Document Name:

0101r249

Section:

TAPPI PRESS

Title:

Process Control Fundamentals for the

Pulp & Paper Industry

TAPPI PRESS
Process Control Fundamentals for the Pulp and Paper Industry
By Dr. Nancy J. Sell, Task Group Chair of the Process, Control, Electrical & Information Division
1995. 612 pp., 8-1/2" x 11" soft cover
Item Number: 0101R249
ISBN: 0898522943
Table of Contents
Chapter 1: Introduction to Process Control
1.1 Why Process Control?
1.2 An Overview of the Technology
1.2.1 Common Control Configurations
1.2.2 Control Hardware
1.2.3 The Mathematics of Feedback
Control
1.2.4 Control Technology Hierarchy
1.3 Historical Background
1.4 Uniqueness of Pulp and Paper
Processes from a Control Perspective
1.5 The Status of Control in the Pulp and
Paper Industry
1.5.1 Control Loop Effectiveness
1.5.2 Types of Control Technology
1.5.3 Application of Control Loops
1.6 Important Control Concepts
Chapter 2: Summary of Conventional Process
Control Concepts
2.1 Overview
2.2 Modeling for Control
2.2.1 Types of Dynamic Processes
2.2.2 Instantaneous or Steady-State
Processes
2.2.3 First-Order Lag
2.2.4 Second-Order Processes
2.2.5 Deadtime or Transport Delay
2.2.6 Higher-Order Processes
2.3 Balances
2.3.1 Mass and Energy
2.3.2 Deviation from the Steady State
2.4 Laplace Transform
2.4.1 Laplace Transforms of Important
Functions
2.4.2 Final Value Theorem

2.4.3 Initial Value Theorem

2.4.4 Laplace Transform of the Driving
Force
2.4.5 Inverting the Transform
2.5 Solving the Dynamic Model
2.5.1 Method of Partial Fractions
2.6 First-Order Response
2.7 Transfer Function
2.8 Gain
2.9 Nonlinearity
2.10 Linearization and Decoupling
2.11 Second-Order Systems
2.11.1 Roots of the Second-Order
Polynomial
2.12 the Characteristic Equation
2.13 Higher than Second-Order Systems
2.14 Process Disturbances
2.15 Summary of Process Dynamics
2.16 Completing the Process Model
2.16.1 Feedback Control
2.17 PID Controllers
2.17.1 Introduction to Controller Dynamics
2.17.2 Basic Elements of PID Control
2.17.3 Summary of PID Controls
2.18 Difficult Control Situations
2.18.1 Controllers for Processes with
Deadtime
2.18.2 Feedforward Control
2.18.3 Cascade Control
Chapter 3: Field Devices: Sensors and
Transmitters
3.1 Introduction
3.2 Brief History of the Evolution of Field
Devices
3.3 Pressure Measurement

3.3.1 Mechanical Pressure Measuring

Devices
3.3.2 Electrical Pressure Sensors
3.3.3 Capillary and Other Filled System
Temperature Sensors
3.3.4 Installation of Temperature Sensors
3.4 Temperature Measurement
3.4.1 Thermocouples
3.4.2 Resistance Temperature Detectors
(RTDs) and Thermistors
3.4.3 Infrared Temperature Sensors
3.4.4 Laser and Laser-Corrected
Emissivity Sensors
3.4.5 Fiber Optic/Infrared Temperature
Sensors
3.4.6 Ultrasonic Temperature Sensors
3.4.7 Filled Thermal Devices
3.4.8 Miscellaneous Temperature Sensors
3.5 Flow Measurement
3.5.1 Head Loss Flowmeters
3.5.2 Electromagnetic Flowmeters
3.5.3 Turbine Flowmeters
3.5.4 Vortex Flowmeters
3.5.5 Mass Flow (Coriolis Force)
Flowmeters
3.5.6 Ultrasonic Flowmeters
3.5.7 Thermal Flowmeters
3.5.8 Positive Displacement Flowmeters
3.5.9 Target Flowmeters
3.5.10 Optical Flowmeters
3.5.11 Steam Flowmeters
3.5.12 Solids Flow Flowmeters
3.6 Level Measurement
3.6.1 Bubble Tube Level Devices
3.6.2 Flanged Differential Pressure
Devices
3.6.3 Ultrasonic Devices
3.6.4 Nuclear Devices
3.6.5 Capacitance Devices
3.6.6 Radar and Microwave Devices
3.7 Common Miscellaneous Sensors
3.7.1 pH Sensors
3.7.2 Oxidation-Reduction Potential (ORP)
Sensors
3.7.3 Conductivity Sensors
3.7.4 Consistency Sensors
3.7.5 Brightness Sensors
3.8 Measurement Technique
Chapter 4: from Instrumentation to
Implementation
4.1 Process Block Diagrams (PBDs)
4.2 Process Flow Diagrams (PFDs)
4.3 Process and Instrumentation Diagrams
(PIDs)
4.4 Instrumentation and Control Standards
4.5 Loop Diagrams
4.6 Instrument Index
4.7 Final Control Elements

