TAPPI PRESS Process Control Fundamentals for the Pulp and Paper Industry By Dr. Nancy J. Sell, Task Group Chair of the Process, Control, Electrical & Information Division
1995. 612 pp., 8-1/2" x 11" soft cover
Item Number: 0101R249
ISBN: 0898522943
Table of Contents
Chapter 1: Introduction to Process Control 2.4.3 Initial Value Theorem
1.1 Why Process Control? 2.4.4 Laplace Transform of the Driving 1.2 An Overview of the Technology Force 1.2.1 Common Control Configurations 2.4.5 Inverting the Transform 1.2.2 Control Hardware 2.5 Solving the Dynamic Model 1.2.3 The Mathematics of Feedback 2.5.1 Method of Partial Fractions Control 2.6 First-Order Response 1.2.4 Control Technology Hierarchy 2.7 Transfer Function 1.3 Historical Background 2.8 Gain 1.4 Uniqueness of Pulp and Paper 2.9 Nonlinearity Processes from a Control Perspective 2.10 Linearization and Decoupling 1.5 The Status of Control in the Pulp and 2.11 Second-Order Systems Paper Industry 2.11.1 Roots of the Second-Order 1.5.1 Control Loop Effectiveness Polynomial 1.5.2 Types of Control Technology 2.12 the Characteristic Equation 1.5.3 Application of Control Loops 2.13 Higher than Second-Order Systems 1.6 Important Control Concepts 2.14 Process Disturbances 2.15 Summary of Process Dynamics Chapter 2: Summary of Conventional Process 2.16 Completing the Process Model Control Concepts 2.16.1 Feedback Control 2.1 Overview 2.17 PID Controllers 2.2 Modeling for Control 2.17.1 Introduction to Controller Dynamics 2.2.1 Types of Dynamic Processes 2.17.2 Basic Elements of PID Control 2.2.2 Instantaneous or Steady-State 2.17.3 Summary of PID Controls Processes 2.18 Difficult Control Situations 2.2.3 First-Order Lag 2.18.1 Controllers for Processes with 2.2.4 Second-Order Processes Deadtime 2.2.5 Deadtime or Transport Delay 2.18.2 Feedforward Control 2.2.6 Higher-Order Processes 2.18.3 Cascade Control 2.3 Balances 2.3.1 Mass and Energy Chapter 3: Field Devices: Sensors and 2.3.2 Deviation from the Steady State Transmitters 2.4 Laplace Transform 3.1 Introduction 2.4.1 Laplace Transforms of Important 3.2 Brief History of the Evolution of Field Functions Devices 2.4.2 Final Value Theorem 3.3 Pressure Measurement 3.3.1 Mechanical Pressure Measuring 4.7.1 Valve Styles Devices 4.7.2 Globe Valves 3.3.2 Electrical Pressure Sensors 4.7.3 Ball Valves 3.3.3 Capillary and Other Filled System 4.7.4 Butterfly Valves Temperature Sensors 4.7.5 Plug Valves 3.3.4 Installation of Temperature Sensors 4.8 Valve Connections 3.4 Temperature Measurement 4.8.1 Screw Connections 3.4.1 Thermocouples 4.8.2 Butt or Socket Connections 3.4.2 Resistance Temperature Detectors 4.8.3 Wafer Connections (RTDs) and Thermistors 4.8.4 Flanged Connections 3.4.3 Infrared Temperature Sensors 4.9 Valve Actuators 3.4.4 Laser and Laser-Corrected 4.9.1 Pneumatic and Hydraulic Actuators Emissivity Sensors 4.9.2 Electric Actuators 3.4.5 Fiber Optic/Infrared Temperature 4.9.3 Process-Based Actuators Sensors 4.10 Variable Speed Drive Systems 3.4.6 Ultrasonic Temperature Sensors 4.10.1 DC Drives 3.4.7 Filled Thermal Devices 4.10.2 AC Drives 3.4.8 Miscellaneous Temperature Sensors 4.11 Drives Versus Valves