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Control of Batch Processes PDF

337 Pages·2014·14.914 MB·English
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CONTROL OF BATCH PROCESSES CONTROL OF BATCH PROCESSES CECIL L. SMITH Copyright © 2014 by John Wiley & Sons, Inc. All rights reserved Published by John Wiley & Sons, Inc., Hoboken, New Jersey Published simultaneously in Canada No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, scanning, or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without either the prior written permission of the Publisher, or authorization through payment of the appropriate per-copy fee to the Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923, (978) 750-8400, fax (978) 750-4470, or on the web at www.copyright.com. Requests to the Publisher for permission should be addressed to the Permissions Department, John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, (201) 748-6011, fax (201) 748-6008, or online at http://www.wiley.com/go/permissions. Limit of Liability/Disclaimer of Warranty: While the publisher and author have used their best efforts in preparing this book, they make no representations or warranties with respect to the accuracy or completeness of the contents of this book and specifically disclaim any implied warranties of merchantability or fitness for a particular purpose. No warranty may be created or extended by sales representatives or written sales materials. The advice and strategies contained herein may not be suitable for your situation. You should consult with a professional where appropriate. Neither the publisher nor author shall be liable for any loss of profit or any other commercial damages, including but not limited to special, incidental, consequential, or other damages. For general information on our other products and services or for technical support, please contact our Customer Care Department within the United States at (800) 762-2974, outside the United States at (317) 572-3993 or fax (317) 572-4002. Wiley also publishes its books in a variety of electronic formats. Some content that appears in print may not be available in electronic formats. For more information about Wiley products, visit our web site at www.wiley.com. Library of Congress Cataloging-in-Publication Data: Smith, Cecil L. Control of batch processes / Cecil L. Smith. pages cm Includes index. ISBN 978-0-470-38199-1 (hardback) 1. Chemical process control. 2. Mass production. I. Title. TP155.75.S584 2014 660'.2815–dc23 2014007295 Printed in the United States of America 10 9 8 7 6 5 4 3 2 1 CONTENTS Preface ix 1 Introduction 1 1.1. Categories of Processes 3 1.2. The Industry 5 1.3. The Ultimate Batch Process: The Kitchen in Your Home 13 1.4. Categories of Batch Processes 14 1.5. Automation Functions Required for Batch 18 1.6. Automation Equipment 26 Reference 30 2 Measurement Considerations 31 2.1. Temperature Measurement 32 2.2. Pressure Measurement 39 2.3. Weight and Level 47 2.4. Flow Measurements 61 2.5. Loss-in-Weight Application 67 References 72 3 Continuous Control Issues 73 3.1. Loops That Operate Intermittently 74 3.2. Emptying a Vessel 80 3.3. Terminating a Co-Feed 85 3.4. Adjusting Ratio Targets 89 v vi COnTEnTs 3.5. Attaining Temperature Target for the Heel 97 3.6. Characterization Functions in Batch Applications 100 3.7. scheduled Tuning in Batch Applications 101 3.8. Edge of the Envelope 104 3.9. no Flow Through Control Valve 107 3.10. no Pressure Drop across Control Valve 111 3.11. Attempting to Operate above a Process-Imposed Maximum 115 3.12. Attempting to Operate Below a Process-Imposed Minimum 121 3.13. Jacket switching 124 3.14. smooth Transitions between Heating and One Cooling Mode 129 3.15. smooth Transitions between Two Cooling Modes 140 References 148 4 Discrete Devices 149 4.1. Discrete Inputs 149 4.2. Discrete Outputs 157 4.3. state Feedbacks 167 4.4. Associated Functions 176 4.5. Beyond Two-state Final Control Elements 182 5 Material Transfers 185 5.1. Multiple-source, single-Destination Material Transfer system 186 5.2. single-source, Multiple-Destination Material Transfer system 189 5.3. Multiple-source, Multiple-Destination Material Transfer system 191 5.4. Validating a Material Transfer 194 5.5. Dribble Flow 197 5.6. simultaneous Material Transfers 202 5.7. Drums 203 6 Structured Logic for Batch 205 6.1. structured Programming 207 6.2. Product Recipes and Product Batches 212 6.3. Formula 215 6.4. Operations 216 6.5. Phases 220 6.6. Actions 223 References 226 7 Batch Unit or Process Unit 227 7.1. Defining a Batch Unit 228 7.2. supporting Equipment 232 7.3. step Programmer 237 COnTEnTs vii 7.4. Failure Considerations 241 7.5. Coordination 254 7.6. shared Equipment: Exclusive Use 257 7.7. shared Equipment: Limited Capacity 261 7.8. Identical Batch Units 262 8 Sequence Logic 265 8.1. Features Provided by sequence Logic 265 8.2. Failure Monitoring and Response 267 8.3. Relay Ladder Diagrams 273 8.4. Procedural Languages 276 8.5. special Languages 278 8.6. state Machine 280 8.7. Grafcet/sequential Function Charts (sFCs) 283 9 Batches and Recipes 290 9.1. Organization of Recipes 291 9.2. Corporate Recipes 294 9.3. Executing Product Batches simultaneously 299 9.4. Managing Product Batches 302 9.5. Executing Operations 305 9.6. Batch History Data 309 9.7. Performance Parameters 313 Index 319

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