PROCESS CONTROL

CHE F 342

JAIDEEP CHATTERJEE
BITS Pilani, Hyderabad Campus
 THE CLOSED LOOP
CONTROL SYSTEM

JAIDEEP CHATTERJEE
BITS Pilani, Hyderabad Campus
BLOCK DIAGRAM OF A FEED BACK CONTROL SYSTEM

Set- Load / Disturbance

Point ε = Error
+ CONTROLLER
CONTROL
ELEMENT
+ + PROCESS Output
𝐺𝐶 (𝑠) 𝐺𝑃 (𝑠) = 𝑇𝑟𝑎𝑛𝑠 .
- 𝐺𝑉 𝑠 (𝑉𝐴𝐿𝑉𝐸) Control 𝑓𝑢𝑛𝑐𝑡𝑖𝑜𝑛
Variable

SENSOR
Measurement
𝐺𝑚 (𝑠) = 𝑇𝑟𝑎𝑛𝑠𝑓𝑒𝑟
𝑓𝑢𝑛𝑐𝑡𝑖𝑜𝑛

Each BLOCK represents the Laplace Domain Transfer function

G(s) which is a relation between its INPUT and its OUTPUT

JAIDEEP CHATTERJEE
BITS Pilani, Hyderabad Campus
 THE PROCESS TRANSFER
FUNCTION

JAIDEEP CHATTERJEE
BITS Pilani, Hyderabad Campus
DEVELOPING BLOCK DIAGRAM FOR A CONTROL SYSTEM
𝑠
𝑇𝑖𝑛 = 30 ℃ ;
THE TANK TEMPERATURE CONTROL SYSTEM
𝑞 = 200 𝐿/𝑚𝑖𝑛 Output = T(t) (Tank Temperature) Note :
q = Input flow rate
Set-point = 80 ℃ (Desired tank Temperature)
= Output flow rate
Load / Disturbance = 𝑇𝐼𝑁 (t) (Input Temperature) = Constant

Q=? Control Variable = Q(t) (Heating Power)

Watts
V = 1000 L Steady State Energy Balance
𝑠 𝑠
𝑞𝜌𝐶𝑝 𝑇𝐼𝑁 − 𝑇0 + 𝑄 = 𝑞𝜌 𝐶𝑝 𝑇 𝑠 − 𝑇0 𝑄 = 𝑞𝜌𝐶𝑝 𝑇 𝑠 − 𝑇𝐼𝑁