in Control 3.5 Flow Measurement Applications 3.5.1 Head Loss Flowmeters 4.12 Miscellaneous Actuators 3.5.2 Electromagnetic Flowmeters 4.12.1 Linear Actuators 3.5.3 Turbine Flowmeters 4.12.2 Heaters 3.5.4 Vortex Flowmeters 4.13 Automatic Control Valve Selection 3.5.5 Mass Flow (Coriolis Force) 4.13.1 Determining Process Conditions Flowmeters 4.13.2 Determining Pressure Drops Across 3.5.6 Ultrasonic Flowmeters Valves 3.5.7 Thermal Flowmeters 4.13.3 Determining Valve Flow 3.5.8 Positive Displacement Flowmeters Characteristics 3.5.9 Target Flowmeters 4.13.4 Choosing Valve Body Styles 3.5.10 Optical Flowmeters 4.13.5 Determining Valve Flow 3.5.11 Steam Flowmeters Coefficients (CV) 3.5.12 Solids Flow Flowmeters 4.13.6 Selecting Proper Valve Sizes 3.6 Level Measurement 4.13.7 Selecting Proper Valve 3.6.1 Bubble Tube Level Devices Construction Materials 3.6.2 Flanged Differential Pressure 4.14 Hysteresis/Backlash/Stiction Devices 4.14.1 Hysteresis 3.6.3 Ultrasonic Devices 4.14.2 Backlash 3.6.4 Nuclear Devices 4.14.3 Stiction 3.6.5 Capacitance Devices 4.14.4 Result of Hysteresis, Backlash, 3.6.6 Radar and Microwave Devices Stiction 3.7 Common Miscellaneous Sensors 3.7.1 pH Sensors Chapter 5: Review of Control Analysis 3.7.2 Oxidation-Reduction Potential (ORP) Techniques Sensors 5.1 Introduction 3.7.3 Conductivity Sensors 5.2 the Control Loop Analysis 3.7.4 Consistency Sensors 5.3 the Process Transfer Function 3.7.5 Brightness Sensors 5.3.1 First-Order plus Deadtime 3.8 Measurement Technique 5.3.2 Second-Order Overdamped Response Chapter 4: from Instrumentation to 5.3.3 Integrating Process Response Implementation 5.4 Modeling Deadtime 4.1 Process Block Diagrams (PBDs) 5.4.1 First-Order Taylor Series 4.2 Process Flow Diagrams (PFDs) Approximation 4.3 Process and Instrumentation Diagrams 5.4.2 Padè Approximation (PIDs) 5.5 the Controller Transfer Function 4.4 Instrumentation and Control Standards 5.5.1 Sampled Data or Discrete Form 4.5 Loop Diagrams 5.5.2 Bump Test Method 4.6 Instrument Index 5.6 Calculating the Loop Transfer Function 4.7 Final Control Elements 5.7 Root Locus Analysis to Predict Closed- Loop Behavior from the Loop Transfer 7.3.2 Old Concepts of Variability Function 7.3.3 Process Variability Spectrum as 5.7.1 Rules for Interpreting Root Locus Seen at the Paper Machine Plots 7.3.4 Very High Frequency Furnish Mix 5.7.2 Root Locus Examples 7.3.5 High Frequency Process 5.7.3 Root Locus Manual Sketching Rules Design/Maintenance Problems 5.8 Frequency Response Design Criteris - 7.3.6 Low Frequency Process Control Gain and Phase Margin Considerations and Problems 5.8.1 Stability - Gain Margin, Phase 7.3.7 Very Low Frequency Pulp and Paper Margin, and the Bode Plot Tests 5.8.2 Robustness - Gain Margin, Phase 7.4 Sensors, Signal Filtering, and Margin, and the Bode Plot Interpretation 5.8.3 Stability and Robustness 7.4.1 Digital Sampling and Aliasing 5.8.4 Setpoint Response and Load 7.4.2 Data Averaging Response 7.4.3 Cross-Direction Data Points (Data 5.8.5 Robustness Boxes) 5.8.6 Robustness, Gain Margin, and 7.4.4 Single-Point (Fixed-Point) Data Phase Margin Criteria 7.4.5 Scan-Average 5.9 Calculation