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COMPUTERS AND PROCESS CONTROL T. J. WILLIAMS VOL. 5 8
NO. 1 2
DECEMBER 1 9 6 6
55
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deliveries of the “third generation” of digital Firstcomputers and a fast breaking general acceptance of direct digital computer control systems by industry have characterized the computer and process control fields during the past year. Other major developments of interest have been the perfection of computer-directed chromatographic analysis laboratories by several computer vendor and systems supplier companies, a continued major interest in the theoretical and practical application aspects of both dynamic and steady-state optimization, and a blossoming of interest in hybrid computers and hybrid simulation outside of the aerospace and astronautics fields. Although this review this year comprises almost twice as many references as were carried by this journal in its predecessor review last year (70Q),those references cited can cover only a fraction of the articles actually appearing in the areas of endeavor encompassed by this review. Thus while this review can still not be exhaustive, it will point out the highlights of equipment and application advances as well as those theoretical areas of interest where progress has been noteworthy. As in past years, the bibliography entries have been organized into tables showing areas of progress to supplement the bibliography and to serve as direct references as well as giving impressions of the rate and direction of progress which has been made. This review covers the literature for the period of April 1, 1965 to March 31, 1966.
COMPUTER SYSTEMS DEVELOPMENTS The period covered by this review has seen the first deliveries of the new “third generation” of digital computer systems both in the commercial and scientific areas with the early models of the IBM System 360 and its counterparts among the other manufacturers, and in the process control area with the CDC 1700, the IBM 1800, and other corresponding models. One need not detail here the whole range of problems associated with the introduction of these new classes of machines since 56
INDUSTRIAL A N D ENGINEERING CHEMISTRY
-
they have been covered at length in such journals as Datamation, and Computers and Automation, and in news media such as Electronic News. It is evident that the manufacturers as a complete group have most seriously underestimated the rate of growth of the computer field and the resulting sales volume, the ready acceptance of the new machine concepts on the part of the customers, the major problems of mass producing completely new types of circuitry in order of magnitude for larger volumes, and the tremendous difficulty of generating a whole new level of software capability for a whole series of machines all at the same time. The result has been a very serious delivery delay in the machines themselves and a n even larger delay in delivery of the associated software or programming. This latter has resulted in computing systems being delivered without software or with a n inadequate partial system adding further to the customers’ problems. Fortunately, the majority of these problems will soon be behind us since the hardware d i s culties associated with these new machines have now largely been solved and the advanced programming systems originally promised are now actually in operation or planned for delivery in the next few months. Illustrative of the newfound maturity of the computer field is the fact that the difficulties and attendant bad publicity of the problems associated with the introduction of these new machines have not slackened the customer’s desires for them or his faith in their ultimate capabilities. Indeed, the whole computer field is a t present enjoying a very definite seller’s market, particularly in the process computer control areas. There has, of course, been some minor switching from one manufacturer to another by customers as one or the other particular class of machine has shown some particular difficulty or delay, but there has been no pause in the rapid growth of the acceptance of computing in its various applications by customers. New machines have continued to be announced by the various manufacturers. Perhaps the most significant this past year has been the SIGMA series of the SDS Co. which includes a small process control machine designated the SIGMA 2. This latter machine is apparently being adopted by several of the process computer systems suppliers as the computer mainframe to go with their direct control and supervisory computer control systems. Other important announcements have been the GE/PAC 4020 by General Electric to provide a direct digital control system to round out their process control computer line and the microcircuit ARGUS 400 and 500 by Ferranti Ltd., among others. Unfortunately, space does not permit a detailed listing of all such announcements here. However, one should not leave this particular subject without calling the reader’s attention to the PDP8S recently announced by Digital Equipment Corp. This is billed as a complete computing system for less than $10,000. Since the specifications are at the same time quite satisfactory for many purposes and equal to the best of only a few years ago, it is hoped that this is indeed a harbinger of what
we may expect in the relatively near future. This latter development could give a further major boost to this already booming field. Two areas of computer development mentioned in the previous review (70Q), time-shared computer systems and hybrid computers, have begun to find ready customer acceptance during the past year. Several hundred time-shared systems, where several or many remote consoles each have equal access to the computer mainframe on a share-and-share-alike basis, have been placed on order. Since deliveries of these are only now beginning, it is too early to assess completely their acceptance by industry in general and individual users in particular. However the acceptance of the experimental systems, such as MIT’s PROJECT MAC, has been excellent indeed. The hybrid computer has until just recently been used mainly by NASA and the Department of Defense and their contractors for development of missile, aircraft, and space systems. The development of the small process control-type computer, along with the newer very fast analog computers, has suddenly made the hybrid computer an attractive simulation tool for industry as well. Several petrochemical companies and large universities now have them on order or installed. Again, though, deliveries are still too few and new to have a complete report on the acceptance of these powerful but complex systems by our industry. Further to illustrate the importance of software or programming in modern computing systems, a separate section of the bibliography has been devoted to this subject. A major development here during the past year has been the acceptance by the manufacturers of a directive from the programmers of industrial computer control systems that not only should these machines be capable of being programmed in FORTRAN (73B, 23B, 35B) or other procedural language, but that in addition these machines should be capable of compiling the resulting program into a form usable by the machine itself while on-line, that is, while it is also carrying out its normal function of plant control (TB, 26B). This concept is now in the process of being implemented, and the required programming systems for this purpose are due to be completed within the next year. Use of such techniques will, in most cases, require the addition of a disk file to the computing system otherwise required for the process control task itself in order to store and handle the large programming system necessary for this task. The development of on-line debugging routines to check out the correct operation of a new program, again while the computer is carrying out its regularly assigned task of plant control ( Q B ) ,and of “emulation” (38B), which allows one computer to develop, test, and carry out programs designed for another possibly quite different machine, have been other programming techniques of AUTHOR Theodore J . Williams is Professor of Engineering and Director of the Automatic Control Laboratory, Purdue University. He has authored ItYEC’s annual reviews on process control and automation since 7958. VOL. 5 8
NO. 1 2 D E C E M B E R 1 9 6 6
57
importance which have come to our attention during the recent past.
