Standard Actuator Symbols ..................................................................................................................53
ISA Standard Symbol for Limit Switches on Valve Actuator .......................................................................54
Calculating the size of the actuator ............................................................................................................54
Example Actuator Sizing .............................................................................................................................55
Split Ranging Control Valves ..................................................................................................................57
Valve Positioner Applications ................................................................................................................58
ISA Standard Valve Positioner Symbol .......................................................................................................58
Summary of Positioners .............................................................................................................................59
When should a positioner be used? ...........................................................................................................59
Control Valve Application Comparison Chart ........................................................................................60
Sizing Control Valves ..............................................................................................................................61
Sizing Valves for Liquid ......................................................................................................................63
Sizing Valves for Gas ..........................................................................................................................65
Sizing Valves for Vapor and Steam ....................................................................................................68
Sizing Valves for Two Phase Flow ......................................................................................................71
Sizing Pressure Relief Valves and Rupture Disks ........................................................................................75
ASME VIII Code for Sizing Relief Valves and Rupture Disks ...................................................................75
Pressure Limits in Sizing .........................................................................................................................75
ISA Pressure Relief Valve and Rupture Disc Symbols .............................................................................76
Sizing Pressure Relief Valves and Rupture Disks ....................................................................................77
Sizing Rupture Disks Worked Examples .................................................................................................80
Sizing Pressure Relief Valves Worked Examples ....................................................................................83
ASME Standard Nozzle Orifice Data .......................................................................................................88
Table 7 - Typical Properties of Gases ......................................................................................................89

Process Control Theory and Calculations ....................................................................................................91

Degrees Of Freedom in Process Control Systems .................................................................................91
Controllers and control stratigies (models-modes) ...............................................................................93
Process Characteristics from the transfer function ...............................................................................95
Controller Tuning Closed Loop ...............................................................................................................98
Controller Tuning Open Loop ...............................................................................................................100
A Typical Process Reaction curve for tuning a controller ....................................................................101
Block Diagram Algebra .........................................................................................................................103
Block Diagram Algebra Reduction (Example) ......................................................................................104
Nyquist Stability Criterion ....................................................................................................................105
Routh Stability Criterion .......................................................................................................................107
Check for Stability using Routh (Example) .......................................................................................110
A First Analysis of Feedback Control .......................................................................................................113
Compare Open Loop Control to Closed Loop Control .........................................................................113
Open Loop Example A Mathematical Analysis ..................................................................................113
Closed Loop Example A Mathematical Analysis ................................................................................115
The Transfer Function for the Automobile ..........................................................................................117
A First Analysis of Frequency Response ...................................................................................................119
Electrical Application A First Order System .......................................................................................119
Bode Plot of First Order System ...........................................................................................................120
Calculate data for the Bode Plot ..........................................................................................................121
Creating a Bode Plot First Order System using Frequency ...............................................................124
Hydraulic Application A First Order System ......................................................................................125
Overview of Discrete Control Subjects .....................................................................................................127
Overview of Digital Logic ......................................................................................................................127
Digital Logic Gate symbold ...................................................................................................................127
Digital Logic Gate Truth Tables ............................................................................................................128
ISA Binary Logic ....................................................................................................................................129
Relay Ladder Logic ................................................................................................................................130
Sealing Circuits .....................................................................................................................................131
PLC Programming .................................................................................................................................132
PLC Programming (RLL) relay ladder logic .......................................................................................132
PLC Programming (ST) structured text ............................................................................................132
PLC Programming (FBD) functional block diagram ..........................................................................133
PLC Programming (SFC) sequential function chart ..........................................................................133
Analog Control Signals ..............................................................................................................................135
Overview of Analog Signals ..................................................................................................................135
Typical Analog Loop Wiring Diagram ...................................................................................................135
Signal Filtering in Process Control ........................................................................................................136
Appling Signal Filters ........................................................................................................................136
Filter Time Constant and Sample Time ............................................................................................137
Example of Filter Time Selection .....................................................................................................138

ISA Standards for Documentation ............................................................................................................141

