ISA BATCH CNTRL SYS-2006 Batch Control Systems - Design Application and Implementation (Second Edition).pdf

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1、Batch Control SystemsDesign, Application, and Implementation, 2nd Editionbatch front of book copy.qxd 4/24/2006 10:50 PM Page ibatch front of book copy.qxd 4/24/2006 10:50 PM Page iiBatch ControlSystemsDesign, Application, and Implementation,2nd EditionWilliam M. Hawkins and Thomas G. Fisherbatch fr

2、ont of book copy.qxd 4/24/2006 10:50 PM Page iiiNotice The information presented in this publication is for the general education of the reader.Because neither the author nor the publisher have any control over the use of the informationby the reader, both the author and the publisher disclaim any a

3、nd all liability of any kind arising out of such use. The reader is expected to exercise sound professional judgment in usingany of the information presented in a particular application. Additionally, neither the author nor the publisher have investigated or considered the affect ofany patents on th

4、e ability of the reader to use any of the information in a particular application. The reader is responsible for reviewing any possible patents that may affect any particular useof the information presented. Any references to commercial products in the work are cited as examples only. Neither theaut

5、hor nor the publisher endorses any referenced commercial product. Any trademarks or tradenames referenced belong to the respective owner of the mark or name. Neither the author northe publisher makes any representation regarding the availability of any referenced commercialproduct at any time. The m

6、anufacturers instructions on use of any commercial product must befollowed at all times, even if in conflict with the information in this publication. Copyright 2006 ISA The Instrumentation, Systems, and Automation Society All rights reserved. Printed in the United States of America. 10 9 8 7 6 5 4

7、3 2ISBN-10: 1-55617-967-7ISBN-13: 978-1-55617-967-9No part of this work may be reproduced, stored in a retrieval system, or transmitted in anyform or by any means, electronic, mechanical, photocopying, recording or otherwise, withoutthe prior written permission of the publisher. ISA 67 Alexander Dri

8、ve P.O. Box 12277 Research Triangle Park, NC 27709 Library of Congress Cataloging-in-Publication DataHawkins, William M., 1938-Batch control systems : design, application, and implementation /William M. Hawkins and Thomas Fisher.- 2nd ed.p. cm.Rev. ed. of: Batch control systems / Thomas G. FisherISB

9、N 1-55617-967-71. Process control-Data processing. 2. Process control-Automation.I. Fisher, Thomas. II. Fisher, Thomas. Batch control systems. III.Title. TS156.8.F573 2005660.2815-dc222005029956batch front of book copy.qxd 4/27/2006 4:05 PM Page ivThis book is dedicated to the memory ofThomas G. Fis

10、herThe following is extracted from Bill Wrays obituary for Tom, written for the WorldBatch Forum:It is with profound sadness that we announce the loss of our friend and colleague,Tom Fisher. Tom passed away peacefully on December 6, 2001 after a long battle withcancer. He faced this struggle as he f

11、aced other challenges in his life, with dignity andcourage. Tom had a long career with The Lubrizol Corporation, joining as a process engineer in 1967 and rising to become Operations Technology Manager. He had previouslyworked for DuPont and NASA. His vision led to the formation of the ISA SP88 comm

12、ittee in 1988 and to the subsequent development of the batch automation standards we benefit from today. He served as Chairman and Editor of this committeeas well as a leader of the IEC SC65A Working Group 11 for batch control. Further, Tomserved as ISA Publications Vice President, was active in the

13、 ISA SP84 committee, and amember of the Process Control Safety subcommittee of the Center for ChemicalProcess Safety. His many contributions were recognized by ISA when he was named aFellow of the organization. Tom was also a Registered Professional Engineer andmember of the AIChE.Without Toms leade

14、rship and vision, there would be no ANSI/ISA-S88.01-1995, BatchControl Part 1: Models and Terminology, he is therefore rightfully known as the Fatherof Batch Automation. Tom was a teacher and taught courses through the ISA, WBF, and other organizationson topics such as safety interlock systems, prog

15、rammable controllers, and batchautomation. Above all else, teaching was his passion. Further, he was an accomplishedauthor, having written several books and articles on batch automation and safetyinterlock systems.If you ever met Tom, you know he was one of the truly nice guys in this world. Tom is

16、survived by his wife Shirley, his children, Gary, Jeff, and Rebecca and several grandchildren. We will miss him greatly, not only as a mentor, but more importantly as a friend.vbatch front of book copy.qxd 4/24/2006 10:50 PM Page vvibatch front of book copy.qxd 4/24/2006 10:50 PM Page viForward . .

17、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvPreface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xixAcknowled

18、gments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiAbout the Author . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiiiAbout the Book . . . . . . .

19、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxvChapter 1 Introduction to Manufacturing Processes. . . . . . . . . . . . . . . . . . . . . . . . 1Process Classification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20、. . . . . . . . . . . 3Process Properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Batch Process Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Auxiliary Processes . . . . . . . . . . . . . . . . . . . .