COMPUTER APPLICATIONS T O CONTROL As was mentioned earlier, computer control has seen a degree of acceptance during the past year which has converted the vendor-purchaser relationship from one of the great competition between vendors for a particular job to one of a distinct seller’s market. Vendors now find their production capacity sold out for months ahead and are in the position of picking those projects which round out their experience or allow them to enter market or application areas not previously covered by them. One of the chief benefactors of this greatly increased interest in computer control has been the field of direct digital control. During this past year, nearly every company of consequence in the process industries has become involved in direct digital control in some way, from a joint study project with a vendor, through a trial or test installation, to a complete commitment to new plant control systems of this type. During the past year several reports of existing installations of direct digital control have appeared. Among them has been that of the Dow Chemical Co. at Midland, Mich. ( 2 8 3 , a distillation pilot plant established by IRM a t its San Jose, Calif., laboratories ( 3 5 C ) , and ICI’s Fleetwood, England, system (59C),among others ( 1 2 2 , 23C, 6 8 2 ) . The technical aspects of direct digital control such as adaptive mode-gain changing (25C), word-length effects (55C,SSC), and programming (7ZC, 81C) have been extensively treated. An announcement by the Esso Research and Engineering Co. of a large Fawley, England, Refinery digital control system in ESSO’S brought much speculation as to its physical and operational configurations (3C, 6C, IOC). This installation undoubtedly represents the major application of these control systems to date. The March 1966 issue of Automatisme is largely devoted to the technical aspects of computer control as applied to nuclear reactor systems in France. Several articles review the field of power plant computer control systems (33C, 36C, 37C, 40C), of paper mill applications (17C, ZZC), and of the computer control field in general (38C, 42C, 46C, 57C, 58C, 67C,68C, 69C). The tasks of justification and economic payout are treated by Snow ( 7 3 C ) , Webb ( 7 8 C ) , and Williams (79C). The books of Savas (7UC) and Miller (59C) are particularly recommended for their coverage of the field. That edited by Miller is the report of the 1964 IFAC/IFIP Symposium on Digital Computer Applications to Process Control held in Stockholm, Sweden, in September of that year. The reader’s attention is also invited to the June 7, 1965, issue of Chemical Engineering which contains that journal’s extensive periodic review of the instrumentation and process control field. This particular issue is largely devoted to computer control. Cundall (523)has given a complete treatment of the control output systems and manual backup systems as 58
INDUSTRIAL A N D ENGINEERING CHEMISTRY
employed by Ferranti in England for direct digital control systems. These are somewhat different from those used on this continent but are quite interesting in their own right as developments of the IC1 installation mentioned earlier (59C). Pond and Sangregorio (79E) correspondingly treat the interface problems between digital computers and conventional control systems as used for supervisory control. Any analog or digital data collection system is continually subject to influence by extraneous electrical and magnetic interference from surrounding electrical equipment. Elimination of the possibility of such interference is a vital part of the design of any such system, particularly ones to be used for plant control. Fortunately several articles outling the problem and its solution are available (73E, 17E, 21E, 23E-27E).
I NSTRU M ENTATlON Analytic instrumentation developments and their application reports and use techniques continue to dominate the instrumentation literature as these all important methods find ever wider use in industry. AS usual, chromatography comes in for the most attention because of its overall importance. Although descriptions of it had not yet reached the open literature during the period covered by this review, there have been several recently successful applications of small digital computers to control large numbers of chromatographs, such as in quality control laboratories in refineries or petrochemical plants. By eliminating the controllers, peak pickers, etc., on 30 to 40 such chromatographs, the computer can not only render better service but can at the same time apparently break even costwise with the previously used analog equipment-to our knowledge the first major instance of such an accomplishment. It had been hoped that the direct digital control field would do this but it has not yet done so and probably will not in the immediately foreseeable future. Other analytical techniques than chromatography which have seen wide treatment in the recent literature are automatic titration techniques covered in a series of articles in German in Chemie Ingenieur Technik (75F, 35F, 36F, 43F) as well as emission spectroscopy (74F) and phosphorescence spectroscopy (50F) in the same journal. Also covered were hydrogen and chlorine analysis (16F, 38F), mass spectrometry (32F), octane measurement (3F, 19F),pH measurement in a lengthy review by Aronson ( 5 F ) , and x-ray analytical methods (48F). Fluidics, the formation of digital and logic functions as well as high performance analog functions with special fluid elements of very small size and compactness, has continued to dominanate control component discussions. These elements (3OF, 7G, 21G, 34G) have until recently been mainly laboratory curiosities or of application only to the missile and space industry. They are, however, now beginning to find ever wider use in industry where a fluid, such as air or a gaseous fuel, is required in any case and where their somewhat slower speeds than those in electronic systems are no handicap.
While there have been no developments in these following areas which have been of overriding importance there have been several review and tutorial articles worthy of note. These have been in the usual measurement and control areas such as conductivity (24F), flow (7F, 70F, 77F), level (7F, 78F, 29F, 78G, 27G), temperature (8F,72F, 20F, 27F, 40F, GG, 20G), and pressure (27F, 45F,28G) as well as in special techniques areas such as strain gage applications (33F, 26G, 33G) and magnetic control devices (77G).