ISA Identification Letters ......................................................................................................................141
ISA Letter Combinations ......................................................................................................................142
ISA Instrument or Function Symbol .....................................................................................................145
ISA Line Type Symbols ..........................................................................................................................146
ISA Standard P&ID ................................................................................................................................147
ISA Standard PFD ..................................................................................................................................150
ISA Standard Loop Diagram .................................................................................................................151
ISA Standard (HMI) Graphical Display Symbols & Designations ..........................................................153
NFPA 79 Colors for Graphical Displays (Industrial Machinery) ............................................................154
Overview of Safety Instrumented Systems ..............................................................................................155
Overview of Process Safety and Shutdown .........................................................................................155
SIS (Safety Instrumented Systems) ......................................................................................................155
SIF (Safety Instrumented Function) .....................................................................................................156
SIL (Safety Integrity Level) ....................................................................................................................157
SIS Calculations ....................................................................................................................................160
Overview of Industrial Control Networks .................................................................................................163
Overview of Networks and Communications ......................................................................................163
Layers That Make Up the OSI Layers ....................................................................................................165
Intelligent and Smart Devices ..............................................................................................................165
Overview of NEC and NFPA Codes ...........................................................................................................167
List of NFPA Codes ...............................................................................................................................167
NFPA 70 NEC (National Electrical Code) ............................................................................................167
Voltage Drop Calculations ...............................................................................................................168
Substitute Specific Resistance (k) for Resistance (R) of wire ...................................................................168
Wire and Cable Sizing formulas for Voltage Drop ....................................................................................168
Example: Voltage Drop Calculation 1 .....................................................................................................169
Example: Voltage Drop Calculation 2 ......................................................................................................169
Explosion Proof Installations NEC Article 500 (Hazardous Locations) ...........................................170
Class I Hazardous Location NEC Article 501 .............................................................................................170
Class I Location Definition .......................................................................................................170
Class I Division Definitions ......................................................................................................170
Class I Group Definitions .........................................................................................................171
Class I Temperature Definition ...............................................................................................171
Class II Hazardous Location NEC Article 502 ............................................................................................172
Class II Location Definition ......................................................................................................172
Class II Division Definitions .....................................................................................................172
Class II Group Definitions ........................................................................................................173
Class II Temperature Class ......................................................................................................173
Class III Hazardous Location NEC Article 503 ...........................................................................................174
Class III Location Definition .....................................................................................................174
Class III Division Definitions ....................................................................................................174
Class III Group Definitions .......................................................................................................174
Use of Zone Classifications .......................................................................................................................175
Classification Comparison (Zone/Division) for a Class I Location ...........................................175
Group Comparison (Zone/ Division) for a Class I Location .....................................................175
Protection Methods Comparison Class I ..................................................................................................176

Example: Designation of NEC/CEC Classification .....................................................................................177

