O'shima / Rijn Production Control in the Process Industry

1. Auflage 2014
ISBN: 978-1-4832-9832-0
Verlag: Elsevier Science & Techn.
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, Band Volume 8, 264 Seiten, Web PDF

Reihe: IFAC Workshop Series

The papers within this volume reflect the multidisciplinary approach taken by the workshop to the development and improvement of existing production control theories and practices as applied to the process industry. Subjects covered include production planning, quality control and assurance, operational control and maintenance strategy. The development of this area is seen by those at the workshop as only being achieved by various groups working together rather than in isolation, so that the overall aim of production control is not lost in too much detail. This volume will provide the reader with essential information on new initiatives in the process industry with regard to production control.

Autoren/Hrsg.

O'Shima, E.

Rijn, C. F. H. van

Inhaltsverzeichnis

1;Front Cover;1
2;Production Control in the Process Industry;4
3;Copyright Page;5
4;Table of Contents;10
5;IFAC Workshop on Production Control in the Process Industry;6
6;Production Control: A Multidisciplinary Problem;14
6.1;1. INTRODUCTION;14
6.2;2. THE PROBLEMS OF A PRODUCTION MANAGER;15
6.3;3. PRODUCTION PLANNING AND SCHEDULING (PPS);16
6.4;4. CONTROL AND OPTIMISATION;18
6.5;5. PRODUCT QUALITY CONTROL;19
6.6;6. PROCESS SAFETY;20
6.7;7. PLANT MAINTENANCE;22
6.8;8. EPILOGUE;23
6.9;REFERENCES;27
7;SESSION 1: PRODUCTION PLANNING;10
7.1;Chapter 1. Production Management in Downstream Oil Industry;30
7.1.1;INTRODUCTION;31
7.1.2;INFORMATION PLANNING;31
7.1.3;TRENDS IN DOWNSTREAM OIL ACTIVITIES;31
7.1.4;REFINERY COMPUTER SYSTEMS;32
7.1.5;LOGISTIC SYSTEMS;33
7.1.6;EXPERIENCES AND NEEDS FOR FURHTER DEVELOPMENTS;33
7.1.7;CONCLUSIONS;35
7.1.8;REFERENCES;35
7.2;Chapter 2. Production Planning and Control - A Hierarchical Framework and Technology Structure;36
7.2.1;INTRODUCTION;36
7.2.2;MANUFACTURING FUNCTIONS;36
7.2.3;PLANNING AND CONTROL HIERARCHY;36
7.2.4;PRODUCTION PLANNING AND CONTROL;37
7.2.5;BATCH PRODUCTION EXAMPLE: PROBLEM DESCRIPTION;38
7.2.6;PLANNING AND CONTROL DECISION MODELING;38
7.2.7;CAMPAIGNED PRODUCTION EXAMPLE: DESCRIPTION PROBLEM;39
7.2.8;PLANNING AND CONTROL HIERARCHY: AN ADDED DIMENSION;39
7.2.9;VALUES OF MODELS;40
7.2.10;PLANNING, CONTROL, AND INFORMATION NEEDS;40
7.2.11;CONCLUSION;40
7.2.12;REFERENCES;41
7.3;Chapter 3. Application of or Method to Production Planning;42
7.3.1;INTRODUCTION;42
7.3.2;PRODUCTION PLANNING;43
7.3.3;DAILY SCHEDULING;44
7.3.4;APPLICATION OF OR METHOD TO OTHER AREA;44
7.3.5;CONCLUSION;44
7.4;Chapter 4. Practical Use of Operations Research for Production Planning;46
7.4.1;PROBLEM-SOLVING IN PRODUCTION CONTROL;46
7.4.2;USE OF OPERATIONS RESEARCH FOR PRODUCTION PLANNING;47
7.4.3;CONCLUSION;49
7.4.4;REFERENCES;49
7.5;Chapter 5. Optimization of Process Plant Production Through Computer-aided-manufacturing;50
7.5.1;ABSTRACT;50
7.6;Discussion;54