𝑇 𝑠 = 80 ℃; 𝐿 𝑔𝑚 𝐽
𝑞 = 200 𝐿/𝑚𝑖𝑛
𝑄 = 200 × 1000 × 4.2 × 80 − 30 °𝐶
𝑚𝑖𝑛 𝐿 𝑔𝑚 °𝐶
𝐾𝐽
𝑄 = 42000 = 700 𝐾𝑊
𝑚𝑖𝑛
JAIDEEP CHATTERJEE
BITS Pilani, Hyderabad Campus
DEVELOPING BLOCK DIAGRAM FOR A CONTROL SYSTEM
𝑇𝐼𝑁 𝑡 THE TANK TEMPERATURE CONTROL SYSTEM
𝑞 = 200 𝐿/𝑚𝑖𝑛
Unsteady State Energy Balance
𝑑 𝑉 𝜌 𝐶𝑝 𝑇(𝑡) − 𝑇0
= 𝑞 𝜌 𝐶𝑝 𝑇𝐼𝑁 − 𝑇0 + 𝑄 − 𝑞 𝜌 𝐶𝑝 𝑇(𝑡) − 𝑇0
𝑑𝑡
Q= 𝑉 𝑑𝑇 𝑡 𝑄
𝐷𝑖𝑣𝑖𝑑𝑖𝑛𝑔 𝑏𝑦 𝑞𝜌 𝐶𝑝 = 𝑇𝐼𝑁 + −𝑇 𝑡
700 𝑞 𝑑𝑡 𝑞 ρ 𝐶𝑝
KW V = 1000 L @ 𝑆𝑡𝑒𝑎𝑑𝑦 − 𝑆𝑡𝑎𝑡𝑒 𝑉 𝑑𝑇 𝑠 𝑄 𝑠
𝑠
= 𝑇𝐼𝑁 + − 𝑇𝑠
𝑞 𝑑𝑡 𝑞 ρ 𝐶𝑝
𝑉 1000 𝐿
𝜏= = = 5 𝑚𝑖𝑛𝑠
𝑇 𝑡 𝑞 200 𝐿Τ𝑚𝑖𝑛
𝑞 = 200 𝐿/𝑚𝑖𝑛
𝑑 𝑇ത 𝑡 𝑄ത Where 𝑄ത , 𝑇ത 𝑡 𝑎𝑛𝑑 𝑇ത𝐼𝑁 (t)
𝑆𝑢𝑏𝑡𝑟𝑎𝑐𝑡𝑖𝑛𝑔 𝜏 = 𝑇ത𝐼𝑁 + ത
− 𝑇(𝑡) are deviation variables
𝑑𝑡 𝑞 ρ 𝐶𝑝
JAIDEEP CHATTERJEE
BITS Pilani, Hyderabad Campus
DEVELOPING BLOCK DIAGRAM FOR A CONTROL SYSTEM
THE TANK TEMPERATURE CONTROL SYSTEM
Unsteady State 𝑑𝑇ത 𝑡 𝑄ത Where 𝑄ത , 𝑇ത 𝑡 𝑎𝑛𝑑 𝑇ത𝐼𝑁 (t)
𝜏 = 𝑇ത𝐼𝑁 + ത
− 𝑇(𝑡) are deviation variables
Energy Balance 𝑑𝑡 𝑞 ρ 𝐶𝑝
𝐿 𝑔 𝐽 𝐾𝐽 1 𝑚𝑖𝑛 𝐾𝑊
𝑞ρ𝐶𝑝 = 200
𝑚𝑖𝑛
× 1000 × 4.2
𝐿 𝑔℃
= 840
𝑚𝑖𝑛 ℃
×
60 𝑠𝑒𝑐
= 14
℃

On Laplace ത
𝑄(𝑠) All terms have units
𝜏𝑠𝑇ത 𝑠 + 𝑇(𝑠)
ത = 𝑇ത𝐼𝑁 (𝑠) + of Temperature
Transformation 𝑞ρ𝐶𝑝

ത
𝑄(𝑠) 1 1Τ𝑞ρ𝐶𝑝
ത
𝜏𝑠 + 1 𝑇(𝑠) = 𝑇ത𝐼𝑁 (𝑠) + 𝑇ത 𝑠 = 𝑇ത𝐼𝑁 𝑠 + ത
𝑄(𝑠)
14 𝜏𝑠 + 1 𝜏𝑠 + 1

JAIDEEP CHATTERJEE
BITS Pilani, Hyderabad Campus
DEVELOPING BLOCK DIAGRAM FOR A CONTROL SYSTEM

1 1Τ14 1
ത ത ത ഥ 𝑰𝑵 𝒔
𝑻 𝐺𝑃 (𝑠) =
𝑇 𝑠 = 𝑇𝐼𝑁 𝑠 + 𝑄(𝑠) 5𝑠 + 1
5𝑠 + 1 5𝑠 + 1
1 1
+
ഥ
𝑸(𝒔) 𝐺𝑃 (𝑠) =
14 5𝑠 + 1

1 ത
𝑄(𝑠) ഥ 𝑰𝑵 𝒔
𝑻
𝑇ത 𝑠 = 𝑇ത𝐼𝑁 𝑠 +
5𝑠 + 1 14 1 + 1
ഥ (𝒔)
𝑸 𝐺𝑃 (𝑠) =
14 5𝑠 + 1

JAIDEEP CHATTERJEE
BITS Pilani, Hyderabad Campus
 OPEN LOOP OR UN-CONTROLLED
PROCESS RESPONSE