Example: Hazardous Location Classification ............................................................................................178
Purged and Pressurized Systems ..............................................................................................................179
Intrinsically Safe Systems .........................................................................................................................179
Zener diode barrier (configurations) ........................................................................................................179
Conventional Passive IS Zener Barriers ...................................................................................179
Active (Powered) IS Isolation Barriers .....................................................................................179
Electrical Enclosures Types and Uses ..............................................................................................180
Table 10 Indoor Nonhazardous Locations .............................................................................................181
Table 11 - Outdoor Nonhazardous Locations ...........................................................................................182
Table 12 - Hazardous Locations ................................................................................................................183
Determining Temperature Rise ................................................................................................................183
NFPA 77 Static Electricity .....................................................................................................................184
1.2 Purpose ......................................................................................................................................184
8.1 General Overview ......................................................................................................................184
8.3.1 Charge Generation ..................................................................................................................185
G.1 Grounding Diagrams .................................................................................................................186
NFPA 780 Lightning Protection (formerly NFPA 78) ............................................................................187
Air Terminal Height ..........................................................................................................................187
Conductor Bends .............................................................................................................................187
Conductor Size and Material ...........................................................................................................188
NFPA 79 Industrial Machinery .............................................................................................................190
Conductor sizing ..............................................................................................................................190
Conductor colors ..............................................................................................................................190
Pushbutton functions for color ........................................................................................................190
Colors for Machine Indicator Lights and Icons Table 10.3.2 ............................................................190
NFPA 496 Purged and Pressurized Systems .........................................................................................191
Overview of the NFPA 496 articles ..................................................................................................191
Factors to consider (NFPA 496, Sec. 5-3) .........................................................................................191
Location of the control room (NFPA 496, Secs. 5-3.1(c) and 5-3.2) ................................................192
Positive pressure air systems (NFPA 496, Sec. 5-4.1) ......................................................................192
Type X equipment (NFPA 496, Sec. 5-4.4) .......................................................................................192
Type Y equipment (NFPA 496, Sec. 5-4.5) .......................................................................................192
Type Z equipment (NFPA 496, Sec. 5-4.5) .......................................................................................192
Basic Design of Purged Enclosures ..................................................................................................193
Basic Design of Purged Buildings .....................................................................................................194
The Fisher Control Valve Handbook .........................................................................................................195
Guide to Using the Control Valve Handbook .......................................................................................195
Examination Sample Questions ................................................................................................................197
Sample Questions ................................................................................................................................197
Answers to Examination Sample Questions ........................................................................................204
Explanations and Proofs of Examination Sample Questions ...............................................................205

Useful Equations for Pumping and Piping ................................................................................................217

Find pipe diameter with velocity of flow known .................................................................................217
Find flow velocity with pipe diameter known ......................................................................................217
Find pipe diameter with temperature and pressure correction ..........................................................217
Find flow velocity with temperature and pressure correction ............................................................217
Find the Reynolds Number for the flow ...............................................................................................218
Find the pressure loss in piping system ...............................................................................................218
Find the pump motor size (break horsepower) ...................................................................................218
Calculating the Volume of Tanks ..............................................................................................................219
Cylindrical Tanks Upright .....................................................................................................................219
Cylindrical Tanks on Side ......................................................................................................................219
Spherical Tanks ....................................................................................................................................220
Bullet Tanks ..........................................................................................................................................220
Appendix ...................................................................................................................................................221
Table A1 Thermocouple Table (Type J) .............................................................................................221
Table A2 - Thermocouple Table (Type K) .............................................................................................223
Table A3 - Thermocouple Table (Type E) .............................................................................................226
Table A4 - Thermocouple Table (Type T) .............................................................................................228
Table A5 - Platinum 100 Ohm RTD Table in ohms ................................................................................229
Table A6 - Properties of Water Specific Gravity and LBs/HR to GPM ..................................................230
Table A7 - Properties of Water Specific Volume and Density ..............................................................231
Table A8 Properties of Water Kinematic Viscosity centistokes ........................................................232
Table A9 - Properties of Saturated Steam ...........................................................................................233
Table A10 - Specific Gravity and Gas Constants for Some Common Gases .........................................238
Table A11 Properties and Sizing Coefficients for Globe Valves ........................................................240
Table A12 Properties and Sizing Coefficients for Rotary Valves .......................................................241
Table A13 - Numerical Constants for Control Valve Sizing Formulas ..................................................242
Table A14 Service Temperature Limits for Non-Metallic Materials ..................................................243
Table A15 Standard Pipe Dimensions and Data ................................................................................244
Table A16 NEC Wire Ampacity Table 310.16 ....................................................................................245
Table A17 NEC Table 8 Conductor Properties ...................................................................................246
Table A18 NEC Full Load Motor Currents ..........................................................................................247
References ................................................................................................................................................249

Review of Process Control Subjects

OVERVIEW OF PROCESS MEASUREMENT, CONTROL AND
CALIBRATION
The process control industry covers a wide variety of applications: petrochemical; pharmaceutical; pulp
and paper; food processing; material handling; even commercial applications.
Process control in a plant can include discrete logic, such as relay logic or a PLC; analog control, such as
single loop control or a DCS (distributed control system) as well as pneumatic; hydraulic and electrical
systems. The Control Systems Engineer must be versatile and have a broad range of understanding of
the engineering sciences.
The Control Systems Engineer (CSE) examination encompasses a broad range of subjects to ensure
minimum competency. This book will review the foundations of process control and demonstrate the
breadth and width of the CSE examination.
We will review many aspects of process control systems, first the theory, then application and then
calibration and installation of process control equipment. First we will start with basic terminology and
definitions of process measurement and control signals. We will then review the basic process control
elements, their theory of operation and then apply the elements to real world application. We will then
review the calculations for sizing of the elements, as well as applicable laws, standards and codes
governing the installation of a process control system.

