CHE 185 PROCESS

CONTROL AND DYNAMICS

OPTIMIZATION AND PRIMARY
LOOP ELEMENTS

TYPES OF CONTROL
OPTIMIZATION
INTENTION IS TO GET THE BEST
ECONOMIC/QUALITY CONDITIONS
CONTROL IS THE MORE GENERAL FORM
OF RESPONDING TO CHANGE

CONTROL & OPTIMIZATION

FOR A BIOREACTOR

http://www.automation.siemens.com/wcmsnewscenter/details.aspx?
xml=/content/10001666/en/as/Pages/PN-200201-06-Alles_unter_Kontrolle.xml?
NoRedirect=true&xsl=publication-en-www4.xsl

EXAMPLE OF OPTIMIZATION
OPTIMIZATION AND CONTROL OF A
CSTR

EXAMPLE OF OPTIMIZATION
ECONOMIC OBJECTIVE FUNCTION
Q C A VA Q C B VB Q CC VC Q C A0 V AF
ECONOMIC VALUES , VB > VC, VA, OR VAF
AT LOW T, LITTLE FORMATION OF B
AT HIGH T, TOO MUCH OF B REACTS TO
FORM C
SO THERE EXISTS AN OPTIMUM REACTOR
TEMPERATURE, T*

OPTIMZATION EXAMPLE
METHOD OF SOLUTION
1. SELECT INITIAL GUESS FOR
REACTOR TEMPERATURE, T*
2. EVALUATE CA, CB, AND CC
3. EVALUATE
4. CHOOSE NEW REACTOR
TEMPERATURE AND RECYCLE
THROUGH STEP 2 UNTIL T* IS
IDENTIFIED.

EXAMPLE OF OPTIMIZATION
ABC
Mole balance on A :
Q C A0 Q C A k1 exp[ E1 / RT ] C A Vr
Solving for C A
C A0
CA
k1 exp[ E1 / RT ]Vr
1
Q
Likewise, C B and CC are calculated from mole
balances.

EXAMPLE OF OPTIMIZATION
GRAPHICAL SOLUTION OF OPTIMUM
REACTOR TEMPERATURE, T*
Economic Objective
Function,

2
1.5
1
T*

0.5
0
250
-0.5

275

300

325

Reactor Temperature (K)

350

OTHER TYPES OF CONTROL

SUPERVISORY
RESPONDS TO THE SIGNAL FROM THE
OPTIMIZATION CONTROLLER
SENDS A SIGNAL TO THE REGULATORY
CONTROL LOOP

TYPES OF CONTROL
REGULATORY
RECEIVES A SIGNAL FROM THE
SUPERVISORY CONTROLLER
ACTUALLY ADJUSTS A PROCESS
VARIABLE TO MAKE NECESSARY
CHANGES FOR OPERATION.

REGULATORY CONTROL EXAMPLE

TEMPERATURE CONTROL FOR A HEAT
EXCHANGER

CATEGORIES OF LOOP
COMPONENTS
FEEDBACK LOOP THE PRIMARY COMPONENTS ARE
SHOWN SCHEMATICALLY

LOOP COMPONENTS - SENSORS

MEASURE THE VALUE OF THE TARGET
AND MANIPULATED VARIABLES
TYPICALLY P, T, L, D, ,, COMPOSITION,
MASS
LOCATED IN-LINE, EVEN IF THEY DO
NOT CONTACT PROCESS FLUIDS

LOOP COMPONENTS - SENSORS

TYPICALLY ANALOG DEVICES WITH
FULL SCALE RANGES:
20 MA CURRENT SIGNAL
mV VOLTAGE SIGNAL
3 - 15 PSIG PNEUMATIC SIGNAL

LOOP COMPONENTS TRANSMITTERS

ANALOG DEVICES
CONVERT SIGNAL INTO A VALUE THAT
CAN BE TRANSMITTED WITHOUT
SIGNIFICANT LOSS IN VALUE
TYPICAL OUTPUT IS 4 - 20 MA CURRENT
FULL SCALE RANGE

LOOP COMPONENTS TRANSDUCERS

CONVERT THE ANALOG SIGNAL FROM
THE TRANSMITTER INTO A DIGITAL
SIGNAL
LABELED A/D FOR ANALOG TO DIGITAL
LABELED D/A FOR DIGITAL TO ANALOG

CAN TRANSFER ELECTRONIC TO

PNEUMATIC

LOOP COMPONENTS CONTROLLERS

RECEIVES DIGITAL SET/POINT AND
MEASURED SIGNALS FOR A VARIABLE
MAKES A COMPARISON BETWEEN THE
SIGNALS USING A BRIDGE
PRODUCES A DIGITAL OUTPUT SIGNAL
TO ADJUST THE MEASURED VALUE TO
THE SET/POINT VALUE

LOOP COMPONENTS - ACTUATORS

RECEIVES THE OUTPUT SIGNAL FROM
THE CONTROLLER, VIA THE
TRANSDUCER
ADJUSTS THE POSITION OF A DEVICE
(FINAL CONTROL ELEMENT) TO
CHANGE A PROCESS VARIABLE

