Instrumentation Systems- Fundamentals and Applications Copyright © 1991 by Yokogawa Electric Corporation All rights reserved No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, recording or otherwise, without the prior written permission of the copyright owner First published in Japanese in 1987 by Ohmsha, Ltd Tokyo as 'Keisou Shisutemu no Kiso to OUYOUJ © 1987 Tasuku Senbon and Futoshi Hanabuchi Exclusive worldwide distribution by : \ ISBN 3-540-53628-0 Springer-Verlag Berlin Heidelberg New York ISBN 0-387-53628-0 Springer-Verlag New York Berlin Heidelberg PREFACE This book, though small, contains a wealth of technical information on control engineering and instrumentation engineering for industrial quantities, on control-system component elements (sensing, conversion, control, monitoring, and actuation), and on the system-design approaches (system engineering) used in process automation (PA) and factory automation (FA), discussing them based on examples of their applications, and covering everything from basics to applications Process automation has a long history, with automation of individual functions having begun as early as the 1920's The feedback control techniques that constitute its basis grew into an indispensable core technology along with the rapid advance of control theory and control devices from the 1960's onward Today we are progressing further towards system-scale optimal control technology One of the influences that spurred major innovation along the way was the birth of microprocessor~based digital computer control in the 1970's This enabled the realization of batch and sequential control together with feedback control in the same processor thus allowing an intimate interlinkage among them all Technology for communication between multiple processors was also introduced, fostering rapid advances in functional sophistication and installation density Moreover, this did not stop with process automation, but also spread to total factory automation covering entire plants This included factory autQplation aimed at discrete processes This book begins with a discussion of control theory It moves on to discuss the product hardware and software that implement the theory, and then proceeds to describe instrumentation examples and the system-design approaches (system engineering) suitable for a variety of production processes Thus, we believe it to be ideally suited for use as a college-level textbook on instrumentation and automation for undergraduate or graduate students, or as a reference book for practicing instrument engineers in industry Since the subject matter deals with extremely specialized technolop~ v gy, the responsibility for the authorship has been undertaken by Yokogawa Electric experts continually involved in these areas The Yokogawa Electric Training Center has undertaken the task of editing and compiling these writings into a text At the same time that we express our gratitude to the authors of the many works used for reference, we would also like to offer our deepest thanks to the staff of our publisher, Ohmsha, Ltd., for their hard work and earnest cooperation We hope that this book will be of assistance to our readers in their study of instrumentation and control systems ABOUT THE ENGLISH-LANGUAGE EDITION September, 1987 Hisashi Tamura, Senior Vice President Director, SBD Administration Yokogawa Electric Corporation Since its publication in 1987, the original Japanese-language edition of Instrumentataion Systems has already gone through several printings This is due to its wide readership among those responsible for instrumentation and control in Japan There is a significant relationship between the expanding number of readers of this book and the continuing rapid growth of Japan's industry and economy, with process automation and factory automation as two of its driving forces Today as the barriers between East and West crumble away, we hope that an even wider international dissemination of this book will lend support to the world's movement toward global industrial and economic development The authors and editors have felt this to be one of their missions A necessary condition has been the creation of this English-language edition This opportunity to carry the English-language version to realization with the full cooperation of Ohmsha, Ltd and Springer-Verlag has been a source of great pleasure to the authors and editors We wish to extend our thanks for the assistance of those who undertook the translation and editorial supervision It is the hope of all those involved that this book will be widely read and found useful by members of the instrumentation and control community all over the world Akio Yamamoto, General Manager Yokogawa Electric Training Center VI Preface About the English-Language Edition vii LIST OF CONTRIBUTORS EDITORS Tasuku Senbon Futoshi Hanabuchi AUTHORS (alphabetical order) Naoki Asakawa Yoshio Fukai Katsuhiro Hikasa Kiyokazu Ishii Tadamichi Kai Isao Katsuoka Hiroshi Kawai Toshio Kimura Takane Kudo Hidesada Kurioka Tetsuro Matsumoto Kiyoshi Matsunaga Teruyoshi Minaki Yoshiaki Murakami Yoshio Nagasaki Shinobu Nagase Eizo Oku Kazuo Omori Yoshikatsu Sakai Makoto Sekiya lun Shiozawa Fuso Takamura Shin-ichi Takigishi Akira Tanaka Yukio Tanaka Katsuaki Tokunaga Masahito Tsukamoto Hideo Tsurumaki Masahiko Ushioda Sadahito Watanabe Shigehiko Yamamoto Shigeru Yamamoto Michio Yoshioka, Tsuneo Zeniya EDITORIAL ASSISTANCE Akio Yamamoto Sumiaki Nishikata List of Contributors ix CONTENTS Preface v About the English-Language IX List of Contributors Edition Vll Chapter INDUSTRY AND INSTRUMENT ATION 1.1 The Word "Instrumentation " 1.2 The Development of Instrumentation 1.3 Trend toward Total FA 1.4 Classification and Use of Instruments References Chapter PROCESS CONTROL 2.1 Fundamentals of Feedback Control 2.1.1 Configuration of a control system 2.1 Characteristics of a control system 2.1 Feedback control and stability 2 Process Characteristics 2.2.1 Process degrees of freedom and controlled and manipulated variables 2.2 Process characteristics 2.2.3 Process models 2.3 Control Formats for Various Types of Processes 2.3.1 Single loop control systems 2.3.2 Compound loop control system • A •••••••••••••••••• 2.4 Optimal Adjustment of Control Systems 2.5 Sequential Control 2.5.1 Meaning of "sequential control" 2.5.2 Types of sequential controL 2.5.3 Sequential control description 2.5.4 Devices for sequential control Practice