Process Dynamics And Control

LECTURE:
Introduction to Process Dynamics And Control
 Process Dynamics And Control

Subject Process Dynamics And Control

Semester 8th

Course No. Ch.E-411

Weekly Contact Hrs. Th. 3 Pr. 3

Credit Hrs. Th. 3 Pr. 1

 Process Dynamics And Control

8th SEMESTER PLAN

Evaluation Marks Date

QUIZ # 1 10 Feb-2013

MID TERM EXAM 30 25-Mar-2013

QUIZ # 2 10 April-2012

END TERM EXAM 40 27-May-2012

 Process Dynamics And Control

Course Outline
1. Introduction and significance of process control
2. Feedback & Feed Forward control
3. Design & Hardware elements of control
4. Dynamics of first and second order systems
5. Overall Transfer function testability
6. Controllers (P, PI , PID etc) and final control element
7. Representation of control systems
8. Multiple control loops; cascade ratio overriding etc.
9. Introduction to stability of chemical processes
10. Introduction to frequency response techniques
11. Routh’s Criteria, Bode Plots, Nyquit’s method
12. Computer control; Introduction to DCS
13. Case Study; Development of control scheme of complete plants
Process Dynamics And Control

 Reference Book:
o Chemical Process Control An
Introduction to Theory and Practice George
Stephanopoulos
 Process Dynamics And Control

Lecture Outline
Introduction and significance of process control
Incentives of chemical process control
 Process Dynamics And Control
Why are we having Process Dynamics and Control
course in 8th semester?
What is a process?
A process is an operation that takes an INPUT or a
DISTURBANCE and gives an OUTPUT.
Input
Process Output
Disturbance

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
 Process Dynamics And Control

Process Dynamics:
Study of the transient behavior of processes

Process Control
The use of process dynamics to alleviate the effect of
undesirable (unstable) process behaviors
or
The use of process dynamics for the improvement of process
operation and performance
 Process Dynamics And Control
Process Dynamics & Control Requirements
 Safety
 Pressure , temperature and composition should be within allowable
limits
 Reactor pressure e.g 100 psig
 To avoid explosive mixture formation during operation of plant
 Production specifications
 Product quality and quantity
 Environmental regulation
 SO2 and toxic chemical concentration
 Quality of water returned to lake or river
 Process Dynamics And Control

 Operational Constraints
 Pump NPSH requirement
 Tank level
 Catalytic reactor temperature
 Economics
 Utilization of raw material and product
 Optimum operating conditions
 Operational costs
Process Dynamics And Control

Input Process Output

Controller
 Process Dynamics And Control
Core Issues
Suppressing the influence of external disturbances
Ensuring the stability of a chemical process
Optimizing the performance of a chemical process
 Process Dynamics And Control
Suppressing the influence of external disturbances

Fi , Ti
Objective:
T = Ts

Thermocouple ε = Ts - T
T
T ε > 0 Ts > T
_ Q h
Set Point More Steam
F,T
Ts +
ε ε < 0 Ts < T
Less Steam
Controller

Fst

Steam
 Process Dynamics And Control
Suppressing the influence of external disturbances

Fi , Ti
Objective:
T = Ts

Thermocouple ε = Ts - T
T
T ε > 0 Ts > T
_ Q h
Set Point More Steam
F,T
Ts +
ε ε < 0 Ts < T
Less Steam
Controller

Fst

Steam
 Process Dynamics And Control
Fi , Ti

Objective:
h = hs
Level Measuring
Device ε = hs - h
T _ h
hs ε > 0 hs > h
h
+ Set Point
ε ε < 0 hs < h

Controller

Fst

Steam
 Process Controller
DynamicsεAnd Control
Fi , Ti + hs Objective:
h = hs
_ Set Point
h
Level Measuring ε = hs - h
Device
T ε > 0 hs > h
h
ε < 0 hs < h

Fst

Steam
 Process Dynamics And Control
Insuring the stability of a process

Time
t0 Stable
System
y

t0 Un stable Time
System
 Process Dynamics And Control
Insuring the stability of a process
Heat/time
Fi , Ti , cAi

Reactant P3
a

Q2
Fc , Tco
Q1 b
P2
h
Fc , Product
AB
Tci P1
Coolant F,T,
cA T1 T2 T2a T3

Temperature 
 Process Dynamics And Control
Insuring the stability of a process

T3 T3

T2 T2
T1 T1
0 Time 0 Time

T3 T3

T2 T2

T1 T1
0 Time 0 Time
 Control
Optimize the performance of chemical process

Steam

A---> B---> Controller

C
Condensate

Maximize Profit = f ( revenue from sales of product B) – (cost of steam + cost of purchasing
A)
 Control
Optimize the performance of chemical process

Q Steam Flow Rate

Qmax

Qmin =0
tR Time
 Process Dynamics
Classification of variables And Control
Variables

Input Output
Variables Variables

Disturbance / Manipulated / Un Measured

Measured Output
Load variable Control variable Output

Measured

Unmeasured
Controlled Variable
 Process Dynamics And Control
Measured (d) Un Measured (d)

Manipulated Measured
Variables (x) Outputs (y)
PROCESSING SYSTEM

Unmeasured
Outputs (z)
Process Dynamics And Control
Example

Fi , Ti
Objective:
T = Ts
h = hs
CV
T Ts , h s
Q h
MV
F,T
Fst , Fi , (F)

Fst

Steam
 Process Dynamics And Control
Fi , Ti , cAi Objective:
T = Ts
Reactant
h = hs
Input Variables
Fc , Tco Fi , Ti , cAi , Tci , Fc , (F)

T Output Variables
Tco , T , V , cA
h
Fc , Product
AB
Tci
Coolant F,T,
cA
 Process Dynamics And Control
Design elements of control system

Define control objectives

Select measurements

Select Manipulated variables

Select Control Configuration

Design controller based on

model

Test by simulation

Implement and tune

Monitor Performance
 Process Dynamics And Control
Define Control Objectives

 What are the operational objectives that a control system is

called upon to achieve?

