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
A
R/L
MODCELLTM 2050
RECIPE 1
AUTO
OFF
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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