CENG 4120: Process Dynamics and Control

Fall Term, 2011

Instructor:

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Professor Furong Gao Room: 4555 Tel: 7139 E-mail: kefgao@ust.hk Mr. Linkai Luo Room: 7119 Tel: 7146 E-mail: lkluo@ust.hk Miss Luping Zhao Room 7119 Tel: 7146 E-mail: kelpzhao@ust.hk
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TAs:

Class Rules
(a) Come to the class 5 minutes earlier (b) Turn off your mobile phone (c) No discussions among students during lecturing (d) Honesty & respect (e) Hand-in assignment on time
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Textbook:

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Major Reference Books

Process Control: Design Processes and Control Systems for P C t l D i P dC t lS t f Dynamic Performance, by T.E. Marlin, McGraw Hill, (1995) [ [This book provide some good practical examples, it will be used p g p p , as the major reference book for this course.]

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Matlab/Simulink software manuals (available from ITSC and Library). Library) Principles and Practice of Automatic Process Control, By C.A. Smith and A.B. Corripio, John Wiley Inc., 2nd (1997) [Appendix A, B, & C are useful for this course and project design]. Chemical Process Control: An Introduction to the Theory and Practice, By G. Stephanopoulos, Prentice-Hall, Inc., (1984) Process Modeling, simulation and Control for Chemical g Engineers, 2nd Edition, by Luyben, McGraw Hill, (1990)
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Course Objectives
After the Aft th completion of thi course, l ti f this (a) Students will have in depth understanding of the basic principles, principles process dynamics feedback control design dynamics, and synthesis. (b) Students will have a good understanding of advanced control methods such as delay compensation, cascade control, feedfoward control, ratio control, decoupling, and computer control. (c) Students will have some knowledge of hardware instrument, sensors and final control element. (d) Students will be able to use computer software (MATLAB/SIMULINK) to assist the understanding of the p concepts and visualization of control results.

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Marking Schemes
Assignments (6): 30% 25%

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Mid-Term:

Final Examination: 45% ----------------------------------------Total: Total 100%

Late penalty: 10% per day except pre-approved cases with valid reasons day, pre approved Zero mark after TA returned corrected assignment
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Linkage to other courses

CENG241 Heat & mass Transfer CENG 231 Process Fluid Mechanics CENG 211 Reaction Engineering CENG 221 Separation Processes

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MAT 150 Differential Eq. q

Process Modeling

MATH 113 Linear Algebra MATH 230 Numerical Methods

Process Transfer Functions and Responses

Control Systems Design & Tuning C lS i i

CENG 303 Plant Design

CENG 397 Design Projects

CENG 391 Laboratory Course L b t C

Examples of Control

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Where controls are used?

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Transportation pp Home appliance Industries

Chemical Mining Mechanical Electrical & Electronics

Finance and marketing Every where

Why chemical process control?

Monitoring and diagnosis Safety Environmental protection Equipment protection Smooth operation Product quality insurance Profit

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Process Dynamics
a) Refers to unsteady-state or transient behavior. b) Steady-state vs. unsteady-state behavior i. Steady state: variables do not change with time ii. But on what scale? cf., noisy measurement c) P ChE curriculum emphasized steady-state or equilibrium ) Past i l h i d d ilib i situations. d) Continuous processes: Examples of transient behavior: i. Start up & shutdown ii. ii Grade changes iii. Major disturbance, e.g., refinery during sudden weather conditions iv. Equipment or instrument failure (e.g., pump failure)
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e) Batch processes i. Inherently unsteady-state operation i I h l d i ii. Example: Batch reactor

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1. Composition changes with time 2. Other variables such as temperature could be constant.

Process Control
a) Large scale, continuous processes: i. Oil refinery, ethylene plant, pulp mill ii. Typically, 1000 5000 process variables are measured. 1. Most of these variables are also controlled.
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Process Control (contd.)

iii. Examples: flow rate, T, P, liquid level, composition iv. Sampling rates: p g

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1. Process variables: A few seconds to minutes 2. 2 Quality variables: once per 8 hr shift daily, or weekly shift, daily b) Manipulated variables i. We implement process control by manipulating process variables, usually flow rates. Examples: feed rate, cooling rate, product flow rate, etc. ii. Typically, several thousand manipulated variables in a yp y, p large continuous plant
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Process Control (contd.)

c) Batch plants: i. Smaller plants in most industries

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Exception: microelectronics (200 300 processing E i i l i i steps). ii. But ill l ii B still large numbers of measured variables. b f d i bl d) Question: How do we control processes? i. We will consider an illustrative example.