PROCESS D Y N A M I C S AND CONTROL Distillation column control and chemical reactor control are as usual the most popular topics in the literature on process control. Among the topics covered in reactor control are those of adaptive ( I H , 7 5 H ) and feedforward control ( 7 9 H ) . I n adaptive control the reactor’s control system automatically compensates for the changing dynamics and response of the reactor as temperature, varying catalyst activity, and component concentrations change reaction rates. I n feedforward control, upsets to the reactor system are detected as they enter the reactor system. The effect of these upsets of the output response of the reactor is then computed along with the required time pattern of the compensation to be made by the control system to counteract these effects. Presented material includes discussions of the computing algorithms or transfer functions necessary to compute the control system compensation necessary. Another important reactor control topic is that of minimum time processing ( 1 7 H ) . Considerable information on chemical reactor dynamics of ammonia reactors (31),polymerization reactors (291), styrene reactors (73J) and reactor systems ( 7 7 1 , 771, 781,79Z), kinetics in general ( 7 1 , 251), and on simulation of reactors (ZJ, 8 J , 25J)has also appeared. Especially important in the distillation dynamics and control literature is the article on two-variable control systems by Rijnsdorp (7GH). This paper discusses the decoupling of heads and bottoms composition responses so that control applications to correct tops product will not have a detrimental effect on bottoms product quality and vice versa. Feedforward control is also becoming very important in the distillation area and the papers by are especially to be Luyben ( 1 7 2 3 ) and Shinskey (7” noted here. Mathematical models of distillation column responses are very popular topics. During this period noteworthy articles by Morinaga and Yao ( 7 4 7 ) Heinke, Langers, and Wagner ( I & ) , Huckaba et al. (76Z), and Moczek, Otto, and Williams (201) were published. Other general articles on distillation control have been presented by Forman (5H)as part of his process control tutorial series, and by Kropholler and Spikins ( 70H). Heat transfer dynamics, always a popular subject, is represented by another of Forman’s series (81), by Ray’s article on responses to flow disturbances ( 7 3 Z ) , and Weber’s and Harriott’s study of agitated tank temperature responses.
Other topics which should be brought to the reader’s attention are the articles by Esterson (71)and Schiesser (231) on fluid system responses, and Schuder’s on level responses (241).
PROCESS CONTROL T H E O R Y During the past few years the process control theory field has mainly been engaged in a development and continuous minor extension of theoretical principles originally proposed in the last decade or even earlier. I n the meantime, there has been a major increase in the number of organizations and individuals taking part in these studies. A very healthy development is the rapidly growing concern on the part of most researchers in the automatic control field of the need for more “real system” application studies and fewer purely theoretical ones. This should result in major advances in the control systems proposed for all types of processes, particularly in the areas of advanced control systems such as adaptive control and optimization. The accompanying tables outline the distribution of important topics which have appeared in recent literature.
APPLICATION STUDIES A major need in the literature is for continuing reports of the details of successful installations of new instrumentation and control techniques and of new and different applications of established principles. Unfortunately these are still quite scarce despite the major effort expended by industrial organizations in this area. Proprietary considerations do play a major and necessary role here but reporting of more such installations would be a very great help in furthering the whole field and the eventual gain of both reporter and reader. During the past year several important articles have appeared covering the conventional and computer control of electrical power plants. These included the discussions of distribution systems by Cohn ( 7 7 0 ) and Ringlee (300), automatic start-up as developed in Russia ( 7 6 0 ) and an extensive discussion of systems as used in England ( 4 0 , 90). The steel industry has also been the subject of several articles on the various processes involved there. Among these were those on ore enrichment ( 3 0 ) ,blast furnace charging ( 2 2 0 ) , billet handling ( 2 7 0 ) , and on instrumentation techniques (700, 280, 330). Pilot plant automation is another area of considerable importance to the process industries and one which will continue to grow in the immediate future, particularly in conjunction with the computer-based automatic analysis techniques mentioned earlier. Articles on this subject to be noted here are those by Dean, Angelo, and Young (740),Garmon, Morrow, and Anhorn ( 2 7 0 ) , Herring and Shields (230),and Horvath (240).
M A N A G E M E N T ] MAINTENANCE, EDUCATIONl AND GENERAL I n the instrument installation and maintenance area, the appearance of the installation manual sponsored by VOL. 5 8
NO. 1 2
DECEMBER 1966
59
the American Petroleum Institute (7P) is especially important. Maintenance topics included in recent articles are those concerned with cost trends (2P), a roundup of maintenance methods (78P),and orifice maintenance (22P). A subject of ever increasing importance is that of system reliability and of its increase through redundancy as well as its theoretical aspects. Reliability topics include its calculation (7P; 9P, 23P) and indicators of its effects (77P) and reliability of protective devices (75P) and of restorable systems (13P). Redundancy is discussed in two articles ( 7 7P, 23P). Related theoretical topics include those of Deutsch (6P) on precision, accuracy‘ and resolution and of Bartholomew on random errors (5P). Malfunction detection by automatic means is already an important function in the space program as described in the article on the Gemini project by Miller and Weaver (16P). This subject also promises to become of ever increasing importance to the process industries since its perfection is a necessary preliminary to the establishment of automated startup procedures for our plants.
A topic of great interest during the past few months has been the progress of discussions concerning the Exner patent (44, 5Q) which purports to cover the field of supervisory control where a digital computer is used to reset the set points of the basic analog control system of the plant i n order to optimize the process. Some interesting articles have appeared during the past year on various historical and review topics. Especially to be noted among these is the article by Schussel on the IBhl-Rernington Rand Univac competition for the digital computer market over the years (55Q). Also worth the reader‘s attention are the reviews and histories of the overall automatic control field by Gibson (354) and Oldenburger (574). Two interesting forecast articles of the instrumentation and control field which have appeared in the past year are those by Jacobs (474) and Smith (574). CLOSING COMMENTS The author gratefully acknowledges the contributions of Mrs. Phyllis Haldeman to the preparation of this review. She has been largely responsible for the collection of the bibliography items presented herein.
