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There is a considerable scope for improving the temperature control of exothermic processes. In this thesis, a sub-optimal control strategy is developed through utilizing the dynamic, simulation tool. This scheme is built around easily obtained knowledge of the system and still retains flexibility. It can be applied to both exothermic batch and fed-batch processes. It consists of servo and regulatory modes, where a Generalized Predictive Controller (GPC) was used to provide self-tuning facilities. The methods outlined allow for limited thermal runaway whilst keeping some spare cooling capacity to ensure that operation at constraints are not violated. A special feature of the method proposed is that switching temperatures and temperature profiles can be readily found from plant trials whilst the addition rate profile Is capable of fairly straightforward computation. The work shows that It is unnecessary to demand stability for the whole of the exothermic reaction cycle, permitting a small runaway has resulted in a fast temperature response within the given safety margin. The Idea was employed for an exothermic single Irreversible reaction and also to a set of complex reactions. Both are carried out in a vessel with a heating/cooling coil. Two constraints are Imposed; (1) limited heat transfer area, and (11) a maximum allowable reaction temperature Tmax. The non-minimum phase problem can be considered as one of the difficulties in managing exothermic fed-batch process when cold reactant Is added to vessel at the maximum operating temperature. The control system coped with this within limits, a not unexpected result. In all cases, the new strategy out-performed the conventional controller and produced smoother variations in the manipulated variable. The simulation results showed that batch to batch variations and disturbances In cooling were successfully handled. GPC worked well but can be susceptible to measurement noise.

There is a considerable scope for improving the temperature control of exothermic processes. In this thesis, a sub-optimal control strategy is developed through utilizing the dynamic, simulation tool. This scheme is built around easily obtained knowledge of the system and still retains flexibility. It can be applied to both exothermic batch and fed-batch processes. It consists of servo and regulatory modes, where a Generalized Predictive Controller (GPC) was used to provide self-tuning facilities. The methods outlined allow for limited thermal runaway whilst keeping some spare cooling capacity to ensure that operation at constraints are not violated. A special feature of the method proposed is that switching temperatures and temperature profiles can be readily found from plant trials whilst the addition rate profile Is capable of fairly straightforward computation. The work shows that It is unnecessary to demand stability for the whole of the exothermic reaction cycle, permitting a small runaway has resulted in a fast temperature response within the given safety margin. The Idea was employed for an exothermic single Irreversible reaction and also to a set of complex reactions. Both are carried out in a vessel with a heating/cooling coil. Two constraints are Imposed; (1) limited heat transfer area, and (11) a maximum allowable reaction temperature Tmax. The non-minimum phase problem can be considered as one of the difficulties in managing exothermic fed-batch process when cold reactant Is added to vessel at the maximum operating temperature. The control system coped with this within limits, a not unexpected result. In all cases, the new strategy out-performed the conventional controller and produced smoother variations in the manipulated variable. The simulation results showed that batch to batch variations and disturbances In cooling were successfully handled. GPC worked well but can be susceptible to measurement noise. / Higher Education Ministry and Scientific Research

This diploma thesis deals with the design and application of the ISA 95 standard for a semi-automatic barman machine. The thesis is divided into theoretical and practical part. The theoretical part deals with the description of the ISA 95 models, together with FactoryTalk platform and its products related to the ISA 95 standard. In the practical part batch procedure is designed and applied on the machine. Based on this, implementation of standard ISA 95 using Rockwell Automation products is made. The last chapter of this thesis deals with verification of functionality and overall system design, from which concludes an overall machine performance and production deficiencies.

This thesis deals with the design and implementation of the ISA-95 standard on a newly created production line. The standard and its models are described in the theoretical part, following with the individual selected software solutions, which were used for the standard’s application. Subsequently, a description of the construction and program tools of both devices, which by physical arrangement and their connection create the production line, is provided. The next part of the thesis deals with the design and application of a batch control process. This is the basis for an ISA-95 standard implementation, which uses specific software resources for data acquisition and visualization. A functional verification of the production line and realized design was done within the last part. The conclusion presents an evaluation of production based on analyzed data from the test production.