Pressure Measurement and Calibration

Pressure Measurement and Head Pressure
Pressure is measured in typically two different forms. Pounds per square inch (psi) or head pressure.
Head pressure is measured in inches or feet of water column (H2O).
Head pressure is independent of the tanks height or area. The transmitter measures head pressure. Head
pressure is the measure of the potential energy in the system. The transmitter measurement is from how
high is the fluid falling. The distance the fluid falls indicates the force generated (F=ma). This is why the
density of the fluid must be known to calibrate a pressure transmitter for a process, to obtain the fluid
mass. The calibration process uses specific gravity (S.G.), the ratio of a
known density of a fluid divided by the density of water (H2O).
To illustrate these facts we will start with one gallon of water. The gallon
of water equals 231 cubic inches and weighs approximately 8.324 pounds
at 60F. Pressure is measured in PSI (pounds per square inch). Only one
(1) square inch of area is needed to calculate the height of the water and
the force it is excerpting. Remember force divided by area = pressure.
Stack 231 cubic inches of water on top of each other, to form a tall column
of water, with a base of one (1) square inch. The column of water will be
231 inches tall. Divide the height of the column of water, 231 inches, by the
weight of one (1) gallon of water, 8.324 pounds. The result will be 27.691 or
27.7 inches of water per pound of water, over a one square inch of area.
Therefore 27.7 inches H2O, of head pressure, equals one (1) PSI.
By knowing the specific gravity of the fluid to be measured, multiplied by the height of the tank in inches,
an equivalent value in inches of water can be found. The transmitter can now be calibrated in inches of
water, regardless of the fluid. If the tanks fluid has a S.G. equal to 0.8 and a height of 100 inches tall, then
the height in inches of H2O will be (100 of fluid x 0.8 s.g.= 80 of H2O).
Pressure transmitters are purchased in different sizes of measurement. They are in ranges of inches H2O,
psig (the g stands for gauge pressure) or psia (the a stands for absolute pressure). When the symbol
psid (the d stands for differential pressure) is called for, a standard psig transmitter is used. Most
industrial pressure transmitters are differential pressure transmitters. They act on differential forces
applied to each side of the transmitter. The force is produced by the pressure in the system multiplied by
the area of the diaphragm.

21

Sizing Process Control Valves

Process Control Valves
A wide variety of valve types exist, the most widely used for process control systems other industrial
fluid applications are the valve types which have linear stem and rotary spindle movement:

Linear stem movement type valves include globe valves and slide valves
Rotary spindle type valves include ball valves, butterfly valves, plug valves and their variants

The first choice to be made is between two-port and three-port valves:

Two-port valves 'throttle' (restrict) the fluid passing

through them
Three-port valves can be used to 'mix' or 'divert'
liquid passing through them

Globe valves are frequently used for control applications

because of their suitability for throttling flow and the ease
with which they can be given a specific 'characteristic',
relating valve opening to flow. For any given valve orifice
size, the greater the differential pressure the greater the
flow rate. The valve flow coefficient Cv is defined as the
number of U.S. gallons of water per minute (at standard
pressure and temperature) that will flow through a wide
open valve when there is 1 psig pressure drop across the
valve. The flow rate can be determined by the by the
following equation:

1 gpm 1 CV *
=

1 Ppsig

Control valve sizing will be discussed in detail for water, steam, gas, vapor and two phase applications
later in this guide. Later in this guide we will take a look at the accessories that are used on common
valves.