Questions Answers to Questions References 23 25 26 32 32 39 45 50 51 51 52 57 58 59 59 Contents xi 11 11 13 19 23 Chapter DETECTION AND CONVERSION OF INDUSTRIAL VARIABLES 3.1 Measurement of Industrial Variables 3.1.1 Methods of measurement 3.1.2 Accuracy of measurement 3.2 Measurement of Temperature 3.2.1 Thermoelectric thermometers 3.2 Resistance thermometers 3.2.3 Protective tube Thermistor thermometers 3.3 Measurement of Flow 3.3.1 Differential pressure flowmeters 3.3.2 Float-type area flowmeters 3.3.3 Volumetric flowmeters 3.3.4 Turbine flowmeters 3.3.5 Magnetic flowmeters 3.3.6 Vortex flowmeters 3.3.7 Ultrasonic flowmeters 3.4 Measurement of Pressure 3.4.1 Pressure transmitters 3.4.2 Types of pressure detectors 3.5 Measurement of Liquid Level 3.5.1 Float liquid-level meters 3.5.2 Pressure differential liquid-level meters 3.5.3 Displacer liquid-level detectors 3.5.4 Purge-type liquid-level meters 3.5.5 Ultrasonic liquid-level meters Capaci tance liquid -level meters 3.6 Measurement of Displacement and Angle 3.6.1 Resistance potentiometer methods 3.6.2 Electromagnetic induction methods 3.6.3 Magnetic balance method 3.6.4 Magnetic strain method 3.7 Measurement of Rotation 3.7.1 Measurement using tachometer genera tors 3.7.2 Pulse output sensors 3.7.3 Digital counting tachometers 3.8 Measurement of Composition 3.8.1 Gas chromatography 3.8.2 Infrared analyzers Oxygen analyzers 3.8.4 pH meters and ORP meters xu 62 62 66 71 72 84 91 92 98 99 l05 110 113 117 125 130 135 136 138 141 141 141 144 145 146 147 148 148 148 152 153 153 153 155 156 158 158 163 166 169 Contents 3.8.5 Moisture/humidity meters 3.8.6 Turbidity meters 3.8.7 Conductivity meters 3.8.8 Other composition measuring devices 3.9 B/M Systems 3.9.1 Basis weight sensor (B sensor) 3.9.2 Moisture sensors (M sensors) 3.9.3 Calipers (paper thickness gauges) 3.9.4 Moisture sensor for thick paper 3.9.5 Color sensors 3.9.6 Ash sensors 3.10 Signal Converters 3.10.1 The purpose of signal converters 3.10.2 Thermocouple signal converters 3.10.3 Resistance signal converters 3.10.4 Two-wire signal transmission 3.10.5 Pulse signal converters 3.10.6 Computer input equipment Practice Questions Answers to Questions References 172 174 176 179 188 189 191 192 193 194 195 195 195 197 199 200 201 202 205 205 205 Chapter RECORDERS AND CONTROLLERS 4.1 Recorders 1.1 Types of recorders 4.1.2 Recorder functions 4.1.3 Pen recorders 4.1.4 Multipoint recorders 4.2 Controllers 4.2.1 Pneumatic and electronic controllers 4.2.2 Analog electronic controllers 4.2.3 Digital controllers 4.2.4 Programmable controllers 4.2.5 Batch controllers and blending controllers • 4.3 Computing Stations and Set Stations 4.3.1 Alarm set stations 4.3.2 Programmable computing units 4.3.3 Manual set stations and manual operating stations References 209 209 210 212 218 222 222 223 226 231 235 241 241 242 243 245 Chapter SYSTEM CONTROL EQUIPMENT 5.1 Overview of System Control Equipment 5.1.1 Development 248 248 Contents XlZl 5.1 Configuration of a total FA system 252 5.2 Distributed Control System 256 5.2.1 Concept of the distributed control system 256 5.2.2 Configuration of the distributed control system and its functions 259 5.2.3 Feedback control 267 5.2.4 Sequential control 271 5.2.5 Man-machine interface 276 5.2.6 Communication with other systems 284 5.2.7 Engineering 285 5.3 Production Line Control System 291 5.3.1 Summary of production line control systems 291 5.3.2 Types of production line control systems 292 5.3.3 FA computer systems , 295 5.3.4 FA computer system hardware 298 5.3.5 FA computer software 303 5.4 Computer System Equipment for Production Management 306 5.4.1 Computer components and configuration 306 5.4.2 Software for production management computer systems 316 5.5 Data Communication and Equipment 325 5.5.1 Data communication and standards 325 5.5.2 Methods of data communications 327 5.5.3 The IEEE -488 instrument bus 329 5.5.4 The RS-232 C interface and modems 331 5.5.5 Local area networks 334 5.5.6 Optical communications 335 5.6 Basic Components of Digital Control 336 5.6.1 Microprocessors 336 5.6.2 Memory elements and storage equipment 343 5.6.3 Display elements and devices 346 5.6.4 Analogi digital conversion 351 5.6.5 Optical communication elements 353 References 354 Chapter FINAL CONTROL ELEMENTS 6.1 Types of Control Valves 6.1.1 Pneumatic control valves 6.1.2 Electrical control valves 6.1.3 Hydraulic control valves 6.1.4 Self-powered control valves 6.2 Choice of Control Valves 6.2.1 Various conditions affecting choice 6.2.2 Sizing xzv 355 355 355 356 356 356 356 360 Contents 6.2.3 Flow characteristics 361 6.2.4 Rangeability 363 6.2.5 Materials 364 6.3 Control Valve Bodies , 367 6.3.1 Characteristics of various types of valves 367 6.3.2 Rating 373 6.3.3 Connection to piping 374 6.4 Control Valve Actuators 374 6.4.1 Conditions under which an actuator should be installed 374 6.4.2 Power sources 374 6.4.3 Types of actuators and their characteristics 376 6.5 Positioners and Accessories 384 6.5.1 Positioner functions 384 6.5.2 Pneumatic pressure positioners 384 6.5.3 Current-to-pneumatic positioners 384 6.5.4 Current-to-current positioners 386 6.5 Accessories 386 6.6 Self-powered Valves 388 6.6.1 Pressure-regulating valves 388 6.6.2 Temperature control valves 389 6.6.3 Flow control valves 389 6.6.4 Float valves 389 Practice Questions 390 Answers to Questions 390 References , , , 390 Chapter SYSTEM ENGINEERING 7.1 System Engineering Basics 7.1.1 Plant construction overview 7.1.2 System design considerations 7.2 Instrumentation System Design 7.2.1 Job planning 7.2.2 System specifications 7.2.3 Device and function specifications •• 7.2.4 Instrumentation work specifications : 7.2.5 Related work 7.2.6 Instrumentation drive system design 7.2.7 Other system functions (safety, failsafe and redundancy measures) 7.3 Control Room and Man-Machine Interface 7.3.1 Human engineering and control panel design 7.3.2 Control room engineering 7.4 Instrumentation Work and Startup Contents 392 392 , 395 399 399 403 407 430 434 436 444 453 453 457 460 xv 7.4.1 Overview 7.4.2 Instrumentation work planning 7.4.3 Instrumentation work design 7.4.4 Startup execution 7.4.5 Startup operations 7.5 Quality Assurance 7.5.1 Engineering quality 7.5.2 Design review (DR) References 460 460 463 467 469 470 470 471 482 Chapter ADVANCED CONTROL 8.1 Control Theory Considerations Control 8.2 Feedforward Control 8.2.1 Feedforward control in a heat exchanger 8.2.2 Combining feedforward