4.7.1 Valve Styles

4.7.2 Globe Valves
4.7.3 Ball Valves
4.7.4 Butterfly Valves
4.7.5 Plug Valves
4.8 Valve Connections
4.8.1 Screw Connections
4.8.2 Butt or Socket Connections
4.8.3 Wafer Connections
4.8.4 Flanged Connections
4.9 Valve Actuators
4.9.1 Pneumatic and Hydraulic Actuators
4.9.2 Electric Actuators
4.9.3 Process-Based Actuators
4.10 Variable Speed Drive Systems
4.10.1 DC Drives
4.10.2 AC Drives
4.11 Drives Versus Valves in Control
Applications
4.12 Miscellaneous Actuators
4.12.1 Linear Actuators
4.12.2 Heaters
4.13 Automatic Control Valve Selection
4.13.1 Determining Process Conditions
4.13.2 Determining Pressure Drops Across
Valves
4.13.3 Determining Valve Flow
Characteristics
4.13.4 Choosing Valve Body Styles
4.13.5 Determining Valve Flow
Coefficients (CV)
4.13.6 Selecting Proper Valve Sizes
4.13.7 Selecting Proper Valve
Construction Materials
4.14 Hysteresis/Backlash/Stiction
4.14.1 Hysteresis
4.14.2 Backlash
4.14.3 Stiction
4.14.4 Result of Hysteresis, Backlash,
Stiction
Chapter 5: Review of Control Analysis
Techniques
5.1 Introduction
5.2 the Control Loop Analysis
5.3 the Process Transfer Function
5.3.1 First-Order plus Deadtime
5.3.2 Second-Order Overdamped
Response
5.3.3 Integrating Process Response
5.4 Modeling Deadtime
5.4.1 First-Order Taylor Series
Approximation
5.4.2 Pad Approximation
5.5 the Controller Transfer Function
5.5.1 Sampled Data or Discrete Form
5.5.2 Bump Test Method
5.6 Calculating the Loop Transfer Function
5.7 Root Locus Analysis to Predict Closed-