8;POSTER SESSION: 1;10
8.1;Chapter 1. On-line Scheduling for a Polymerization Process;56
8.1.1;INTRODUCTION;56
8.1.2;A POLYMERIZATION PLANT;56
8.1.3;PRODUCTION CONTROL SYSTEM IN A NARROW SENSE;57
8.1.4;PRODUCTION SCHEDULING METHOD;58
8.1.5;AN ON-LINE SCHEDULING SYSTEM;58
8.1.6;A TOTAL PRODUCTION CONTROL SYSTEM;59
8.1.7;ILLUSTRATIVE EXAMPLE;60
8.1.8;CONCLUSIONS;61
8.1.9;ACKNOWLEDGEMENT;61
8.1.10;REFERENCES;61
8.2;Chapter 2. A General Simulation Programme for Scheduling of Batch Processes;62
8.2.1;INTRODUCTION;62
8.2.2;FORMULATION OF THE PROBLEM;62
8.2.3;CLASSIFICATION OF THE CONSTRAINTS;63
8.2.4;QUICK CALCULATON OF THE STARTING MOMENTS OF JOBS;64
8.2.5;CALCULATION OF THE STARTING MOMENTS OF BASIC OPERATIONS;66
8.2.6;CONCLUSION;67
8.2.7;REFERENCES;67
8.3;Chapter 3. Adaptive Discretization of Continuous-time Inventory Control Problems
and its Application to Production Planning and Smoothing;68
8.3.1;INTRODUCTION;68
8.3.2;PROBLEM STATEMENT;68
8.3.3;ADAPTIVE DISCRETIZATION;69
8.3.4;NUMERICAL TEST;70
8.3.5;CONCLUSIONS;71
8.3.6;AKNOWLEDGEMENTS;71
8.3.7;REFERENCES;71
8.4;Chapter 4. Optimal Production of Glutathione by Controlling the Specific Growth
Rate of Yeast in Fed-batch Culture;80
8.4.1;IHTRODUCTION;80
8.4.2;GLUTATHIONE PRODUCTION RATE;80
8.4.3;MODEL OF GLUTATHIONE PRODUCTION IN FEDBATCH CULTURE;81
8.4.4;FORMULATION OF OPTIMIZATION PROBLEM;81
8.4.5;OPTIMDM PROFILE OF THE SPECIFIC GROWTH RATE;82
8.4.6;REALIZATION OF OPTIMAL PRODUCTION OF GSH;83
8.4.7;CONCLUSIONS;85
8.4.8;ACKNOWLEDGEMENT;85
8.4.9;References;85
8.5;Chapter 5. Design of the Intelligent Alarm System for Chemical Processes;86
8.5.1;INTRODUCTION;86
8.5.2;THE INTELLIGENT ALARM SYSTEM;86
8.5.3;AN EXAMPLE IN CHEMICAL REACTOR DOMAIN;87
8.5.4;OPTIMAL ALARM-PLACEMENT;88
8.5.5;CONCLUSIONS;89
8.5.6;REFERENCES;89
9;SESSION 2: QUALITY CONTROL AND QUALITY ASSURANCE;11
9.1;Chapter 1. Practical Aspects of a Mill Wide Quality Control System in a Modern Newsprint Mill;92
9.1.1;INTRODUCTION;92
9.1.2;TASKS OF THE QUALITY CONTROL SYSTEM IN A NEWSPRINT MILL;92
9.1.3;PRESENT STATUS OF PAPER MILL CONTROL SYSTEMS;92
9.1.4;DESCRIPTION OF ONE EXISTING SYSTEM;93
9.1.5;SHORTCOMINGS OF THE PRESENT SYSTEM;94
9.1.6;IMPACT OF AUTOMATION AND ELECTRONIC DATA PROCESSING ON QUALITY CONTROL;94
9.1.7;FUTURE DEVELOPMENT POSSIBILITIES;94
9.2;Chapter 2. On the Quality Management and Technology of Process Industry;96
9.2.1;0 Introduction;96
9.2.2;1 The Recent Aspects Of Chemical Industry In Japan;96
9.2.3;2 On The Features Of Process Technologies;96
9.2.4;3 Quality And Its Connotations;97
9.2.5;4 On the Quality Efforts In Chemical Industry;98
9.2.6;5 Quality Technology In Process Systems Engineering(PSE);98
9.2.7;6 Process Quality Modelings;99
9.2.8;7 Conclusions;99
9.2.9;REFERENCES;100
9.3;Chapter 3. Quality Control and Quality Assurance - QC and QA Systems in Japan;106
9.3.1;INTRODUCTION;106
9.3.2;1. The Development of Quality Control;106
9.3.3;2. The Characteristics of Quality Control in Japan (TQC);107
9.3.4;3. Quality Assurance and its Role in the System of TQC;107