control and feedback control 8.2.3 Determination of feedforward elements 8.2.4 Feedforward control application examples 8.3 Control of Dead-Time Processes 8.3.1 Dead~time processes 8.3.2 Smith controllers 8.3.3 Sampling PI controller 8.4 Non-interacting Control 8.4.1 Interaction between process variables 8.4.2 Influence exerted by mutual interaction 8.4.3 Expressing the degree of interaction 8.4.4 Controlled variable and manipulated variable combination 8.4.5 Non-interacting control 8.4.6 An example of non-interacting control 8.5 Self-tuning Controller 8.5.1 Overview 8.5.2 Gain-scheduling controL 8.5.3 Self-tuning controller (STC) 8.5.4 STC based on the expert method 8.5.5 STC application considerations 8.6 Optimal ControL 8.6.1 The meaning of "state" 8.6.2 Integral optimal regulator 8.7 Kalman Filter 8.7.1 Kalman filter formula 8.7.2 Application to the parameter estimation problem 8.8 Other Forms of Advanced Control References xvi 483 486 486 488 489 490 492 492 494 500 502 502 504 504 508 509 511 511 511 514 515 517 521 521 521 522 524 524 525 527 527 Contents Chapter CONTROL OF PROCESS UNITS (Application I ) 9.1 Overview 9.2 Control of Fluid Transport Processes 9.2.1 Pump control 9.2.2 Compressor control 9.3 Control of Heat Transfer Processes 9.3.1 Control of heat exchangers 9.3.2 Heating furnace controL 9.4 Control of Distillation Processes 9.4.1 Binary-component distillation column control 9.4.2 Multi -component distillation column control 9.5 Control of Reaction Processes 9.5.1 Control of a stirred-tank polymerization reactor 9.5.2 Control of a gas-phase solid-catalytic reactor 9.6 Other Process Control 9.6.1 Control of refrigeration equipment 9.6.2 Evaporator control 9.6.3 Drying process control Practice Questions Answers to Questions References 529 530 530 533 540 540 546 550 550 566 573 573 580 590 590 592 595 600 601 602 Chapter 10 INSTRUMENTATION TO MANUFACTURING INDUSTRIES (Application n) 10.1 Instrumentation Application in the Petroleum Industry 604 10.1.1 The petroleum industry and instrumentation 604 10.1.2 Topping unit instrumentation 606 10.1.3 Off-site instrumentation 614 10.2 Instrumentation Applications in the Iron- and Steel- Industry 621 10.2.1 Overview of instrumentation in the iron-and steelmaking process 621 10.2.2 Blast furnace instrumentation ~ 624 10.2.3 Continuous casting equipment instrumentation 635 10.2.4 Instrumentation for an electrolytic galvanizing line 642 10.3 Instrumentation Applications in the Power Industry 648 10.3.1 Overview 648 10.3.2 Thermal power plants 648 10.3.3 Boiler control 649 10.3.4 Turbine control 663 10.3.5 Power plant system control 667 10.3.6 Nuclear power plant overview 669 Contents xvn 10.3.7 Pressurized water reactor control system 10.4 Instrumentation Applications in the Food Processing Industry 10.4.1 Overview 10.4.2 Whiskey distillery instrumentation 10.4.3 Sugar refinery instrumentation 10.5 Instrumentation Applications in the Paper Manufacturing Industry , , 10.5.1 Overview of an integrated paper mill 10.5.2 Pulp plant instrumentation 10.5.3 Instrumentation applied to the papermaking process 10.6 Waterworks Instrumentation Applications 10.6.1 Overview of waterworks facilities 10.6.2 Water treatment-related detectors 10.6.3 Filtration equipment instrumentation 10.6.4 Chemical injection equipment instrumentation 10.6.5 Instrumentation for water-supply and distribution facilities 10.6.6 An integrated control system for large-scale, wide-area waterworks facilities 10.6.7 Water distribution information management system 10.6.8 Wastewater system overview 10.6.9 Overview of activated-sludge processes 10.6.10 Wastewater treatment instrumentation 10.6.11 Sludge treatment instrumentation 10.7 Instrumentation Application in the Automobile Industry 10.7.1 Overview of automobile industry instrumentation 10.7.2 Production management at a painting factory 10.7.3 Storage control 10.8 Product Control in Batch Processing 10.8.1 Batch process recipe management 10.8.2 Batch process control 10.8.3 Recipe management and operation methods References 675 Chapter 687 687 689 693 706 706 709 719 726 726 727 731 732 737 738 739 745 745 747 749 751 751 752 755 759 760 763 769 773 APPENDIXES App.1 Reference Thermoelectromotive Force Tables App.2 Reference Resistance Value of Pt 100 App.3 Tables of Laplace Transform 778 782 784 Index 785 xviii , Contents INDUSTRY AND INSTRUMENTATION 1.1 The Word "Instrumentation" Within the various topics covered in this book, a number of com-' pound words and expressions appear utilizing the word "instrumentation," such as "Instrumentation System," "Instrumentation Engineer" and "Instrumentation Technology." Although the usage here is purely technical, it's interesting to note that dictionaries also define "instrumentation" as a musical term meaning the "composition of musical instruments in an orchestra," or in other words, the technique of selecting an appropriate musical instrument makeup for an orchestra so as to achieve optimum results for performing a particular piece of music This definition, as it turns out, can serve as a fitting analogy to the industrial use of "instrumentation." If we replace the words musical instrument, orchestra and piece with industrial instrument, manufacturing plant and manufacturing process, we can define industrial instrumentation as the technique of selecting appropriate measurement devices for a manufacturing plant so as to achieve optimum results for a particular manufacturing process In this case, the results include quality of products, cost of production, ease of operation, and so on However, as words very often seem to have i life of their own, their meaning can change from generation to generation, and technical terms in particular seem to evolve quite rapidly A case in point is the word "instrument." As applied to instrumentation within American industry of the 1950's, it then referred to relatively simple measuring instruments, but with time has come to include very complex and sophisticated industrial instruments as well Moreover, with the advent of information processing tools based on computer and communication technology, it has also become necessary to include computerized systems when talking about instrumentation In addition, the range of object 1.1 The Word 'Instrumentation' processes to which instrumentation panded over the years is applied has also quickly exTable 1.1 Year Definition of Industrial Instrument: According to lIS (Japanese