of the Setpoint Response 7.4.6 2-Sigma Variability Analysis 5.10 Calculation of the Load Response 7.5 Control Loop Characteristics 5.11 Variability Analysis 7.5.1 Closed-Loop Time Constant Lambda 5.11.1 the Nature of Noise and (7) Disturbances 7.5.2 Operational Motivation 5.11.2 Statistics and Variability 7.5.3 Generic Characteristics of 5.11.3 Variability and the Power Spectrum Regulatory Control Loops 5.11.4 the Period Plot 7.5.4 Loop Cut-Off Frequency 5.11.5 Power Spectrum Log-Log Plot 7.5.5 Common Causes of Cycling and 5.12 Conclusion Variability 7.5.6 Variability Impact of Control Loop Chapter 6: Controller Tuning Methods Tuning 6.1 Introduction 7.6 Market Perspective - Variability Audit 6.1.1 Types of PID Algorithms Results 6.1.2 Historical Methods of Loop Tuning 7.6.1 Basis Weight Machine Direction 6.1.3 Modern Tuning Methods (Lambda (MD) variability Tuning) 7.6.2 Causes of Variability on the Paper 6.1.4 PID Tuning Procedures Machine 6.2 Simple Models 7.7 Pulp Mill Variability and its Impact on the 6.2.1 Obtaining Simple Models Paper Machine 6.2.2 Determining P, I, and D Parameters 7.8 Paper Variability and Converting 6.2.3 Other Tuning Considerations Equipment Runnability 6.3 Specific Control Applications 7.8.1 Pressroom Operation 6.3.1 Tuning Flow Control Loops 7.8.2 Converting Operations 6.3.2 Tuning Temperature Control Loops 7.8.3 Boxplants and Corrugators 6.3.3 Tuning Level Control Loops 7.9 Status of Control Loops in the North 6.3.4 Tuning Control Loops for First Order American Pulp and Paper Industry Plus Deadtime Processes (Consistency 7.9.1 Control Technology Control) 7.9.2 Applications 6.3.5 Tuning Cascade Control Loops 7.9.3 Control Algorithms 7.9.4 Typical Process Variability Chapter 7: Control Objectives for Unifomity in 7.9.5 Impact of Process Variability on Pulp and Paper Manufacturing Product Uniformity 7.1 Introduction 7.9.6 Control Engineering and the Human 7.1.1 Historical Perspective Dimension 7.2 Nature of Pulp and Paper Manufacturing 7.9.7 Pulp and Paper Control Engineering Process Skills 7.2.1 Pulp and Paper Agitation and Mixing 7.10 Old Tuning Methods and Their Legacy 7.3 Process Related Variability and the Link 7.10.1 Fatal Flaws of the Quarter to End-Use Performance Amplitude damping method 7.3.1 Competitive Position 7.11 Control Objectives for Pulp and Paper Manufacturing 9.11 Mill Audit Report - Diffusion Washer 7.11.1 Characteristics of the Pulp and Seal Tank Levels Paper Control Environment 9.12 Control Engineering Quiz 7.11.2 Objectives for Robust Control of 9.13 Mill Audit Example - Headbox Single Loops Secondary Fan Pump Drive 9.14 Control Engineering Quiz Chapter 8: Internal Model Control: a General 9.15 Mill Audit Example - Blend Chest Unifying Concept Consistency Control 8.1 Introduction 9.16 Control Engineering Quiz 8.2 Historical Perspective 9.17 Mill Audit Example - Brownstock Flow 8.3 Internal Model Control Structure Loop 8.4 Relationship Between IMC and Standard 9.18 Mill Audit Example - Total Head on a Feedback Control Fine Paper Machine 8.5 IMC Design Concept 9.19 Control Engineering Quiz 8.5.1 Invertibility of Transfer Functions 9.20 Mill Audit