control of a pharmaceutical batch process

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Project Document for Final Year Project

TRANSCRIPT

Karl Phelan

Control of a Batch Process

27-04-2012

Control of a Pharmaceutical Batch Process By Karl Phelan Project Document submitted to the Faculty of the Institute of Technology, Blanchardstown In partial fulfilment of the requirements for the degree of Bachelor of Science In Sustainable Electrical & Control Technology APPROVED: _______________________ David Peyton, Co-Advisor _______________________ Gerard Duke, Co-Advisor

April 27th, 2012 Dublin, Ireland Keywords: Batch Process, PLC, LabVIEW, VSD Level Measurement, Temperature Measurement

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Karl Phelan

Control of a Batch Process

27-04-2012

Declaration Page

Student Name: Karl Phelan ID Number: B00036379 Course: Sustainable Electrical & Control Technology Year: 3 Lecturer: Mr David Peyton/Gerard Duke Title of Assignment: Final Project

Due Date:

27/04/2012

Date Submitted:

27/04/2012

I hereby certify that the material, which is submitted in this assignment/project, is entirely my own work and has not been submitted for any academic assessment other than as part fulfilment of the assessment procedures for the programme Bachelor of Science in Sustainable Electrical & Control Technology(BN039). Any sources cited have been duly acknowledged in the text.

Signed: ____________________________

Date: 27/04/2012

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Karl Phelan

Control of a Batch Process

27-04-2012

1 Acknowledgements

I would like to express my deepest thanks to the lecturers of the BSc. Sustainable Electrical & Control Technology course for their unfaltering support over the last 3 years. They have provided me invaluable knowledge required to undertake this project. In particular I would like to thank David Peyton and Gerard Duke for their hard work and dedication in setting up this course as a whole. If it wasnt for these two none of this would be possible. During the course of the previous semester Dave and Ger have provided help on numerous occasions when I found myself languishing in a problem. Their patience and understanding is a model for all. Of the many lecturers on the faculty there are several who have provided a helping hand whenever needed. I would sincerely like to give thanks to John Kilcoyne and Owen Flood. They have provided vital assistance in their respective fields of knowledge when required over the course of the project. Without their help I wouldnt have gotten this far in the project. I would also like to thank the lab technician Ciaran OBrien for maintaining the hardware with which we used to build the project. I would like to thank my colleague Francis Gibson for his input and help on the project. I believe we worked well as a team and I feel privileged to have been paired with him during the project. As a final word I would like to say I appreciate the opportunity to attend this course of study. The Institute has provided me with a great opportunity to better myself both as a professional and personal individual.

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Karl Phelan

Control of a Batch Process

27-04-2012

2 Abstract

The following document comprises of the completed final year project for the control of a batch process (pharmaceutical). The project was undertaken over a 12 week period by student Karl Phelan who is enrolled in BSc. Sustainable Electrical & Control Technology degree course in the Institute of Technology, Blanchardstown. Compiled inside this document is the knowledge gained by the student over the previous semester and years. Discussed within is an overview of the project and what is required of the student as outlined in the project specification document. It was required by the student to create a control process for the pharmaceutical development of two recipes in a vessel. A selector switch selects either of the two recipes which must be controlled in a specific manner as outlined in the project specification chapter. There are several sections to this document which can be described as: A literature review which comprises of an overall description of each component used to complete the project. A description of the project specification. A control and monitoring strategy which describes in detail the specific components used to build the project, the software used to build the process and methods which were undertaken to put it all together. There is a chapter of technical drawings which describe how each component is physically connected. The programming and monitoring methods are discussed in detail in later chapters and provide an overview of what software was used and how effectively it was utilised. As a whole the document encompasses several weeks of hard work broken down into a formatted product for ease of understanding for the reader.

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Karl Phelan

Control of a Batch Process

27-04-2012

3 Contents1 2 3 4 5 6 7 Acknowledgements ............................................................................................. iii Abstract ...............................................................................................................iv Contents .............................................................................................................. v Acronyms .......................................................................................................... viii List of Figures......................................................................................................ix Introduction ......................................................................................................... 1 Literature Review Introduction............................................................................. 3 7.1 7.2 Introduction ................................................................................................... 3 Variable Speed Drives .................................................................................. 5 Eurotherm 601 Series (HA464518) ........................................................ 5

7.2.1 7.3

Electrical Installation; Eurotherm 601 ............................................................ 8 Control and Power .................................................................................. 8

7.3.1 7.4 7.5 7.6 7.7 7.8 7.9 7.10 8

Operating Configuration ................................................................................ 9 Thermocouple Temperature Measurement and Calibration ........................ 11 Thermocouple Temperature Calibrations .................................................... 13 PLC (FX3G & FX2N -5A) ............................................................................ 15 Level Measurement using Pressure Methods ............................................. 16 Current/Voltage Calibrator........................................................................... 18 Octocoupler ............................................................................................. 18

Project Specification.......................................................................................... 19 8.1 8.2 8.3 Recipe 1: ..................................................................................................... 19 Recipe 2: ..................................................................................................... 19 Tasks .......................................................................................................... 21

9

Control and Monitoring Strategy........................................................................ 22 9.1 9.2 Introduction ................................................................................................. 22 The Process ................................................................................................ 23 v

Karl Phelan 9.2.1 9.2.2 9.2.3 9.2.4 9.2.5 9.2.6 9.2.7 9.2.8 9.3

Control of a Batch Process

27-04-2012

K Type Thermocouple .......................................................................... 23 Pressure Transmitter ............................................................................ 23 Mitsubishi FX3G & Programming Station ............................................. 24 Mitsubishi FX2n-5A ................................................................................ 25 Eurotherm Variable Speed Drive .......................................................... 26 National Instruments myDaq ................................................................ 28 Monitoring Station/ LabVIEW ................................................................ 29 Block Diagram of Process .................................................................... 30

Schedule of Inputs and Outputs .................................................................. 31 Mitsubishi FX3g PLC Inputs/Outputs .................................................... 31 Mitsubishi FX2n-5A Special Function Block Inputs/Outputs ................. 32 National Instruments My DAQ .............................................................. 33 Eurotherm Variable Speed Drive 601 ................................................... 33 Octo-Coupler ........................................................................................ 34 Calibrators ............................................................................................ 34

9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.3.6 9.4

ISA 5.1 Process Drawings........................................................................... 35 Process Drawing .................................................................................. 35 PLC Wiring Diagram ............................................................................. 36 myDaq Card .........................................................

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