This revision of the 1990 work by Thomas Fisher covers an introduction to batch processes; batch control system structures; batch control; batch communications and batch control system design. Hawkins offers a comprehensive analysis of the development and evolution of batch control from the original NAMUR model through the most current publications in the 88 series. Through examples, commentary, analogies and at times wry humor the author provides an in-depth philosophical discussion of how batch control and all manufacturing enterprises have been impacted by the work of 88. Hawkins in-depth coverage and practical insights make this book an indispensable tool for designers, control engineers, project engineers, and managers who desire to achieve the full cost and production benefits of implementing the 88 series.
Gives a real world explanation of how to analyze and troubleshoot a process control system in a batch process plant • Explains how to analyze the requirements for controlling a batch process, develop the control logic to meet these requirements, and troubleshoot the process controls in batch processes • Presents three categories of batch processes (cyclical batch, multigrade facilities, and flexible batch) and examines the differences in the control requirements in each • Examines various concepts of a product recipe and what its nature must be in a flexible batch facility • Approaches the subject from the process perspective, with emphasis on the advantages of using structured logic in the automation of all but the simplest batch processes. • Discusses the flow of information starting at the plant floor and continuing through various levels of the control logic up to the corporate IT level
In this in-depth book, the authors address the concepts and terminology that are needed to work in the field of process control. The material is presented in a straightforward manner that is independent of the control system manufacturer. It is assumed that the reader may not have worked in a process plant environment and may be unfamiliar with the field devices and control systems. Much of the material on the practical aspects of control design and process applications is based on the authors personal experience gained in working with process control systems. Thus, the book is written to act as a guide for engineers, managers, technicians, and others that are new to process control or experienced control engineers who are unfamiliar with multi-loop control techniques. After the traditional single-loop and multi-loop techniques that are most often used in industry are covered, a brief introduction to advanced control techniques is provided. Whether the reader of this book is working as a process control engineer, working in a control group or working in an instrument department, the information will set the solid foundation needed to understand and work with existing control systems or to design new control applications. At various points in the chapters on process characterization and control design, the reader has an opportunity to apply what was learned using web-based workshops. The only items required to access these workshops are a high-speed Internet connection and a web browser. Dynamic process simulations are built into the workshops to give the reader a realistic "hands-on" experience. Also, one chapter of the book is dedicated to techniques that may be used to create process simulations using tools that are commonly available within most distributed control systems. At various points in the chapters on process characterization and control design, the reader has an opportunity to apply what was learned using web-based workshops. The only items required to access these workshops are a high-speed Internet connection and a web browser. Dynamic process simulations are built into the workshops to give the reader a realistic "hands-on" experience. Also, one chapter of the book is dedicated to techniques that may be used to create process simulations using tools that are commonly available within most distributed control systems. As control techniques are introduced, simple process examples are used to illustrate how these techniques are applied in industry. The last chapter of the book, on process applications, contains several more complex examples from industry that illustrate how basic control techniques may be combined to meet a variety of application requirements. As control techniques are introduced, simple process examples are used to illustrate how these techniques are applied in industry. The last chapter of the book, on process applications, contains several more complex examples from industry that illustrate how basic control techniques may be combined to meet a variety of application requirements.
Historically batch control systems were designed individually to match a specific arrangement of plant equipment. They lacked the ability to convert to new products without having to modify the control systems, and did not lend themselves to integration with manufacturing management systems. Practical Batch Management Systems explains how to utilize the building blocks and arrange the structures of modern batch management systems to produce flexible schemes suitable for automated batch management, with the capability to be reconfigured to use the same plant equipment in different combinations. It introduces current best practice in the automation of batch processes, including the drive for integration with MES (Manufacturing Execution System) and ERP (Enterprise Resource Planning) products from major IT vendors. References and examples are drawn from DCS / PLC batch control products currently on the market. - Implement modern batch management systems that are flexible and easily reconfigured - Integrate batch management with other manufacturing systems including MES and ERP - Increase productivity through industry best practice
Modeling and Control of Batch Processes presents state-of-the-art techniques ranging from mechanistic to data-driven models. These methods are specifically tailored to handle issues pertinent to batch processes, such as nonlinear dynamics and lack of online quality measurements. In particular, the book proposes: a novel batch control design with well characterized feasibility properties; a modeling approach that unites multi-model and partial least squares techniques; a generalization of the subspace identification approach for batch processes; and applications to several detailed case studies, ranging from a complex simulation test bed to industrial data. The book’s proposed methodology employs statistical tools, such as partial least squares and subspace identification, and couples them with notions from state-space-based models to provide solutions to the quality control problem for batch processes. Practical implementation issues are discussed to help readers understand the application of the methods in greater depth. The book includes numerous comments and remarks providing insight and fundamental understanding into the modeling and control of batch processes. Modeling and Control of Batch Processes includes many detailed examples of industrial relevance that can be tailored by process control engineers or researchers to a specific application. The book is also of interest to graduate students studying control systems, as it contains new research topics and references to significant recent work. Advances in Industrial Control reports and encourages the transfer of technology in control engineering. The rapid development of control technology has an impact on all areas of the control discipline. The series offers an opportunity for researchers to present an extended exposition of new work in all aspects of industrial control.
