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Practical Batch Process Management
1st Edition - November 18, 2004
Authors: Mike Barker, Jawahar Rawtani
Language: English
Paperback ISBN:9780750662772
9 7 8 - 0 - 7 5 0 6 - 6 2 7 7 - 2
eBook ISBN:9780080455433
9 7 8 - 0 - 0 8 - 0 4 5 5 4 3 - 3
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…Read more
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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
Professional engineersSpecialist students* Engineers and Technicians in process or control/instrument fields who are involved in batch process control projects* Production Supervisors or Managers interested in developing improved batch management techniques through the use of automation systems* System Integrators seeking to provide a design service to clients* Those in businesses that have automated batch manufacturing as a part of their production activity* Instrumentation and Design Engineers* Chemical Engineers * Process Engineers* Electrical Engineers * Project Engineers* Design Engineers * Field Technicians* Electrical Technicians * Electricians* Plant Operators
Preface
Chapter 1: Introduction
Publisher Summary
1.1 Introduction
1.2 Identification of batch processes
1.3 Background of the need for integrated batch systems
1.4 Overview of batch systems engineering
1.5 Introduction to standards
Chapter 2: Identify and define physical models
Publisher Summary
2.1 Introduction
2.2 Define the physical model
2.3 Define tags
Chapter 3: Identify and define process models, actions, operations and stages
Publisher Summary
3.1 Introduction
3.2 Process model
3.3 Relationship between process model and physical model
Chapter 4: Identify and define procedural models
Publisher Summary
4.1 Introduction
4.2 Procedural model
4.3 Concept of equipment entities
Chapter 5: Introduction to recipes
Publisher Summary
5.1 Introduction
5.2 S88 recipe model
5.3 Types of recipes
5.4 Building recipe procedures
Chapter 6: Batch manufacturing basics
Publisher Summary
6.1 Introduction
6.2 Batch numbering, tracking and reporting
6.3 Batch planning and scheduling
6.3.7 Core simulation model
6.3.8 Simulation
6.3.9 The scheduling model
Chapter 7: Batch and sequence programming fundamentals
Publisher Summary
7.1 Introduction
7.2 Techniques for batch control elements
7.3 Implementation
7.4 Interaction with continuous process sections
Chapter 8: Practical techniques in sequence control design
Publisher Summary
8.1 Introduction
8.2 Programming PLCs/DCS
8.3 Practical methods of functional specification
8.4 Defining equipment procedures
8.5 Phase logic programming
8.6 Phase logic interface
Chapter 9: Operator and supervisor interface
Publisher Summary
9.1 Introduction
9.2 Display screens for batch management
9.3 Guidelines for building user interfaces
9.4 Consideration of human and ergonomic factors
Chapter 10: Batch management issues
Publisher Summary
10.1 Introduction
10.2 Control activity model
10.3 Practical problems in batch management
10.4 Implementation of safety issues in batch management
Chapter 11: Batch control technologies
Publisher Summary
11.1 Introduction
11.2 Overview of DCS/PLC architecture
11.3 Integration of batch control systems to production management and ERP systems
11.4 Standards for enterprise/control systems integration
11.5 Sending process quality and production reports back to ERP
Chapter 12: Practical software project planning and implementation
Publisher Summary
12.1 Introduction
12.2 What to look for in batch software packages
12.3 Batch control software products
Exercise 1
Exercise 2
Exercise 3
Exercise 4
Exercise 5
Appendix A: Modular approach
Appendix B: Case study of batch automation in a biotech manufacturing plant
Glossary
Solution 1
Solution 2
Solution 3
Solution 4
Solution 5
Index
No. of pages: 192
Language: English
Edition: 1
Published: November 18, 2004
Imprint: Newnes
Paperback ISBN: 9780750662772
eBook ISBN: 9780080455433
MB
Mike Barker
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.
Affiliations and expertise
Senior Electrical Consultant, Johannesburg, South Africa
JR
Jawahar Rawtani
Jawahar’s focus over the past few years has been in the project planning, engineering and commissioning of process control systems and instrumentation systems for two 1 Mtpa cement plants from conceptual stage to production. His experience has extended to installation of instrumentation to programming and configuration of the PLC’s and distributed control systems. He has collaborated in the writing of a number of the IDC Technologies books with solid expertise in Motion Control, alarm management, SCADA systems and latterly Distributed Control Systems.
Affiliations and expertise
Senior Electrical Engineer, Nashik, India
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