JAIDEEP CHATTERJEE
BITS Pilani, Hyderabad Campus
OPEN LOOP RESPONSE TO STEP CHANGE IN LOAD
𝑠
𝑇𝑖𝑛 = 30 ℃ STEP CHANGE IN LOAD: The Temperature of Input dropped to 20 °C
𝑞 = 200 𝐿/𝑚𝑖𝑛
1 1Τ14 20 − 30
𝑇ത 𝑠 = ത
𝑇𝐼𝑁 𝑠 + ത
𝑄(𝑠) 𝑇ത𝐼𝑁 𝑠 =
5𝑠 + 1 5𝑠 + 1 𝑠
−10 −10/5 𝐴 𝐵
𝑇ത 𝑠 = 𝑇ത 𝑠 = = +
𝑠 5𝑠 + 1 𝑠 𝑠 + 1/5 𝑠 𝑠 + 1/5
Q=
700 Multiply with 𝐴 = −10 Multiply with s+1/5 𝐵 = 10
KW V = 1000 L s and let s = 0 and let s = -1/5

−10/5 10 10 𝑡
𝑇ത 𝑠 = −
𝑠 𝑠 + 1/5
=−
𝑠
+
𝑠 + 1/5 𝑇ത 𝑡 = −10 + 10 𝑒 5
𝑇 𝑠 = 80 ℃
𝑡 𝒕
𝑞 = 200 𝐿/𝑚𝑖𝑛 − −
𝑇ത 𝑡 = 𝑇 𝑡 − 80 = −10 + 10 𝑒 5 𝑻 𝒕 = 𝟖𝟎 − 𝟏𝟎 𝟏 − 𝒆 𝟓

JAIDEEP CHATTERJEE
BITS Pilani, Hyderabad Campus
OPEN LOOP RESPONSE TO STEP CHANGE IN SET-POINT
STEP CHANGE IN SET-POINT : The Heating power (Q) is increased by 140 KW
1 1Τ14 140 1Τ14 1Τ14 140
𝑇ത 𝑠 = ത
𝑇𝐼𝑁 𝑠 + ത
𝑄(𝑠) ത
𝑄(𝑠) = ത
5𝑠 + 1 5𝑠 + 1 𝑠 𝑇ത 𝑠 = 𝑄 𝑠 =
5𝑠 + 1 5𝑠 + 1 𝑠
10/5 𝐴 𝐵
𝑇ത 𝑠 = = + Multiply with
𝐴 = 10
Multiply with s+1/5
𝑠 𝑠 + 1/5 𝑠 𝑠 + 1/5 s and let s = 0 and let s = -1/5
𝐵 = −10
𝑡 𝑡
10/5 10 10 𝑇ത 𝑡 = 𝑇 𝑡 − 80 = 10 − −
10 𝑒 5 = 10 1 − −
𝑒 5
ത
𝑇 𝑠 = = −
𝑠 𝑠 + 1/5 𝑠 𝑠 + 1/5
𝒕
−
BOTH STEP CHANGES OCCUR: Input 𝑻 𝒕 = 𝟖𝟎 + 𝟏𝟎 𝟏 − 𝒆 𝟓
Temp drops to 20 °C + Heating power 𝒕 𝒕
− −
is increased by 140 KW 𝑻 𝒕 = 𝟖𝟎 + 𝟏𝟎 𝟏 − 𝒆 𝟓 − 𝟏𝟎 𝟏 − 𝒆 𝟓

JAIDEEP CHATTERJEE
BITS Pilani, Hyderabad Campus
OPEN LOOP RESPONSES TO STEP CHANGES
STEP CHANGE IN LOAD: The Temp. of STEP CHANGE IN SET POINT: The Heating
Input dropped to 20°C from 30°C power (Q) is increased by 140 KW
𝒕 𝒕
− −
𝑻 𝒕 = 𝟖𝟎 − 𝟏𝟎 𝟏 − 𝒆 𝟓 𝑻 𝒕 = 𝟖𝟎 + 𝟏𝟎 𝟏 − 𝒆 𝟓

