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Dynamic Modelling and Process Control
Dynamic Modelling and Process Control
Mariana Titica
Associate Professor, NU GEPEA UMR 6144 CNRS
mariana.titica@univ-nantes.fr
Chapter I: Introductory concepts of Process
Control
- An introductory overview of process control and how it is
practiced in the chemical and biochemical process industry
Chemical process: any single units or combinations of processing units, used for the
conversion of row materials (through any combination of chemical, mechanical or
termal changes) and input energy into finished products
Reactors
Separation
units
Waste effluent
treatment unit
2
Basical principles for the operation of the
processing units: (½)
• Operate safely
– No unit should be operated near potentially dangerous conditions (either to the health of
the operator, or equipments life, or to the violation of environmental rules)
• Need to MONITOR
• Need to INDUCE change in key process variables that are
related to safety, production rate and product quality
4
• Process Dynamics and Control is concerned with the
analysis, design and implementation of control systems
that facilitate the achievement of specified objectives of
process safety, production rates and product quality
Ogunnaike B. and Ray W.H., “Process Dynamics, Modeling, and Control”, Oxford University Press, New
York, 1994
Bequette B., “Process Control: Modeling, Design and Simulation”, Prentice-Hall, 2003
5
Conceptual process block diagram –
Definitions (1/2)
Inputs Outputs
Measured
Manipulated variables
variables
Disturbance Process Unmeasured
variables variables
CAUSES EFFECTS
6
Conceptual process block diagram –
Definitions (2/2)
• A controller calculates changes in a manipulated
variable to be applied based on the difference between
the variable measurement and its desired value (the
desired set-point)
Controller
Manipulated
input
Process Controlled
Disturbances variable
input
7
Control System Configuration (1/3)
Open-Loop Control
Transmitter
Actuator
Finite control
element Controller
Manipulated
input Control
Process variable
Disturbances
input
8
Control System Configuration (2/3)
Feedback control
Transmitter Transmitter
Actuator
Finite control
element Controller
Sensor
Manipulated
input Control
Process variable
Disturbances
input
9
Control System Configuration (3/3)
Feedforward Control
Controller
Manipulated
input Controlled
Process variable
Transmitter Disturbances
input
Sensor
10
Control strategy definition
11
“Real” Control Block Diagram
Disturbance
Disturbance
process
Error
Setpoint +
mA mA m + Measured
+ Controller Actuator Process
- A variable
Physical world
mA
Sensor
Electrical world
TI
v1
4-20 mA
TI
4-20 mA
3-15 psi
v2
12
Dynamic systems
- Dynamic system means that its response at a given time depends not only on the input
at that time but also on the past inputs
- A dynamic system is described by one ore more differential equations
- Static system means that its response at a given time (output) depends only on the
input at that time
- A static system is described by a one ore more algebraic equations
- Linear system: A system is linear if and only if it satisfies the superposition principle, or
equivalently both the additivity and homogeneity properties, without restrictions (that
is, for all inputs, all scaling constants and all time
u(t) y(t)
- Stationary system (time invariant): if all parameters are constant with time
13
Modelling of dynamic systems
Introduction to the design of feedback controllers
14
References
• Bastin G. and Dochain D., “On-line Estimation and
Adaptive Control of Bioreactors”, Elsevier, 1990.
• Bequette B., “Process Control: Modeling, Design and
Simulation”, Prentice-Hall, 2003.
• Ogunnaike B. and Ray W.H., “Process Dynamics, Modeling,
and Control”, Oxford University Press, New York, 1994.
• Camacho E.F. and Bordons C., “Model Predictive Control in the
Process Industry”, Springer-Verlag, London, 1995.
