CHEE 319

Process Dynamics and Control

Winter 2012

Instructor:
M.Guay

TAs: S. Dougherty, D. Park and E. Moshksar

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 Organization

Instructor: Dr. Martin Guay

Office: Dupuis 406
Phone: 533-2788
Email: guaym@chee.queensu.ca
Web: http://chee.queensu.ca/courses/CHEE319/

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 Schedule

Lectures: (DUN 14 (for

today only), JEF 127)
Monday 10:30 – 11:20
Wednesday 9:30 – 10:20
Friday 8:30 – 9:20
Tutorials:
Section A (DUP 244) Friday 9:30 – 10:20
Section B (DUP 244) Friday 10:30 – 11:20
Office Hours (MG):
Monday 15:30 – 17:00
(Tentative) Tuesday 15:30 – 17:00

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 References
 All lectures will be available online
 Derivations will be done on the board
 Powerpoint slides are to support lectures

 Textbook (highly recommended)

D.E. Seborg, T.F. Edgar, D.A. Mellichamp, Process Dynamics and

Control (2nd or 3rd Edition), Wiley, NJ (2003, 2009).

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 Grading
Grading

Midterm (TBDIC) 25%

Assignments 15%
Final Exam 60%

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 Guidelines
 i) Assignments

 Problems will be assigned every week. Although they will not be

marked, weekly tutorials will be concentrated on the solution of the
problems and on questions that may arise from the course.
 Collaboration is encouraged throughout the course. It is recommended
that the students develop their own individual solutions.
 There will be a set of assignments that will be marked. They are to be
completed in groups of 4-5. With one assignment per group.

 ii) Exams

 Midterm exam will be open-book. Textbooks, course notes and

assignments will be allowed. The final will be closed-book.
 The timing of the midterm exam will be decided in class. (Likely to
be after reading week.)

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 Course Objectives
 By the end of this course the student should be able to:

 derive transfer function models from process models and

process data
 recognize important process dynamic features of SISO linear
dynamical systems
 apply modern control theory to design a controller for
uncertain SISO linear dynamical systems
 understand the trade-off in performance that arise in the
design of a controller

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 Teaching Approach and Expectations

 Each student is ultimately responsible for learning the

material in a course. Every professor is responsible for
presenting the course material in a manner that facilitates
learning as much as possible for the class as a whole.

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 Teaching Approach and Expectations

 In fulfilling this contract, I expect that you will actively

and constructively participate in the course.
 ask questions whenever something is not clear,
 help each other understand the course material,
 perform all assigned reading on time,
 arrive on-time for class,
 be courteous to each other and myself,
 provide me with feedback / suggestions as to how the course and
my delivery can be improved.

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 Teaching Approach and Expectations
 In return you should expect me to:
 treat each of you with courtesy and respect,
 be committed to help you understand and master the course
material,
 by being available for out of class assistance,
 by providing competent teaching assistants,
 by working to continually improve the course,
 treat each question or concern seriously and answer these to the
best of my ability.

 Class discussions and student participation are encouraged

as much as possible, in and out of the classroom

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 Course Outline

1. Introduction
2. Modeling for control
3. Solution of Linear ODEs using Laplace transforms
4. Transfer function models of mechanical systems
5. Analysis of Continuous-time Linear Systems
6. SISO Control System Analysis
7. Synthesis of SISO Controllers
8. SISO Controller Design

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 Introduction
 Feedback systems are commonplace in almost every aspect of life
 Standing, walking, running etc… are all forms of control systems where
the central nervous system reacts to various biosensor mechanisms
 Gene regulation is controlled by complex responses that trigger various
biological mechanisms

 In engineering applications, feedback systems arise in the design of

control systems
 Aircraft flight control, satellite altitude control
 Automotive control
 Communication systems
 Robotics
 Manugfacturing systems and industrial process cotnrol

 Control is the hidden technology

 It’s everywhere, but hidden by the machinery.

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 Introduction
 Feedback systems: Interconnection of two systems

System 1

System 2

 E.g. Glucose concentration regulation:

 System 1 is the liver
 System 2 is the pancreas
 the output of interest, , is glucose concentration
 the input of interest, , is insulin release rate

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 Control
What is a feedback controller?