COMPUTER USES OTHER THAN CONTROL OR S I MU LAT I ON Subject
References
Absorber design Algebraic equation solution Analog compiiter uses Base two logarithms Character recognition Computer uses-general
COMPUTER CONTROL AND RELATED TOPICS
(480) ( 2 3 0 , 370) ( 4 D , 9 0 , 2 4 0 : 2 5 0 , 2DD, 5 0 0 , 5 4 0 , 5 6 0 , 5 Q D , 60D)
(20,50, 80, IOD, 2 0 0 , 2 6 0 , 320, 3 7 0 ,
Computing algorithms Correlation analysis Crirical path method Curve fitting Data processing Decomposition methods Design with computers-general Differential equation solution Flow table simplification Function minimizarion Hybrid computer uses Integer linear programming Power system analysis Reactor design Real-time computation Theorem probing on computers Uses in the petroleum industry IVork schediiling
4 0 0 , 470, 580) 1760. 220. 330)
isr~j
Subject
-
Aerospace applications Airline reservation system Rillet cutting Cornpurer control General Technical considcrations Direct digital control
(140)
(150) (60,l Y D , 2 7 D , 4 2 0 )
(70) ( 1 1 0 ; 340, 4 3 0 , 45D, 4 9 0 ) (510, 5 3 0 ) (57X
(270) (3QD,550) (120) (180: 3 6 0 ) (30, 350, 3 8 0 ) (280,300)
(460)
Discrete manufacturing syitems Hierarchy systems Hydro pawrr syitem? Medical applications Nuclear plant applications Paper mill applications Petroleum refinery uses Pipeline applications Power system applications SBli plant SoftwaTc Traffic applications
ii ,
Re/trenc.U
y;50C’ (76C) (ZC 15C. 16C: 26C 30C; 32C 38C 42C 43C 4kC, 46C, 57C, :58C, 59C, ’67C,’ GSC: SSC: 70C, 71C, 73C, 78C, 7QC) ( 5 l C , 52C, 53C, 54C, 55C, 56C, 65C, 75C,8OC) (3C, 6C: 7C, XC, 9C. IOC, 12C, 23C, 25C, 27C, 28C, 35C, 3YC, 65C, 67C,77C, 8 l C ) (74C, 20C,3 d C ) (13C, 49C)
(24C) (37C, 6 4 C ) ( l C , 5C, 21C, 47C, 6GC) (17C, 22C, 48C) (lYC, 47C) (fi2C) ( l a c , 29C, 33C, 36C, 37C, 4 0 C ) (74C)
(72C) (42,4 4 C )
(lD, 130) (410)
PROCESS DYNAMICS Subject Chemical reactor dynamics Crystallization system dynamics Distillation and related processes Experimental determination of process dynamics Fluid systems dynamics Heat transfer dynamics Level control response Nuclear reactors Pressure control systems Process dynamics-general Strain gage sysrem Valve actuator
60
I
Re ferencei
Subject Crvoeenic temuerature measurement Electronic D P cells Fluidics applications Fuel element failure detection High power control Hydrogen mass flow Interlock sequences Limit switch applications p H Conrrol systems Stream analyzers Temperature control Thickness eaees l
(141, 151, 161, 201) (ZI. 701) (71, 231)
(81,731, 281) ( 2 4 (121, 271)
(41) (91, 211, 301) (261) (51)
I N D U S T R I A L A N D E N G I N E E R I N G CHEMISTRY
Y
Re/erences (3‘W (75)
(8.V) (12’Vj (74.V) (ION)
(77V) (7.V) (15,V)
( 5 N ,6 N , Si\’) (2N, 13N)
(4N)
PROCESS S I M U L A T I O N
PROCESS CONTROL
I
Subiect Analog computers and simulation Chemical reactor simulation Digital simulation Frequency response on an analog computer Hybrid computation Hydrodynamic system simulation Matliieu’s equation Kuclear reactor simulation Simulation in equipment design r i m e delavs
Subject
(lOJ, 74J, 1 9 J , ZOJ,245) ( 2 5 , 4J,8 J , 73.7, 22J, 2 5 J , 26J) (5J, 15J, 21J, 2 3 J , 2 7 J ) (34 (17J, 76J, 1 7 J )
Chemical reactor control Distillation column control Level and temperature control Nonferrous.metals industry Process control-general Steam sparging control
(QJ)
References ( l H , ZH, 6 H , 7 H , 75H, 17H, 7QH, ZOH, Z l H ) ( 5 H , lOH, I l H , 14H, 76H, 1 8 H ) (4H, 8H) (13H) (QH, 72H) (3H)
( 1 4 (7J) (7ZJ) (6,J. 1 8 J )
ANALOG-DIGITAL CONVERSION, PLANT DATA HANDLING, TELEMETRY, AND RELATED TOPICS Subject
References
Analog-digital conversion Backup methods for D D C Carrier systems Data processing-general Data transmission-general Input output-general Magnetic tape recording Noise pickup and shielding PCM telemetrv
( 6 E , I l E , ZOE) (5E) @E, QE) (76E, 22E) ( l E , IOE, lZE, 1 8 E ) ( Z E , 1QE) ( 3 E , 4E, 1 5 E ) ( 1 3 E , 74E, 77E, Z l E , 23E-27E) (7E)
i
I
References
Subject
INSTRUMENTATION TECHNIQUES (GENERAL) Subject
References
Automatic titration Chlorine analyzers Chromatography and analyzers-general Color control Conductivity measurement Cryogenic measurement Emission spectroscopy Flow measurement Fluidics Level measurement Mass spectrometry Nuclear gaging Octane measurement Optical instrumentation Phase angle measurement p H Measurement Phosphorescence spectroscopy Pneumatic conveying Pressure measurement Techniques-general Temperature measurement Temperature sensitivity of strain gages Water monitoring X-ray analyzers
(15F, 35F, 36F, 4 3 F ) (76F, 3 8 F ) (4F, 13F, 22F, 28F, 34F, 3 7 F , 4 7 F ) (31F) (24F)
References
