Integration of Design & Control

CHEN 4470 Process Design Practice

Dr. Mario Richard Eden
Department of Chemical Engineering
Auburn University

Lecture No. 19 Integration of Design and Control I
March 27, 2012

Contains Material Developed by Dr. Daniel R. Lewin, Technion, Israel

Outline
Part I: This Lecture

Provide motivation for handling flowsheet
controllability and resiliency as an integral part of
the design process

Outline qualitative approach for control variable
selection and unit by unit control structuring

Part II Next Lecture

Introduce a qualitative plantwide control structure
selection method
Importance of Early-Stage Decision
Motivation 1:2

Process Design Stages and Tools
Motivation 2:2
Process Objectives

Classification of Variables

Degree of Freedom (DOF) Analysis

Unit by Unit Control

Basic Control Concepts 1:7
Process Objectives
The design of a control system for a chemical plant is
guided by the objective to maximize profits by
transforming raw materials into useful products while
satisfying:

Product specifications: quality, rate.
Safety
Operational constraints
Environmental regulations - on air and water quality as well
as waste disposal.
Basic Control Concepts 2:7
Classification of Variables
Variables that effect and are affected by the process
should be categorized as either control (manipulated)
variables, disturbances and outputs.





It is usually not possible to control all outputs (why?)
Thus, once the number of manipulated variables are
defined, one selects which of the outputs should be
controlled variables.
Basic Control Concepts 3:7
Process
Outputs
Manipulated
variables
Disturbances
Selection of Controlled Variables
Rule 1: Select variables that are not self-regulating.

Rule 2: Select output variables that would exceed the
equipment and operating constraints without control.

Rule 3: Select output variables that are a direct
measure of the product quality or that strongly affect it.

Rule 4: Choose output variables that seriously interact
with other controlled variables.

Rule 5: Choose output variables that have favorable
static and dynamic responses to the available control
variables.
Basic Control Concepts 4:7
Selection of Manipulated Variables
Rule 6: Select inputs that significantly affect the
controlled variables.

Rule 7: Select inputs that rapidly affect the controlled
variables.

Rule 8: The manipulated variables should affect the
controlled variables directly rather than indirectly.

Rule 9: Avoid recycling disturbances.
Basic Control Concepts 5:7
Selection of Measured Variables
Rule 10: Reliable, accurate measurements are
essential for good control.

Rule 11: Select measurement points that are
sufficiently sensitive.

Rule 12: Select measurement points that minimize
time delays and time constants.
Basic Control Concepts 6:7
Degree of Freedom Analysis
Before selecting the controlled and manipulated
variables, one must determine the number of variables
permissible. The number of manipulated variables
cannot exceed the degrees of freedom, which are
determined using a process model according to:
Basic Control Concepts 7:7
N
D
= N
Variables
- N
Equations
N
D
= N
manipulated
+ N
Externally

Defined
Degrees of
freedom
Number of
variables
Number of
equations
N
Manipulated
= N
Variables
- N
externally defined
- N
Equations







Classification of Variables
ND = N
Variables
= 10


Externally defined (disturbances): C
Ai
, T
i
, T
co
Example 1: CSTR Control 1:6
T, C
A
T
i
, C
Ai
F
c
T, C
A
T
c
h
T
co
F
o
F
i
h, T, C
A
, C
Ai
, T
i
,
F
i
, F
o
, F
c
, T
c
, T
co
Balance Equations

Example 1: CSTR Control 2:6
T, C
A
T
i
, C
Ai
F
c
T, C
A
T
c
h
T
co
F
o
F
i
o i
F F
dt
dh
A =
( ) { } T C r Ah C F C F hC
dt
d
A
A A o Ai i A
, =
( )
{ }( ) ( )
c s A
o i i
T T UA H T C r Ah
CpT F CpT F T h
dt
d
Cp A
A +
=
,
( )
c s c c c co c c
c
c c
T T UA T Cp F T Cp F
dt
dT
Cp V + =
Overall Mass Balance
Component Balance
Energy Balance Mixture
Energy Balance Coolant
N
Equations
= 4







Degrees of Freedom
N
Manipulated
= N
Variables
N
Ext. Defined
N
Equations
N
Manipulated
= 10 3 4
N
Manipulated
= 3
Example 1: CSTR Control 3:6
T, C
A
T
i
, C
Ai
F
c
T, C
A
T
c
h
T
co
F
o
F
i
Thus we need to select 3
variables to be controlled.
Each must be controlled by
varying one or more of the
remaining variables




Selection of Controlled Variables
C
A
should be selected since it directly affects the
product quality (Rule 3).
T should be selected because it must be regulated
properly to avoid safety problems (Rule 2) and because
it interacts with C
A
(Rule 4).
h must be selected as a controlled output because it is
non-self-regulating (Rule 1).

Example 1: CSTR Control 4:6
T, C
A
T
i
, C
Ai
F
c
T, C
A
T
c
h
T
co
F
o
F
i




Selection of Manipulated Variables
F
i
should be selected as it directly and rapidly affects C
A

(Rules 6, 7 and 8).
F
c
should be selected as it directly and rapidly affects T
(Rules 6, 7 and 8).
F
o
should be selected as it directly and rapidly affects h
(Rules 6, 7 and 8).
Example 1: CSTR Control 5:6
T, C
A
T
i
, C
Ai
F
c
T, C
A
T
c
h
T
co
F
o
F
i
Suggested Control Structure

Example 1: CSTR Control 6:6
T, C
A
T
i
, C
Ai
F
c
T, C
A
T
c
h
T
co
F
o
F
i
TC
CC
LC
Summary
Part I: This Lecture

Provide motivation for handling flowsheet
controllability and resiliency as an integral part of
the design process

Outline qualitative approach for control variable
selection

Part II Next Lecture

Introduce a qualitative plantwide control structure
selection method
Next Lecture March 29
Integration of design and control Part II (Plantwide)
SSLW 322-340

Milliken Plant Visit March 29
Directions and official excuse placed on website
Leave from Ross Hall at 1:00 PM
No open shoes/sandals/shorts/sleeveless shirts
Limited jewelry
3:00 EST Arrive at plant
3:15 EST Introductions / Safety Review
3:45 EST High level plant tour
4:30 EST Discussion
5:30 EST Wrap up with dinner




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