Industrial Standard) Z 8104, "industrial instrument" is defined as "measuring/controlling equipment used in production processes in industry." Here, "measuring/con trolling equipment" is in turn defined as apparatus which indicate and/or record quantities or physical properties, as well as having computing, controlling or alarm functions, thus including detectors, transmitters, and the like 1.2 The Development of Instrumentation The automatic control of the measurement of industrial quantities, such as temperature, flow and pressure, first began in the 1920's in American oil refining processes This period was characterized by local instrumentation in which large-size mechanical controllers were installed in the process area The subsequent development of instrumentation technology in following periods came about as the needs of various industries and the advancement of industrial instruments became closely intertwined The development of instrumentation technology in postwar Japan and corresponding background events in society are listed in Table 1.1 [1] The 1950's and 1960's During the 1950's, instrumentation technology experienced major development together with Japan's economic restoration centered in its petroleum, steel and textile process industries Instrumentation in this period was mainly characterized by control systems consisting of a number of controllers each of which performed analog operation processing for one loop In the beginning, pneumatic controllers driven by air pressure were used, but with the advancement of electronics and the shift toward largescale processes, control equipment progressed from pneumaic-operated to electronic-operated models On entering the 1960's, computers for use in process control first appeared in the field of instrumentation At first, they were mainly used for the monitoring and record taking of process operations (data logging) In addition, by making use of the computer's computational ability, they were used for computing optimum process conditions or safe operation conditions with calculated setpoints passed on to control1 Development of instrumentation technology Instrumentation Social events in Japan Technology 1950 • Recovery period after World War n • Technology introduction from abroad · Prosperity of synthetic textile industry • Germanium transistor • Standardization of transmission signal (3 to 15 psi) · Practical use of electronic tube self-balancing instruments 1955 · Construction of petroleum industrial complex • Construction of power station • Computer · Silicone transistor · Practical use of electronic control systems • Graphic panel 1960 • Construction of blast furnace • In vestment for labor saving · Computer control systems 1965 ·IC • Scalp up and integration plant construction ·DDC trends of 1970 • Microprocessor • Investment for environmental maintenance (Environmental pollution problem) · First oil crisis • Standardization of transmission signal in electronic control systems to 20 mA DC (lEC) • Hierarchy systems ·CAD • Robot • Office automation • A utomation of machine tool 1975 • Second oil crisis · Popularization of microcomputer • Distributed control systems • Package type control systems 1980 • Low economical growth period · Diversification of social needs • Single loop DDC • Factory automation (FA) lers This is known as Supervisory Process Control or Setpoint Control (SPC) In time, however, thought was given to replacing the functions performed by analog controllers and computational t1hits by using the increasing computational power of the computer Accordingly, direct digital control by computer, or DDC, came to be realized At this time, centralized DDC was employed in which many loops up to several huhdred were controlled by one computer unit As a consequence, however, since an unexpected computer problem could bring plant operations to a halt, the incorporation of redundant design elements such as CPU duplication, backup devices, etc., came to be necessary, resulting in increased costs As a result, due to economic considerations at this time, centralized DDC did not fully replace analog control systems Chap.1 Industry and Instrumentation 1.2 The Development of Iustrumentation to assure that the raise in temperature follows the prescribed pattern Furthermore, in the latter half of the reaction, reactant is depleted and process sensitivity declines When this happens, it is easy for temperature deviations to occur An appropriate means to counter this effect is conversion of temperature control sensitivity Because the extent of compensation needed and the amount of sensitivity cut-over for temperature control are recipe dependent, these data must be prepared in advance for each recipe Here, as we saw before, the data settings can be easily changed whenever necessary by means of a DCS Figure 10.135 shows an example of precise temperature ramping for a particular recipe using a DCS Turning now to sequence operations, Figure 10.136 shows how sequence phases can be changed for different recipes In the case of multipurpose reactors, not only operating conditions such as raw mate- rial and charging volumes, temperature, and time, but also sequence operation phases must be changed depending on the type of recipe Thus, the sequence control method must be configured in such a way that the operation phases can also be rearranged in different ways according to the specific parameters involved Moreover, each phase contains a series of detailed sequence steps: What valve is to be operated, what pump is to be activated, how control loops are to be configured, and so on It is essential, therefore, that the detailed sequence steps within the phases are also capable of being rearranged to coordinate with the rearranged phases In other words, the series of detailed sequence steps expressing, say, pump and valve actions, is typical of a specific phase, and the sequence of phases is stipulated in the product-specific recipe data How finelly the detailed sequence steps are divided, or the scale of the units, will vary Generally, however, it can be said that if the degree of freedom is large, the detailed sequence step units can be made small, and the corresponding phases will increase Conversely, if the degree of freedom is reduced, the detailed sequence step units can be increased in size, and the corresponding number of phases can be reduced The relation between phases and detailed sequence steps is summarized in