15
Chapter II: Modeling for Control
http://www.pc-education.mcmaster.ca/LearningSupport%20Page.htm
16
Chapter II: Modeling for Control
u Mathematical
y
Model
INPUT OUTPUT
Chapter 2. Outline
18
Chapter 2 Modelling of Dynamic Systems
2.1 Phenomenological modeling
2.1.1 Material and Energy Balances
rate of mass or rate of mass or rate of mass or
energy = energy entering - energy leaving
accumulation in a a system a system
system
• Methodology
1. Write the differential equations corresponding to the
mass and energy balances
2. Re-write these equations around a given steady-
state, using the following formula for a variable V:
V V V
3. Simplify the equations using the steady-state
equation and linearize the nonlinear terms, if
necessary (i.e. linear control)
19
Chapter 2 Modelling of Dynamic Systems 20
Assumptions:
-Fi=Fo=F0
Batch:
Fed-batch:
Continu:
An example: Bioreactor
Haldane law
Monod law
Chapter 2 Modelling of Dynamic Systems 26
3 equilibrium points
Chapter 2 Modelling of Dynamic Systems 28
29
Chapter 2 Modelling of Dynamic Systems 30
31
Laplace Transform
- Itis used to convert linear differential equations into algebraic
equations,
- Laplace transforms are useful for solving linear dynamic systems
problems, particularly nonhomogeneous (heterogeneous) problems
(where the input to the process system is changed), and are
commonly used in process control system design and analysis
F ( s) L[ f (t )] f (t )e st dt
0
F(s) = Laplace transform of the function f(t)
d
s
dt
Laplace transforms are used to create transfer function models, which are the basis for many
32
control system design techniques.
Laplace Transform - Properties
t
F ( s)
L[ f (t )dt ]
0
s
d
L[ f (t )] sF ( s) f (0)
dt f(0) = the initial value of f at t=0
Translation in time:
s
L[ f (t )] e L[ f (t )]
34
Laplace Transform – Properties
Laplace Transform is a linear operation:
𝐿 𝑎1 𝑓1 𝑡 + 𝑎2 𝑓2 𝑡 =𝑎1 𝐿[𝑓1 (t)]+𝑎2 𝐿[𝑓2 (t)]
d
Temporal derivation: L[ f (t )] sF ( s) f (0)
dt
t
F ( s)
Temporal integration: L[ f (t )dt ]
0
s
Translation in time: L[ f (t )] e s L[ f (t )]
SYSTEM
37
Chapter 2: Modeling for Control
Transfer function
u Transfert y
Function
INPUT OUTPUT
(H(s)
L[ y (t )]
H ( s)
L[u (t )]
38
Transfer function
u(t) Process y(t)
(system)
Laplace Transform
U(s) Y(s)
H(s)
bm m bm 1 m 1 b
m 1 s s ... 1 s 1
Y ( s ) bm s bm 1s ... b1s b0
m
Y ( s ) b0 b0 b0 b0
H (s) H (s)
U ( s ) bn s n an 1s n 1 ... a1s a0 U ( s ) a0 an s n an 1 s n 1 ... a1 s 1
a0 a0 a0
a and b constants ; m <n 39
u y
L[ y (t )]
Exercice INPUT
H ( s)
L[u (t )] OUTPUT
U(s) Y(s)
H(s)
Y(s) et U(s): Laplace transform of input and output signals expressed in terms of
deviation variable with respect to the steady state (equilibrium) (zero initial