Turndown Ratio in Valves

Turndown is the ratio of maximum to minimum controllable flow. For a pinch valve, 10:1 is typical, so if
you have a maximum flow of 5,000 SCFM, you can expect to maintain stable control down to 500 SCFM.
Of course, the valve can close or drop tight to zero flow, but its difficult to maintain stable control
between zero and your minimum controllable flow. Turndown says nothing about the response, speed
of valve, undershoot, overshoot or duty cycle.

51

ISA Standard Symbol for Limit Switches on Valve Actuator

A typical application of a valve for a gas service is shown below. Limit switches are attached to the
actuator to verify the valve position status. The limit switches send a full open signal (ZSO) or full closed
signal (ZSC). If neither signal is received by the DCS or PLC within a reasonable time, the limit switches
provide a valve stuck or malfunctioning indication. The solenoid is a safety shutdown lockout type
mechanism. The diamond symbol with the R, indicates a manual reset of the solenoid valve in the field
is necessary, to provide instrument air to the gas valve for operation. This insures that personal inspect
the furnace or heater before restoring the gas, to prevent explosions or fire.

Calculating the size of the actuator

The actuator must be sized to not only hold the valve closed against the differential pressure excerpted
upward on the plug by the process fluids pressure, but also to overcome the spring force in the
actuator, which hold the valve closed against the differential pressure of the process fluid. Also extra
pressure may be required to securely seat the valve.
The actuator must be sized for the total forces need to move the valve stem into position.

The force upward (Fp): Process fluid pressure (psig) * area of the plug (in2) in pounds force (lbf).
The force doward by the spring (Fk): force in (lbf) varies with spring size.
The force upward of the diaphragm (Fd): The I/P supplied device pressure (psig) * area of the
valve diaphragm (in2) in pounds force (lbf).
The force to overcome friction (Ff): To move valve against the friction of the stem packing.
The force applied to the seat (Fs): The force applied to the plug to prevent leakage through the
valve seat.

The diaphragm force (Fd) must equal the sum of the process fluid force (Fp) and the force excerpted by
the stem packing (Ff), before the valve stem will start moving. This is because the spring is already
forcing down to overcome the force of the process fluid (Fp) and added force (Fs) need to properly seat
the plug. This force (Fd) may equal 8 pisg * 100 in2 for the diaphragm to equal 800 lbf excepted upward
by the actuator diaphragm.
54

Split Ranging Control Valves

In a split range control loop, output of the controller is split and sent to two or more control valves. The
splitter defines how each valve is sequenced as the controller output changes from 0 to 100%. In most
split range applications, the controller adjusts the opening of one of the valves when its output is in the
range of 0 to 50% (4 to 12 mA) and the other valve when its output is in the range of 50% to 100% (12
to 20 mA).
In this example when the gas pressure exceeds the pressure that the compressors can handle, the extra
gas is sent to the flare to burn, this relieves the pressure on the vessel.

In this example the reactor needs to maintain at a specific temperature range. This requires heating and
cooling the jacket to regulate the temperature for the reaction.

57

Block Diagram Algebra

Simplification Method
Original Block Diagram

Equivalent Block Diagram

103

Check for Stability using Routh (Example)

P ( s ) =s 4 + 7 s 3 + (19 + K ) s 2 + (13 + 7 K ) s + 12 K

Note : { P( s ) = a0 + a1 + a2 + a3 + a4 }

The Routh schema is:

s4
a0
a2
s3
a1
a3
s2
b1
b2
1
s
c1
c2
s0
d1

a4
a5
b3
0

0
0

Building the cross products, you start with the elements of the first row. The calculation of these b
values will be continued until all remaining elements become zero. The coefficients b1 , b2 ,... in the
third row are the results from cross multiplication the first two rows according to

b1
=

a1a2 a0 a3
=
a1

( 7 )(19 + K ) (1)(13 + 7 K )
7

133 + 7 K ) (13 + 7 K )
(=

120
7
7
a1a4 a0 a5 ( 7 )(12 K ) (1)( 0 )
b2 =
=
7
a1

=
b1

b2 = 12 K
b3
=

a1a6 a0 a7
=
a1

( 7 )( 0=
) (1)( 0 )
7

Note: We do not have s5 so a5 will equal 0.

