Cover -- Title page -- Copyright page -- Contents -- Preface -- 1: Introduction -- 1.1. Categories of Processes -- 1.1.1. Continuous Processes -- 1.1.2. Batch Processes -- 1.1.3. Semi-Batch Processes -- 1.2. The Industry -- 1.2.1. Intellectual Property -- 1.2.2. Manual Operations -- 1.2.3. Driving Force for Change -- 1.2.4. Product Specifications -- 1.2.5. Automation Technology for Batch -- 1.2.6. Safety and Process Interlocks -- 1.2.7. Safe State -- 1.2.8. Safety Issues Pertaining to the Product -- 1.3. The Ultimate Batch Process: The Kitchen in Your Home -- 1.3.1. Recipe from a Cookbook -- 1.3.2. Home Kitchen versus Commercial Bakery -- 1.4. Categories of Batch Processes -- 1.4.1. Cyclical Batch -- 1.4.2. Multigrade Batch -- 1.4.3. Flexible Batch -- 1.5. Automation Functions Required for Batch -- 1.5.1. Basic Regulatory Control -- 1.5.2. Discrete Device Drivers -- 1.5.3. Step Programmers -- 1.5.4. Sequence Logic -- 1.5.5. Recipe Management -- 1.5.6. Production Control -- 1.5.7. Scheduling -- 1.5.8. Software Issues -- 1.6. Automation Equipment -- 1.6.1. Analog -- 1.6.2. Hardwired Logic -- 1.6.3. Distributed Control System (DCS) -- 1.6.4. Programmable Logic Controller (PLC) -- Reference -- 2: Measurement Considerations -- 2.1. Temperature Measurement -- 2.1.1. Resistance Temperature Detectors (RTDs) -- 2.1.2. Thermocouples -- 2.1.3. Thermistors -- 2.1.4. Thermowells -- 2.1.5. Accuracy versus Repeatability -- 2.1.6. Multiple Probes -- 2.2. Pressure Measurement -- 2.2.1. Atmospheric -- 2.2.2. Vacuum -- 2.2.3. Establishing Vacuum -- 2.2.4. Flow to Vacuum System -- 2.2.5. Pressure as a Function of Time -- 2.2.6. Valve Opening as a Function of Pressure -- 2.2.7. Leaking Agitator Seal -- 2.3. Weight and Level -- 2.3.1. Level -- 2.3.2. Load Cells -- 2.3.3. Noise -- 2.3.4. Lag Filters -- 2.3.5. Material Transfers.

2.3.6. Noise on Vessel Weight Measurement -- 2.3.7. Moving Average Filter -- 2.3.8. Vessel Weight during a Material Transfer -- 2.3.9. Least Squares Filter -- 2.4. Flow Measurements -- 2.4.1. Mass Flow -- 2.4.2. Coriolis Meters -- 2.4.3. Density -- 2.4.4. Heating or Cooling Media Flows -- 2.4.5. Coriolis Meters versus Load Cells -- 2.5. Loss-in-Weight Application -- 2.5.1. Weight to Flow -- 2.5.2. Exponential Smoothing -- 2.5.3. Least Squares Filter -- 2.5.4. Control Alternatives -- References -- 3: Continuous Control Issues -- 3.1. Loops That Operate Intermittently -- 3.1.1. Zero Flow -- 3.1.2. Stopping the Flow -- 3.1.3. Final Control Element Issues -- 3.1.4. Flow Measurement Issues -- 3.1.5. Discrete Logic -- 3.1.6. Windup in Flow Controller -- 3.2. Emptying a Vessel -- 3.2.1. Feed Tank -- 3.2.2. Ascertaining That a Vessel Is Empty -- 3.2.3. Driving Force for Fluid Flow -- 3.2.4. Transfer Piping -- 3.3. Terminating a Co-Feed -- 3.3.1. Ratio to Master Flow Set Point -- 3.3.2. Terminating Master Flow But Not Co-feed Flows -- 3.3.3. Cross-Limiters -- 3.4. Adjusting Ratio Targets -- 3.4.1. Interval for Taking Corrective Actions -- 3.4.2. Flow Meter Deemed to Be Most Accurate -- 3.4.3. Weight Measurement Deemed to Be Most Accurate -- 3.4.4. Compensating Ratio Targets -- 3.4.5. Flow Correction Factors -- 3.4.6. Terminate All Feeds at Same Time -- 3.5. Attaining Temperature Target for the Heel -- 3.5.1. Mixing Hot and Cold Fluids -- 3.5.2. Contribution of Vessel and Jacket -- 3.5.3. Two-Stage Addition of the Heel -- 3.6. Characterization Functions in Batch Applications -- 3.6.1. Throughput in a Batch Process -- 3.7. Scheduled Tuning in Batch Applications -- 3.7.1. Re-Tuning Controllers -- 3.7.2. Components of Scheduled Tuning -- 3.7.3. Limits of Scheduled Tuning -- 3.8. Edge of the Envelope -- 3.8.1. Behavior at the Edge of the Envelope -- 3.8.2. Windup.