LOOP COMPONENTS - FINAL

CONTROL ELEMENT
CHANGES A PROCESS VARIABLE TO
OBTAIN A CORRECTION TO THE
MEASURED VARIABLE
FOR CHEMICAL PLANTS, MOST OF
THE TIME THESE DEVICES ARE
VALVES

SOURCE OF SET/POINTS
FOR A SIMPLE PROCESS, THESE MAY
BE ENTERED MANUALLY
FOR CONTEMPORARY SYSTEMS,
THESE SIGNALS COME FROM A
COMPUTER
PLC - PROGRAMMABLE LOGIC
CONTROLLER
DCS COMPUTER - DISTRIBUTED
CONTROL SYSTEM COMPUTER

DCS FUNDAMENTALS
DCS HAS THE FOLLOWING GENERAL
COMPONENTS
LOCAL CONTROLLERS
INPUT/OUTPUT PANELS (I/O PANELS) TO
RECEIVE PROCESS VARIABLE VALUES
FROM THE CONTROLLER AND SEND
SET/POINT VALUES
DATA HIGHWAY/MULTIPLEXER TO SAMPLE
THE VALUES ON A REGULAR FREQUENCY

DATA HIGHWAY/MULTIPLEXER

DCS FUNDAMENTAL COMPONENTS

HOST COMPUTER TO ENTER
SET/POINTS
ALARM COMPUTER - PLCS TO
INITIATE ALARMS AND/OR
INTERLOCKS
DATA STORAGE COMPUTER
KEEPS TREND DATA
LOGS ALARMS
OTHER COMPUTERS THAT HAVE ACCESS

FINAL CONTROL ELEMENT

CHARACTERIZATION - VALVES
VALVES ARE USED FOR EITHER
ON/OFF OR THROTTLING OPERATION SEE PERRYS 7TH PAGE 8-64
ON/OFF VALVE CHARACTERISTICS
HAVE A COMPLETELY OPEN AND
COMPLETELY CLOSED POSITION
HAVE A TIGHT SHUT-OFF CAPABILITY
HAVE LIMITED VALUE FOR THROTTLING

PLUG VALVES AND BALL VALVES

90 RANGE FROM OPEN TO CLOSED
USE PNEUMATIC OR MOTOR
ACTUATORS

GATE VALVES
TYPICALLY USED
FOR ISOLATION
VALVES - FOR
MAINTENANCE AND
AS BACK-UP FOR
CLOSED
THROTTLING VALVES

GATE VALVES
MAY HAVE SEVERAL TURNS
BETWEEN OPEN AND CLOSED
MAY HAVE MOTOR OPERATORS
BUT MORE FREQUENTLY USE
MANUAL OPERATION

THROTTLING (CONTROL) VALVES

VARIOUS FLOW CHARACTERISTICS BASED ON THE
SHAPE OF THE PLUG AND THE SEAT
FLOW THROUGH THE VALVE DEPENDS ON THE
FRACTION OPEN AND THE NET PRESSURE DROP
HAVE COMPLETELY OPEN AND COMPLETELY
CLOSED POSITION, BUT DESIGNED FOR
INTERMEDIATE POSITION FOR CONTINUOUS
OPERATION - NOT TIGHT SHUT OFF
GENERAL REFERENCE HTTP://WWW.DOCUMENTATION.EMERSONPROCESS
.COM/GROUPS/PUBLIC/DOCUMENTS/BOOK/CVH99
.PDF

GLOBE (THROTTLING) CONTROL

VALVE

CROSS-SECTION OF A GLOBE
VALVE

THROTTLING (CONTROL) VALVES

BASIC FLOW EQUATION IS THE SAME AS
FOR AN ORIFICE:
CV IS SIMILAR TO AN ORIFICE COEFFICIENT,
HOWEVER IT VARIES WITH VALVE POSITION
K IS EQUAL TO UNITY WHEN IS
EXPRESSED AS SPECIFIC GRAVITY,
FLOWRATES ARE IN gpm AND PRESSURE
DROP IS IN psi

GLOBE VALVE TYPES

QUICK OPENING- FOR SAFETY BY-PASS
APPLICATIONS WHERE QUICK OPENING IS
DESIRED
EQUAL PERCENTAGE- FOR ABOUT 90% OF
CONTROL VALVE APPLICATIONS SINCE IT
RESULTS IN THE MOST LINEAR INSTALLED
CHARACTERISTICS
LINEAR- WHEN A RELATIVELY CONSTANT
PRESSURE DROP IS MAINTAINED ACROSS
THE VALVE

GLOBE VALVE FLOW

CHARACTERISTICS

GLOBE VALVES - LINEAR

PLUGS/SEATS DESIGNED TO HAVE
THE FRACTION OF FLOW BE LINEAR
WITH THE VALVE STEM POSITION FOR
A CONSTANT p
f(x) = x WHERE x IS VALVE POSITION
DESIGN POSITION IS ABOUT 50%
OPEN

