Advanced Temperature

Measurement and Control

Second Edition

Gregory K. McMillan
 Contents

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
Exercises 35
References 35

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
Exercises 74
References 75

Chapter 3 Basic Feedback Control 79

3-1. Introduction 79
3-2. PID Modes, Structure, and Form 82

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3-3. PID Tuning 94

3-4. Adaptive Control 109
3-5. Set-Point Response Optimization 113
Exercises 119
References 119

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
Exercises 141
References 141

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
Exercises 157
References 158

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
Exercises 177
References 178

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
 Contents vii

7-5. Control Errors 184

7-6. Control Strategies 185
Exercises 191
References 192

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
Exercises 206
References 206

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
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Appendix H – Convective Heat Transfer Coefficients 307

Appendix I – Implementation Checklist for Best Performance 311

Index 315