Table Of ContentAPPLIED TECHNOLOGY AND
INSTRUMENTATION FOR PROCESS CONTROL
APPLIED TECHNOLOGY AND
INSTRUMENTATION FOR
PROCESS CONTROL
Douglas O.J.deSá
TAYLOR & FRANCIS
NEW YORK AND LONDON
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Published in 2004 by
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Copyright © 2004 by Taylor & Francis Books, Inc.
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10 9 8 7 6 5 4 3 2 1
Library of Congress Cataloging-in-Publication Data
deSá, Douglas O.J.
Applied technology and instrumentation for process control/by Douglas O.J.deSá.
p. cm.
Includes bibliographical references and index.
ISBN 1-59169-021-8
1. Engineering instruments. 2. Process control—Instruments. I. Title.
TA165.D46 2003
670.42′75–dc22
2003049339
ISBN 0-203-49087-8 Master e-book ISBN
ISBN 0-203-59495-9 (Adobe eReader Format)
ISBN 1-59169-021-8 (Print Edition)
Contents
PREFACE viii
INTRODUCTION ix
NOTATION USED IN THIS BOOK xi
INSTRUMENTATION SYMBOLS USED IN THIS BOOK xiv
TAG NUMBER SYSTEM USED IN THIS BOOK xvi
CHAPTER 1 APPLICABILITY OF MISCELLANEOUS CONTROL 1
STRATEGIES—INDUSTRYWIDE
CHAPTER 2 DIGESTERS—PAPER PULP 38
CHAPTER 3 PAPER MACHINE 92
CHAPTER 4 EVAPORATORS 162
CHAPTER 5 PRODUCT DISTILLATION 205
CHAPTER 6 PRODUCT BLENDING 289
CHAPTER 7 THE BREWING INDUSTRY 332
CHAPTER 8 PROJECT MANAGEMENT AND ADMINISTRATION 379
BIBLIOGRAPHY 407
INDEX 409
Preface
This work is an extension to the earlier publication Instrumentation Fundamentals for
Process Control (2001) in which the basics of instrumentation were given along with
some applications of instruments and control systems to real processes. Because the
present work is an extension of this latter aspect, it is therefore confined mainly to the
techniques of applying instrumentation and control systems to manipulate the process to
give the desired results.
The topics covered in this book will expose the reader to even more actual
requirements that are to be found in real process plants, as well as to some of the methods
used as solutions to control them. Many complex industrial applications have several
common elements. Therefore, the similarity in operation of parts of the process can allow
the control philosophy developed for the control loops involved in the common elements
to be applied across several different industries. The reader is encouraged to look for and
exploit, where possible, this feature to advantage. As mentioned earlier, much of the
instrumentation used in the systems presently discussed have been previously covered in
Instrumentation Fundamentals for Process Control (2001). The present text, however,
has not assumed any prior knowledge, and as far as possible, steps have been taken to
make this book self-sufficient.
Once again I am indebted to many of my former colleagues in the Foxboro Company,
especially M.J.Cooper for his constant encouragement and cooperation, J.F. Whiting,
E.A.Wright, Professor G.W.Skates, and to many other friends for their useful comments
to enrich this work. I owe a particular debt of gratitude to D.R. Beeton, a personal friend
and former colleague for his forbearance, patience, long hours of work, and invaluable
comments in his review of this text. My patient wife Halina, also, once again deserves
special mention for the warmth of her encouragement and her equanimity in tolerating
the many long hours I have had to spend away from her company while this book was
being prepared.
Doug deSá
October 2003
Introduction
The objective of this book is not to cover only a few selected industries. Rather it is
one which, via the industries covered, shows that most of the techniques are
applicable (perhaps with some modification) to many diverse industries.
The things we use every day are made by a variety of processes using raw materials
that in many instances do not bear any resemblance to the finished product. For example,
the clothes we wear do not resemble the cotton or the wool from which they were made.
The difference is even more striking if the clothes were manufactured from synthetic
fibers. There is very little, if any similarity between the nylon stockings or the acrylic
sweater and the crude oil from which they were produced. Even the food we eat is the
subject of processing of one kind or another.
This book seeks to give the reader an insight into a number of different manufacturing
processes. There are far too many processes to even contemplate covering more than a
small number of process industries—but many of the topics covered are universally
applicable to a much wider range of industrial plant. The examples covered represent a
convenient way of giving the reader insight into how basic loops are configured and
made to “hang together” to produce the control techniques (sub-applications) that can tie
into the real-world overall plant philosophy
Solutions are seldom written on “tablets of stone,” for specific plant requirements will
in almost all cases dictate a course of action that takes into account the prevailing
circumstances. The control systems discussed represent one way that has been found to
make the process manageable and able to consistently produce the product required. In
order to concentrate on the regulatory control aspects for the control systems illustrated in
the book, parameters that need to be recorded (i.e., a chart record to be made, and/or
indicated or alarmed) have very largely not been included. These additional features,
important as they are in any system, can always be added to the appropriate loop(s) quite
easily when required, but only after their use and position within the control system have
been discussed, defined, and agreed to with the process personnel involved.
Therefore, the challenge to the readership is to provide other solutions that are even
subtler, more advantageous, and simpler when applied to the process, but most important,
the solutions offered should be easily understood by all concerned. To do this effectively,
the underlying principles of the process must be understood. The objective of giving a
reasonably clear understanding of these process principles and the controls without
demanding that the readers have tremendous familiarity with heavy math or the
intricacies of physics and chemistry has been another motivation for the work. Let it be
said up front, however, that on occasion readers, in the course of their work, will be
called upon to give a theoretical explanation of their design. In this case, one would be
compelled to make use of the knowledge gained in the hallowed halls of academia.
Therefore, the advice to the reader now, as it has been in the past, is not to ignore the
theoretical approach to control engineering.