condition: y(0)=0 et u(0)=0)
! : The transfer function doesn’t depend on the nature of input signal, whille Y(s)
depends on the TF and on the nature of the input signal:
𝑌 𝑠 = 𝐻 𝑠 𝑈(𝑠)
41
Transfer function – zero / poles notions
Y ( s ) N ( s ) bm (s z ) i
H (s) i 1
n
Zéros : roots of N(s)
U ( s ) D ( s ) an
(s p )
i 1
i
Pôles : roots of D(s)
If zero input: 𝑫 𝒔 𝒀 𝒔 =𝟎
42
Determining equivalent transfer function
Fonctions
Transfer de transfert
functions en série :
in series
U(s) Y(s) U(s) Y(s)
R(s) H(s) R(s) H(s)
Transfer
Fonctionsfunctions in parallel:
de transfert en parallèle :
R(s)
Y(s)
U(s) Y(s)
U(s) +
R(s) + H(s)
+
H(s)
Cas particulier:
Unitary feedbackle retour unitaire
U(s) Y(s) U(s) Y(s)
+ H(s)
-
43
Determining equivalent transfer function
U1(s) U1(s)
H(s) Y(s)
Y(s)
+ +
H(s)
+ +
U2(s) U2(s)
44
How to obtain the transfer function of a system from
a theoretical model
• Write the dynamic model describing the behaviour of the system
Examples:
45
Example: variable level tank
𝑞𝑙
𝑞𝑟
𝑣 2 =2gh – liquid speed at the bottom of the tank
𝑞𝑠 =𝐴2 𝑣 = 𝐴2 2𝑔ℎ
h 𝑞𝑠
𝑑ℎ(𝑡)
𝐴1 = 𝑞𝑟 (t)+ 𝑞𝑙 (𝑡) − 𝑞𝑠 (t)= 𝑞𝑟 (t)+ 𝑞𝑙 𝑡 − 𝐴2 2𝑔ℎ Nonlinear model
𝑑𝑡
𝑑ℎ(𝑡)
𝐴1 = 𝑞𝑟 (t)+ 𝑞𝑙 (𝑡) − 𝑞𝑠 (t)= 𝑞𝑟 (t)+ 𝑞𝑙 𝑡 − 𝐴2 2𝑔ℎ
𝑑𝑡
1
Linear approximation: 𝐴2 2𝑔ℎ(𝑡) = 𝐴2 2𝑔ℎ + 2 𝐴2 2𝑔 ℎ−1/2 ℎ 𝑡 − ℎ
𝑑ℎ(𝑡) ℎ 𝑡 −ℎ
𝐴1 = 𝑞𝑟 (t)+ 𝑞𝑙 (𝑡) − 𝑞𝑠 (t)= 𝑞𝑟 (t)+ 𝑞𝑙 𝑡 − 𝐴2 2𝑔ℎ −
𝑑𝑡 𝑅 46
Example: variable level tank
Equa diff expressed with variational variables: 𝑑ℎ 𝑡 ℎ(𝑡)
𝐴1 = 𝑞𝑟 𝑡 + 𝑞𝑙 𝑡 −
𝑑𝑡 𝑅
𝑞𝑟 (t) u1(t)
y(t)
u2(t) Procédé
𝑞𝑙 (t) ℎ(t)
𝐿ℎ 𝑡 𝐿ℎ 𝑡
𝐻1 𝑠 = 𝐻2 𝑠 =
𝐿 𝑞𝑟 𝑡 𝐿 𝑞𝑙 𝑡
𝐿ℎ 𝑡 = 𝐻1 𝑠 𝐿 𝑞𝑟 𝑡 + 𝐻2 𝑠 𝐿[𝑞𝑙 𝑡 ]
47
Example: variable level tank
• Bloc diagramm:
𝐿[𝑞𝑙 𝑡 ]
𝑅
(𝐴1 𝑅 𝑠 + 1)
𝐿 𝑞𝑟 𝑡 𝑅 𝐿ℎ 𝑡
(𝐴1 𝑅 𝑠 + 1)
48
Chapter 2 Modeling for Control 49
1
1 𝑞𝑐𝑝
𝐿𝑇 𝑡 = 𝐿 𝑇𝑖𝑛 𝑡 + 𝐿[𝑄 𝑡 ]
𝑉 𝑉
𝑞 𝑠+1 𝑞 𝑠+1
𝐿 𝑇𝑖𝑛 𝑡
1
𝑉
1 𝑞 𝑠+1
𝑞𝑐𝑝
𝐿𝑄 𝑡 𝐿𝑇 𝑡
𝑉
𝑞 𝑠+1
50
51
Chapter 2 Modeling for Control
2.1 Phenomenological modeling
2.1.4 Linearization of nonlinear models
• Transfer function – State-space model
52
Chapter 2 Modeling for Control
2.1 Phenomenological modeling
2.1.4 Linearization of nonlinear models
• Transfer function – State-space model
• Non-isothermal reactor
~ ~
y T, u F
~ ~
y C, u F
Chapter 2 Modeling for Control
2.1 Phenomenological modeling
2.1.4 Linearization of nonlinear models
• Transfer function – State-space model
• Non-isothermal reactor
~ ~
y C, u F
Disturbances:
53
Process classification:
- unstable
- stable
- 1st order - second order - …- order n
54
Chapter 2: Modeling for Control
Responses of first order systems
dy(t )
a y(t ) b u (t )
dt
dy (t )
1 y (t ) G st u (t )
dt
= time constant (units of time)
Gst = steady-state process gain (units of output/input)
y = output variable
u = input variable
55
Chapter 2: Modeling for Control