3.8.3. Invoking Windup Protection Other Than at the Output Limits -- 3.8.4. Recognizing Why Loops Cease to Function -- 3.9. No Flow Through Control Valve -- 3.9.1. Control Objective -- 3.9.2. Vacuum Control -- 3.9.3. Inert Gas Bleed -- 3.9.4. Recycle -- 3.10. No Pressure Drop across Control Valve -- 3.10.1. Flow through Control Valve -- 3.10.2. Windup Issues -- 3.10.3. Windup Protection -- 3.10.4. Advantage of the Cascade Configuration -- 3.11. Attempting to Operate above a Process-Imposed Maximum -- 3.11.1. Maximum Cooling Rate -- 3.11.2. "Edge of the Envelope" for Control with Cooling Water Flow -- 3.11.3. Override Control -- 3.11.4. Vessel Temperature to Cooling Water Temperature Rise Cascade -- 3.11.5. Vessel Temperature to Cooling Water Return Temperature Cascade -- 3.11.6. Consequences for Vessel Temperature -- 3.12. Attempting to Operate Below a Process-Imposed Minimum -- 3.12.1. Cycling -- 3.12.2. Alternate Configuration -- 3.12.3. Blowing Steam -- 3.13. Jacket Switching -- 3.13.1. Jacket with Four Heating/Cooling Modes -- 3.13.2. Transitions -- 3.13.3. Instrumentation Considerations -- 3.13.4. Implementing the Logic for Jacket Switching -- 3.14. Smooth Transitions between Heating and One Cooling Mode -- 3.14.1. Type of Jacket -- 3.14.2. Steam Heating -- One Cooling Mode -- 3.14.3. Control Configuration -- 3.14.4. Split-Range Control Logic -- 3.14.5. Practical Considerations -- 3.14.6. Implementing Split Range -- 3.14.7. Exchanger Configurations -- 3.14.8. Control Valve on Steam Supply versus Condensate -- 3.14.9. Exchanger Bypass -- 3.14.10. Maximum Recirculation Water Temperature -- 3.15. Smooth Transitions between TWO COOLING MODES -- 3.15.1. Split-Range Logic -- 3.15.2. Getting the Most from the Available Glycol -- 3.15.3. Heat Addition By Tower Water Exchanger -- 3.15.4. Freezing in Tower Water Exchanger.