Example - "Smart" 8.5.2 GIMC Structuring Rules Transmitters and Digital Processing 8.6 Examples of IMC Controllers and Their 9.21 Control Engineering Quiz Standard Feedback Equivalents 9.22 Mill Audit Example - Stock Tank Mixing 8.6.1 Pure Gain Process and Agitation 8.6.2 First-Order Process 9.23 Control Engineering Quiz 8.6.3 Second-Order Overdamped Process 9.24 Mill Audit Example - Headbox Showers 8.6.4 First-Order plus Deadtime and Basis Weight Variability 8.7 IMC-PID Tuning Rules 9.25 Control Engineering Quiz 8.7.1 Example of a Chip Bin Level Control Problem Chapter 10: Control Design: Intuition or 8.7.2 Control Analysis Analysis? 8.7.3 Tuning Conclusion 10.1 Introduction 8.7.4 Handling a Noisy Signal 10.2 the Blend System Process Design 8.8 Implementation Issues - IMC vs. 10.3 Control Design by Intuition Conventional Control Structure 10.4 Control Design by Analysis 8.9 Robustness 10.4.1 Consistency 10.4.2 Energy Chapter 9: Process Control Sample Problems 10.5 Applications 9.1 Introduction 9.2 Paper Machine Blend Chest Example Chapter 11: Beyond the Loop 9.2.1 Dry Stock Blending 11.1 Introduction 9.2.2 Flow Control Tuning 11.2 Convergent Evolution 9.2.3 Flow Loops - Control Analysis - Pine 11.2.1 Evolution of Control Technology Flow FIC-102 11.2.2 Evolution of Control Algorithms 9.2.4 Blend Chest Level Controller Tuning 11.2.3 Evolution of Database Technology 9.2.5 Control Analysis - Level Control LIC- 11.2.4 Evolution of Other Information 100 Based Functions 9.2.6 Consistency Control Tuning 11.2.5 Evolution of Organizational Models 9.2.7 Consistency - Control Analysis - Pine 11.2.6 Evolution of Architecture Models Consistency NIC-104 11.3 Collision/Integration 9.2.8 Ziegler-Nichols Tuning and Valve 11.4 Justification Stiction 11.5 Summary 9.2.9 Control Valve Dynamic Specification 9.2.10 Level Noise and Other Results Chapter 12: Distributed Control Systems 9.2.11 Conclusion 12.1 Overview 9.3 Mill Audit Example - Wet-End White 12.2 DCS Architecture Water Header Pressure 12.2.1 Distributed Control System 9.4 Control Engineering Quiz Components 9.5 Mill Audit Examples - Chlorination Stage 12.2.2 Types of DCS Highway Networks Brightness Loop 12.2.3 Local Area Networks 9.6 Control Engineering Quiz 12.2.4 Protocol 9.9 Mill Audit Example - Groundwood and 12.2.5 LAN Speeds and Application Stock Flow 12.2.6 Data Acquisition - Input and Output 9.10 Control Engineering Quiz Devices 12.2.7 Programmable Logic Controllers 14.4.1 Background (PLCs) 14.4.2 Training 12.2.8 Smart Sensor Measurement 14.4.3 Input and Output Selection Network Interfaces 14.4.4 Hidden Nodes and Hidden Layers 12.2.9 Other Distributed Control Interfaces 14.4.5 Accuracy 12.2.10 Controller Devices 14.4.6 Training Technique and Computing 12.2.11 DCS Consoles and Work Stations Time 12.2.12 Engineer's Work Station 14.4.7 Robustness 12.2.13 Peripheral Devices 14.4.8 Inferences and Generalizations 12.2.14 Distributed Control Service Tools 14.5 Combined Systems 12.3 DCS Configuration 12.3.1 DCS System Configuration Chapter 15: Economic Analysis and 12.3.2 DCS Controller Software Justification 12.3.3 Alarm Configuration 15.1 Introduction 12.3.4 