Loop Behavior from the Loop Transfer

Function
5.7.1 Rules for Interpreting Root Locus
Plots
5.7.2 Root Locus Examples
5.7.3 Root Locus Manual Sketching Rules
5.8 Frequency Response Design Criteris Gain and Phase Margin
5.8.1 Stability - Gain Margin, Phase
Margin, and the Bode Plot
5.8.2 Robustness - Gain Margin, Phase
Margin, and the Bode Plot
5.8.3 Stability and Robustness
5.8.4 Setpoint Response and Load
Response
5.8.5 Robustness
5.8.6 Robustness, Gain Margin, and
Phase Margin Criteria
5.9 Calculation of the Setpoint Response
5.10 Calculation of the Load Response
5.11 Variability Analysis
5.11.1 the Nature of Noise and
Disturbances
5.11.2 Statistics and Variability
5.11.3 Variability and the Power Spectrum
5.11.4 the Period Plot
5.11.5 Power Spectrum Log-Log Plot
5.12 Conclusion
Chapter 6: Controller Tuning Methods
6.1 Introduction
6.1.1 Types of PID Algorithms
6.1.2 Historical Methods of Loop Tuning
6.1.3 Modern Tuning Methods (Lambda
Tuning)
6.1.4 PID Tuning Procedures
6.2 Simple Models
6.2.1 Obtaining Simple Models
6.2.2 Determining P, I, and D Parameters
6.2.3 Other Tuning Considerations
6.3 Specific Control Applications
6.3.1 Tuning Flow Control Loops
6.3.2 Tuning Temperature Control Loops
6.3.3 Tuning Level Control Loops
6.3.4 Tuning Control Loops for First Order
Plus Deadtime Processes (Consistency
Control)
6.3.5 Tuning Cascade Control Loops
Chapter 7: Control Objectives for Unifomity in
Pulp and Paper Manufacturing
7.1 Introduction
7.1.1 Historical Perspective
7.2 Nature of Pulp and Paper Manufacturing
Process
7.2.1 Pulp and Paper Agitation and Mixing
7.3 Process Related Variability and the Link
to End-Use Performance
7.3.1 Competitive Position

7.3.2 Old Concepts of Variability

7.3.3 Process Variability Spectrum as
Seen at the Paper Machine
7.3.4 Very High Frequency Furnish Mix
7.3.5 High Frequency Process
Design/Maintenance Problems
7.3.6 Low Frequency Process Control
Considerations and Problems
7.3.7 Very Low Frequency Pulp and Paper
Tests
7.4 Sensors, Signal Filtering, and
Interpretation
7.4.1 Digital Sampling and Aliasing
7.4.2 Data Averaging
7.4.3 Cross-Direction Data Points (Data
Boxes)
7.4.4 Single-Point (Fixed-Point) Data
7.4.5 Scan-Average
7.4.6 2-Sigma Variability Analysis
7.5 Control Loop Characteristics
7.5.1 Closed-Loop Time Constant Lambda
(7)
7.5.2 Operational Motivation
7.5.3 Generic Characteristics of
Regulatory Control Loops
7.5.4 Loop Cut-Off Frequency
7.5.5 Common Causes of Cycling and
Variability
7.5.6 Variability Impact of Control Loop
Tuning
7.6 Market Perspective - Variability Audit
Results
7.6.1 Basis Weight Machine Direction
(MD) variability
7.6.2 Causes of Variability on the Paper
Machine
7.7 Pulp Mill Variability and its Impact on the
Paper Machine
7.8 Paper Variability and Converting
Equipment Runnability
7.8.1 Pressroom Operation
7.8.2 Converting Operations
7.8.3 Boxplants and Corrugators
7.9 Status of Control Loops in the North
American Pulp and Paper Industry
7.9.1 Control Technology
7.9.2 Applications
7.9.3 Control Algorithms
7.9.4 Typical Process Variability
7.9.5 Impact of Process Variability on
Product Uniformity
7.9.6 Control Engineering and the Human
Dimension
7.9.7 Pulp and Paper Control Engineering
Skills
7.10 Old Tuning Methods and Their Legacy
7.10.1 Fatal Flaws of the Quarter
Amplitude damping method
7.11 Control Objectives for Pulp and Paper