We do not have a6 or a7 so they will equal 0.
The calculation of the cvalues are performed accordingly from the two rows above as follows:

120
(13 + 7 K ) ( 7 )(12 K )
b1a3 a1b2 7
=
c1 =
b1
120

120

(13 + 7 K ) ( 7 )(12 K ) 13 + 7 K 84 K
7

=
=

c1
120
120

7
7
110

First Order Filter

The Derivative Term of the PV Filtered

Plot of the Process Variable Signal Filtered

The plot below shows the random behavior of a raw (unfiltered) PV signal and the smoother trace of a
filtered PV signal.

Filter Time Constant and Sample Time

From the plot above it can be seen that the derivative mode would add to the output tremendously,
without filtering. It can be seen the derivative mode (rate action), would see a gain of about 10/1
compared to 0.5/1 in the signal filtered.
To select a filter time for attenuation of or to eliminate the noise in the process signal (PV) signal, we
would take the reciprocal of the angular frequency, 2 Hz or 2 (cps ) , of the noise signal and select a
filter time constant that is equal to greater than the time constant of the corner frequency
For the first order filter we must pick a corner frequency ( f C ) that is smaller or less than that of the
frequency of noise we wish to attenuate. This will allow the lower frequencies of the process signal (PV)
137

Overview of Safety Instrumented Systems

Overview of Process Safety and Shutdown
On the CSE Exam there will be a few questions on SIS (Safety Instrumented Systems) and SIL (Safety
Integrity Levels). We will discuss some of the calculations and data you may encounter on the test.

SIS (Safety Instrumented Systems)

OSHA law incorporates as the guideline that good engineering practice will be used in evaluating and
engineering safety instrumented systems (SIS). This means that the program follows the codes and
standards published by such organizations as the American Society of Mechanical Engineers, American
Petroleum Institute, American National Standards Institute, National Fire Protection Association,
American Society for Testing and Materials, National Board of Boiler and Pressure Vessel Inspectors, and
ISA. Other countries have similar requirements.

The OSHA approved code standards for the implementation of SIS are ANSI/ISA-84.00.01 (IEC 61511
modified): [For Safety Integrated System Designers, Integrators and Users], and IEC 61508: [For
Manufacturers and Suppliers of Devices and Equipment].
IEC-61508 is currently divided into seven parts:
1. General Requirements
2. Requirements for Electrical/Electronic/Programmable Electronic Safety Systems
3. Software Requirements
4. Definitions and abbreviations of terms
5. Guidelines for application of part 1
155

Overview of Industrial Control Networks

Overview of Networks and Communications
On the CSE Exam there may be a few questions on Fieldbus, Intelligent Devices and networks. We will
briefly review the highlights of these subjects. For more information on fieldbus, contact your local
distributor or the web sites of Fieldbus.org or ProfiBus.org or AB)com.

Fieldbus is a digital, two-way, multi-drop communication link among intelligent control devices that
replace the 4-20 mA analog standard devices. The key to fieldbus is that the device is digital not analog.
There are numerous protocols on the international market: Foundation Fieldbus, ProfiBus, Asi,
ControlNet, DeviceNet, Modbus, and Hart are the most popular in the process industry.
The most popular types of Fieldbus typically use EIA-485 protocol with token passing and 31.25kbps on a
single twisted pair wire that can be run up to 1900 Meters. They can have 32 segments and 1024
intelligent devices per network.
The connected intelligent devices are not calibrated; the data is scaled in software. Intelligent devices
may deliver from one (1) up to twelve (12) or more data variables of information from one instrument.
The data is delivered in data packets to the intelligent control device or master. Possibly the valve may
be the intelligent controller.
Intelligent devices need to be configured when first installed. This is done through EDDL (Electronic
Device Description Language) or FDT (Field Device Tools). Most of the intelligent devices are plug and
play (PnP). ProfiBus devices can even be changed out without reconfiguring the device once initially
configured. The configuration data is stored by the master controller and is then automatically
downloaded to the new device upon connection to the network.

163