H83PDC Process

Dynamic & Control

Lecture 1 - Introduction

Lecture Outline
About this module
! Introduction of process dynamics & control
! Identification of process variables
! Process control strategies
! Process control diagram
!

Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 2

About this module

!
!

Credit: 10
Pre-requisites:
" Process Principles
!
!
!
!

Mass and energy balances

Fluid mechanics
Heat transfer
Unit operations (e.g. distillation, gas absorption, evaporation, etc.)

" Mathematics
! Solution of Ordinary Differential Equations (classical, numerical &
Laplace transform methods)
! Taylor Series; Newton-Raphson Iterative Method
! Complex Numbers
" Computing
! Use of PC spreadsheets
! Dynamic simulation (e.g. using Matlab/Simulink)
Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 3

About this module contd

!

Aim: To provide a basis for understanding the dynamic behaviour of a

Objectives: To provide:

process system and the options available for its safe single loop control
"
"
"

Method & frequency of classes:

"
"

An appreciation of the dynamic behaviour of processes and single

loop controllers
An appreciation of the features and constraints on choice of
conventional process control instruments and equipment
A basis for process analysis and design using dynamic process
models and dynamic simulation
2 hours lecture per week plus examples class
Computer laboratory sessions

Assessment:
"
"
"

Coursework (20%)
2 hours final examination (80%)
Reassessment by examination

Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 4

Dynamics

Unsteady-state (transient) process behaviour

Occurs during:
# Start-up
# Shutdown
# Unusual process disturbances
# Product grade changes

Process Dynamics & Control

Control

Autumn 2012-13

To maintain a process at the desired operating

conditions, safely & efficiently
To satisfy environmental & product quality
requirements
Computer-based control system
Systematic approach to design control system

H83PDC Process Dynamic & Control

Lecture 1 - 5

About this module contd

Week
No
1
2
3
4
5
6
7
8
9

Lecture Topic

Introduction to Process Control

Mathematical Modelling of Chemical Processes
Laplace Transforms
Transfer Functions
Dynamic Behaviour of Processes
Empirical Models
Feedback Controllers
Control System Instrumentation
Dynamic Behaviour and Stability of Feedback (Closed-Loop)
Control Systems
10
Controller Tuning
11
Frequency Response Analysis
12Autumn
Revision
Lecture 1 - 6
H83PDC Process Dynamic & Control
2012-13

About this module contd

References:

G. Stephanopoulos (1984) Chemical Process Control: An Introduction to Theory and

Practice, PTR Prentice Hall, New Jersey

D. E. Seborg et al. (2011) Process Dynamics and Control, John Wiley & Sons

T. Marlin (2000) Process Control: Designing Processes and Control Systems for Dynamic
Performance, McGraw-Hill

W. L. Luyben and M. L. Luyben (1997) Essential of Process Control, McGraw-Hill

Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 7

Contribution to Learning Outcomes

Knowledge and understanding of
!

A1 - appropriate mathematical methods

A3 - computer-based methods for modelling and analysing

chemical engineering problems

A4 - the main principles of chemical engineering

A5 - procedures used to create a process, product or plant

to meet a defined need

A6 - the function and operating characteristics and

applicability of a range of commonly-encountered items of
equipment
Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 8

Contribution to Learning Outcomes

Intellectual skills - ability to
!

B1 - select and apply appropriate mathematical methods for

modelling and analysing chemical engineering problems

B2 - apply scientific principles to chemical engineering

problems

B3 - select and apply appropriate computer-based methods

for modelling and analysing chemical engineering
problems

B6 - select and apply commonly-encountered equipment

Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 9

Contribution to Learning Outcomes

Professional practical skills - ability to
!

C1 - use appropriate mathematical methods for modelling

and analysing chemical engineering problems

C3 - use appropriate computer software for modelling and

analysing problems in process engineering

C6 - use commonly-encountered equipment and analyse

performance from experimental data

Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 10

Contribution to Learning Outcomes

General transferable skills - ability to
!

D1 - sort, manipulate and analyse data

D3 - use computer packages and programmes effectively

D4 - apply logical reasoning to problems

D5 - communicate effectively in a variety of media

Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 11

Why do we need automatic process control?

Maintain the
desired operating
conditions

High-value-added products
Increase yield
Minimize off-specification products

Meet product
specifications
Meet
environmental &
safety regulations
Autumn 2012-13

Processes are subject to random disturbances in:

Feed stream, supply stream, weather
(diurnal/seasonal variation), throughput (feed
supply/equipment failure)
Reduce energy consumption
Reduce production labor
Maintain operational constrains (pump suction
head, flooding in distillation column, etc.)