Analog computers-General Centralization us. decentralization Computer selection methods Digital computer characteristics Digital computer components Digital computers-General Digital differential analyzers Disk files Frequency analysis of R C networks Graphical systems High speed multipliers Integrated circuits Light pen systems Logic and logic elements
( 4 A , 2 7 A , 5 0 A , 7 2 A , 7QA) (63A) ( 1 9 A , 2 3 A , 43A) ( 3 A , 6 A , 18A,33A,45A, 78A) ( l Z A , 2 1 A , 4 2 A , 4 9 A , 5QA,67A) ( Z A , 22A, 16.4, 3 2 A , 5 2 A , 62A, 7 6 A ) (74A, 34A) (7437’4) (75A) (734 ( 1 l A , 5 5 A , 60A) (674 (684 ( I A , 15.4, ZOA, 24A, 3 5 A , 4 1 A , 44A, 46A, 64A. 7 1 A ) (25A, ZQA, 3OA, 3 8 A , 3QA, 5 1 A , 5 3 A , 6 5 A , 6 6 A , 80A) (28‘4) (774 ( 5 A , 8 A , 56A, 5 7 A , 7 4 4 (SA, 48A, 70A) (31A, 47A) (lOA, 13ri, 2 6 A , 3 6 1 1 , 4 0 8 , 5 4 A , 694, 7 8 A )
Memory devices Pattern recognition Priority interrupts Small digital computers Special purpose digital computers Switching functions Time-shared systems
@OF) (74F) ( 7 F , IOF, l l F , 77F, 3 9 F ) (30F) ( l F , 18F, 4 9 F ) (32F) (QF,ZQF) ( 3 F , 7QF) (6F) (44F) (5F) (508) (26F) (27F, 4 5 F ) (25F, 41F, 42F, 4 6 F ) ( 8 F , 72F, Z l F , 4 0 F ) (33F) (ZF, 2 3 F ) (48F)
COMPUTER PROGRAM M I N G 1
Subiect Automated checkout Chemical applications Compilers-general Dynamic programming algorithms Emulation F O R T R A N programming systems Hybrid simulation On-line debugging techniques Programming-general Real-time executive routines 360 Systems
PROCESS LOOP COMPONENTS AND IN STRU M ENTAT ION HARDWARE
References (273) ( 8 E , 40E) ( 7 1 3 , 373, 5 l E ) ( 76B (384 (738, l 5 E , 22~4,2 3 B , 2 8 E , 29E, 3 0 E , 3 5 3 ) (711, 14E, 19E) (gE) (2E 38 4B 6E 70E IZE 20E 27E 24E, 2 i B , >ZE: 3 4 b , 3 6 B , 3 7 E , 3 9 B , 4 1 h (18, 26E) (178. 780. 3 3 E )
PROCESS CONTROL TH EORY-BAS1 C Subject
Subject Amplifiers Belt scales Color filters Control elements-general Control valves Flow measurement Hardness gages Magnetic elements Moisture measurement Pneumatic elements and fluidics Pressure measurement and control Reed relays Silicon controlled rectifiers Special purpose digital control Strain gages Temperature measurement
References
References
Automation of continuous processes Controller adjustment Dead time Effect of measurement accuracy and speed Feedforward us. feedback control Identification and sensitivity Nichols chart uses Root locus methods Sampled data methods Signal flow methods Special control methods Stability Statistical methods Textbooks Time-domain methods Tutorial topics
(7G, 22G) (3ZG)
W G ) ( l Z G , 73G, 16G) (5G, 71G, 74G, 30G) (18G, 7QG,27G) (296)
(3G, XG, 77G) (TOG)
(4G, 7G, 27G, 25G, 34G, 38G) (28G, 35G, 36G) (ZG) (37G) (23G) (QG, 26G, 33G) (6G, 75G, 20G, 31G)
(28-V (ZOK, 3 2 K ) (30K) (42K)
(16K, 26K) ( S K , 3 9 4 40K) (70k) (ZK, 2 3 K ) ( 7 K , 74K, 3 7 K , 41K) ( l K , 73K) (72K, 27K, ZQK, 3 3 K ) (ZZK, 3 1 K , 3 5 K ) (4K) ( 5 K , 6K, 9K, 7SK, 21K, 3 4 K , 3 6 K , 4 4 K ) ( 3 K , 17K, 2 4 K ) (15K, 77K, 7 8 K , 25K, 3 8 K , 4 3 K )
VOL. 5 8
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61
CONTROL SYSTEM T H EORY-ADVANCED CONCEPTS APPLICABLE T O PROCESS CONTROL Subject
Control system synthesis-general Correlation analysis Distributed parameter systems Learning systems Method of Popov Multivariable systems Konlinear systems Performance criteria Process identification Reactor control system synthesis Sampled-data systems Sensitivity analysis Stability-general Stability of nonlinear systcms
I
1
References
( 6 7 L , 7 4 L , 8 7 L , 6 3 L , 93L) ( 3 L , 4 L , 25L, 55Lj ( 7 8 L , SOL) (26L, 79L, 89L) ( 7 L , 74L) (63L, 6 9 L , 8 5 L ) ( 7 3 L , 3 7 L , 56L, 67L, 7 7 L ) (29L,44Lj (50L, 95L) ( 6 L , 79L) (ZZL, 28L, 4 S L , 5 7 L , 53L, 58L, 5YL, 7 2 L , 73L, 87L) ( 3 7 L , 62L,66L, 7 0 L , 7 6 L , 8 6 L ) ( 9 L , 15L, 8 0 L ) ( 7 6 L , ZOL, 21L, 32L, 33L, 3 5 L , 46L, 6 5 L ,
68L)
I NSTRU M ENTAT ION AN D CONTROL APPL ICAT1ONS (SYSTEMS)
Subject
References (780, 2 5 0 ) (40, 50, 9 0 , 7 7 0 , 7 6 0 , 300) (70) (80)
Chemical plants Electric power systems Fabrication and assembly plants Glass manufacture Heat exchangers Nuclear reactors and accelerators Petroleum refinery Pilot plant3 Railroads Steelmaking Warehousine
(70) (150, 7 7 0 , 190, 200, 310, 340) (60) ( 7 4 0 , 210, 230, 2 4 0 , 260, 320) (290) ( 2 0 , 3 0 , 100, 220, 2 7 0 , 2 8 0 , 3 3 0 )
(720, 730)
MANAGEMENT AND MAINTENANCE ASPECTS I NSTRU M ENTAT I O N AND CONTROL Subject Calibration Development and market forecasting Insrallation methods Instrument air Maintenance methods and costs Malfunction detection Management trends Reliability Safety in automation
OF
References
,
1
I
1