JAIDEEP CHATTERJEE
BITS Pilani, Hyderabad Campus
 THE MEASUREMENT
SYSTEM TRANSFER
FUNCTION

JAIDEEP CHATTERJEE
BITS Pilani, Hyderabad Campus
 MEASUREMENT SYSTEM TRANSFER FUNCTION
𝑇𝑀 (𝑠) 1 𝑆𝑒𝑛𝑠𝑜𝑟 𝑇𝑖𝑚𝑒 1
= 𝑇 𝑠 𝑇𝑀 𝑠
𝑇(𝑠) 𝜏𝑀 𝑠 + 1 𝐶𝑜𝑛𝑠𝑡𝑎𝑛𝑡 = 𝜏𝑀 𝜏𝑀 𝑠 + 1

Most Sensors have SHORT Time Constants (Compared to Process)

ഥ 𝑰𝑵 𝒔 1
𝑻 ഥ𝑰𝑵 𝒔
𝑻 𝑇 𝑠
𝜏𝑝 𝑠 + 1
1
ഥ (𝒔)
𝑸 𝑻 𝒔 1
𝜏𝑠 + 1 ഥ𝑰𝑵 𝒔
𝑻 𝑇𝑀 𝑠
𝜏𝑀 𝑠 + 1 𝜏𝑝 𝑠 + 1
1
𝑻𝑴 𝒔 𝑇𝑀 (𝑠) 1
𝜏𝑀 𝑠 + 1 =
ഥ
𝑻𝑰𝑵 (𝑠) 𝜏𝑀 𝑠 + 1 𝜏 𝑝 𝑠 + 1

JAIDEEP CHATTERJEE
BITS Pilani, Hyderabad Campus
SIGNIFICANCE OF MEASUREMENT SYSTEM TRANSFER FUNCTION
𝑇𝑀 (𝑠) 1
SENSOR Response to a STEP-CHANGE in LOAD =
𝑇(𝑠) 𝜏𝑀 𝑠 + 1 𝜏𝑝 𝑠 + 1
1Τ𝜏𝑃 𝜏𝑀 1Τ𝜏𝑃 𝜏𝑀 𝐴 𝐵 𝐶
𝑇𝑀 (𝑠) = = + +
𝑠 𝑠 + 1Τ𝜏𝑃 𝑠 + 1Τ𝜏𝑀 𝑠 𝑠 + 1Τ𝜏𝑃 𝑠 + 1Τ𝜏𝑀 𝑠 𝑠 + 1Τ𝜏𝑃 𝑠 + 1Τ𝜏𝑀

Multiply with Multiply with 𝑠 + 1Τ𝜏𝑃 1Τ𝜏𝑃 𝜏𝑀 −𝜏𝑃

𝐴=1 𝐵= =
s and let s = 0 and let s = −1Τ𝜏𝑃 − 1Τ𝜏𝑃 1Τ𝜏𝑀 − 1Τ𝜏𝑃 𝜏𝑃 − 𝜏𝑀
1Τ𝜏𝑃 𝜏𝑀 𝜏𝑀
Multiply with 𝑠 + 1Τ𝜏𝑀 𝐶= =
and let s = −1Τ𝜏𝑀 Τ Τ Τ
− 1 𝜏𝑀 1 𝜏𝑃 − 1 𝜏𝑀 𝜏𝑃 − 𝜏𝑀
1 𝜏𝑃 1 𝜏𝑀 1
𝑇𝑀 𝑠 = − +
𝑠 𝜏𝑃 − 𝜏𝑀 Τ
𝑠 + 1 𝜏𝑃 𝜏𝑃 − 𝜏𝑀 𝑠 + 1Τ𝜏𝑀