Fig 10.137 So-called decision tables are shown in the same figure When input conditions are entered in the upper tiers of the tables, then the corresponding output operations shown in the lower tiers are executed according to rules This type of table is a useful device for describing the logical relations between input conditions and output operations Moreover, since operatoin instructions of one decision table can be executed from another decision table, this is also an appropriate description for sequence control methods with a hierarchical structure The step execution table is used to describe the detailed se- quence steps for a single phase These could include, for example, opening and closing valves, activating and stopping the temperature program setting module, implementing and severing control loop cascades, changing settings, changing outputs, and so on The phase control table, on the other hand, determines what step execution table is to be executed and in what order according to the parameter conditions designated for the particular recipe Since indicator lamps and push buttons are generally required for batch process sequence operations, an example of what these can look like is shown in Fig 10.138 The selector switch is set to full-auto mode when one wants the processing to proceed from phase to phase automatically Semi-auto mode allows automatic processing of only the operations within a phase; when the phase is completed, the process stops and waits for a instruction to proceed to the next phase Setting the selector switch to manual mode discontinues the automatic sequencing up to that point This means that, as soon as a point is reached where it is appropriate to stop, the process does so, and subsequent operations are controlled manually Start, stop, stepping, and reset are activated by the push buttons labeled with those functions shown in the same figure Since this status transfer diagram can be easily modified using the decision table, the contents of the phase control table can be designed In other words, the system has been designed so that the phases are controlled by the movement conditions of the status transfer, and the order of the phases can be rearranged by referencing the parameters 10.8.3 Recipe management and operation methods In order to produce a diverse range of products by changing the batch process operating conditions, two things are required; a great volume of recipe data for each product, and a recipe data mangement function The recipe management function is used to select the product line, display it on screen, and view the operating status to see if operating conditions need to be changed In this section we will consider the recipe management function, and selection operation method It has already been mentioned that the recipe management function will differ depending on the configuration of the batch process The first configuration we will consider is a single unit process Through a sequence of panel operations such as shown in Fig 10.139, the recipe to be executed is selected, data respecting the selected recipe is brought up on the screen, and instructions altering operating conditions are entered The first panel that appears is a menu of the recipes available A selection is made from among the available choices, and this brings the corresponding recipe data up on the screen Since the software permits altering the data on this panel, the batch isn't started until after the recipe data has been verified Once the batch has been started, process operating conditions proceed in accordance with the recipe data shown on the screen Another point is that the recipe data is expressed as ratios of standard production units In some cases the ratios are calculated when the production volume is set In other cases, when the desired production volume cannot be ascertained from the volume of the raw materials, the ratios are obtained indirectly either by calculating the residual volume or through a volume conversion based on the concentration or purity of a weight standard chemical additive Sometimes this recipe data is also shown on the screen In configurations involving multiple equipment and reactor units, a first requirement is to designate in which reactor a recipe is to be produced This is generally handled by creating lot numbers for all of the reactors involved indicating the type of recipe and the reactor These numbers are then displayed along with the production conditions In some cases, the kind of recipe that can be produced in a given reactor will depend on the lines for charging raw material or additives, or on the type of reactor In such cases, the recipe selection to be carried out in a certain reactor is made only from among those recipes that are appropriate for the reactor in question When the product under production requires the use of a multi-unit configuration, the following information is shown: the unit in which the process starts, the sequence of succeeding units, and the recipe 10.8 Product Control in Batch Processing 769 In cases such as illustrated in Fig 10.140, where the equipment is arranged in a multistage configuratoin, operating conditions cannot simply cut over all at once in accordance with the recipe data Rather, cut over must follow the sequence of the equipment units In other words, the recipe data must be broken into segments corresponding to each unit, so that when one unit is started, only the operating conditions for that unit will be modified Figure 10.141 illustrates how the unit sequence and recipe selection are shown on the screen In the recipe shown in the figure, the maximum number of stages that can be designated for each sequence, eight, has been designated When one wishes to display that recipe data, first an overview of the data for each recipe is displayed In cases where the production involves a multistage unit configuration, the volume of recipe data generally increases Since it is not possible to display all of the data at the same time, the data is broken up into groups The groups, first displayed altogether on a menu screen, are segmented so as to keep all data pertaining to each stage of each unit together in one group When a data group is indicated on the recipe overview screen, this brings up the recipe data base for a single equipment unit, such as shown for example in Fig 10.139 If the unit start instruction is given on the multi-unit batch selection panel, only the