The control of batch pulp digesters is hampered by insufficient measurements as well as nonlinearity and weak correlation between consecutive cooks. This makes a model-based approach to control attractive. Due to the age of the industry, many legacy controllers are in place on digesters around the world. The theoretical variance obtained by Monte Carlo modelling of a new controller is used as a benchmark for performance comparison between an old control system (S-factor) and a new model based controller developed by the University of Pretoria (the UP controller). This study covers the development of the controller, Monte Carlo modelling of the old and new controllers and in-situ testing of the UP controller on an operating digester. During Monte Carlo simulation, the UP controller outperformed the legacy controller, obtaining a theoretical overall variance of 3,07 (which will be used as the baseline for performance measurement) while also showing larger responses to tuning factors. The S-factor performed at 6,8 times the theoretical optimum variance during in situ testing, while the UP controller performed at 3,9 times the theoretical optimum (43% better than the S-factor controller). An average error 90% lower than that of the S-factor controller was obtained when using the UP controller. Additional benefits of the new controller include easy inclusion of new measurements and clear relations between the tuning parameters used and the conditions in the digester. / Dissertation (MEng (Control))--University of Pretoria, 2003. / Chemical Engineering / unrestricted

Made available in DSpace on 2016-06-02T19:50:25Z (GMT). No. of bitstreams: 1 6422.pdf: 2110662 bytes, checksum: eb693b2b653ba32626459f3fd72fa98b (MD5) Previous issue date: 2014-12-05 / The PBC System is a well-known Ordering System that periodically syncronizes the material flow of the shop floor. The PBC has the property of constant and planned production lead-time, a policy of minimal lot sizing and a constant frequency on order releasing. An exhaustive literature review presented in this thesis has shown that work uses PBC when the production capacity is not constant. This is a reality presented in companies where compensatory times off allows the capacity be tranfer between time stamps and employees that can work on diferente positions, allowing the capacity to be managed from one working center to another. This work formally defines those issues using mathematical programming, and defines a set of heuristics to solve it. After the application of the models and heuristics to a set of instances, one can note that the heuristics are eficiente to solve the problem, and the strategy of using PBC is very successful in the studied environment (production system with variable capacity). / O sistema PBC é conhecido como um sistema de controle da produção que sincroniza periodicamente o fluxo de materiais no chão de fábrica. O PBC tem a característica de possuir lead-time de produção constante e planejado, política de dimensionamento de lote conforme o mínimo necessário e frequência estável na liberação de ordens. Uma revisão exaustiva da literatura, apresentada neste trabalho, mostrou que não existem relatos do uso do PBC em ambientes onde a capacidade produtiva não é constante, uma realidade que se apresenta às empresas com a adoção de políticas de banco de horas (que permitem a transferência de capacidade produtiva entre diferentes períodos) e funcionários polivantes (que permitem a transferência de capacidade produtiva entre diferentes centros de trabalho). O presente trabalho define formalmente esse problema, usando técnicas de programação matemática, e propõe um conjunto de heurísticas para resolvê-lo. Após a aplicação dos modelos e heurísticas em um conjunto de casos de teste, mostra-se que as heurísticas propostas são eficazes para a resolução do problema, sendo estratégias viáveis para a implementação do PBC em ambientes de manufatura com capacidade variável.

This thesis deals with the batch controlling of a distillation column model. The thesis is divided into several parts. The first part, which is more theoretical, summarizes the description of the batch controlling, the distillation process and the equipment used, including the model of the distillation column itself. The second part is focused on the practical implementation. The beginning of this part displays different types of the models produced by the Standard 88. This section is followed by a description of a device database in the environment of FactoryTalk Batch Equipment Editor, creation of a logical phase codes using functions of the PhaseManager in the environment of RSLogix5000 and a creation of a recipe in the environment of FactoryTalk Batch Recipe Editor. The last part of this thesis deals with the visualization created in the FactoryTalk View Studio SE and final testing of the entire process.

The diploma thesis focuses on analyzing current information system of small company and proposal of modifications. Improvements of current batch control sheet system are designed as extensions of already implemented functionality and integration of attendance sheet which is related to it. Within the frame of modifications thesis proposes extensions of database model with emphasis to simplicity and complexity of target solution.