Manufacturing
7.11.1 Characteristics of the Pulp and
Paper Control Environment
7.11.2 Objectives for Robust Control of
Single Loops
Chapter 8: Internal Model Control: a General
Unifying Concept
8.1 Introduction
8.2 Historical Perspective
8.3 Internal Model Control Structure
8.4 Relationship Between IMC and Standard
Feedback Control
8.5 IMC Design Concept
8.5.1 Invertibility of Transfer Functions
8.5.2 GIMC Structuring Rules
8.6 Examples of IMC Controllers and Their
Standard Feedback Equivalents
8.6.1 Pure Gain Process
8.6.2 First-Order Process
8.6.3 Second-Order Overdamped Process
8.6.4 First-Order plus Deadtime
8.7 IMC-PID Tuning Rules
8.7.1 Example of a Chip Bin Level Control
Problem
8.7.2 Control Analysis
8.7.3 Tuning Conclusion
8.7.4 Handling a Noisy Signal
8.8 Implementation Issues - IMC vs.
Conventional Control Structure
8.9 Robustness
Chapter 9: Process Control Sample Problems
9.1 Introduction
9.2 Paper Machine Blend Chest Example
9.2.1 Dry Stock Blending
9.2.2 Flow Control Tuning
9.2.3 Flow Loops - Control Analysis - Pine
Flow FIC-102
9.2.4 Blend Chest Level Controller Tuning
9.2.5 Control Analysis - Level Control LIC100
9.2.6 Consistency Control Tuning
9.2.7 Consistency - Control Analysis - Pine
Consistency NIC-104
9.2.8 Ziegler-Nichols Tuning and Valve
Stiction
9.2.9 Control Valve Dynamic Specification
9.2.10 Level Noise and Other Results
9.2.11 Conclusion
9.3 Mill Audit Example - Wet-End White
Water Header Pressure
9.4 Control Engineering Quiz
9.5 Mill Audit Examples - Chlorination Stage
Brightness Loop
9.6 Control Engineering Quiz
9.9 Mill Audit Example - Groundwood and
Stock Flow
9.10 Control Engineering Quiz

9.11 Mill Audit Report - Diffusion Washer

Seal Tank Levels
9.12 Control Engineering Quiz
9.13 Mill Audit Example - Headbox
Secondary Fan Pump Drive
9.14 Control Engineering Quiz
9.15 Mill Audit Example - Blend Chest
Consistency Control
9.16 Control Engineering Quiz
9.17 Mill Audit Example - Brownstock Flow
Loop
9.18 Mill Audit Example - Total Head on a
Fine Paper Machine
9.19 Control Engineering Quiz
9.20 Mill Audit Example - "Smart"
Transmitters and Digital Processing
9.21 Control Engineering Quiz
9.22 Mill Audit Example - Stock Tank Mixing
and Agitation
9.23 Control Engineering Quiz
9.24 Mill Audit Example - Headbox Showers
and Basis Weight Variability
9.25 Control Engineering Quiz
Chapter 10: Control Design: Intuition or
Analysis?
10.1 Introduction
10.2 the Blend System Process Design
10.3 Control Design by Intuition
10.4 Control Design by Analysis
10.4.1 Consistency
10.4.2 Energy
10.5 Applications
Chapter 11: Beyond the Loop
11.1 Introduction
11.2 Convergent Evolution
11.2.1 Evolution of Control Technology
11.2.2 Evolution of Control Algorithms
11.2.3 Evolution of Database Technology
11.2.4 Evolution of Other Information
Based Functions
11.2.5 Evolution of Organizational Models
11.2.6 Evolution of Architecture Models
11.3 Collision/Integration
11.4 Justification
11.5 Summary
Chapter 12: Distributed Control Systems
12.1 Overview
12.2 DCS Architecture
12.2.1 Distributed Control System
Components
12.2.2 Types of DCS Highway Networks
12.2.3 Local Area Networks
12.2.4 Protocol
12.2.5 LAN Speeds and Application
12.2.6 Data Acquisition - Input and Output
Devices