 Ensuring the stability of the process

 Suppressing the influence of any external disturbances
 Optimize the economic performance of a plant
Fi , Ti
Objective:
T = Ts
h = hs
T Q
h
F,T

Fst
Steam
 Process Dynamics And Control
Select measurements

 What variable should we measure in order to monitor the

operational performance of a plant?

 Primary Measurements

Fi , Ti
Objective:
T = Ts
h = hs
T Q
h
F,T

Fst
Steam
 Process Dynamics And Control
Select measurements
 What variable should we measure in order to monitor the
operational performance of a plant?

 Secondary Measurements

Controller Condenser
Set Point
Distillate
T1
Temperature T2 Reflux
Estimator T3
Feed

Column Reboiler

Bottoms
 Process Dynamics And Control
Select Manipulated Variables

 What are the manipulated variables to be used to control a

chemical process?

 Stirred Tank Example

Fi , Ti
Objective:
T = Ts
h = hs
T Q
h MV
F,T Fst , Fi , (F)

Fst
Steam
 Process Dynamics And Control
Select Control
Configurations

 What is the best control configuration for a given chemical

process control situation?

 Information structure to connect the available measurements to available

manipulated variables.
 Types;
 Feedback control configuration
 Feed forward control configuration
 Inferential control configuration
 Process Dynamics And Control
Feedback control configuration

Disturbances

Manipulated Measured
Variables (x) Outputs (y)
PROCESSING SYSTEM

Unmeasured Set Point

Outputs (z)

Controller
Process Dynamics And Control
Feedback control configuration

Condenser

Reflux Distillate

Composition Analyzer
_ x
Feed Xs

ε + Set Point

Column Controller

Reboiler

Bottoms
 Process Dynamics And Control
Inferential control configuration

Disturbances

Manipulated Measured
Variables (x) Outputs (y)
PROCESSING SYSTEM

Unmeasured
Outputs (z)

Set Point Controller Estimator

Process Dynamics And Control
Inferential control configuration

Controller Condenser
Set Point
Distillate

Temperature T Reflux
Estimator
T
1
T
2
Feed 3

Column

Reboiler
Bottoms
 Process Dynamics And Control
Feed Forward control configuration

Set Point Disturbances

Controller

Manipulated Measured
Variables (x) Outputs (y)
PROCESSING SYSTEM

Unmeasured
Outputs (z)
Process Dynamics And Control
Feed Forward control configuration

Controller Condenser
Set Point + ε
Xs _ Distillate
x
Composition Analyzer Reflux

Feed

Column

Reboiler
Bottoms
 Process Dynamics And Control
General Control
Configurations
 Depends on number of input or output variables control
configuration can be divided into

 Single Input Single Output (SISO)

Input Process Output

 Multiple Input Multiple Output (MIMO)

Input (x) Output (y)
Process
Input (a) Output (b)
 Process Dynamics And Control
Design Controller based on model

 How is the information, taken from the measurements, used to

adjust the values of the manipulated variables?

 Proportional control
 Integral control
 Proportional integral control
 Proportional integral derivative control
 Process Dynamics And Control
Design Controller based on model

Fi , Ti
Control Law
Q - Qs = -α (T – Ts)

Q – Qs = - α ʃ (T – Ts) dt
Thermocouple
T
T Q – Qs = -α (T – Ts)- α ʃ (T – Ts)
_ Q h
Set Point dt
F,T
Ts +
ε Q – Qs = - α (T – Ts) - α ʃ (T – Ts)
dt - α dT/dt
Controller

Fst

Steam
 Process Dynamics And Control
Hardware elements of a control system

The chemical process

The measuring instruments or sensors
Transducers
Transmission lines
The controller
The final control element
Recording elements
 Process Dynamics And Control
Stirred Tank Example;

Fi , Ti
Temperature
Recorder

Thermocouple
T
T
_ Q h
Set Point
F,T
Ts +
ε
Controller

Fst
Transmission Lines Final
Control Steam
Element
 Process Dynamics And Control
Digital computers in process control

Direct Digital Control (DDC)

Supervisory Computer Control
Scheduling Computer Control
 Process Dynamics And Control
Direct Digital Control (DDC)
Disturbances

Manipulated Measured
Variables (x) Outputs (y)
PROCESSING
SYSTEM

Unmeasured
Outputs (z)

Computer to Process to
Digital
process computer
Computer
interface interface
Process Dynamics And Control
Supervisory Computer Control
Computer for
supervisory
control

DDC for Unit DDC for Unit DDC for Unit

1 2 N Plant

Process Unit
Process Unit 1 Process Unit 1
N