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1.1 Illustrative Example: Blending system

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Notation: w1, w2 and w are mass flow rates x1, x2 and x are mass fractions of component A

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Assumptions: 1. 1 w1 is constant 2. x2 = constant = 1 (stream 2 is pure A)

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3. Perfect mixing in the tank Control Objective: Keep x at a desired value (or set point) xsp, despite variations in x1(t). Flow rate w2 can be adjusted for this purpose. Terminology: Controlled variable (or output variable): x Manipulated variable (or input variable): w2 Disturbance variable (or load variable): x1
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Design Question. What value of w2 is required to have

x = xSP ?

Overall balance:

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0 = w1 + w2 w

(1-1)

Component A balance: p
w1 x1 + w2 x2 wx = 0 (1-2)

(The overbars denote nominal steady-state design values.) At the design conditions x = xSP. Substitute Eq. 1 2, conditions, Eq 1-2 x2 = 1 , then solve Eq. 1-2 for w2 :
w2 = w1 xSP x1 1 xSP
x = xSP

and

(1-3) (1 3)
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Equation 1-3 is the design equation for the blending system. system If our assumptions are correct, then this value of w2 will keep x at xSP . But what if conditions change?

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Control Question. Suppose that the inlet concentration x1 changes with time. How can we ensure that x remains at or near the set point xSP ? As a specific example, if x1 > x1 and w2 = w2 , then x > xSP.

Some Possible Control Strategies:

Method 1. Measure x and adjust w2. Intuitively, if x is too high, we should reduce w2;
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 Manual control vs. automatic control Proportional feedback control law, law
w2 ( t ) = w2 + K c xSP x ( t ) (1-4)

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1. where Kc is called the controller gain. 2. w2(t) and x(t) denote variables that change with time t. () () g 3. The change in the flow rate, w2 ( t ) w2 , is proportional to the deviation from the set point, xSP x(t) point x(t).

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Method 2. Measure x1 and adjust w2. Th s if x1 is greater than x1, we would decrease w2 so that Thus, e o ld
w2 < w2 ;

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One approach: Consider Eq. (1-3) and replace x1 and w2 with x1(t) and w2(t) to get a control law:
w2 ( t ) = w1 xSP x1 ( t ) 1 xSP (1-5)

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 Because Eq. (1-3) applies only at steady state, it is not clear how effective the control law in (1-5) will be for transient conditions. Method 3 Measure x1 and x, adjust w2. 3. x

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This approach is a combination of Methods 1 and 2. Method 4. Use a larger tank. If a larger tank is used, fluctuations in x1 will tend to be damped l t ki d fl t ti i ill t d t b d d out due to the larger capacitance of the tank contents. However, a larger tank means an increased capital cost.

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1.2 Classification of Control Strategies

Table. 1.1 Control Strategies for the Blending System Method M th d

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Measured M d Variable x x1 x1 and x -

Manipulated M i l t d Variable w2 w2 w2 -

Category C t FBa FF FF/FB Design change

1 2 3 4

Feedback Control:
Distinguishing feature: measure the controlled variable
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 It is important to make a distinction between negative feedback and positive feedback. Engineering Usage vs. Social Sciences F db k Ad Feedback Advantages: t

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Corrective action is taken regardless of the source of the disturbance. h di b Reduces sensitivity of the controlled variable to disturbances and changes in the process (shown later). di b d h i h (h l ) Disadvantages: No corrective action occurs until after the disturbance has upset the process, that is, until after x differs from xsp. Oscillatory responses, or even instability
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Feedforward Control:
Distinguishing feature: measure a disturbance variable Advantage:

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Correct for disturbance before it upsets the process. Disadvantage: Must be able to measure the disturbance disturbance. No corrective action for unmeasured disturbances.

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(days-months

5. Planning and Scheduling

(hours-days )

4. Real-Time Optimization

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(minutes-hours

3b. Multivariable and Constraint Control

Figure 1.7 Hierarchy of process control activities activities.

(seconds-minutes

3a. Regulatory Control

(< 1 second )

2. Safety, Environment and Equipment Protection

(< 1 second )

1. Measurement and Actuation

Process

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Figure 1.9 Major steps in control system development

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