CHE517

Advanced
Process Control
Prof. Shi-Shang Jang
Chemical Engineering Department
National Tsing-Hua University
Hsin Chu, Taiwan

Course Description
Course: CHE517 Advanced Process Control
Instructor: Professor Shi-Shang Jang
Text: Seborg, D.E., Process Dynamics and
Control, 2nd Ed., Wiley, USA, 2003.
Course Objective: To study the application of
advanced control methods to chemical and
electronic manufacturing processes
Course Policies: One Exam(40%), a final
project (30%) and biweekly homework(30%)

Course Outline
1. Review of Feedback Control System
2. Dynamic Simulation Using MATLAB
and Simu-link
3. Feedforward Control and Cascade
Control
4. Selective Control System
5. Time Delay Compensation
6. Multivariable Control

Course Outline - Continued

7. Computer Process Control
8. Model Predictive Control
9. R2R Process Control

Chapter 1 Review of
Feedback Control Systems

Feedback Control
Terminology
Modeling
Transfer Functions
P, PI, PID Controllers
Block Diagram Analysis
Stability
Frequency Response
Stability in Frequency Domain

Feedback Control
Transmitter
Controller
Set point

Temp
sensor

Heat loss

stream
condensate

Examples:
Room temperature control
Automatic cruise control
Steering an automobile
Supply and demand of chemical engineers

Feedback Control-block
diagram
error

+
Set point

Manipulated
variable
Controller

disturbance
process

Controlled variable

Measured value

Sensor +
transmitter

Terminology:
Set point
Manipulated variable (MV)
Controlled variable (CV)
Disturbance or load (DV)
Process
controller

Instrumentation
Transmitter
Controller
Set point

Temp
sensor

Heat loss

stream
condensate

Signal Transmission: Pneumatic 3-15psig, safe longer time lags, reliable

Electronic 4-20mA, current, fast, easy to interface with computers, may be sensitive to
magnetic and/or electric fields
Transducers: to transform the signals between two types of signals, I/P: current to
pneumatic, P/I, pneumatic to current

Modeling
Q

Mass M
Cp
T

Q=UA(T-T0)

Rate of accumulation = Input output + generation consumption

d
( MC PT ) Q UA(T T0 )
dt

At steady state : let T = TS and Q = QS 0 = QS UA(TS - T0S)

Deviation variables : let T = TS+Td , Q = QS+Qd , T0 = T0s+T0d
Then :
d
MC P (Td ) Qd UA(Td T0d )
dt
If system is at steady
state initially T d(0) = 0

Transfer Functions
Laplace Transforming:
M Cp S Td(S) = qd(S) - U A (Td(S) Tod(S))
Or

q d S
UATod S
Td S

SMC p UA SMC p UA

qd(S)

UA
MsC p UA

1
Tod(S)

MsC p UA

Td(S)

Non-isothermal CSTR
F0
0
CA0
T0
steam

AB
rA = - KCA mol/ft3
T V C A CB

condensate

CA
T

K = e-E/RT

Total mass balance: d (V ) F0 F

dt

Mass balance :

d
(V C A ) F0 C A0 F C A ( KC A )V
dt

d
Energy balance : (V C PT ) F0C PT0 F C PT (Hr )( KC A ) UA(Ts T )
dt

Initial conditions :
Input variables :

V(t=0) = Vi , T(t=0) = Ti , CA(t=0) = CAi

F0 , CA0 , T0 ,F

Linearization of a Function
F(X)

aX+b

X0 -

X0

X0+

Linearization
dx
f
f x, u
dt
x

x x0
u u0

x x0

f ( x0 , u0 )
dxd
axd bud 0
dt
Laplace Transform
sxd s axd s bud s
or
xd ( s )
b
K

ud s s a s 1

f
u

x x0
u u0

u u0

Linearization of Nonisothermal CSTR

dVd
b11 F0,d b12 Fd
dt
dC A,d
a21Vd a22C A,d b11 F0, d b12 Fd
dt
dTd
a31Vd a32C A,d a33Td b31 F0, d b32C A, d b33Tsd
dt
i.e.
Vd
d

C
A
,
d

dt
Td

21

a31

0
a22
a32

0
0

a 33

Vd
b11 b12
C
b b

A
,
d

21 22
Td
b31 b32

0
b23
b33

F0,d
Vd

y 0 0 1 C A,d 0 0 0 Fd CX DU
Ts ,d
Td

Td s C ( sI A) 1 B D U (s )
G p s Tsd s GL s F0,d (s ) GL ' s Fd s

F0,d

F
d

AX ( s ) BU ( s )
Ts ,d

Common Transfer Functions

K=Gain; =time constant;
=damping factor; D=delay

First Order System

Second Order System

CV ( s )
K

MV s s 1

CV ( s )
K
2 2
MV s s 2s 1

First Order Plus Time Delay

CV ( s )
K Ds

e
MV s s 1

Second Order Plus Time Delay

CV ( s)
K
2 2
e Ds
MV s s 2s 1

Transfer Functions of
Controllers
Proportional Control (P)
m(s) = Kc[ e(s) ]

e(s)

e = Tspt - T

m(s)