12.2.7 Programmable Logic Controllers

(PLCs)
12.2.8 Smart Sensor Measurement
Network Interfaces
12.2.9 Other Distributed Control Interfaces
12.2.10 Controller Devices
12.2.11 DCS Consoles and Work Stations
12.2.12 Engineer's Work Station
12.2.13 Peripheral Devices
12.2.14 Distributed Control Service Tools
12.3 DCS Configuration
12.3.1 DCS System Configuration
12.3.2 DCS Controller Software
12.3.3 Alarm Configuration
12.3.4 Console Displays
12.4 Distributed Control and its Effect on Mill
Operations
Chapter 13: Process Optimization
13.1 Introduction
13.2 Definitions
13.2.1 Variables
13.2.2 Model
13.2.3 Objective Function
13.2.4 Constraints
13.2.5 Degrees of Freedom
13.2.6 Math Program
13.3 Optimization Methods
13.3.1 Analytical Methods
13.3.2 Linearization
13.3.3 Numerical Search Methods
13.4 Strategies and Examples
13.4.1 Off-Line Optimization
13.4.2 Real-Time Optimization
13.5 Summary
Chapter 14: Artificial Intelligence
14.1 Definitions and Background
14.2 Expert Systems
14.2.1 Background
14.2.2 Problem Selection
14.2.3 Structure
14.2.4 Predicate Calculus
14.2.5 Production Rules
14.2.6 Frames and Scripts
14.3 Fuzzy Logic Control (FLC)
14.3.1 Background
14.3.2 Basic Concepts of Fuzzy Logic
Control
14.3.3 Fuzzy Logic Control Design
14.3.4 Comments on the Use of Fuzzy
Logic
14.3.5 Potential Applications of Fuzzy
Logic in the Pulp and Paper Industry
14.3.6 an Example of Fuzzy Consistency
Control
14.3.7 Tuning the Fuzzy Consistency
Control
14.4 Neural Network Systems

14.4.1 Background
14.4.2 Training
14.4.3 Input and Output Selection
14.4.4 Hidden Nodes and Hidden Layers
14.4.5 Accuracy
14.4.6 Training Technique and Computing
Time
14.4.7 Robustness
14.4.8 Inferences and Generalizations
14.5 Combined Systems
Chapter 15: Economic Analysis and
Justification
15.1 Introduction
15.2 Financial Analysis Concepts
15.2.1 Depreciation
15.2.2 Time Value of Money
15.3 Financial Analysis Methods
15.3.1 Payback Period
15.3.2 Net Present Value
15.3.3 Internal Rate of Return
15.3.4 Incremental Benefits
15.4 Process Areas
15.4.1 Powerhouse Systems
15.4.2 Woodyard
15.4.3 Digesters
15.4.4 Brown Stock Washers
15.4.5 Bleach Plants
15.4.6 Tower Level Control
15.4.7 Paper Machines
15.4.8 Coaters
15.4.9 Supercalenders
15.4.10 Roll Finishing and Shipping
15.4.11 Information Systems
15.4.12 Customer Information/Quality
15.4.13 Continuous Improvement
15.5 Sample Economic Analysis Decision
Chapter 16: Case Study: the MWCS Project
16.1 Introduction
16.2 Project Description
16.3 Corporate Background
16.3.1 Business Unit
16.3.2 Technology Organization
16.3.3 Corporate Engineering
16.3.4 Management Information Systems
Organization
16.4 Technology Transfer: Overcoming the
Barriers
16.4.1 Credibility of the Technology
16.4.2 Organizational Changes
16.4.3 Perceived Benefits
16.4.4 Consensus
16.5 Project Results
16.5.1 Quantifiable Benefits
16.5.2 Mill Ownership
16.5.3 Team Building
16.5.4 Mill-Resident Technology
Engineers

16.5.5 Cultural Change

16.6 Time Line
16.7 Summary
16.8 Conclusion
Chapter 17: the Marketplace and the Future
17.1 Introduction
17.2 Pulp and Paper Process Control - the
Current Status
17.2.1 Steady State Thinking and
Variability
17.2.2 Lessons Learned from Variability
Audits
17.2.3 the Manufacturing Team
17.2.4 Process Control Competence of the
Manufacturing Team
17.2.5 Control Education and the Control
Engineer
17.3 A View from the Chemical Industry
17.3.1 Focus on Quality and SPC in the
Chemical Industry
17.3.2 Chemical Industry Algorithm Design
- Trending Toward Generality
17.3.3 The Chemical Industry's Control
Strategy Focus
17.3.4 Process Design and Process
Control in the Chemical Industry
17.3.5 Process Control Education in the
Chemical Industry
17.4 Staffing, Organizations, and "Culture"
17.4.1 Process Control Staffing Levels
17.4.2 Organizations, Culture, and "Turf"
17.4.3 Management Awareness
17.5 A View of the Future
17.6 Conclusion