Process

Controller

 A controller is a system designed to regulate a given process

 Process typically obeys physical and chemical conservation laws
 Controller obeys laws of mathematics and logic (sometimes
intelligent)

e.g. - Riding a bike (human controller)

- Driving a car
- Automatic control (computer programmed to control)
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 Control
 A controlled process is a system which is comprised of two interacting
systems:

e.g. Most controlled systems are feedback control systems

Disturbances Outputs
Process
Action Observation
intervene Controller monitor

The controller is designed to provide regulation of process outputs in the

presence of disturbances

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 Classical Feedback Control
 Control is meant to provide regulation of process outputs about a
reference, r, despite inherent disturbances
d

r + e u y
Controller Process
-

Classical Feedback Control System

 The deviation of the plant output, e=(r-y), from its intended reference
is used to make appropriate adjustments in the plant input, u

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 Feedforward Control
 Feedforward control is used to remove the effect of
measurable disturbances

Disturbance
M

Nominal Cff A P
Input +
+ Corrected
Input Input
Correction

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 Open-loop vs. Closed-loop
 Feedback control is an example of closed-loop control:
 The process output is sent back to the controller before affecting
the process

Process

Control

 Open-loop control

Control Process

 Controller affects the behavior of Process in a non reactive way

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 Hist orical Perspect ive
 Control goes back to the 19th century
 Central theme in many important areas

 Major impact in flight control

“We know how to construct airplanes. Men also know how to build
engines. Inability to balance and steer still confronts students of
the flying problem. When one feature has been worked out, the
age of flying will have arrived, for all other difficulties are of
minor importance.”
Wilbur Wright (1901)

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 Historical Perspective
 History of flight control is a testament to the importance of
control theory

 Wright Brothers 1903

 Sperry’s Autopilot 1912
 V1 and V2 (A4) 1942
 Robert E. Lee 1947
 Sputnik 1957
 Apollo 1969
 Mars Pathfinder 1997

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 Examples

e.g. Landing on Mars

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 Historical Perspective
 The feedback amplifier
 Invented by Black (1928) to improve signal strength
 Enables telephone calls over long distances

Input + Output
-

 Open-loop amplification

Becomes

 Amplification of the feedback amplifier depends on feedback gain

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 Historical Perspective
 The invention of the feedback amplifier is fundamental

 Forms the basis for the design of world wide telephone/television

networks

 Confirms the importance of feedback system design

Nyquist stability theorem 1932
Bode’s work on feedback design 1940

 Provides the framework for modern control system theory and

control system design

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 Historical Perspective
 By 1940, the magic of feedback was understood
 An extra component to be considered for process design to:
 Keep key variables constant
 Stabilize unstable systems
 Reduce the effects of disturbances and process variations
 Main drawback: can de-stabilize stable processes

 Principles of feedback applied in:

 Power electronics
 Industrial process control
 Flight control
 Telecommunications

 But, the similarities between all applications were not understood yet.

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 Historical Perspective
 From 40s, a new field emerges
 Similarities between applications are understood leading to the
unification of
Solid theoretical framework
Sound design methodology
Design principles
Applications

 Modern Control systems

 Well established body of ideas, concepts, theory and design
methods.
 Wide and growing scope of applications
 Remains a very active area of research and development…

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 Introduction
In engineering applications, the design of a control system is essential to
ensure:
 Good Process Operation
 Process Safety
 Product Quality
 Minimization of Environmental Impact

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 Introduction

 What is the purpose of a control system?

“To maintain important process characteristics at desired targets

despite the effects of external perturbations.”

Perturbations Processing
objectives
Plant

Market Safety
Economy Make $$$
Climate Environment...
Upsets...

Control
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 Introduction
 Dynamics:

 Study of the transient behavior of processes

 Control:

 the use of process dynamics for the improvement of process

operation and performance

 the use of process dynamics to alleviate the effect of undesirable

(unstable) process behaviors

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 Introduction
What do we mean by process, plant or system?

A process (plant or system), , is an operation that takes an INPUT or a

DISTURBANCE and gives an OUTPUT

Information Flow

INPUT: ( ) Something that you can manipulate

DISTURBANCE: ( ) Something that comes as a result of some outside
phenomenon
OUTPUT: ( ) An observable quantity that we want to regulate
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 Examples

 The speed of an automobile

Aerodynamic Force of
Friction Engine
Inputs Output
Friction
Process Speed
Engine

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 Examples
 Stirred tank heater
M
Tin, w

T, w
Q
Inputs Output
Tin
w Process T
Q
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 Block representations
 Block diagrams are models of the physical systems

Input variables Output variables

Process

System Physical
Transfer of
Boundary
fundamental Physical
quantities
Mass, Energy and Momentum

Abstract
Operation

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 Introduction
What is required for the development of a control system?

