Process Control

Spring, 1999
Professor: In-Beum Lee
Department of Chemical Engineering

Text and References

Text
Su whan Sung and In-Beum Lee, PID Controllers and
Automatic Tuning Ajin Press, 1998

References
Seborg D. E., T. F. Edgar, and D. A. Mellichamp, Process
Dynamics and Control,John Wiley & Sons, New York, 1989
Stephanopoulos G., Chemical Process Control-An
Introduction to Theory and Practice,Prentice -Hall, New
Jersey, 1984.
Luyben W. L., Process Modeling, Simulation and Control
for Chemical Engineers, McGraw-Hill, New York, 2nd Ed.,
1990

Contents of the Lecture

1. Introduction to Process Control.
2. Mathematical Modeling of Chemical Processes.
3. Laplace Transforms.
4. The Transfer Function.
5. Dynamic Behavior of the Processes.
6. Feedback Controllers.
7. Closed-loop Control Systems.
Dynamic Behavior.
Stability.
8. Feedback Controller design and Tuning.
9. Process Identification and Controller Design.

1. Introduction to Process Control

Process Control makes processes satisfy following
requirements.

Safety
Production specifications
Environmental regulations
Operational constraints
Economics

Mathematical model of the process should be

known(Process Modeling & Identification).

1.1 Illustrative Examples

EX 1. Continuous stirred-tank heater
Question ; Assume that inlet temperature changes with
time. How can we ensure that T remains at or near the set
point TR?

Figure 1.1. Continuous stirred-tank heater.

 Possible Strategies
1. Measure T and adjust Q .
2. Measure Ti and adjust Q.
3. Measure T and adjust w.
4. Measure Ti and adjust w.
5. Measure T and Ti and adjust Q.
6. Measure T and Ti and adjust w.
7. Place a heat exchanger on the inlet stream.
8. Use a large tank.

Classification
1 & 3; Feedback control
2 & 4; Feedfoward control
5 & 6; Feedfoward-Feedback control
7 & 8; Design change

 EX 2. Furnace using electrical power

Question ; Can you find any problem in controlling the
following furnace process?
well insulated

thermocouple

y(t)
temperature

heating coil

SCR unit

+
thermocouple

power

u(t)
SCR unit input

thermocouple

Figure 1.2. Furnace using electrical power

 EX 2. Furnace using electrical power

Question ; Can you find any problem in controlling the
following furnace process?
well insulated

y(t)
temperature

thermocouple
heating coil

SCR unit

+
thermocouple

power

u(t)
SCR unit input

thermocouple

Figure 1.2. Furnace using electrical power

There is no way to decrease the temperature!

The power cannot be negative.
The heat loss is nearly zero.

1.2 Classification of the variables

Input variables
; denote the effect of the surroundings on the chemical
process.
1. Manipulated variable (MV or Control variable)
; Its value can be adjusted freely by the human operator
or a control mechanism.
Ex) In heated tank, the amount of heat added(Q) or mass
flow rate(w).

2. Disturbance variable(DV)
; Its value is not the result of the adjustment by an
operator or a control system.
Ex) In heated tank, inlet temperature, because we cant
usually control the temperature of inlet water.

 Output variables
; denote the effect of the process oh the surroundings.
1. Measured output variable or Controlled variable(CV)
; Its value is known by directly measuring it.
Ex) In heated tank, outlet temperature.

2. Unmeasured output variables

; It is not or cannot be measured directly.

1.3 Classification of Control Strategies

Feedfoward Control
; The disturbance variable is measured and the measurement
is used to manipulate MV.
Advantages
If all sources of the disturbances are known and these values
can be measured accurately. Perfect Control !
Disadvantages
No corrective action for unmeasured disturbances.
In industrial applications, feedfoward control should be
used in combination with feedback control.

 Feedback Control
; The process variable to be controlled is measured and
used to adjust another process variable which can be
manipulated.
Advantage
Corrective action is taken regardless of the source of the
disturbance.
Disadvantage
The controlled variable must be deviate from the set point
before corrective action is taken. Not Perfect Control!
Classification
Negative feedback ; The desirable situation where the corrective
action taken by the controller tends to move the controlled variable
toward set point.
Positive feedback ; The controller tends to make things worse by
forcing the controlled variable farther away from the set point.

1.4 Block Diagram

Schematic diagram
; Physical connection between the components of the control
system.

Figure 1.3. Schematic diagram of a temperature feedback control system

for a stirred-tank heater. ---, Electrical instrument line; TT, temperature
transmitter;TC, temperature controller.

 Block diagram
; Flow of information within the control system.
Each block represents a dynamic or static process
elements.
Dynamic elements; variable which depends on time.
Static elements; variable which is independent of time.

Figure 1.4. Block diagram for temperature feedback control system in Figure 3.

1.5 Control and Modeling Philosophies

Two approaches to design control system.
1. Traditional Approach
; Control strategy and system hardware are selected based on
the knowledge of process, experience and insight. After the
control system is installed in the plant, the controller
settings are adjusted, that is, the controller is tuned.
2. Model-Based Approach
; A process model is developed and based on the model,
suitable control strategy and system hardware are selected.
The model-based approach is more advantageous.

 Usage of the Process Model

It can be used as the basis for classical controller design
methods.
It can be incorporated directly in the control law, an
approach that now is the starting point for many
advanced control techniques.
It can be used to develop a computer simulation of the
process to allow exploration of alternative control
strategies and to calculate preliminary values of
controller setting.

1.6 Analog and Digital Control

Analog controller
; Controller that has continuous input and output signals.

Digital controller
; Controller which involves input input and output signals that
change only at discrete instants in time, the so-called
sampling instants.
Merits ; increased flexibility and accuracy, and improved
monitoring of the plant through data acquisition, storage,
and analysis.

1.7 Economic Justification of Process Control

Justification based on
Safe operation
Satisfying environmental constraints
Economic benefit(ex.increased production level, reduced
raw material costs or enhanced production quality)
Extended equipment life
Example)

Figure 1.5. Production validity over time: (a) before improved control; (b) after.
The operating variable is % ethane.