GLOBE VALVES - EQUAL

PERCENTAGE
EQUAL PERCENTAGE CHANGE IN
VALVE POSITION RESULT IN EQUAL
PERCENTAGE CHANGE IN FLOW
AND x IS VALVE OPENING
DESIGN POSITION IS ABOUT 70%
OPEN

GLOBE VALVES - QUICK OPENING

TRIM IS DESIGNED TO HAVE LARGE
INCREASE IN FLOW WITH SMALL CHANGE
IN VALVE OPENING
DESIGN POSITION IS OPEN OR CLOSED

GLOBE VALVES - OTHER TYPES

ECCENTRIC PLUG VALVES
COMBINATION OF PLUG AND GLOBE IN THEIR
CHARACTERISTICS
CLAIM TO BE TIGHT SHUT OFF

REFERENCE:

http://www.millikenvalve.com/pdf/plug2011
.pdf

CHARACTERIZATION OF CONTROL
ELEMENTS
TIME CONSTANTS
TIME IT TAKES FOR A UNIT TO RESPOND
TO A SIGNAL AND COMPLETE A CHANGE
FOR VALVES THIS IS THE TIME TO
STROKE TO A NEW POSITION

DEADBAND
RANGE OF SIGNAL THAT REQUIRED TO
INDICATE AN ACTUAL CHANGE

CHARACTERIZATION OF CONTROL
ELEMENTS
POSITION
DEADBAND
RANGE OF SIGNAL THAT REQUIRED TO
INDICATE AN ACTUAL CHANGE
FOR THERMOCOUPLES THIS MIGHT BE +1
C.

CHARACTERIZATION OF CONTROL
ELEMENTS
TURNDOWN RATIO
SPECIFIES THE RANGE OF STABLE
OPERATION FOR THE DEVICE, MINIMUM
TO MAXIMUM
NORMAL OPERATING RANGE SHOULD
NOT BE AT EITHER EXTREME POSITION

CONTROL VALVE DESIGN

EVALUATE CV AT THE MAXIMUM AND

MINIMUM FLOW RATE

DETERMINE WHICH VALVES CAN
EFFECTIVELY PROVIDE THE MAX AND MIN
FLOW RATE
THE VALVE POSITION SHOULD BE GREATER
THAN ABOUT 15% OPEN FOR THE MINIMUM
FLOW RATE
AND LESS THAN 85% OPEN FOR THE MAXIMUM
FLOW RATE.

CONTROL VALVE DESIGN

CHOOSE
SMALLEST VALVE THAT MEETS THE RANGE CRITERION
FOR THE MINIMUM CAPITAL INVESTMENT
THE LARGEST VALVE TO ALLOW FOR FUTURE
THROUGHPUT EXPANSION.

CV VERSUS % OPEN FOR DIFFERENT VALVE SIZES.

AVAILABLE PRESSURE DROP ACROSS THE VALVE
VERSUS FLOW RATE FOR EACH VALVE. NOTE
THAT THE EFFECT OF FLOW ON THE UPSTREAM
AND DOWNSTREAM PRESSURE MUST BE KNOWN.
http://www.norriseal.com/files/comm_id_47/Valve_Size_Manual.pdf

CONTROL VALVE DESIGN EXAMPLE

SIZE A CONTROL VALVE FOR MAX 150
GPM OF WATER AND MIN OF 50 GPM.
USE THE VALVE FLOW EQUATION TO
CALCULATE CV
FOR P, USE PRESSURE DROP
VERSUS FLOW RATE (E.G., TABLE ON
PAGE 82)

CONTROL VALVE DESIGN EXAMPLE

EQUATION AT LIMITS

VALVE POSITION FOR MAX AND MIN

FLOWS BASED ON SIZE

ANALYSIS OF RESULTS
2-INCH VALVE APPEARS TO BE BEST
OVERALL CHOICE: LEAST EXPENSIVE
CAPITAL AND IT CAN PROVIDE UP TO A 50%
INCREASE IN THROUGHPUT.
3-INCH AND 4-INCH VALVE WILL WORK, BUT
NOT RECOMMENDED BECAUSE THEY WILL
COST MORE TO PURCHASE. THE 2-INCH
VALVE WILL PROVIDE MORE THAN ENOUGH
EXTRA CAPACITY (I.E., SOMETHING ELSE
WILL LIMIT CAPACITY FOR IT)

ADJUSTABLE SPEED PUMPS FOR

FLOW CONTROL
USED EXTENSIVELY IN THE BIOPROCESSING INDUSTRIES TO MAINTAIN
STERILE CONDITIONS AND RELATIVELY
LOW FLOW RATES.
FAST AND PRECISE.
DO REQUIRE AN INSTRUMENT AIR SYSTEM
(I.E., 4-20 MA SIGNAL GOES DIRECTLY TO
PUMP).
MUCH HIGHER CAPITAL COSTS THAN
CONTROL VALVES FOR LARGE FLOW RATE
APPLICATIONS.