Console Displays 15.2 Financial Analysis Concepts 12.4 Distributed Control and its Effect on Mill 15.2.1 Depreciation Operations 15.2.2 Time Value of Money 15.3 Financial Analysis Methods Chapter 13: Process Optimization 15.3.1 Payback Period 13.1 Introduction 15.3.2 Net Present Value 13.2 Definitions 15.3.3 Internal Rate of Return 13.2.1 Variables 15.3.4 Incremental Benefits 13.2.2 Model 15.4 Process Areas 13.2.3 Objective Function 15.4.1 Powerhouse Systems 13.2.4 Constraints 15.4.2 Woodyard 13.2.5 Degrees of Freedom 15.4.3 Digesters 13.2.6 Math Program 15.4.4 Brown Stock Washers 13.3 Optimization Methods 15.4.5 Bleach Plants 13.3.1 Analytical Methods 15.4.6 Tower Level Control 13.3.2 Linearization 15.4.7 Paper Machines 13.3.3 Numerical Search Methods 15.4.8 Coaters 13.4 Strategies and Examples 15.4.9 Supercalenders 13.4.1 Off-Line Optimization 15.4.10 Roll Finishing and Shipping 13.4.2 Real-Time Optimization 15.4.11 Information Systems 13.5 Summary 15.4.12 Customer Information/Quality 15.4.13 Continuous Improvement Chapter 14: Artificial Intelligence 15.5 Sample Economic Analysis Decision 14.1 Definitions and Background 14.2 Expert Systems Chapter 16: Case Study: the MWCS Project 14.2.1 Background 16.1 Introduction 14.2.2 Problem Selection 16.2 Project Description 14.2.3 Structure 16.3 Corporate Background 14.2.4 Predicate Calculus 16.3.1 Business Unit 14.2.5 Production Rules 16.3.2 Technology Organization 14.2.6 Frames and Scripts 16.3.3 Corporate Engineering 14.3 Fuzzy Logic Control (FLC) 16.3.4 Management Information Systems 14.3.1 Background Organization 14.3.2 Basic Concepts of Fuzzy Logic 16.4 Technology Transfer: Overcoming the Control Barriers 14.3.3 Fuzzy Logic Control Design 16.4.1 Credibility of the Technology 14.3.4 Comments on the Use of Fuzzy 16.4.2 Organizational Changes Logic 16.4.3 Perceived Benefits 14.3.5 Potential Applications of Fuzzy 16.4.4 Consensus Logic in the Pulp and Paper Industry 16.5 Project Results 14.3.6 an Example of Fuzzy Consistency 16.5.1 Quantifiable Benefits Control 16.5.2 Mill Ownership 14.3.7 Tuning the Fuzzy Consistency 16.5.3 Team Building Control 16.5.4 Mill-Resident Technology 14.4 Neural Network Systems Engineers 16.5.5 Cultural Change 16.6 Time Line 16.7 Summary 16.8 Conclusion
Chapter 17: the Marketplace and the Future
17.1 Introduction 17.2 Pulp and Paper Process Control - the Current Status 17.2.1 Steady State Thinking and Variability 17.2.2 Lessons Learned from Variability Audits 17.2.3 the Manufacturing Team 17.2.4 Process Control Competence of the Manufacturing Team 17.2.5 Control Education and the Control Engineer 17.3 A View from the Chemical Industry 17.3.1 Focus on Quality and SPC in the Chemical Industry 17.3.2 Chemical Industry Algorithm Design - Trending Toward Generality 17.3.3 The Chemical Industry's Control Strategy Focus 17.3.4 Process Design and Process Control in the Chemical Industry 17.3.5 Process Control Education in the Chemical Industry 17.4 Staffing, Organizations, and "Culture" 17.4.1 Process Control Staffing Levels 17.4.2 Organizations, Culture, and "Turf" 17.4.3 Management Awareness 17.5 A View of the Future 17.6 Conclusion