1 −𝑡ൗ −𝑡ൗ
𝑇𝑀 𝑡 = 1− 𝜏𝑃 𝑒 𝜏𝑃 − 𝜏𝑀 𝑒 𝜏𝑀
𝜏𝑃 − 𝜏 𝑀
JAIDEEP CHATTERJEE
BITS Pilani, Hyderabad Campus
SIGNIFICANCE OF MEASUREMENT SYSTEM TRANSFER FUNCTION
Effect of the SENSOR / 1 −𝒕ൗ −𝒕ൗ
MEASUREMENT system Dynamics 𝑻𝑴 𝒕 =𝟏− 𝜏𝑃 𝒆 𝝉𝑷 − 𝜏𝑀 𝒆 𝝉𝑴
𝜏𝑃 − 𝜏𝑀
Process & Measurement behave like
Two, 1st order systems in SERIES

If 𝜏𝑀 ≪ 𝜏𝑃 , NO Effect
on measured T(t)

If 𝜏𝑀 ~ 𝜏𝑃 , Overall Time
Constant ~ sum of Individual
Time constants

JAIDEEP CHATTERJEE
BITS Pilani, Hyderabad Campus
 TYPICAL SENSOR TIME CONSTANT
Example : If the Temperature sensor reaches 90 % of its final value in 45 seconds
(specified by the manufacturer) after a STEP CHANGE in INPUT its 𝜏𝑀 is:
−𝑡ൗ 𝑡 45
−
𝑇𝑀 𝑡 = 1 − 𝑒 𝜏𝑀 𝑇𝑀 (𝑡) = 0.9 = 1 − 𝑒 𝜏𝑀 45 𝑠𝑒𝑐 = = 0.75 𝑚𝑖𝑛𝑠
60
−
0.75 0.75 0.75
− − = ln 0.1 𝜏𝑀 = 0.3257 𝑚𝑖𝑛𝑠
0.9 = 1 − 𝑒 𝜏𝑀 𝑒 𝜏𝑀 = 0.1 𝜏𝑀

𝑇𝑀 (𝑠) 1 1 1Τ14
= 𝑇ത 𝑠 = ത
𝑇𝐼𝑁 𝑠 + ത
𝑄(𝑠)
𝑇(𝑠) 0.33 𝑠 + 1 5𝑠 + 1 5𝑠 + 1

1 1Τ14
𝑇𝑀 𝑠 = ത
𝑇𝐼𝑁 𝑠 + ത
𝑄(𝑠)
0.33 𝑠 + 1 5𝑠 + 1 0.33 𝑠 + 1 5𝑠 + 1

JAIDEEP CHATTERJEE
BITS Pilani, Hyderabad Campus
 THE CLOSED LOOP
CONTROL SYSTEM

JAIDEEP CHATTERJEE
BITS Pilani, Hyderabad Campus
 CLOSING THE LOOP WITH THE CONTROLLER
Set-Point + ε Control 𝝐 𝒔 = 𝑻𝑹 𝒔 − 𝑻𝑴 𝒔 = 𝑬𝒓𝒓𝒐𝒓
TR(s)
𝐺𝑐 Variable Q(s)
- 𝑸 𝒔 = 𝑸𝒔 + 𝑲𝒄 𝝐 𝒔
Measurement 𝑸𝒔 = Bias OR the SS value 𝑲𝒄 = Controller Gain
TM(s) of the Control variable = = 14 KW/°C (in this
Controller Transfer Functions will be 700 KW in this example example)
discussed in the Next Chapter
COMPLETE BLOCK DIAGRAM
Load / Disturbance
+ ε 1 1
+ + 𝟏 Output
Set-
𝐺𝑐 =
Point - 𝑞ρ𝐶𝑝 14 𝟓𝒔 + 𝟏
1
0.33 𝑠 + 1 Measurement
JAIDEEP CHATTERJEE
BITS Pilani, Hyderabad Campus
 CONTINUED IN 10

JAIDEEP CHATTERJEE
BITS Pilani, Hyderabad Campus