Barker B. Sc (Elec. Eng) / Barker / Rawtani M. Sc(Tech) Practical Batch Process Management

1. Auflage 2004
ISBN: 978-0-08-045543-3
Verlag: Elsevier Science & Techn.
Format: EPUB
Kopierschutz: 6 - ePub Watermark

E-Book, Englisch, 192 Seiten

Historically batch control systems were designed individually to match a specific arrangement of plant equipment. They lacked the ability to convert to new products without having to modify the control systems, and did not lend themselves to integration with manufacturing management systems.
Practical Batch Management Systems explains how to utilize the building blocks and arrange the structures of modern batch management systems to produce flexible schemes suitable for automated batch management, with the capability to be reconfigured to use the same plant equipment in different combinations.
It introduces current best practice in the automation of batch processes, including the drive for integration with MES (Manufacturing Execution System) and ERP (Enterprise Resource Planning) products from major IT vendors. References and examples are drawn from DCS / PLC batch control products currently on the market.
- Implement modern batch management systems that are flexible and easily reconfigured
- Integrate batch management with other manufacturing systems including MES and ERP
- Increase productivity through industry best practice

Mike is an accomplished engineer and well known consultant in Southern Africa who has worked in the instrumentation and control world for most of his professional life. He commenced his career in the writing and installation of real time software ranging from Fortran CAD to SCADA systems. He has also worked as an editor of a well known Instrumentation and Control magazine and built it into the leading magazine of its class. Mike recently led a team that designed and engineered a large batch management and control system for a multimillion dollar blue-chip consumer products plant and this has now been successfully running for 12 months. He is an entertaining and knowledgeable instructor with an interest in applying practical proven techniques to problems facing today's engineers and technicians working in this area of expertise. He has presented extensively on IDC Technologies range of Batch Management courses.

Autoren/Hrsg.

Barker B. Sc (Elec. Eng), Mike

Barker, Mike

Rawtani M. Sc(Tech), Mba

Rawtani, Jawahar

Inhaltsverzeichnis

1;Front cover;1
2;Contents;6
3;1. Introduction;11
3.1;1.1 Introduction;11
3.2;1.2 Identification of batch processes;12
3.3;1.3 Background of the need for integrated batch systems;18
3.4;1.4 Overview of batch systems engineering;20
3.5;1.5 Introduction to standards;24
4;2. Identify and define physical models;27
4.1;2.1 Introduction;27
4.2;2.2 Define the physical model;31
4.3;2.3 Define tags;34
5;3. Identify and define process models, actions, operations and stages;36
5.1;3.1 Introduction;36
5.2;3.2 Process model;37
5.3;3.3 Relationship between process model and physical model;38
6;4. Identify and define procedural models;41
6.1;4.1 Introduction;41
6.2;4.2 Procedural model;41
6.3;4.3 Concept of equipment entities;44
7;5. Introduction to recipes;47
7.1;5.1 Introduction;47
7.2;5.2 S88 recipe model;49
7.3;5.3 Types of recipes;50
7.4;5.4 Building recipe procedures;55
8;6. Batch manufacturing basics;58
8.1;6.1 Introduction;58
8.2;6.2 Batch numbering, tracking and reporting;58
8.3;6.3 Batch planning and scheduling;60
9;7. Batch and sequence programming fundamentals;72
9.1;7.1 Introduction;72
9.2;7.2 Techniques for batch control elements;72
9.3;7.3 Implementation;73
9.4;7.4 Interaction with continuous process sections;78
10;8. Practical techniques in sequence control design;80
10.1;8.1 Introduction;80
10.2;8.2 Programming PLCs/DCS;80
10.3;8.3 Practical methods of functional specification;83
10.4;8.4 Defining equipment procedures;84
10.5;8.5 Phase logic programming;85
10.6;8.6 Phase logic interface;88
11;9. Operator and supervisor interface;96
11.1;9.1 Introduction;96
11.2;9.2 Display screens for batch management;96
11.3;9.3 Guidelines for building user interfaces;97
11.4;9.4 Consideration of human and ergonomic factors;99
12;10. Batch management issues;103
12.1;10.1 Introduction;103
12.2;10.2 Control activity model;103
12.3;10.3 Practical problems in batch management;106
12.4;10.4 Implementation of safety issues in batch management;108
13;11. Batch control technologies;112
13.1;11.1 Introduction;112
13.2;11.2 Overview of DCS/PLC architecture;112
13.3;11.3 Integration of batch control systems to production management and ERP systems;115
13.4;11.4 Standards for enterprise/control systems integration;120
13.5;11.5 Sending process quality and production reports back to ERP;124
14;12. Practical software project planning and implementation;126
14.1;12.1 Introduction;126
14.2;12.2 What to look for in batch software packages;126
14.3;12.3 Batch control software products;132
15;Exercises;142
16;Apprendix A: Modular approach;161
16.1;A. 1 Introduction;161
16.2;A. 2 Concepts of modular manufacturing;161
16.3;A. 3 Modular approach in batch process manufacturing;162
16.4;A. 4 Modularity using ISA S88 standard;163
17;Appendix B: Case study of batch automation in a biotech manufacturing plant;166
17.1;B.1 Introduction;166
17.2;B.2 Introduction of manufacturing facility;166
17.3;B.3 The manufacturing process;167
17.4;B.4 The automation project objectives and requirements;169
17.5;B.5 The batch system requirements;169
17.6;B.6 The system architecture;173
17.7;B.7 The plant startup and validation;174
17.8;B.8 Conclusion;175
18;Solutions;176
19;Index;185