Stringent regulations
Reduce pollution (SO2 emission, harmful
substances in waste water, etc.)
Ensure safety (avoid development of explosive
mixtures, maintain pressure below rupture, etc.)

H83PDC Process Dynamic & Control

Lecture 1 - 12

Aims of Process Control

To provide safe
plant operation

To maintain
consistent product
quality during
normal operation
Reduced give-away

To enable smooth
movement
between
alternative
operating
conditions with
minimum off-spec
product
Product grade
changes

Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 13

Reducing Product Giveaway

Product Purity %

100
99
98

Auto
Manual

97
96

Product giveaway
can be reduced

95
0

Time

Min Product Spec

Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 14

Approaches to Problem Solving

Engineering
Technician
Define Practical
Problem

Convert to
theoretical form

Analyse &
Solve Theoretical
Problem

Implement
Practical
solution

Convert to
practical form

Professional Engineer

Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 15

Control Terminology (1)

Process
Conversion of feed materials to products using chemical & physical operations
Processing equipment & operation (continuous, batch, semi-batch)

Process variables
! Controlled variables (CV)

Process variables that are controlled

Desired value of CV = set point

Manipulated variables (MV)

Process variables that adjusted to keep CV at/ near their set points

Disturbance variables (DV)

Process variables that affect the CV but can not be manipulated
Related to changes in the operating environment

Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 16

Control Terminology (2)

Set-point change
Implementing a change in the operating conditions
When the set-point signal changes the manipulated variable is
adjusted appropriately to achieve the new operating conditions
Also called servomechanics or servo-control

Disturbance change
The process transient behaviour when a disturbance enters
Also called regulatory-control or load charge
A control system should be able to return each controlled
variable to its set-point
Controllers are used to enhance the stability of the process

Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 17

Process Variables
!

What are the process variables for a shower water heater?

Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 18

Illustrative Example Blending System

Control objective:
Keep x at a desired value (set point) xsp, despite variations in x1(t).
Flow rate w2 can be adjusted for this purpose

Assumptions:
1.
2.
3.

w1 is constant
x2 = 1 (pure A)
Perfect mixing in the tank

Notation:

x1, x2 and x are mass fractions of component A

w1, w2 and w are mass flow rates

Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 19

Identify
Controlled variable
(output variable)
Manipulated
variable
(input variable)
Disturbance variable
(load variable)
Autumn 2012-13

H83PDC Process Dynamic & Control

x
w2
x1
Lecture 1 - 20

Some Possible Control Strategies (1)

Method 1: Measure x and adjust w2
Manual control:
Intuitively, if x is too high,
we should reduce w2
Automatic control:
Feedback control

Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 21

Some Possible Control Strategies (2)

Method 2: Measure x1 and adjust w2
Manual control:
If x1 is too high,
we should reduce w2
Automatic control:
Feedforward control

Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 22

Some Possible Control Strategies (3)

Method 3: Measure x1 and x then adjust w2
Combination of method 1 & 2
Automatic control:
Feedforward-feedback control
Method 4: Use a larger tank
!

If a larger tank is used, fluctuations in x1 will tend to be

damped out due to the larger capacitance of the tank
contents
However, a larger tank means an increased capital cost

Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 23

Classification of Control Strategies

Control Strategies for the Blending System
Method

Measured
Variable

Manipulated
Variable

Category

w2

FB

x1

w2

FF

x1 and x

w2

FF/FB

Design
change

FB = Feedback controller
FF = Feedforward controller
Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 24

Feedback Control
Distinguishing feature
! Measure the controlled variable
Advantages
! Corrective action is taken regardless of the source of the
disturbance
! Reduces sensitivity of the controlled variable to
disturbances & changes in the process
Disadvantages
! No corrective action occurs until after the disturbance
has upset the process, that is, until after x differs from xsp
! Very oscillatory responses, or even instability
Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 25

Feedforward Control
Distinguishing feature
! Measure the disturbance variable
Advantages
! Correct for disturbance before it upsets the process
Disadvantages
! Must be able to measure the disturbance
! No corrective action for the unmeasured disturbances

Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 26

Process Control Diagram

Schematic diagram of
the blending process
with feedback control
system

Block diagram for

composition
feedback control
system
Autumn 2012-13

H83PDC Process Dynamic & Control

Lecture 1 - 27

Learning Outcomes
Set point change
Disturbance change

Controlled
Manipulated
Disturbance

Feedback
Feedforward
Combined
Autumn 2012-13

Process
variables

Control
objectives

Control
strategies

Process
control
diagram
Block diagram for
controller

H83PDC Process Dynamic & Control

Lecture 1 - 28