Advanced Temperature Measurement and Control, Second Edition
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Gregory K. McMillan, CAP, has more than 50 years of experience in industrial process automation, with an emphasis on the synergy of dynamic modeling and process control. He retired as a Senior Fellow from Solutia and a senior principal software engineer from Emerson Process Systems and Solutions. He was also an adjunct professor in the Washington University Saint Louis Chemical Engineering department from 2001 to 2004. McMillan is the author of numerous ISA books and columns on process control, and he has been the monthly Control Talk columnist for Control magazine since 2002. He started and guided the ISA Standards and Practices committee on ISA-TR5.9-2023, PID Algorithms and Performance Technical Report, and he wrote "Annex A - Valve Response and Control Loop Performance, Sources, Consequences, Fixes, and Specifications" in ISA-TR75.25.02-2000 (R2023), Control Valve Response Measurement from Step Inputs. McMillan's achievements include the ISA Kermit Fischer Environmental Award for pH control in 1991, appointment to ISA Fellow in 1991, the Control magazine Engineer of the Year Award for the Process Industry in 1994, induction into the Control magazine Process Automation Hall of Fame in 2001, selection as one of InTech magazine's 50 Most Influential Innovators in 2003, the ISA Life Achievement Award in 2010, and the ISA Mentoring Excellence award in 2020. He has a BS in engineering physics from Kansas University and an MS in control theory from Missouri University of Science and Technology, both with emphasis on industrial processes.
Content
Preface ix
Chapter 1 Temperature Measurement 1
1-1. Introduction and Overview 1
1-2. Thermocouples and RTDs 12
1-3. Selection of a Temperature Sensor 20
1-4. Specifications 21
1-5. Setup and Calibration 23
1-6. Installation 23
1-7. Maintenance 33
Chapter 2 Measurement Error 37
2-1. Heat Conduction Error 37
2-2. Radiation Error 46
2-3. Dynamic Error 48
2-4. Velocity Error 51
2-5. Electronic Error 52
2-6. Sensor Error 56
2-7. Nonlinearity Error 61
2-8. Decalibration Error 63
2-9. Insulation Error 65
2-10. Leadwire Error 66
2-11. Error Accumulation 68
2-12. New Sensors 70
Chapter 3 Basic Feedback Control 79
3-1. Introduction 79
3-2. PID Modes, Structure, and Form 82
3-3. PID Tuning 94
3-4. Adaptive Control 109
3-5. Set-Point Response Optimization 113
Chapter 4 Process Dynamics 121
4-1. Introduction 121
4-2. Performance Limits 122
4-3. Self-Regulating Processes 132
4-4. Integrating Processes 137
Chapter 5 Exchangers 143
5-1. Process and Equipment Design Considerations 143
5-2. Disturbances and Difficulties 147
5-3. Effect of Loop Performance 148
5-4 Controller Tuning 149
5-5. Control Errors 152
5-6. Control Strategies 156
Chapter 6 Reactors 159
6-1. Process and Equipment Design Considerations 159
6-2. Disturbances and Difficulties 160
6-3. Loop Performance 163
6-4. Controller Tuning 164
6-5. Control Errors 170
6-6. Control Strategies 171
Chapter 7 Columns 179
7-1. Process and Equipment Design Considerations 179
7-2. Disturbances and Difficulties 181
7-3. Effect of Loop Performance 183
7-4. Controller Tuning 183
7-5. Control Errors 184
7-6. Control Strategies 185
Chapter 8 Vessels, Desuperheaters, Dryers, Kilns, Calciners, Crystallizers, Extruders, Chambers, and Rooms 193
8-1. Process and Equipment Design Considerations 193
8-2. Disturbances and Difficulties 195
8-3. Effect of Loop Performance 196
8-4. Controller Tuning 197
8-5. Control Strategies 197
Chapter 9 Wireless 207
9-1. Introduction and Overview 207
9-2. Principles 216
9-3. Security and Reliability 220
9-4. Communication Rules 224
9-5. Process Control 238
9-6. Installation of a Wireless Network 251
Exercises 253
References 254
Appendix A - Suggested Readings and Study Materials 257
Appendix B - Solutions to Exercises 259
Appendix C - Unification of Controller Tuning Relationships 271
Appendix D - Physical Property Data 281
Appendix E - Emissivities 285
Appendix F - First Principle Process Gains, Dead Times, and Time Constants 287
Appendix G - FORTRAN Subroutine for Dynamic Simulation of Extruders 301
Appendix H - Convective Heat Transfer Coefficients 307
Appendix I - Implementation Checklist for Best Performance 311
Index 315