Kc

Proportional Integral Control (PI)

1
m ( t ) K c e( t )
I

e(t )dt
0

1
m(s) K c e(s)
e(s)

s
I

e(s)

K c (1

1
)
Is

m(s)

Proportional-Integral-Derivative Control (PID)

1
m ( t ) K c e( t )
I

m(s) K c

de
0 e(t )dt D dt
t

1
e(s) 1 Ds
Is

e(s)

K c (1

1
D s)
Is

m(s)

The Stability of a Linear

System
Given a linear system y(s)/u(s)=
G(s)=N(s)/D(s) where N, D are
polynomials
A linear system is stable if and only if
all the roots of D(s) is at LHS, i.e.,
the real parts of the roots of D(s) are
negative.

Stability in a Complex Plane

Im
Exponential Decay
with oscillatory

Purdy oscillatory
Exponential growth
with oscillatory

Fast Exponential
growth

Exponential Decay

Fast Decay

Slow Decay

Slow growth

Purdy oscillatory
Stable (LHP)

Unstable (RHP)

Re

Partial Proof of the Theory

For example: y(s)/u(s)=K/(s+1)
The root of D(s)=-1/
In time domain: y+y=ku(t)
The solution of this ODE can be
derived by y(t)=e [e ku(t)dt+c]
It is clear that if <0, limty .
-t/

1/

Transfer functions in parallel

X(S)= G1(S)*U1(S) + G2(S)*U2(S)
X1(S)

U1(S)

X2(S)

G1(S)
X1(S)

G2(S)
U2(S)

X2(S)

X (S)

Transfer function Block

diagram
Tset

Kc

QS

control

1
MC P S UA
process

Measuring device
1

Proportional control
No measurement lags
Td
Tset

1
MC P S UA

1
1 KC
MC P S UA
KC

Td

Block Diagram Analysis

Xs

Gc(S)

L(S)

GL(S)

GP(S)

Xm

X1

+
+

Gm(S)

e = Xs Xm
m = Gc (S) e(s) = Gc e
X1 = Gp m = Gp Gc e
X = GL L + X1 = GL L + Gp Gc e
Xm = Gm X = Gm GL L + Gp Gc e
X = GL L + Gp Gc[Xs Xm]
= GL L + Gp Gc [Xs] Gp Gc [Xm]
=GL L + Gp Gc Xs Gp Gc Gm X

G pG c
GL
X
L
Xs
1 G pG cG m
1 G pG cG m

X(S)

Stability of a Closed Loop

System
A closed loop system is stable if and
only of the roots of its characteristic
equation :
1+Gc(s)Gp(s)Gm(s)=0
are all in LHP

Level System
dh
Fin Fout Fin k h
dt
Given a reference point Fin 0 , h0
A

dhd
f
Fin Fin 0 f h h0 Fin,d k hd

dt
Fin
h
2 h0

Laplacing

Ashd (s) ahd s Fin ,d s

or
hd s
1
1/ a
K

Fin.d s As a A / a s 1 s 1

The jacketed CSTR

W
Set Point

TRC

FC
2A B
Tc
Wc
T, Ca

A Nonisothermal Jacketed CSTR

(i) Material balance of species A

dC A W (C A f C A )
2

kC A
dt
V
(ii) Energy balance of the jacket

dTc A(T Tc ) Wc (Tc Tw )

dt
M cCP '
Mc
(iii) Energy balance for the reactor
2
dT W (T f T ) A(T Tc ) HkC A

dt
V
C PV
C P

(iv) Dependence of the rate constant on

temperature

Q
k A0 exp(
)
T 273

Linearization of
Nonisothermal CSTR
CV=T(t)
MV=Wc(t)
It can be shown that

Td s
K
3
Wc ,d s as bs 2 cs 1

A Practical Example Temperature

Control of a CSTR
Method of Reaction Curve
Process
output

Maximum slope
C

D
Dead time

Time constant

time

Ziegler-Nichols Reaction Curve

Tuning Rule
P only

PI

PID

Kc

/DKp

0.9/DKp 1.2/DKp

n.a.

D/0.3

D/0.5

n.a.

n.a.

