ABB MOD 30ML User manual

ABB Instrumentation

MOD 30ML Demonstration Guide

INDUSTRY: Chemical / Pharmaceutical

REACTOR.DOC 11/8/99 Batch Reactor Demonstration

Unit Reactor Control

Introduction

Control of a batch reactor includes sequential and continuous elements, and tight control of the reaction

temperature. Ideally, only one device is used to perform both types of control, with a common local display

interface providing complete process information. The following demonstration will show:

•integration of automatic sequential and continuous control

•front panel display of sequence steps

•cascade control

•front panel recipe selection and entry of recipe data

•manual control of sequence steps through front panel

The Control System

The batch reaction is conducted according to a definite time-temperature cycle. Figure 1 illustrates a typical

cycle of many industrial processes.

Reactants are added to the reactor at room temperature; the reaction mass is heated to reaction temperature;

the reaction is carried out to form products; the batch is cooled; and the reactor is emptied. Total batch time

in reactors used in the manufacture of PVC or polystyrene, for example, is approximately fourteen to

eighteen hours. The progression of the batch cycle is controlled by the sequence operation. It may

sometimes be necessary for the operators to pause, stop, or manually advance the cycle to another step.

REACTOR.DOC 11/8/99 Batch Reactor Demonstration

During the heat stage of the batch cycle, a cascade temperature loop is used to control temperature. At the

time the sequence enters the heating step, the setpoint of the master controller is ramped to the reaction

temperature; the master controller measures the product temperature while the slave measures jacket

temperature. At the cooling stage, the setpoint is ramped back to the cool setpoint.

Demonstration Guide

The MOD 30ML is performing the process simulation as well as the sequence control and temperature

cascade control. Once started, the batch cycle will progress automatically unless it is switched to manual

mode.

Operator Changes

The following operations may be done from the front panel displays:

Batch initialization

Recipe selection

Recipe parameter entry

Manual advance of sequence

Initial Conditions

Batch AUTO, OFF (Note: once the batch has been started, Line 2 will indicate the Time in Step for each

step. If the batch is put into manual mode, Line 2 will display Manual. The “time in step” timer does not

stop if the batch is put into manual. However, if you manually advance to another step, the step timer re-

starts).

RECIPE 1 selected

Temperature setpoint LOCAL

Level 0.0” H2O

Step OFF

TIC-201

TIC-202

Fill A Fill B

Drain

Steam

REACTOR.DOC 11/8/99 Batch Reactor Demonstration

The main batch display is arranged as shown below:

1. Activity: Step through the tag displays (Main batch display, TIC-100, TIC-101, Fill )

Look for: Batch in AUTO, OFF (non running), setpoint LOC

Master temperature controller TIC-100 setpoint 100ºF

Slave temperature controller TIC-101 setpoint 200ºF

Product A and B flow 0 GPM

Level in vessel 0.0” H2O

Benefit: The operator can display and manipulate on one instrument, all process and calculated

values associated with the process unit, including both sequence and continuous control.

2. Activity: Display tuning pages for TIC-100 and TIC-101

Hold down Scroll key to access tuning displays

Look for: Tuning displays for controller algorithm type, controller action, gain, reset

Benefit: Commissioning activity can take place through front panel of instrument

3. Activity: Display recipe selection by returning to main batch display and holding down

scroll key

Enter tuning password of 1 (if required; the tuning password from the previous

activity may still be in effect)

Select recipe 1 using up/down arrows and ENT

Look for: Once tuning password is entered the recipe can be scrolled between the choices

of Recipe 1 and Recipe 2

Benefit: Recipe selection can be done from the front panel

Access to recipes and parameters can be restricted using passwords

Keys may be assigned different functions from different displays depending on

application and operational needs

Selected recipe

Batch status

(OFF/RUN)

Temperature

setpoint

Current step

TAG

R/L

MODCELLTM 2050

RECIPE 1

AUTO

OFF

REM

Mode or

Time in Step Change mode

(auto/manual)

Start/stop batch

Temp SP

Steps

(cumulative)

REACTOR.DOC 11/8/99 Batch Reactor Demonstration

4. Activity: Press NXT key to view recipe parameters

Look for: Reaction temperature setpoint entry

Reactor level

Fill A rate

Fill B rate

Activity: Change Recipe 1 target level to 15 inches water

Benefit: Recipe data can be entered from the front panel without the need of an external

data entry terminal

5. Activity: Press the TAG key to return to main Batch display

Press AUTO key to start the batch

Look for: Batch status changes to RUN

Setpoint status changes to REMOTE

Step indication on Line 6 changes to START, then FILL

Activity: Scroll to fill display

Look for: Fill A and Fill B flow rates displayed on lines 1 and 2, left and middle bar

Reactor level displayed on Line 6 and right bar

Benefits: Initiation of batch from front panel; automatic control of sequence thereafter

Current step indicated by name

All necessary process information available on front panel

Activity: Return to main batch display and observe step

REACTOR.DOC 11/8/99 Batch Reactor Demonstration

6. Activity: When controller has entered HEATUP step, scroll to temperature control

displays

Look for: Cascade control for temperature is now active

Master controller setpoint value ramps to 111ºF

Benefit: Continuous control is completely integrated with sequential control without the

need for an external device

Cascade with full tracking provides tight temperature control

7. Activity: When batch cycle has entered HOLD step, return to main batch display

Press MAN key to put batch cycle in manual control

Look for: Batch status on line 2 changes to MANUAL

STP indication appears next to Scroll key

Activity: Press STP key (scroll key) to scroll to COOLDOWN

Press MAN key again to return batch cycle to automatic control

Look for: Batch status on line 2 changes to AUTO

Batch resumes automatic control in COOL step

Activity: Scroll to TIC-100 display

Look for: Temperature setpoint ramping down to cool setpoint

Benefits: Manual control of batch cycle from front panel without need of external

operator terminal

Integration of sequential and continuous control in same device

8. Activity: When batch cycle has entered DRAIN cycle, scroll to level display

Look for: Falling reactor level as vessel is drained

Benefit: Display of all process information on controller front panel

Note: When drain cycle is finished (level has returned to 0 and current step shows as END), press the

MANUAL key, change the step to OFF, and press the AUTO key to return the batch to OFF status. Press

the MAN key again to change to automatic mode, and the demonstration may now be run again.

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