data group for the relevant unit is selected for modification from among the previous stage recipe data In this case the units' path is fixed, and represents a simple, series configuration Of course, there are possibilities: When the units are set up to serve diverse purposes, for example, the paths themselves can be changed according to the recipes In situations such as this, the unit path is included as data in the recipe database Then, depending on the path, the recipe name of the stage prior to that unit and the recipe data group for that unit must be searched Figure 10.142 illustrates a recipe product cut-over method that contains a path table Just as process instrumentation varies widely depending on a multitude of different factors, recipe management methods also vary tre10.8 Product Control in Batch Processing 771 mendously depending on the specific process configuration Our approach here has been to describe prototypical schemes, or formulas, to indicate the range of different possibilities By changing the configuration of equipment, any number of application examples could have been described In adopting a formulaic approach, our intent was to clearly reveal the unique advantage of digital control systems-that is, flexible automation There are other topics relating to recipe management that are also important; collection of actual results data, formation and testing of recipe data, comparison of reaction patterns, optimization of operation scheduling, and so on With respect to digital control systems, however, it is safe to say that as these systems continue to develop and become more sophisticated, increasingly easy-to-use configurations will be realized Japanese) 7) The Iron and Steel Institute of Japan: Iron and Steel Industries in Japan (1985) (in Japanese) 8) Comprehensive Bibliography for Iron Manufacturing Machinery '80, Jukogyo Shinbunsha (in Japanese) 9) Nippon Steel Corporation: Iron Science (Making Process of Iron) (in Japanese) 10) Seitetsu Kenkyu, No 308, Nippon Steel Corporation (1982) (in Japanese) 11) Tekko Kaiho, The Japan Iron and Steel Federation (June 1984) (in Japanese) 12) Sumitomo Metals, Sumitomo Metal Industries, Ltd (in Japanese) 13) Tetsu-to-Hagane, 71, 3, The Iron and Steel Institute of Japan (1985) (in Japanse) 14) Kawasaki Steel Giho; 14, Kawasaki Steel Corporation (1982) (in Japanese) 15) Seitetsu Kenkyu; No 313, Nippon Steel Corporation (1984) (in Japanese) 16) The Thermal and Nuclear Power, 29, 6/8, Thermal and Nuclear Power Engineering Society (1978) (in Japanese) 17) K Shirano: Zymurgy, Kodansha (1982) (in Japanese) 18) Shokuryo Kogyo: Agricultural Food-Sugar, Koseisha Kosei Kaku (1985) (in Japanese) 19) R Machida: "Production control system on YEWCOM at sugar refinery," Factory Automation, 3, (1985) (in Japanese) 20) Shigyo Times, The Latest Pulp and Paper Technology '80 (in Japanese) 21) Y Murakami: Japan Journal of Paper Technology (Aug 1983) (in Japanese) 22) A Nomoto: Japan Journal of Paper Technology (Mar 1982) (in Japanase) 23) T Shibata: Data Systems for Automated Production and Material HandJing, Ryutsu Kenkyu Sha (Mar 1984) (in Japanse) 24) Japan Water Works Association: Recommendation for Design of Water Works Facilities (1977) and Recommendation for Maintenance of Water Works (1982) (in Japanese) 25) S Nagase, et al.: "Data base management system on city water distribution plants," Yokogawa Tech Rep., 28,1 (1984) 8-13 (in Japanese) 26) S Nagase: "Prediction of demand and total control systems for water supply plants," Yokogawa Tech Rep., 24, I, (1980) 17-22 (in Japanese) 27) H Kamei, et al.: "On-line water demand predictions with Kalman filter," Yakogawa Tech Rep., 25, 4, (1981) 36-40 (in Japanese) 28) K Minamimura, et al.: "Simulation of water distribution networks," Yokogawa Tech Rep 28,1 (1984) 14-20 (in Japanese) 29) T Yamamoto: "Hierarchical control system for wide-area water supply network," Yokogawa Tech Rep., 28, I, (1984) 21-25 (in Japanese) 30) Yokogawa Electric Corporation: Application Engineering Data Chemical Injection Control and Water Quality Monitoring at Purification Plant (in Japanese) 31) Yokogawa Electric Corporation: Application Engineering Data Instrumentation on Filter Basin and Washing Control (in Japanese) 32) Japan Sewage Works Association: Recommendation and Explanation for Design of Wastwater Facilities (1984) (in Japanese) 33) K Matsunaga: "The latest instrumentation for batch process by distributed digital control system "CENTUM"," Yokogawa Tech Rep., 23, (1979) 26-31 (in Japanese) 34) T Hirano, et al.: "Distributed control system applications in batch processes and product grating," Yokogawa Tech Rep., 25, I, (1981) 44-52 (in Japanese) 35) K Matsunaga: "Documenting process control sequence by decision tables," Yakogawa Tech Rep., 26, 3, (1982) 44-50 (in Japanese) 36) T Hirano, et al.: "Expediting the design of batch process control systems," Yok- 774 Chap 10 Instrumention to Manufacturing Industries ogawa Tech Rep., 29, (1985) 25-30 (in Japanese) 37) I Miyazaki, et al.: "Functions and usage of CRT consol on batch process," Instrumentation & Control Eng., 29, (1986) 30-36 (in Japanese) 38) T Kadoya: Paper Science, Chugai Sang yo Chosakai (1977) (in Japanese) References 775 APPEN DIXES Appendixes 777 i char bed 718 characteristics equation 22 chemical and volume control system 678 chemical injection equipment instrumentation 732 CIM 247 CIP 689 cleaning in place 689 closed loop 506 cold junction 72,198 color-selection line control 755 colorimetry 183 column system 160 combustion control 649 communication gateway unit 311 communication interface 299 compensating lead wire 80 component cooling water system 679 compressor characteristic 535 compressor control 533 computer - integrated manufacturing 247 concentration control in distillation column train 568 concentrator control 699 concentric orifice 102 conditional control (monitor control) 51 configuration of furnace control system 547 consecutive reaction 583 constant-rate drying 596 containment spray system 680 continuous casting 635 continuous digester 709 continuous process 248 control of a batch fluidized-bed dryer 595 control of a batch polymerization reactor 578 control of a continuous fluidized-bed dryer 598 control of a recycle reaction system 588 control of distillation column pressure 560 control of fluid-to-fluid heat exchanger 542 control of heat exchanger 540 control of reactor 573 786 control of refrigerant compression 