Hardware in Process Control

A.3 Microprocessors and Digital Hardware in Process Control A.3.1 Single-Loop Controllers A.3.2 Programmable Logic Controllers A.3.3 Personal Computer Controllers A.3.4 Distributed Control System... 

Currently, the trend in process control is away from centrahzed process control and toward an increased number of small distributed-control or PLC systems. This trend will put emphasis on the evolution of the fieldbus controller and continued growth of the PC-based controller. Also, as hardware and software improves, the functionality of the controller will increase, and the supporting hardware will be physically smaller. Hence, the traditional lines between the DCS and the PLC will become less distinct as systems will be capable of supporting either function set. 

Some analytical methods are highly mature (NAA, XRD, XRF, XAS), the theory is well assessed, and just instrumental and incremental improvements (more intense sources, better detectors) may be expected. However, in many other areas the sharply increasing power of analytical instrumentation (with regard to both hardware and software) and its transformation into tools for in-process control (such as NIRS, LR-NMR, etc.) are most appropriately considered as breakthroughs. 

First we will look briefly at some of the control hardware that is currently used in process control systems transmitters, control valves, controllers, etc. Then we will discuss the performance of conventional controllers and present empirical tuning techniques. Finally we will talk about some important design concepts and heuristics that are useful in specifying the structure of a control system for a process. 

Criticality safety is a major concern in any fuel fabrication facility. Proper design of the hardware and process control together with administrative precautions prevent criticality accidents. Additional monitoring and alarm systems will be installed. 

In order to operate a process facility in a safe and efficient manner, it is essential to be able to control the process at a desired state or sequence of states. This goal is usually achieved by implementing control strategies on a broad array of hardware and software. The state of a process is characterized by specific values for a relevant set of variables, eg, temperatures, flows, pressures, compositions, etc. Both external and internal conditions, classified as uncontrollable or controllable, affect the state. Controllable conditions may be further classified as controlled, manipulated, or not controlled. Excellent overviews of the basic concepts of process control are available (1 6). 

Classical Feedback Control. The majority of controllers ia a continuous process plant is of the linear feedback controller type. These controllers utilize one or more of three basic modes of control proportional (P), iategral (I), and derivative (D) action (1,2,6,7). In the days of pneumatic or electrical analogue controllers, these modes were implemented ia the controller by hardware devices. These controllers implemented all or parts of the foUowiag control algorithm ... 

Because indirect-heat calciners frequently require close-fitting gas seals, it is customaiy to support aU parts on a selFcontained frame, for sizes up to approximately 2 m in diameter. The furnace can employ elec tric heating elements or oil and/or gas burners as the heat source for the process. The hardware would be zoned down the length of the furnace to match the heat requirements of the process. Process control is normaUy by shell temperature, measured by thermocouples or radiation pyrometers. When a special gas atmosphere must be maintained inside the cyhnder, positive rotaiy gas se s, with one or more pressurized and purged annular chambers, are employed. The diaphragm-type seal ABB Raymond (Bartlett-Snow TM) is suitable for pressures up to 5 cm of water, with no detectable leakage. 

The main factors found to be affecting the decision to blowdown manually were the blowdown philosophy, procedures, and training. Factors affecting the efficiency of the decision making process and the execution of blowdown were the ergonomics of the information presentation in the control room communications, and various aspects of the hardware. 

MW fraction increases the melt flow, thus improving the processability but at the cost of toughness, stiffness, and stress crack resistance. In addition, the improvement in performance through narrowing the MWD is restricted by the catalyst, the process hardware, and the process control limitations. Dow has developed a reactor grade HDPE of optimized breadth, peak, and shape of MWD... 

Products in Group 3 seem to us to represent the future of practical batch process control. In such systems, modern workstations perform the single-user functions (e.g control system design, set-up, and maintenance operator interface data collection historical reporting) for which they were designed, while powerful multitasking controllers perform actual control. As computer hardware and software standards continue to evolve toward distributed networks of processors optimized for specific kinds of tasks, such systems will, we feel, proliferate rapidly. 

In chemical processes, the most common types of controlled variables are liquid level, flow rate, temperature, pressure, and sometimes concentration. Here are some very general ideas. To fully appreciate these tidbits, we also need to know something about the actual hardware—actuators or control elements—which we find in handbooks or equipment manuals. 

Sherwin-Williams has developed such a polymer process control system. The methodology used to accommodate the contrasting requirements has two key elements. First, the software is based on a simple architecture that places the definition of changing reactor hardware elements and characteristics in easily modified configuration files (5). Second, the language uses a small number of basic commands to describe formulations and reactor control. Complex operations are described by reference to commands tables (macros) built using several basic commands or other macros. 

Finally, a well-instrumented experimental distillation column that has been interfaced to an industrial distributed control system was used to show the implementation of the techniques described in previous chapters in an actual on-line framework, using industrial hardware. In this case, the usefulness of data reconciliation, prior to process modeling and optimization, was clearly demonstrated. 

An even greater pitfall into which many young process control engineers fall, particularly in recent years, is to get so involved in the fancy computer control hardware that is now available that they lose sight of the process control objectives. All the beautifiil CRT displays and the blue smoke and mirrors that computer control salespersons are notorious for using to sell hardware and software can easily seduce the unsuspecting control engineer. Keep in mind your main objective to come up with an effective control system. How you implement it, in a sophisticated computer or in simple pneumatic instruments, is of much less importance. 

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