3.15.5. Alternate Exchanger Configurations -- 3.15.6. Reactor Temperature Control -- 3.15.7. Issues Pertaining to Bypass -- References -- 4: Discrete Devices -- 4.1. Discrete Inputs -- 4.1.1. Normally Open/Normally Closed -- 4.1.2. Process Switches -- 4.1.3. Sense Mode -- 4.1.4. Process Normal -- 4.2. Discrete Outputs -- 4.2.1. Output Configurations -- 4.2.2. Latched Configurations -- 4.2.3. Momentary Configurations -- 4.2.4. Latched/Momentary Configurations -- 4.2.5. Role of Programmable Logic Controllers (PLCs) -- 4.3. State Feedbacks -- 4.3.1. Two-State Valves -- 4.3.2. Final Control Element States -- 4.3.3. Two-State Motors -- 4.3.4. Discrete Device Driver -- 4.3.5. Valves on a Piping Header -- 4.3.6. Ignoring a Limit Switch -- 4.4. Associated Functions -- 4.4.1. Tracking -- 4.4.2. Interlocks -- 4.4.3. Emergency Stop -- 4.4.4. Local or Maintenance Mode -- 4.5. Beyond Two-State Final Control Elements -- 4.5.1. Dual Valves -- 4.5.2. Three-State Devices -- 5: Material Transfers -- 5.1. Multiple-Source, Single-Destination Material Transfer System -- 5.1.1. Key Characteristics -- 5.1.2. Metering Issues -- 5.1.3. Purging -- 5.1.4. Impact on Production Operations -- 5.1.5. Solids -- 5.2. Single-Source, Multiple-Destination Material Transfer System -- 5.2.1. Key Characteristics -- 5.2.2. Metering Issues -- 5.2.3. Purging -- 5.2.4. Impact on Production Operations -- 5.3. Multiple-Source, Multiple-Destination Material Transfer System -- 5.3.1. Key Characteristics -- 5.3.2. Pneumatic Conveyers -- 5.3.3. Hose Stand -- 5.3.4. Metering Issues -- 5.3.5. Purging -- 5.3.6. Impact on Production Operations -- 5.4. Validating a Material Transfer -- 5.4.1. Flow Measurement Issues -- 5.4.2. Transfer Amount from Vessel Weight -- 5.4.3. Validation Logic -- 5.4.4. Check Meter -- 5.5. Dribble Flow -- 5.5.1. Logic -- 5.5.2. Two Block Valves.

5.5.3. Single Positioning Valve -- 5.5.4. Dribble Flow for Solids -- 5.6. Simultaneous Material Transfers -- 5.7. Drums -- 6: Structured Logic for Batch -- 6.1. Structured Programming -- 6.1.1. Table-Driven Software -- 6.1.2. Structured Logic for Batch -- 6.1.3. Obstacles -- 6.2. Product Recipes and Product Batches -- 6.2.1. Product Recipe -- 6.2.2. Product Batch -- 6.2.3. Standard Batch Size -- 6.2.4. Product Batch ID -- 6.3. Formula -- 6.3.1. Designating Materials -- 6.3.2. Specifying Values -- 6.4. Operations -- 6.4.1. Parallel Operations within a Product Batch -- 6.4.2. Parallel Product Batches -- 6.4.3. Transitions from One Product to Another -- 6.5. Phases -- 6.5.1. Definition of Phases -- 6.5.2. Phase Parameters -- 6.5.3. List of Available Phases -- 6.5.4. Simple versus Complex Phases -- 6.6. Actions -- 6.6.1. Logic for a Phase -- 6.6.2. Sequence Logic -- References -- 7: Batch Unit or Process Unit -- 7.1. Defining a Batch Unit -- 7.1.1. Reactor with Three Feed Tanks -- 7.1.2. Complex Batch Units -- 7.2. Supporting Equipment -- 7.2.1. Switched Jacket -- 7.2.2. Pressure Control -- 7.2.3. Separation Column -- 7.2.4. Implications for Phase Logic -- 7.2.5. Between Product Batches -- 7.3. Step Programmer -- 7.3.1. Field Device States -- 7.3.2. Drum Timer -- 7.3.3. Enhancements to Drum Timer -- 7.3.4. I/O List -- 7.4. Failure Considerations -- 7.4.1. Indications of a Problem -- 7.4.2. Shutdown State(s) -- 7.4.3. Bypassing or Overriding Process Interlocks -- 7.4.4. Implementation of Process Interlocks -- 7.4.5. Discrete Logic Only -- 7.4.6. Discrete Device Driver Coupled with Discrete Logic -- 7.4.7. Step Programmer -- 7.4.8. Implications for Sequence Logic -- 7.4.9. Failures Initiated by Momentary Events -- 7.5. Coordination -- 7.6. Shared Equipment: Exclusive Use -- 7.7. Shared Equipment: Limited Capacity -- 7.8. Identical Batch Units.

8: Sequence Logic.