590 control panel 453 control station 256 control system for binary-component continuous distillation 556 control-rod control system 682 controlled variable 11 controller with external feedback 566 cooking-process 709 CPU 307 cross-limit 653 CRT 347 CRT operation 257 crude oil feedpump control 609 current-to-current positioner 386 current-to-pneumatic positioner 384 CVCF 438 cycle time 752 D data-base management system 321 DDC 2,249 dead time 27,492 dead-time element 26 decision table 52,272,293 deflection method 63 degrees of freedom of process 23 delay in conveying 492 derivative action 36 design review 471 desired value 11 detailed design review 473 development support software 320 deviation 11 diaphragm 139 diaphragm valve 369 differential pressure flowmeter 99 differential transformer method 149 diffusion current 184 digital counting tachometer 156 digital signal processor 341 dipping thermocouple 84 direct digital control 249 direct measurement 62 discrete process 5,247,251 displacer liquid-level detector 144 distillation column 490 distillation equipment constraints and control 563 Index distributed control system 247,256 distributed DDC 407,414 distributed direct digital control 249 disturbance 13 disturbance compensator 500 DNC 251 Doppler method 134 double-seated valve 368 dry leg method 144 dry part 723 drying speed 597 dual-port disk 315 duplex system 314 E eccentric rotating plug valve 371 economical load dispatching 669 eddy current displacement gage 151 effective wavelength 93 ELD 669 electric pressure transmitter 138 electrolytic cleaning 644 electrolytic galvanizing 642 electromagnetic induction method 148 emergency operation for furnace protection 551 emissivity 93,96,97 end pressure control 738 engineered safety features operation system 682,685 engineering interface 257 equal-percentage 361 equivalent dead time 30 equivalent time constant 30 error 66 estimation error 525 estimation water-delivery demand 742 evaporator control 592 event recording 212 excess air ratio 652 expansion correction factor 100 expert method 517 expert system 527 explosion-proof construction 445 F FA 5,251 FA computer Index factory automation failsafe 448 fan rule 535 fast breeder reactor 673 FBR 673 FDD 344 feasibility study 392 feedback control 11 feedback control function 267 feedforward control 486 feedwater control 655 feedwater supply control 649 FIF 289 file management 319 fill-in-the-form 232,289 filter rate control 731 filtration equipment instrumentation 731 first-order-lag 29,493 first-order-lag element 28 flash point 613 flexible automation 760 flexible disk drive 344 float liquid-level meter 141 float-type area flowmeter 105 flow coefficient 100 flow sheet 403 flowchart 271 fluidized-bed reactor control 585 flying capacitor multiplexer 202 FMEA 444 frequency response 18 FTA 444 fuel! air ratio control 652 fuel-air ratio control system 549 furnace 490 furnace blower 634 furnace purge system 659 fuzziness 527 fuzzy control 527 FWC 655 G gain margin 23 gain-scheduling control 514 gate valve 369 Gaussian white noise 524 glass membrane 169 glass sealed element 88 globe valve 367 251,295 787 \ H hard disk drive 346 HDD 346 headbox 722 heat control of topping unit 610 heat exchanger 486 heater control by drain valve adjustment 541 heating furnace control 546 hierarchical distributed system 296 high top~pressure operation 631 higher~order lag system 30 hookup drawing 466 hot junction 72 hot stove 632 human interface package 322 hybrid recorder 218 hydrogen ion activity 169 hyperbolic 361 I IEEE~488 instrument bus 329 IEEE ~802 method 335 incomplete derivative 37 incomplete differentiation 226 indirect measurement 62 industrial instrument industrial measurement 61 inherent flow characteristic 361 inherent rangeability 363 injection dosage control 735 injection method 732 input noise 524 input scanner 220 installed flow characteristics 362 installed rangeability 363 instrumentation instrumentation air supply 441 instrumentation for water~supply and distribution facilities 737 instrumentation work 460 integral action 34 integral element 27 integral optimal regulator 522 integration type A/D converter 213 integrative process 496 intelligent input/output equipment 309 intelligent terminal 312 788 inter~computer communication package 324 interaction 228 interaction coefficient 508 interface list 409 interlock 451 ionization chamber 180 ironmaking 622 J JOB control job summary 618 436 K Kalman filter 524 Kalman vortex street 125 knowledge base 517 kraft pump manufacturing process 706 L ladder diagram 293 ladle 635 LAN 252,334 language 304 Laplace transform 15 law of intermediate conductors 73 law of successive temperatures 73 LD 353 learning control 527 LED 353 light~emitting diode 353 limit cycle method 516 linear 361 linearizing 195 liquid crystal 350 local area network 252 logic circuit 271 low frequency square wave excitationmethod 121 luminance temperature 93 M machining center 251 magnetic balance method 152 magnetic flowmeter 117 magnetic storage device 344 magnetic strain method 153 magnetic wind method 166 main steam & feedwater system 680 main steam relief valve control system 685 man~machine interface 257,276,301 11 manipulated variable 12 manual control manufacturing automation protocol 327 MAP 327 maritime blending 614 179 mass absorption coefficient melter Brix (concentration) control 695 membership function 527 MFT 660 mica~insulated element 88 495 mismatch mix and charging system 760 mixture preparation control for a reactant gas 587 model reference adaptive control 513 moisture content 724 mold 635 mold molten steel level control 638 molten steel level meter 638 446 MTSF multi~component distillation column control 566 multi~stage fixed~bed reactor control 580 multi~tubular reactor control 582 multiple~effect evaporator 592 N 251 NC Nernst equation 170 noble metal thermocouple 73 nominal resistance 86 non~continuous process non~interacting control 502,509 non ~ linear characteristic 514 nozzle 103 numerical control 251 Nyquist stability determination method 22 observation noise Index Index 524 off~site 614 offset 33 on~line identification device 513 on~line maintenance 262 on~off control 32 on~site 614 open loop 506 operating system 303,316 operation 403,453 operator station 256 optical fiber 353 optical pyrometer 96 optimal adjustment 48 optimal control 521 99 orifice plate 522 output equation 111 oval gear flowmeter overhead method 462 overhead~type