University of KwaZulu-Natal

School of Engineering

MODULE OUTLINE 2023

Module Code: ENCH4DC Credits: 16 (160 hours)

Module Title: Process Dynamics & Control

Study Hours Required

Contact Based Learning Self directed Learning

Category Activity Hours Category Activity Hours
L Lectures 39 H Reading (Self study) 54
T Tutorials 9 R Revision 40
P Practicals 12
A Assessments 6
(Exams & Tests)
Contact based TOTAL 66 Self-directed TOTAL 94
TOTAL HOURS 160

Course Name: ENCH4DC Process Dynamics & Control

SAQA Credits: 16
Pre-requisites: ENCH2ET, ENCH2MB & ENCH3ED
Co-requisites: None

Module coordinator: Prof K Moodley

Prof K Moodley, Room 1A17, Chem Eng Building, moodleyk6@ukzn.ac.za, x1519
Module lecturers:
Prof R Rawatlal, Room 1A20, Chem Eng Building, rawatlalr@ukzn.ac.za, x2156
Prof K Moodley: Monday 12:20 – 14:00 arrange by email appointment
Consultation hours:
Prof R Rawatlal: Arrange by email

Lecture venue: CEW, CEW Chemical Engineering Building;

Lecture days and time: Monday Periods 4 & 5 10:30 – 12:10 CEW
Wednesday Period 2 08:40 – 10:20 CEE
Tutorial venue CEW, Chemical Engineering Building
Tutorial day and time Friday Periods 8 & 9 14:10 – 15:50
Practical venue Main laboratory/LAN (To be confirmed)
Monday Periods 6 - 11 12:20 – 17:30
Practical days & times Wednesday Periods 7 - 11 13:15 – 17:30
(check the practical schedule for your group allocation)
Note: the lecture and tutorial periods will be used interchangeably, depending on the requirements of
the lecturer. Random quizzes may be held in tutorials or lectures.
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Module Outcomes
This module creates an awareness of the importance of chemical process dynamics, and common methods used for
process regulation and protection. A foundation of both modern and classical control theory is laid to enable progress
towards more advanced applications in the workplace.

Candidates will be able to identify the time-variations affecting a chemical process, construct simple models to represent
these, and configure basic and advanced control schemes on the basis of models or their understanding of the flow scheme.

ECSA Knowledge areas and outcomes

Engineering Design and Computing Complementary

Mathematics Basic Sciences
Sciences Synthesis and IT Studies
88% 12%
14Cr 2Cr
This module is a core of the engineering sciences (knowledge area 3) and makes up 14 of the compulsory 168
credits required in this knowledge area towards the degree. The outcomes are: development of problem solving
skills and application of scientific and engineering knowledge. This module is not an exit level module.

Detailed course content

Introduction
General Concepts
Fundamentals
Fundamental laws
Continuity equations
Energy equation
(4 lectures)
Chemical kinetics
K. Moodley
Numerical Methods
Numerical integration of ordinary differential equations
Explicit numerical integrn algorithms
Implicit methods
Simulation examples
Batch reactor

Time-domain dynamics
Classification and definition
(2 lectures)
Linearisation and perturbation variables
K. Moodley
Linearisation
Perturbation variables
Example

Conventional control systems and hardware

Control instrumentation
Symbols
(2 lectures)
Sensors
K. Moodley
Transmitters
Control valves
Analogue and digital controllers
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Case Studies
Inverse response
(4 lectures)
Boiler
K. Moodley
Reactor recycle
Distillation

Advanced control systems

Ratio control
Cascade control
Computed variable control
Override control
Reset windup (5 lectures)
Selective and split-range control K. Moodley
Nonlinear and adaptive control
Adaptive control
Valve-position Control
Feedforward control concepts
Advanced level control

Control system design concepts

General guidelines
Plant-wide control
Dynamic matrix control (4 lectures)
Review of least squares K. Moodley
Step-response models
DMC algorithm
Smith predictor

Multivariable processes: Matrix properties and state variables

Matrix mathematics
Matrix properties
Eigenvalues
Matrix Exponential (3 lectures)
Singular Values K. Moodley
Representation of multivariable processes
State Variables
Openloop and closedloop systems
State Variables

Analysis of multivariable systems

Stability
(2 lectures)
Resiliency (MRI)
K. Moodley
Interaction
Relative gain array (Bristol array)