9.3.5;4. Seven Steps of Quality Assurance;108
9.4;Chapter 4. Use of SPC and RGA for On-line Monitoring of Changing Process Conditions;112
9.4.1;1 Introduction;112
9.4.2;2 SPC and RGA Background;113
9.4.3;3 Relative Standard Deviations;113
9.4.4;4 Examples of Use of RSD;114
9.4.5;5 Conclusion;115
9.4.6;References;116
9.5;Chapter 5. Application of Nonlinear State Estimator in Quality Control of a Polyesterlfication;118
9.5.1;INTRODUCTION;118
9.5.2;MODEL DYNAMIC OF REACTOR;118
9.5.3;NON-LINEAR STATE ESTIMATOR;119
9.5.4;ADAPTIVE ESTIMATOR SCHEME;120
9.5.5;SIMULATION AND RESULTS;120
9.5.6;CONCLUSION;121
9.5.7;REFERENCES;121
9.6;Chapter 6. Stable Production of the Optical Memory Disk by an Iterative Learning Control System;124
9.6.1;INTRODUCTION;124
9.6.2;CONTROL STRUCTURE OF INJECTION MOLDING MACHINE;124
9.6.3;DESIGN OF ITERATIVE LEARNING CONTROL SYSTEM;125
9.6.4;APPLICATION TO INDUSTRIAL USE;126
9.6.5;CONCLUSION;126
9.6.6;REFERENCES;126
10;SESSION 3: OPERATIONAL CONTROL;11
10.1;Chapter 1. An Information System for Production Management in the Chemical Industry;130
10.1.1;Abstract;130
10.1.2;Keywords;130
10.1.3;Information systems in large companies;130
10.1.4;Production Information System (ISP);131
10.1.5;Production Control (PC);132
10.1.6;Implementation;133
10.1.7;Acknowledgement;134
10.2;Chapter 2. Production Integration System in a Chemical Manufacturing Complex;136
10.2.1;PIS PLAN;136
10.2.2;CONCLUSION;138
10.3;Chapter 3. CIM in Process Industry;140
10.3.1;Abstract;140
10.3.2;Keywords;140
10.3.3;Problens of CIM In Process Industry;140
10.3.4;EnvlronMntlal ProbiM;141
10.3.5;Innovation of Production Systoa;141
10.3.6;SystoH Must be operable and aalntelnable;141
10.3.7;For the Future of CIM;142
10.3.8;Conclusions;142
10.4;Chaptert 4. A New Generation Cell Computer/Controller in the CIM Era;144
10.4.1;1. Foreword;144
10.4.2;2. Main Points of CIM Expansion;145
10.4.3;3 .Trends in the Cell Computer/controller;145
10.4.4;4. Functions of Next — Generation Cell Computers/Controllers;147
10.4.5;5. Conclusion;147
10.5;Chapter 5. Operability, Controllability and Observability of Chemical Plants -
A Practical Industrial Point of View;148
10.5.1;INTRODUCTION;148
10.5.2;THE CONCEPT OF EXTENSIVE AND INTENSIVE PROPERTIES.;148
10.5.3;THE CLASSICAL CONSERVATON PRINCIPLE OF MATTER AND ENERGY.;150
10.5.4;THE CONVERSION OF MATTER AND ENERGY FROM ONE FORM TO ANOTHER.;150
10.5.5;THE SENSMVMES OF CONDUCTIVE TRANSPORT PROCESSES;151
10.5.6;ACHEMIC ALPRODUCION COMPLEX;152
10.5.7;CONCLUSION;153
10.5.8;REFERENCES;153
10.6;Chapter 6. Production Control in Petrochemical Complex;154
10.6.1;INTRODUCTION;154
10.6.2;SYSTEM STRUCTURE AND FUNCTION;154
10.6.3;FUNCTIONS OF THE PROCESS COMPUTER;155
10.6.4;EXAMPLE OF ACTUAL APPLICATIONS;155
10.6.5;OUTLOOK FOR THE FUTURE;156
10.7;Discussion;160
11;POSTER SESSION: 2;11
11.1;Chapter 1. An Optimalized Computer Control System of Polyvinyl Chloride Polymerized (PVC) Reactor;162
11.1.1;INTRODUCTION;162
11.1.2;EFFECTING FACTORS;162