21、 . . . . . . . . . . . . . . . . . . . . . . . . . 16Process Boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Chapter 2 Introductio

22、n to Process Design and Construction. . . . . . . . . . . . . . . 19Process Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Pipi

23、ng a simple little standard pro-duced by ISA called ANSI/ISA-88.01-1995 (aka ISA 88). To discuss control of batch process manufacturing without mentioning ISA 88 is a littlelike discussing a sandwich while avoiding the mention of bread. The standard definesan internally consistent approach for contr

24、ol of batch processes and the standard terminology that allows it to be described and understood. Because it addresses theentire scope of manufacturing activities, including procedure and coordination as wellas more traditional single point control, it deals with essentially all of the functionality

25、required in a batch processing plant. It also provides tools to help define the way theprocessing equipment should work with manual control, automatic control or somemixture of both. Whether the challenge is improvement to an existing process or amajor new installation, the standard is a pretty reli

26、able guide for automation. What, precisely, is ISA 88? Physically, it is a combination of five documents; some stillin preparation as this is written. The first part entitled Models and Terminology is adocument that defines most of the important concepts the standard contributes tomanufacturing auto

27、mation. The committee that wrote the standard realized that acommon set of terms would be needed to even start work on a standard, so termi-nology was addressed first. However, names can only be applied to things or conceptsthat are understood. At the time that work on the standard began, much if no

28、t mostaccepted terminology was related in some way to commercial products, most ofwhich differed significantly from supplier to supplier. In addition, functions commonto multiple suppliers often were assigned unique proprietary names. Also, no namexvibatch front of book copy.qxd 4/24/2006 10:50 PM P

29、age xviexisted for many important concepts. To deal with those problems, conceptual orfunctional models were created that could provide a uniform context for terminology.The models are general so that they can represent almost any batch manufacturingprocess and are valid no matter how control is act

30、ually implemented. Terms werethen matched up with elements of the models. This may sound unacceptablyabstract, but it actually works. Once the basis for the models is clear they are intuitiveand the terminology can be applied to any physical process.The purpose of standard terminology was to provide

31、 a common language free oftechno babble. Where words in common use could be applied, they were used.Where more than one word in common use meant the same thing in the context ofthe standard, either one of the conflicting words was chosen or the committee cameup with a more appropriate term. Naming c

32、oncepts that had never had a name wasone of the more difficult tasks. The goal was to arrive at a common language thatwould allow people to communicate clearly and unambiguously with each other engineers with other engineers and specialists, engineers with suppliers, managerswith both, etc. The comm

33、ittee came pretty close. The terminology provides an ade-quate way to communicate concepts as well as references to tangible components ofcontrol, automation and process elements.The models provide a generalized view of the manufacturing process. To be useful,they have to be abstract enough and flex

34、ible enough to fit essentially any batchprocess and still be detailed enough to represent reality. The models that resultedserve their purpose well. They are able to establish a basis for modularization andallow unsynchronized activities in a manufacturing facility to be visualized and under-stood.

35、They represent required functions in each part of the process and identify therelationship between the various parts. Defining models and terminology seemed fairly simple to begin with. Just draw upsome models, plug in some terms, and go on to the important stuff. However, some-thing funny happened

36、on the way to the models. In order to create them, it wasnecessary to really understand and properly represent almost everything that goes on tomake a product in a batch process. That ended up requiring five years in which up to 50batch manufacturing experts met for several days every month or two t

37、o define a muchmore perceptive view of the organization of manufacturing equipment and the hier-archy of control functions needed to enliven that equipment. The result was astructured view of manufacturing function that is very complete. Concepts like modulargrouping of equipment and control, the me

38、aning of recipe, the importance of theschedule, the inherent layering of control functionality, etc., were fitted together tocreate an internally consistent and structured view of essentially any batch manufac-turing process. It became the accepted road map for batch automation. It is important.ISA

39、88 is important for several reasons but is best known because it has been provento deliver measurable benefits when properly applied to define and implement batchprocess automation. Those and many other benefits are the subject of this book. Naturally all benefits come with some cost and the use of

40、ISA 88 is no exception. xviibatch front of book copy.qxd 4/24/2006 10:50 PM Page xviiThe primary cost in the case of ISA 88 is the time that needs to be dedicated tolearning what the standard teaches and how to use it. In the case of a productionmanager, the time required to start participating with

41、 a design team may be no morethan few hours. Engineers, who must learn the technology as well as the principles,will spend more time. The time spent is definitely worth the effort, but it is absolutelynecessary to invest that time in order to derive the benefits that are there for thetaking. This bo

42、ok is a good start.The fundamental difference between traditional control and control as outlined in thestandard is that ISA 88 adds control of procedure and a level of coordination controlnecessary to keep multiple procedures sorted out. The concepts that are spelled outin terms of a manufacturing

43、environment are consistent regardless of whether thecontrol is provided manually or automatically. It treats control as a function thatcauses equipment to do the things necessary to make a product - no matter how thatcontrol is achieved. There is nothing wrong with manual control. It has worked well

44、for many years and is not to be taken lightly. However, there are usually benefits to begained by automating at least some of the procedural control in a manufacturingfacility. ISA 88 works with either case, or both. It is based on the premise that it is thefunction that is important. This is partic

45、ularly important in modern manufacturingapproaches where smooth integration of manual and automatic control activities isneeded. Few processes actually run all night with the lights out and people are not yetobsolete so we will be mixing automatic control and people for some time to come.There is an

46、other signal principle that provides profound benefit. Products change;processes change and products are added. All of these changes require that the con-trol of the process be modified in some way. Product related changes are much morefrequent than changes to the way that process tasks and actions

47、are implemented.ISA 88 leverages the infrequent changes to process-oriented tasks and separates themfrom product processing information. Process oriented tasks are defined, modular-ized and separated from product specific information. A recipe contains theinformation specific to a product. That reci

48、pe is used to orchestrate the sequence inwhich process-oriented tasks are executed, and to provide the values they will use forsuch things as amount, rate, pressure, etc. Most process changes can be made inrecipes written by product experts who understand the process but are not necessarilyexpert in

49、 control. This allows control experts to design and execute the process-ori-ented tasks and for the equipment control to be effectively locked away in a controllerwhile the robust and much less complex recipe can be executed in another part of thesystem. It is a powerful concept that definitely helps keep an automated plant run-ning in automatic.The journey through the concepts and practicalities of batch control is a challenge,but a rewarding one. The following chapters should make that journey towardexpertise more interesting and even more fun. Enjoy yourself along the way.Lynn