1. Process Understanding
Required measurements
Dynamic model
Required actuators
Understand design limitations
2. Process Instrumentation
Appropriate sensor and actuator selection
Integration in control system
Communication and computer architecture
3. Process Control
Appropriate control strategy

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 Examples
 Measure , adjust

Controller Heater

+
C A P
-
Tank
M
Thermocouple

Feedback control

Controller:
where

Q: Is this positive or negative feedback?

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 Example

 Cruise Control

Friction
Process Speed
Engine

Controller
Human or Computer

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 Classical Control
 Control is meant to provide regulation of process outputs about a
reference, r, despite inherent disturbances
d

r + e u y
Controller Process
-

Classical Feedback Control System

 The deviation of the plant output, e=(r-y), from its intended reference
is used to make appropriate adjustments in the plant input, u

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 Control
 Process is a combination of sensors and actuators

 Controller is a computer (or operator) that performs the required

manipulations d
Computer Actuator
r e y
+
C A P
-
Process

Sensor
e.g. Classical feedback control loop

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 Examples

 Driving an automobile
Driver Steering
r + e y
C A P
-
Automobile
M
Visual and tactile measurement

Actual trajectory
Desired trajectory y
r

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 Examples
 Stirred-Tank Heater

Tin, w

Heater
Q T, w
TC
Thermocouple
Tin, w
TR Controller Heater
+ e y
C A P
-
Tank
M
Thermocouple 39
 Examples
 Measure Ti, adjust Q

Ti
M

C A P
+ ΔQ
Qi + Q

Feedforward Control

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 Feedforward Control
 Feedforward control is used to remove the effect of
measurable disturbances

Disturbance
M

Nominal Cff A P
Input +
+ Corrected
Input Input
Correction

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 Control Nomenclature
 Identification of all process variables

 Inputs (affect process)

 Outputs (result of process)

 Inputs

 Disturbance variables
Variables affecting process that are due to external forces
 Manipulated variables
Things that we can directly affect

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 Control Nomenclature
 Outputs
 Measured
speed of a car
 Unmeasured
acceleration of a car
 Control variables
important observable quantities that we want to regulate
can be measured or unmeasured

Disturbances Other
Manipulated Process Control

Controller

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 Examples
 The speed of an automobile

Force of
Friction
Engine
Variables
 Engine force: u
 Car speed: v
 Friction force: ffric
 Aerodynamic forces: faero
 Road inclination:

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 Example

Variables Inputs Outputs

Disturbances Manipulated Measured Unmeasured Control

Task: Classify the variables

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 Example

wi, Ti
Pc L

wc, Tci h T
wc, Tco
Po
wo, To
Variables
T
• wi, wo: Tank inlet and outlet mass flows
• Ti, To: Tank inlet and outlet temperatures
• w c: Cooling jacket mass flow
• Pc: Position of cooling jacket inlet valve
• Po: Position of tank outlet valve
• Tci, Tco: Cooling jacket inlet and outlet
temperatures
• h: Tank liquid level
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 Example

Variables Inputs Outputs

Disturbances Manipulated Measured Unmeasured Control
wi
Ti
Tci
wc
h
wo
To
Pc
Po

Task: Classify the variables

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 Process Control and Modeling

 In designing a controller, we must

 Define control objectives
 Develop a process model
 Design controller based on model
 Test through simulation
 Implement to real process
 Tune and monitor
d
r e u y
Controller Process

Model

Design
Implementation 48
 Control System Development

Control development is usually carried out following these

important steps
Define Objectives

Develop a process
model
Design controller
based on model
Test by
Simulation

Implement and Tune

Monitor
Performance
Often an iterative process, based on performance we may 49
decide to retune, redesign or remodel a given control system
 Control System Development

 Objectives
 “What are we trying to control?”

 Process modeling
 “What do we need?”
 Mechanistic and/or empirical

 Controller design
 “How do we use the knowledge of process behavior to reach our process
control objectives?”
 What variables should we measure?
 What variables should we control?
 What are the best manipulated variables?
 What is the best controller structure?

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 Control System Development
 Implement and tune the controlled process
 Test by simulation
 incorporate control strategy to the process hardware
 theory rarely transcends to reality
 tune and re-tune

 Monitor performance
 periodic retuning and redesign is often necessary based on
sensitivity of process or market demands
 statistical methods can be used to monitor performance

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