Response of first order systems
Process gain and time constant are determined by performing step tests on processes
u 0.95 y
Gst u y y y0
t /
y (t ) G st u 1 e
t , y 0.63 y t 3
t 3 , y 0.95 y
G st
t , y y H (s)
s 1 56
Chapter 2: Modeling for Control
Responses of second order systems
2
2
d y(t ) dy(t ) d y(t ) dy(t )
a a0 y(t ) b u (t ) 2 2
2 y(t ) Gst u (t )
dt 2 1
dt dt dt
Gst
H ( s) 2 2
s 2 s 1
Gst= gain (units of output/input) / =damping factor / = natural period (units of
time) The characteristic equation of the second-order transfer function is:
2 s 2 2 s 1
The roots of the characteristic equation = the poles of the system
57
Characteristic behavior depends on the pole location
Chapter 2: Modeling for Control
Responses of second order systems
58
Not usual for chemical
processes in open loop
Interesting for closed
loop analysis and
controller tuning
59
Chapter 2: Modeling for Control
Second order systems versus first order
• Notice that the main difference between overdamped (or
critically damped) step responses and first-order step responses
is that the second order step responses have « « S » shape with
a maximum slope at an inflexion point, whereas the first-order
responses have their maximum slope initially
First Second
order order
60
Chapter 2: Modeling for Control
About the delay
61
Chapter 2: Modeling for control
Nonminimum-phase (RHP zeros) behavior
62
Exemple: The boiler drum level
If the drum level is low, and more feedwater is added to increase it, the drum level
tends to decrease first before increasing. This is because the cooler feedwater
causes some of the steam in the evaporator to condense, causing the volume
of water/steam to decrease, and hence the drop in drum level.
63
Chapter 2 Modeling for Control
2.2 Empirical modeling
• Methodology
1. Obtain the output response curve to a step input
change
2. Identify the process gain and dynamics from curve
analysis
• Cohen-Coon models
• Strejc models
64
Modeling for Control
Empirical modeling – first order
∆y
∆y = Gst ∆u
65
Modeling for Control
Empirical modeling – second order
66
Modeling for Control
Empirical modeling – first order + delay (Broida model)
∆u
∆y=Gst ∆u
∆y
∆y
t0 t1 t2
y s kP Tableau de S tréjc
gP s
u s T s 1n n Tu / Ta Tu / T Ta / T
y 1 0 0 1
2 0.104 0.282 2.718
yss 3 0.218 0.805 3.695
yss 4 0.319 1.425 4.463
kP
u 5 0.410 2.100 5.119
6 0.493 2.811 5.699
7 0.570 3.549 6.226
Tu Ta 9
10
0.709
0.773
5.081
5.869
7.164
7.590
68
Chapter 2 Modeling for Control
2.2 Empirical modeling
Strejc Models (1/3)
y
yss
yss y s kP
kP gP s
u u s T s 1n
t
Tu Ta
69
70
Modelling for control
Formulate model based on mass and energy balance and constitutive
relationships
(« exact » dynamic behaviour described by model)
Laplace Transform