Performance of feedback controllers

Specifications for closed-loop response
(2 lectures)
Load performance
R. Rawatlal
Controller tuning
On-line Trial-and-Error
Ziegler-Nichols method
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Laplace-domain dynamics
Laplace transformation of important functions
Step function
Ramp
Impulse ( Dirac delta function (t) )
Transfer functions
Differentiation with respect to time (5 lectures)
Integration R. Rawatlal
Deadtime
Properties of transfer functions
Physical realisability
Poles and zeros
Steadystate gains
Inversion of Laplace transforms
Introduction to Stability

Examples: Laplace domain solution for responses

First order: step input
First order: impulse input
First order: sinusoidal input (6 lectures)
Two non-interacting first order systems R. Rawatlal
Two interacting first order systems
Responses of simple linear systems
First-order linear ODE’s
Second-order linear ODE’s

Transfer functions for feedback controllers

Laplace-domain analysis of conventional feedback control
Openloop and closedloop systems
Openloop characteristiic equation
Closed loop char. equation and tr.fn.
(5 lectures)
Stability
R. Rawatlal
Performance specifications
Steadystate performance
Dynamic specifications
Root locus analysis
Definition
Construction of root locus curves

Frequency-domain dynamics
Definition
Basic theorem (3 lectures)
Representation R. Rawatlal
Nyquist plots
Bode plots
Nichols plots

Frequency-domain analysis of closedloop systems (2 lectures)

Nyquist stability criterion R. Rawatlal
Proof
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Examples
Representation

Closedloop specifications in the frequency domain (1 lecture

Phase margin R. Rawatlal
Gain margin

Frequency response of feedback controllers

Proportional controller (P) (2 lectures)
Proportional-integral controller (PI) R. Rawatlal
Proportional-integral-derivative (PID)
Examples (Nichols chart)

Practicals

Details of practicals on Moodle page (learn2023.ukzn.ac.za)

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General assessment strategy

Assessment Task % DP Requirements:
Impromptu Quizzes 2 In order to be granted a Duly-Performed certificate and
access to the final examination, students must meet the
Test 1 (K Moodley) 9
following requirements:
Test 2 (R Rawatlal) 9 • Satisfactory completion of practicals
Practicals & Post-practical Interviews 20 • Attendance and completion of all tutorials
Written Examination (3hr) 60
Total 100
Tests:
TBA (KM) - TEST
TBA (RR) - TEST

Make-up Test (special cases only as detailed below):

TBA

Note that the Impromptu Quizzes will be held randomly and without announcement at any time during properly
scheduled tutorials or lectures. They will have short, simple answers, and will test your understanding of material
just presented in the tutorial, as well as recent lectures. Note that if you miss an impromptu quiz, there is no
provision for a make-up session.

Missed sessions: if a student is absent for a test/tutorial/practical session, he/she must submit an original medical
certificate to the teaching administrator within 48 hours of the scheduled event and consult the lecturer/module
co-ordinator.

Makeup tests: only one make-up test session will be scheduled at the end of the semester. If a student is unable
to sit this session, then they forfeit their opportunity to take the make-up assessment. No medical certificates, etc.
will be accepted for makeup tests.

Submission of assignments/project work: in cases where a student is incapacitated through illness/injury and
cannot personally submit their assignment or project/practical report, they MUST inform the module coordinator
by UKZN email, AND submit an electronic copy of the final report by email prior to the deadline for submission.
Time stamps on the email receipt will be used to ensure the assignment or project report has been submitted by
the deadline. On return to campus, the student must submit an identical printed copy of the report along with a
valid medical certificate to the module coordinator. Failure to follow this procedure, or any changes to the
electronic copy prior to printing will result in a mark of zero for the assignment/report.

Prescribed Books/Reading Materials/ Tutorial Documents/Notes

Prescribed books
Seborg, D.E., Mellichamp, D.A., Edgar, T.F. and Doyle, F.J., “Process Dynamics and Control”, 3rd Edition,
Wiley.
Mulholland, M., “Applied Process Control: Essential Methods”, Wiley.
Documents to be available for Lectures and Tutorials
You will need to print in advance a number of “handout” documents that will be referred to in various lectures.
These, together with Tutorial question sheets may be obtained from Moodle.
Updates & Notices
Please check the course notices on Moodle (moodle.ukzn.ac.za) regularly for further information on this module.