( 6 P , 8P,22P) ( 7 7 P , 74P) ( 7P) (20P,27P) ( Z P , 78P, 2 2 P ) (76C (4P, 79P) ( 5 P , 7 P , 9 P , 17P, 73P, 15P, 77P, 23P (3P)
OPT1 M I ZATION THEORY AND TECHN IQUES Subject
References
Applications to chemical processesgeneral Bang-bang control Batch distillation Boiler conrrol Computational methods Control system design Discrete control systems Distributed parameter systems Graphical and analytical computation methods Green’s functions Hierarchical control systems Learning and adaptive control Linear systemn with constraint? Maximum principle Parameter sensitivity Reactor and recycle control Riccati equations Sequential operations Stochastic systems Suboptimal control Text books Time var)-ing systems Tutorial articles
Subject
Refwencar
( 7 7 1 M , 27M, 32’44,45.M, 48M, 4 Q M )
(57M) ( 14M)
(44.40 ( 7 M , 15M, 27,tl, 3 3 M , 3 7 M ) (25.M, 28.84’) (29.44, 38,W,40.84‘) ( 7 7 M , 20M,4 7 M j (8M, 42M)
(16.U) (37.M) (47‘M) (7021, 23M)
(3021) (2,tf,6 M , 26.44) (9M, 7 3 . w (72.44)
(7M) (24M, 35M ) ( 3 M , 5’M, 19M, 43.M) ( 4 M , 22,44, 3 9 M ) (36.M)
(78.44, 34M, 46M, 5 0 M )
SKips Steelmaking Traffic control Automation-general Computer aided design Compuier dictionary Computer uses in chemical engineering Computers in medicine and biology Exner patent History of compiiter manufacture History of control and state of the art Information systems and retrieval Instrumentation progress International process control and computer status Man-machine communication Microelectronics Pattern recognition and learning systems Pilot plant automation Process control-general Process control laboratory experiments Rosters of computer organizations Social rmponsibility of engineers Systems engineering
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i45;; 54Q, 6 7 Q ) (65Q, 69Q) (56Q) (6Q,2 6 Q , 29Q, a Z Q , 63Q) (36Q,4 3 Q , 5 8 Q ) ( 4 4 , 5 Q , 75Q) (55Q) (234,28Q, 3 5 4 , 57Q) (184, 27Q, 49Q, 5 2 Q , 6 4 Q , 72Q) ( 4 7 4 , 50Q,5 7 Q ) (74Q, 794, 74Q)
BI BLlOG RAPHY A. ANALOG AND DIGITAL COMPUTERS (1.4) Akers: S. B., Jr., “A Diagrammatic Approach to Multilevel Logic Synthcsis.” IEEE Troni. Electron. Computers EC-14 (2), 174 (April 1965). (2.4) Alr, F. L.: Rubinoff, hforris (Eds.), “.Advances in Computers,” Val. 5, 397 pp., Academic Press, Kew York, 1964. (3A) Ayonymous, “hdams’ Computer Characteristics,’’ Datamation 11 (4), 76 (1965,. (4.4) Anonymous: “Characteristics of General Purpose Analog Computers,” Compute8s and Automation 14 (6),81 (1965). (5%) .4nonymous, “Computrrs-Logical Solution,” Electronici 38 (81, 39 (April 19, 1965). (6.4) Anonymous, “Descriptions of General Purpose Digital Computers,” Camputers and Automation 14 (6), 58 (1965). (7A) Anonymous. “Disc Files,” Data Processine 7. 138 (hlav-June 1965). (8.4) Anonymous. “Industry’s Pulse-Process Computers Shrink in Size,” Control Eng. 13 (21, 47 (February 1966). ( 9 4 ) Anonvmous '( l ) , 91 (i966). (39A) Gill, Arthur “ O n the Bound t o the Memory of a Sequential Machine,” Z E E E Trans. Eleclron. Computers EC-14 (3), 464 (June 1965). (40A) Greenber er, Martin, “ T h e Two Sides of Time-sharing,” Dntamation 11 ( l l ) , 33 (19657. (41A) Gurzi K J. “Estimates for Best Placement of Voters in a Triplicated Logic Network,”’IEEE’Trans. Electron. Computers EC-14 (51, 711 (October 1965). (42A) Hamming, R . W Mammel W. L. “A Note on the Location of the Binary Point in a ComputingMachine,”ibid., 260 (April 1965). (43A) Hillegass:, J. R., “Standardized Benchmark Problems Measure Computer Performance, Computers and Automation 15 ( l ) , 16 (1966). (44A) Hilton, A. M., “Logic, Computing Machines, and Automation,” Spartan Books, Washington, D . C., 1963. (45A) Hobbs L. C., “Impact of Hardware in the 1970’s,” Datamation 12 (3), 36 (March 19i6). (46A) HopcFFft, J. E., Mattson, R . I,., “Synthesis of Minimal Threshold Logic Networks, IEEE Trans. Electron. Computers EC-14 (4), 552 (August 1965). (47A) Horna, 0. A. “Figure of Merit of Electronic Switching Devices,” IEEE Trans. Electron. Comiuters EC-14 (4), 643 (August 1965). (48A) Hiick, A . , “Spezielle Und Universelle Rechner Und Ihre Anwendung,” Regehngstaclinik 13 (12), 578 (1965). (49A) Ishida H. Stewart R . M Jr. “A Learning Network Using Adaptive Threshold hlem&ts,” Z E h E Trany. E / e & z . Computers EC-14 (3), 481 (June 1965). (50A) Korn, G. A,, Korn, T. M . “Electronic Analog and H brid Computers,” 552 pp. 4- 19 index xvi pp. 12 appendix references bibliographies by chapter, McGraw-Hill, New York, 1964. (51A) Lewin M H Beelitz H . R . Guarracini J.,“Fixed Resistor-Card Memory,” IEEE T r a d . Elect&. Comiuters Ek-14 (3), 42k (June 1965). (5:‘A) Litton Industries, Inc. Data Systems Division Tech. Training Group, Digital Computer Funda&tals,” xi 221 pp., Prentice-Hall, Wnglewood Cliffs, 1965. (53A) Louis, H . P., Shevel, W. L., “Storage Systems-Present Status and Anticipated Development,” Z E E E Trans. Magnetics MAG-I (3), 206 (September 1965). (54A) Macdonald, Neil, “A Time-shared Computer System-The Disadvantages,” Computers and Automation 14 (9), 21 (1 965). (55A) ?items 38 (5), 125 (1965). (16G) Danatos, Steven, “Instriiment Elements Guide, 1961-1965,” Chem. Eng. 7 2 (121, 1 9 6 (June 7, 1965). (17G) Gcygrr. W. A , , “Konlinear-Magnctic Control Dexicrs,” 406 pp., McGrawHill, h-ew York, 1 9 6 4 . (18G) Grreff: C. E., IIackman, J. R . , “Capillary Flow Meters,” I S A J . 