conveyer 753 44 override control overshoot 45,519 oxidation-reduction potential meter 171 P P&I 393 PA paper plant 708 paper thickness 192 papermaking process 721 parameter change 501 parameter estimation 525 PBS line control 757 251,409 PC PCI 634 peripheral integrated circuit 342 petroleum industry 604 pH control in the carbonization process 697 phase 493 phase control table 768 phase margin 23 pickling 644 PID control 249 PID control algorithm 269 piping network calculation 739 plant operation engineering 530 platinum resistance temperature detector 85,199 136 Pneumatic pressure transmitter 384 pneumatic pressure positioner 789 polarography 183 potentiometer 63 pr~paration of reactant-gas mixture 585 pressure detector 138 pressure differential liquid-level meter 141 pressurized water reactor 671 pressurizer pressure control system 684 pressurizer water-level control system 684 priority processing 318 process automation 5,247 process control 247,248 process control system 247 process data 407 process data acquisition package 322 process data highway 262 process data way 328 process gain change of fluid-fluid heater 544 process interface 256,298 product specifications switchover control 578 production line control system 247,291 production management computer 247,306 production management computer system 247 program control (process control) 51,693 programmable controller 251,292,409 proportional band 33 proportional control 32 proportional element 26 proposal 427 proposal final review 473 proposal review 473 protective tube 91 PROWAY 328 pulse flow signal transmitter 238 pulverized coal injection 634 pump characteristic 531 pump control 530 purge-type liquid-level meter 145 purged gas 589 PV derivative 38 PWR 671 790 Q quadrant edge orifice 103 quality control in continuous polymerization 575 quick-opening 361 R radiation thermometer 93 RAM 343 rangeability 363 raster scan recorder 209 ratio control 41 reaction temperature control 764 reactor control equipment 681 reactor control system 682 reactor coolant system 678 reactor protection system 681,685 reactor safety protection system 685 real-time operating system 317 reboiler steam 503 recipe management 760 recovery boiler process 717 redundant system 446 reference resistance element 87 reflux flow 503 relative gain 504 relative volatility 554 reproducibility 68 reset windup 35,270,579 residual heat removal system 679 resistance potentiometer method 148 resistance ratio 87 resistance temperature detector with protective tube 89 resistance thermometer 84 rheometer 704 Riccati equation 523 rolling 623 ROM 343 Routh/H urwitz stability determinationmethod 22 RS-232 C interface 331 S safety injection system 679 safety protection system 682 sampling controller 494 Index sampling PI controller 500 sanitary detector 689 Saunders valve 369 scaling 212 scheduling 762 sea water system 680 second-order lag element 29 selectivity 584 selector control 42 self-balancing method 63 self-balancing recorder 209 self-documentation function 290 self-powered valve 388 self-regulation 25 self-tuning controller 511 semiconductor detector 164 semiconductor laser diode 353 semiconductor memory 343 sensitivity 69 separation of distillation 556 sequence control 249 sequence control function 267 sheathed resistance bulb 90 sheathed thermocouple 78 short-circuit ring method 149 side-stream concentration control 571 silicon radiation thermometer 98 single loop controller 249 single-chip microprocessor 338 single-seated valve 368 sizing 409 slab 635 sliding pressure operation 667 sludge treatment instrumentation 749 Smith controller 494 software package 305 soot blowing 719 SPC specific gravity-volume conversion table 239 spectral radiant emittance 93 speed regulation 664 spray cooling water control 638 square root 361 standard current 86 standard thermocouple 78 startup 392,460,467 startup preparation review 473 state 522 state equation 522 Index state feedback 521 state transition diagram 272 STC 656 steam temperature control 650,656 steelmaking 623 step response 17,495 step writing method 232 stock preparation-process 719 storage control 755 Strouhal number 126 successive identification method 516 sugar product 693 system configuration 403 system engineering 391 system generation 427 T tachometer 153 tank-inventory control 616 target response curve 519 task management 317 TCD 160 techonology for high reliability telemeter /telecontrol 727 temperature control by hea' bypass 544 temperature control of heat valve 545 thermal conductivity de thermistor thermomet thermocouple thermocouple for ' 84 thermocouple wit' 78 thermoelectric t thermoelectror three-way valv< time chart time delay time slice 31 token card 75 top pressure control top-charging topping unit 6( total FA 252 total FA network total head 723 total production control s refinery 704 total reflux operation for 554 traceability 69 trade-off 395,477 transfer function 13 transient response 16 transient response method 50 transit time differential method 131 transmission-scattering method 174 triangular coordinate 586 trim 364 trip 451 tundish 635 turbine bypass control system 685 turbine flowmeter 113 turbine-follow mode 668 tuyere 628 two-wire signal transmission 200 U 't,imate-sensitivity method "asonic flowmeter 130 Ionic liquid-level meter ',jc position detector TJdmethod 462 ~Ie power supply '8 J3,407 ill \d , i vector locus 19 vector transposition 522 venturi tube 103 volumetric flowmeter 110 vortex flowmeter 125 W wash sequence control 732 wastewater treatment instrumentation 747 water content 188,595 water distribution information management system 739 water supply flow control 737 water-run 394 wavelength spectrum 194 wet leg method 142 whiteness 714 Y 48,516 146 215 YEWMAC yield 583 Z 437 zero method Ziegler- Nichols zirconia method 553 150 296 2-out-of- 3-wire type 63 516 166 447 87 ... Computer components and configuration 306 5.4.2 Software for production management computer systems 316 5.5 Data Communication and Equipment 325 5.5.1 Data communication and standards 325... engineering) used in process automation (PA) and factory automation (FA), discussing them based on examples of their applications, and covering everything from basics to applications Process automation has... significant relationship between the expanding number of readers of this book and the continuing rapid growth of Japan's industry and economy, with process automation and factory automation as two of