11.1.3;DESING OF THE CONTROL MODEL AND CONTROL STRATEGY;163
11.1.4;SIMULATION OF THE CONTROL SYSTEM OF PVC POLYMER-REACTOR;164
11.1.5;THE COMPOSITION OF SYSTEM AND CONTROL SOFTWARE;166
11.1.6;APPLICATION RESULT;167
11.1.7;REFERENCE;167
11.2;Chapter 2. Development of Model Based Predictive Multi-variable Control System;168
11.2.1;INTRODUCTION;168
11.2.2;ALGORITHM OF MODEL PREDICTIVE CONTROL;168
11.2.3;STRUCTURING PROCEDURE OF MULTI-VARIABLE CONTROL SYSTEM;169
11.2.4;MULTI-VARIABLE CONTROL FOR A DISTILLATION COLUMN;170
11.2.5;CONCLUSIONS;172
11.2.6;REFERENCES;172
11.3;Chapter 3. Control System for LNG Receiving Terminal;174
11.3.1;INTRODUCTION;174
11.3.2;DESCRIPTION OF AN LNG TERMINAL;174
11.3.3;MAJOR FUNCTIONS REQUIRED FOR OPERATION CONTROL;174
11.3.4;CONTROL SYSTEM CONFIGURATION AND CONCEPT;175
11.3.5;CHARACTERISTICS OF THE CONTROL SYSTEM CONFIGURATION;175
11.3.6;CONCLUSION;177
11.3.7;REFERENCES;177
11.4;Chapter 4. Multivariable Nonlinear Control System Design for Multistand Rolling Mill;178
11.4.1;I. INTRODUCTION;178
11.4.2;II. STATE EQUATION FOR A MULTISTAND ROLLING MILL;178
11.4.3;III. DECENTRALIZATION BY BLOCKED DECOUPLING METHOD;179
11.4.4;IV. CONFIGURATION OF THE INTERACTIVE SIMULATION SYSTEM;180
11.4.5;VI. TIME RESPONSE ANALYSIS OF DIGITAL CONTROL SYSTEM;180
11.4.6;VII. RESULTS OF SIMULATION TESTS;181
11.4.7;VIII. CONCLUSION;181
11.4.8;REFERENCES;181
11.5;Chapter 5. An Integrator Decoupling Method to the Application Problem in Multivariable Feedback System Control;184
11.5.1;INTRODUCTION;184
11.5.2;DECOUPLING OF MULTIVARIABLE CONTROL SYSTEMS;185
11.5.3;PARTIAL AREA SYSTEMS CONTROL METHOD OF STATE FEEDBACK DECOUPLING;185
11.5.4;COMPUTER RESULTS;186
11.5.5;APPLICATION OF A DECOUPLING METHOD TO PARTIAL AREA SYSTEMS;187
11.5.6;REFERENCES;189
11.6;Chapter 6. Application of the Fuzzy Expert System to Fermentation Processes;190
11.6.1;INTRODUCTION;190
11.6.2;FUZZY EXPERT SYSTEM;190
11.6.3;APPLICATION OF THE FUZZY EXPERT SYSTEM TO THE MARIDOMYCIN PRODUCTION;192
11.6.4;CONCLUSION;195
11.6.5;REFERENCES;195
11.7;Chapter 7. Control of Fermentation Processes as Variable Structure Systems;196
11.7.1;INTRODUCTION;196
11.7.2;BASIC DEFINITIONS;196
11.7.3;FERMENTATION PROCESSES AS VARIABLE STRUCTURE PLANTS;197
11.7.4;CONSIDERATIONS OF THE CONTROL OF FERMENTATION PLANTS EXPRESSING THE VARIABLE STRUCTURE PHENOMENON;197
11.7.5;THE SECOND HIERARCHICAL LEVEL: DETECTION OF STRUCTURE-ALTERING PHENOMENA;198
11.7.6;THE FIRST HIERARCHICAL LEVEL: STRATEGY SWITCHING AND CONTROL IN SUBSPACES OF CONSTANT STRUCTURE;199
11.7.7;SOFTWARE IMPLEMENTATION OF THE CONTROL CONCEPT;200
11.7.8;CONCLUSION;200
11.7.9;REFERENCES;200
12;SESSION 4: MAINTENANCE STRATEGY;12
12.1;Chapter 1. Reduction of Breakdowns Through Productive Maintenance;202
12.1.1;OUTLINE OF OHTAKE PLANT;202
12.1.2;VARIOUS ACTIVITIES IN OHTAKE PLANT;203
12.1.3;REDUCTION OF BREAKDOWNS CAUSED BY PROCESS FAILURES;203
12.1.4;ANALYSYS OF BREAKDOWNS CAUSED BY EQUIPMENT FAILURES;204
12.1.5;SCHEDULED MAINTENANCE ACTIVITIES FOR REDUCTION OF EQUIPMENT FAILURES;205
