412

Control Theory

analog-to-digital conversion. Microprocessor-based smart

transmitters contribute to better accuracy and higher reliability by their improved rangeability. Automatic pressure and
temperature compensation, remote calibration, and self-diagnostics also contribute to better data quality.
The range of process variables that can be measured has
also increased. Advances in online analytical instrumentation have made it possible to measure a variety of physical
properties and chemical compositions that could not be
directly detected in the past. (For more information, refer to
Volume 1 of this handbook, titled Process Measurement and
Analysis.)
Good quality data input (measurement) is useful for
online SPC only if the control system network can transfer
the process information rapidly enough for real-time data
manipulation. The use of MAP (Manufacturing Automation
Protocol) for integration of different vendors products into
a common communications network facilitates streamlined
data transmission. The MAP OSI (Open System Interconnection) model denes communication network functions in
seven layers, allowing software programs to be utilized over
different networks.
Although most of these techniques predate the computer,
the ability to interface a personal computer with the control
system also increases the feasibility of adding real-time SPC
to existing plants. Intelligence at the I/O interface level
enables routine operating functions to be handled locally,
while conserving higher-level processing capability for SPCtype applications.
It is not necessary to implement any or all phases of an
SPC program in a real-time mode. One only needs to automate those portions of an SPC program that one feels comfortable with, and the nonautomated SPC techniques can still
be performed on a non-real-time basis. Many of those who
have automated the data collection and monitoring phases
are still performing the nonmonitoring portions of the SPC
process manually. Others are implementing diagnostic and
process adjustment activities with articial intelligence or
other computer models.

DATA STORAGE, COMPUTATION, AND DISPLAY

The ability to store statistical records of individual process
data points is essential for generating and analyzing SPC
control charts. Historical information is particularly useful
for statistical analysis of cause-and-effect relationships using
shbone diagrams. Figure 2.34p shows the Pareto chart that
enables diagnosis of the most likely causes of off-spec production runs at the component level by searching the historical database.
The desirability of performing identical mathematical
studies as well as providing real-time data points warrants a
dedicated SPC computer for many chemical process industry
applications. Figure 2.34q is a scatter plot showing the use
of a linear regression algorithm to explore the relationship

2006 by Bla Liptk

Cause*
Causo
Carbo
Filaid
Preimo
Coaco
Alumo
Pocho
Prchlo

Percent
Qty
23.1
25
21.3
23
14.8
16
13.0
15
9.3
10
8.3
9
5.6
6
3.7
4
*The causes are specic to the
process and the equipment used

FIG. 2.34p
A historical data search, presented in the form of a Pareto chart,
can help identify the most likely causes of off-spec production runs.

between a selected product property (particle size) and an

input variable (mixing time). Knowing this relationship, the
operator can adjust the problem variable (mixing time) to
restore the product (particle size) to meet specications.
Statistical calculations translate into practical control
results through the interpretation of statistical control charts.
Congurable CRT displays are prerequisites to maximizing
the use of online SPC charting capabilities. Automatic SPC
alarm notications and summary displays can isolate the
problem input variables.
A computerized technique called online diagnostics is
used to determine and anticipate the causes of plant operating
problems before they actually occur. This diagnostic technique is basically a mix of SPC and fault-diagnostic principles that are programmed into an expert system that operates
online. Thereby, process operators can anticipate and react
to potential problems before they occur.

Uncontrolled
process
variable
(particle size)
5.00
4.50
4.00
Slope
0.0248

3.50
Controlled variable (mixing time)
3.00

20 22 24 26 28 30 32 34 36 38 40 42 44 46

Intercept
5.086

FIG 2.34q
Scatter plots can be used to investigate relationships between process variables and can indicate how much a controlled variable
(mixing time) should be adjusted to bring an uncontrolled variable
(particle size) within specifications.