12 ( 8 ) , 75 (1965). (19G) Haalman 4., “Pulsation Errors in Turbine Flowmeters,” Control En!. 12 (5), 89 (1965): (20G) Janicke, J. M . “Direct-Reading Platinum Thermometer,’’ Instr. Control Systems 38 (5), 129 ((965). (21G) Jeglum, N. L., Taft, C. K., “ T h e New Challenge: Fluid Amplifiers,” M e c h . Eng. 88 ( I ) , 36 (1966). (22G) Kin%, R . E . , “ A Dual Amplifier Differentiator,” IEEE Z’rorr. Electron. Computers EC-15 ( I ) , 120 (February 1966). (23G) Love, D. J., “Special-Purpose Digital Controls,” Instr. Control $sterns 38 (8), 139 (1965). (24G) Matovich, E., “Fast Variahlc Color Filter,” IS.4 J. 12 (12), 53 (1965). (25G) Palmer, 0. .J. “TVhich: Air or Electric Instruments?” Hydrocarbon Procesr Petrol. R e j n e r 44 (5): 241 (1965). (26G) Perino, P. R., “Thin-Film Strain-Gage Transducers.” Instr. Control Sytems 38 (121, 119 (1965).
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I N D U S T R I A L A N D ENGINEERING C H E M I S T R Y
(27G) Perrine, E. B., “Displacement Gas Meters,’’ Ibid., 39 (2): 127 (1966). (28G: Perrine, E . B.: “Pressure Regulators and Their Application,” Ibtd., (9): 167
(1965:. (29G) Quittner, G. F.: Hansen, H. J.. Jr., “Koncontact Maperic-Hardness Gaupe for Continuous Testing of Steel Strip,’’ IS.4 T r a n s . 4 (3), 275 (July 1965).
(30G) Schipper. Robert, “Practical \’alve Sizing,” Instr. Con!rol Sytrmr 39 ( 3 ) , 101 11966). , , (31G) Schneider, D. B., “ T h e Thermistor Thermomcter,” Iwtr. Control Systems 38 (5), 119 (1965). (32G) Sma!l, R . L.: Colijn, H., “Belt Scale Got You Buffaloed?” ZSA J . 1 2 (5), 65 (1964). (33G) Stein. P. K., “Strain-Gage Circuit Design Factors,” Insir. Control Systems 3 8 ( 6 ) . 114 (1965). (34Gj Toginn: Kazirto. Inoue, Knniko, “Universal Fluid Logic Element,” Control Eng. 1 2 (5). 78 (1965). (35G) Trekell, H. E., “Pressure Transmitters-Accuracy and Span,” I S A J . 12 ( 7 ) , 59 (1965). (36G) V a n Kuyk, H . J., Husron, W .D., “Spiral and Helical Pressure Gauges,” Inrtr. Control S>js!em,s38 (9), 121 (1965). (37G) TVarren. James. T\-agner, Robrrt. “Applying Silicon Conti o l l d Rcctifiers,” .‘lutotna!icn 1 2 (!I), 115 (1965). (38G) Zalmanzon, L. A . , “Components for Pneumatic Control Instrnmrnis,” 321 pp., Pcrgamon Press, Long Transl. from Russian by R . Hardbottle, xv Island City, 1965.
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PROCESS CONTROL
( I H : Crandall, E. D.. Stevens, T Y . F.. “An Application of Adaptive Control t o a Continuous Stirred Tank Reactor,” A.I.Ch.E, J.11 (51,930 (September 1965). (2H) FznSel, P.. “ A General Method of Dimensioning +e Temperature Control System of a Continuous-Elow Stisred-Tank Reactor,’ Chem. Eng. Sci. 21 ( l ) , 49 (1966). (3Hi’Finneran, Ti’. A . , “Batch Control of Steam Sparging,” ISA J . 1 2 (4), 79 (1 965). (4HJ Forman. E. R . , “Control o f Level and Temperature,” C!iern. t‘ng. 72 (191, 1 9 9 (Sept. 13, 1965). (5H) Forman, L. R.: “Control Systems for Distillation,’’ Ibtd., (23), 213 (Nov. 8, 1965). (6H) Forman. E. R., “Control Systems for Process Rcactors,” Ibrd., (25), 149 (Dcc. 6, 1965). (7H) Haskins. D. E., Sliepcevich, C . h?.,“ T h e Invariance Principle of Conlrol for Chemica! Processes,” I N DExo. . C ~ MFUNDAMENTALS . 4 (31, 241 (August 1 9 6 5 ) . (RH) Hoenig, M . O . , ”Controlling Tcmperature in U1rrahii.h Vacuum.” Inslr. Conlrol $islemi 38 (5), 99 ( 3 9 6 5 ) . (9H) K r o n e , L. H.. TYilliams, T. J . “Process Control and App!icd Mathematics:” 173 pp. Chemical Ensincering Progress S;mposiurn Series, No. 55; Vol. 61, iv Am. Inst. Chem. Engr?., 1965. (10H: KroqmIIri, H . lt-. Spikinq; D . J. “Aiitomaric Control of Disrillation Columns, B n t . Cheni. E&. 10 (8): 544 (1565). (1 1H) Luyhen, W. L.. “Feedforward Control of Distillation Columns,” Chem. Eng. P70U. G1 (8). 74 (1965). (12H) Marton, F. D.. “Process Control Sxsrrms” Instr. Con!rol Sj’stems 38 (41, 131 (1965); (5), 149 ( 1 9 6 5 ) ; ( 6 ) , 111 (1965); P ) , i31 ( 1 9 6 5 ) ; (81,127 (1965). (13H) hlendelsohn. J “Process Control in the h-onferrous Metals Industry,” ISA J . 12 is:, 79 (1925).