12.1.6;THOROUGH ANALYSIS OF EQUIPMENT FAILURES;205
12.1.7;CLASSIFICATION OF EQUIPMENT AND PREVENTIVE MAINTENANCE PROGRAMS FOR EACH RANK;206
12.1.8;ACHIEVEMENTS OF TOTAL PREVENTIVE MAINTENANCE ACTIVITIES;206
12.1.9;CONCLUSIONS;207
12.1.10;ACKNOWLEDGEMENTS;207
12.2;Chapter 2. Essential Elements of Maintenance Improvement Programs;208
12.2.1;INTRODUCTION;208
12.2.2;TRENDS IN MAINTENANCE EXPENSE;208
12.2.3;PACESETTER CHARACTERISTICS;209
12.2.4;RATE OF PERFORMANCE CHANGE;210
12.2.5;ELEMENTS OF SUCCESSFUL PERFORMANCE IMPROVEMENT PROGRAMS;210
12.2.6;CONCLUSION;211
12.3;Chapter 3. Maintenance Practice in Japanese Process Industries;212
12.3.1;INTRODUCTION;212
12.3.2;EQUIPMENT FAILURES AND DETECTION;212
12.3.3;APPROACHES TO MAINTENANCE PROBLEMS;212
12.3.4;DEREGULATING ATTEMPT FOR HIGH PRESSURE GAS PLANTS;214
12.3.5;PRODUCTIVE MAINTENANCE MOVEMENT;214
12.3.6;CONCLUDING REMARKS;215
12.3.7;REFERENCES;215
12.4;Chapter 4. An Experimental Evaluation of Two Realtime Fault Diagnosis Systems
in a Refinery Plant Distributed Control System;222
12.4.1;INTRODUCTION;222
12.4.2;SDG BASED DIAGNOSTIC SYSTEM;222
12.4.3;FIELD T E S T RESULTS;222
12.4.4;IF-THEN RULE BASED DIAGNOSITIC SYSTEM;223
12.4.5;IDEMITSU REFINERY PLANT;223
12.4.6;DIAGNOSIS USING SIGNED DIRECTED GRAPHS;224
12.4.7;DIAGNOSIS SYSTEM STRUCTURE;224
12.4.8;TWO DIAGNOSIS SYSTEMS;224
12.4.9;CONCLUSION;225
12.4.10;REFERENCES;225
13;PLANT TOUR 1;12
13.1;Chapter 1. Application of J.I.T. for Automotive Parts Production;230
13.1.1;INTRODUCTION;230
13.1.2;BASIC CONCEPT OF PRODUCTION;230
13.1.3;EXAMPLE OF PRODUCTIVITY ENHANCEMENT ACTIVITIES;230
13.1.4;CONCLUSION;235
13.2;Discussion;236
13.2.1;1 Introductory Presentation;236
13.2.2;2 Visit to Transmission Assembly Plant at Shiroyama;236
13.2.3;3 Discussion;236
14;PLANT TOUR 2;12
14.1;Chapter 1. Refinery Management and Operation by Advanced Technology;238
14.1.1;1. Idemitsu Refineries Produce Excellent Products;238
14.1.2;2. Aichi Refinery with the Latest Equipment;238
14.1.3;3. Efficient Refinery with New High Technology;238
14.2;Discussion;242
14.2.1;1 Introductory Presentation;242
14.2.2;2 Visit to Aichi Refinery;242
14.2.3;3 Discussion;242
14.2.4;4 Reviewers Comments;243
15;SESSION 5: FINAL DISCUSSION;12
15.1;Chapter 1. Current Status of Chemical Plant Operations in Japan ;244
15.1.1;Introduction;244
15.1.2;Plant automation in the future;246
15.1.3;REFERENCES;246
15.2;Chapter 2. The Development of Computer Integrated Manufacturing at a Chemical Company;248
15.2.1;INTRODUCTION;248
15.2.2;REASONS FOR CIM APPLICATION;248
15.2.3;FUTURE COMPUTER INTEGRATED MANUFACTURING SYSTEM;248
15.2.4;PROBLEMS TO BE SOLVED FOR CIM IMPLEMENTATION;248
15.2.5;INAUGURATION OF THE ACTIVITIES FOR CIM APPLICATION;250
15.2.6;CONCLUSION;250
15.2.7;REFERENCES;250
15.3;Discussion;252
15.3.1;Rationale for Computer Integration;252
15.3.2;Methodology of System Integration;252
15.3.3;Role of University Education;252
15.3.4;Comment from Academia;252
16;LATE PAPER;13
17;Discussion of Session 2;254
18;Author Index;256
19;Keyword Index;258