0.5D

D= 1
=13
k = -0.0202

Kc= -579.2079
i =3.33

setpoint

Ziegler-Nichols Ultimate Gain

Tuning
Find the ultimate gain of the process
Ku. The period of the oscillation is
called ultimate
periodPIPu
P only
PID
Kc

Ku/2

Ku/2.2

Ku/1.7

n.a.

Pu/1.2

Pu/2

n.a.

n.a.

Pu/8

Measuring Controller
Performance

IAE ys y t dt e t dt

ISE y s y t dt e t dt
2

ITAE t y s y dt t e t dt

Upper Limit of Designed

Controller Parameters of
PID Controllers
Q: Given a plant with a transfer
function G(s), one implements a PID
controller for closed loop control,
what is the upper limit of its
parameters?
A: The upper limit of a controller
should be bounded at its closed loop
stability.

Approaches
Direct Substitution for Kc
Root Locus method for Kc
Frequency Analysis for all
parameters

An Example

Kc

1
( s 1)( s 2)( s 3)

1. Stability Limit by Direct

Substitution
At the stability limit (maximum value of Kc
permissible), roots cross over to the RHP.
Hence when Kc=Ku, there are two roots
on the imaginary axis s=i
(s+1)(s+2)(s+3)+Ku=0, and set s= i,
we have (i+1)(i+2)(i+3)+Ku= 0, i.e.
(6+Ku-62)+i(11-3)=0. This can be
true only if both real and imaginary parts
vanishes: 11-3=0 = 11 ;

6+Ku-611=0 Ku=60

2. Method of Root Locus

Rlocus (sys,k)
k(12) ans =69.6706

3. Frequency Domain
Analysis
Definitions: Given a transfer function
G(s)=y(s)/x(s); Given x(t)=Asint;
we have y(t) Bsin(t+)
We denote Amplitude Ratio=AR()
=B/A; Phase Angle=()
Both AR and are function of
frequency ; we hence define AR
and is the frequency response of
system G(s)

An Example
A sin(t)

1
s 1 s 2 s 3

B = sin(t+)

Frequency Response of a
first order system
y(s)
K
A
G( s)
; x(t ) A sin t x( s )
x( s )
s 1
s
A
K
y(s)
s s 1
KA
y (t )
sin(t ); tan
1
K
AR
1
tan
2

Basic Theorem
Given a process with transfer function
G(s);
AR()= G(i)
()= G(i)
Basically, G(i)=a+ib

AR a 2 b 2

tan b / a
1

Example: First Order

System
1
G ( s)
s 1
1
1 i ( )
1
( )
G i

i
a ib
2 2
2 2
2 2
i 1 1
1
1
1
2
2
AR a b
1 2 2
b
tan 1 tan 1
a
Note that
lim AR 0

lim 90

Corollary
If G(s)=G1(s)G2(s)G3(s)
Then AR(G)=AR(G1) AR(G2) AR(G3)
(G)= (G1) + (G2)+ (G3)
Proof: Omitted

Example
K1
K2
G ( s)
G1 s G2 s
1 1 2 1
AR AR1 AR2

K1

1 1
2

K2
2

2 1

1 2 tan 1 1 tan 1 2

Bode Plot: An example

G(s)=1/(s+1)(s+2)(s+3)
where db=20log10(AR)

Nyquist Plot
sys=tf(num,den)
NYQUIST(sys,{wmin,wmax}))

Nyquist Stability Criteria

Given G(i), assume that at a
frequency u, such that =-180
and one has AR(u), the sufficient
and necessary condition of the
stability of the closed loop of G(s) is
such that: AR(u) 1

The Extension of Nyquist

Stability Criteria
Given plant open loop transfer
function G(s), such that at a
frequency u, the phase angle
(u)=-180. At that point, the
amplitude ratio AR= G (u) ,
then the ultimate gain of the closed
loop system is Ku=1/AR, ultimate
period Pu=2/ u.

Simulink Example

Response

0.165 0.5 s
GP
e
2.5s 1

D1.4

3.7-1.4=2.3

time

Simulink Example Continued

>> sys=tf(1,[1 6 11 6])

Transfer function:
1
---------------------s^3 + 6 s^2 + 11 s + 6

u=3.5
>> bode(sys)
ARu=-38db
=10-38/20
=0.0162
Ku=1/ARu=80

Simulink Example Continued

1. Reaction Curve Approach:
KC=1.2/DKp=1.2*2.5/(0.5*0.165)=36;
I=D/0.5=1;D=D*0.5=0.25

2
1.8
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0

10

Simulink Example Continued

1. Ultimate properties Approach:
Ku/1.7=80/1.7=47;I=Pu/2= 2* / 2U =0.9;D=Pu/8=0.22