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(14H) XSorinaSa, T . , Y u o , H.. “Regclung Eincr Distillationikolonnc Fur Ein Rinlrcs Gcrnisch,” Regelungsteshnzk 13 (1 l ) , 543 (1 965). (l5H) Ray, 1%’. H.. A r k , R . , “An Adap:ive Control of the Batch Reactor, 111, Simplified Parameter Estimation,“ Auinmn!,cn 3 ( 2 ) . 53 (Dcccmbcr 1965). (16H; Rijnsdorp. J. E . , “Interacrion in Two-Variable Control Systems for Distillation Columns,” I b i d . . ( l ) , 15 (October 1965). (17H) Schrock, I.. J., “h4inimum-Time Batch Processing.” I S A J . 12 ( l o ) , 75 (1965). (18H) Shinskev F. G. ”Feedforward Control for Distillation-IVhy and How:” Oil Cos J. 63’(15), 9: (April 12, 1965). (19H) Tinkler, J . D., L a m b , D. E. “Dvnamic. and Fcedforward Control of a . 61 (55). 155 (1965). Fixed-Brd Chemical Reactor,“ Chim. EL,?. Z’roq. S ~ m p Ser. (20H) TZ‘eber, T . TY.,Harriott, Peter, “Control of a Continuous-Flow ilgitated‘Tank Reactor:” I ~ DE .N o . CiIr?d. F U Z D A M L ~ T4A( L 3 )S. 264 (Auguct 19651. (21H) IVismer, D. A , , “Conversion Control in a Continuous Reactor Train: Synthesis and Computer Simulation,’’ ICEE Trms. Automatic Coniio1 A G I O (4), 455 (October 1965).
I.
PROCESS DYNAMICS
(11) Anonymous, “Computer SrudieS Rates, Mechanisms of Reactions,” Chrm. Eng. 72 (22): 102 (Oct. 25, 1965). (21) Banham, J. W., Jr., “Obtain Process Dynamics by Pulse Testing,” Control Eng. 12 (4), 83 (1965). (31) Brian, P. L. T., Baddour, R. F. Cvmery J. P..“Transient Behavior of a n Ammonia Synthesis Reactor,” Chem. kni.Sci. i0 ( 4 ) , 297 (1065). (41) Callan. P. C., Eggenberger, M. A , , “Basic Analysis of Pressure-Control Systems I’sed on Large Steam TurbineGenerator Units,” T r a n s . A S M 6 , J . Eng. fot Pover 87, Ser. A , (41, 389 (October 1965). (51) Churkin, V. M.,“Step-Input Response of a Valve-Controlled Actuator with Inertial Loading. Taking the Compressibility pf the Fluid into Account,” Autornntion Rerno!e Control 26 (9),1574 (1965). (61) Clark, Melville, Jr., Hansen, K . F., “hTumericalMethods of Reactor .4nalysis,” 340 p p . , Academic Press, New York, 1964. (71) Esterson, C : , L., “Fluid-Filled Conduit Frequency Rerponscs,” Chem. Eng, Progr. S i m p . Ser. 61 (55), 102 (1965). (81) Farman, E. R . , “Control Dynamics in Heat Transfer,” Chem. Eng. 73 ( I ) , 91 (Jan. 3, 1 9 6 6 ) . (91) Forman, E. R . , “Dynamic Response of Processes,” Ibzd., (3), 83 (Jan. 31, 1966). (101) Fuchs, F., Knauer, M., Lex, J., “Auromatisierung Regeldynamischer Untersuchungen,” Regeiungstrch. Praxis 8 (11, 18 (1 966). (111) Files, E . D., “Die Chemischen Reaktoren AIS Regelstrecke and Ilire Dynamik, Regelunqrtrchnik 13 (8;. 361 (1965): ( l o ) ,493 (1965). (121) Griffin, C. TV., Rumpf, N. K . , “Transirnt Analysis for Nuclear Power Reactors, Cham. En!. Progr. 61 ( l l j , 81 (1965). (131) Ray. W. H., “Forced-Flow Heat Exchanger Dynamics:“ IND.ENG.C r r e ~ . F U x D A M E N T A L s 5 (I), 138 (February 1966).
(141) Heinke, P., Langers, F., Wagner, H. G . , “Dynamisches Verhalten Einer Fullkorperkolonne Bir SprungfBrmigen Anderungen der Ruckflussverhaltnisses,” Chem. Ine. Tech. 37 (7), 681 (1965). (151) Hoerner, G. M . Jr., Schiesser, W. F,.,? “Simultaneous Optimization and Transient Response Evaluation of Packed-Tower Gas Absorption,” Chem. Eng. Progr. Symp. Ser. 61 ( 5 5 ) , 115 (1965). (1): Huckaba, C. E., Frankc, F. R., May, F. P., Fairchild, B. T., Distefano, G . P., Experimental Confirmation of a Predictive Model for Dynamic Distillation,” Chem. Eng. Progr. Symp. Ser. 61 ( 5 5 ) , 126 (1965). (1 71) Koppel, L. E., “Dynamics of a Class of Nonlinear Dis,ributr3d-Parameter Chemical Reactors,” IND. ENO.CHEM.FUNDAMENTALS 4’(3), 269 (August 1965). (181) Leung P. K.: Quon, D., “The Computer Model for the Regenerative Bed,” Canadian J : Chem. En
