CONTROL DE PROCESSOS

CHEMICAL PROCESS CONTROL

Degree in Chemical Engineering

University of Alicante

Juan Javaloyes

2021/2022
 Textbooks
Chemical process control : an introduction to theory and practice
STEPHANOPOULOS, George. (1984)

Process modeling, simulation, and control for chemical engineers

LUYBEN, William L. (1990)

Process Dynamics, Modelling and Control

OGUNNAIKE, Babatunde A. and RAY, Harmon W. (1995)

Process Control: Modeling, Design and Simulation

BEQUETTE, Wayne B. (2003)

Process Dynamics and Control

SEBORG, Dale E. et al. (2003)

Chemical process control [34528] Chapter 6: Introduction to Feedback Control Academic year 2021/22 2
 Course Contents – Block diagram
Motivation

Mathematical Tools
Dynamic modeling of
chemical processes Ordinary Differential
Equations

Transfer Functions Input‐Output model

Linearization of nonlinear systems
Deviation variables

Dynamic Behavior of First‐, Second‐ and

Laplace Transforms
Higher‐Order Systems

Solution of ODEs using

Stability Analysis of Design of Feedback Laplace Transforms
Feedback Systems Controllers

Instrumentation and
Frequency Response
Control valves

Design of Feedback Controllers by

Advanced Process Control
Frequency Response

Chemical process control [34528] Chapter 6: Introduction to Feedback Control Academic year 2021/22 3
Introduction to Feedback Control

(Concept of feedback control. Basic hardware components

of a feedback control loop. Basic control modes: P‐control,
PI‐control and PID‐control)
 Concept of feedback control
Tank level feedback control

Fi
d

m y
h Process
F
Generalized process block diagram
Open loop process
y  output variable
m  manipulated variable
d  disturvance ( or load )

Objective: to keep the value of the output (tank level) at

desired values

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 Concept of feedback control
Tank level feedback control c

LC
C
Fi
e
ym - + hsp
LT

h
F
Feedback control action steps:
1. Measure the value of the output using the appropriate measuring device
2. Compare the indicated value ym to the desired value of the output ysp . The error or
deviation is given by e t = y -y t ( ) sp m ( )
3. The value of the deviation e is supplied to the controller. The controller computes
the action to be implemented in the manipulated variable, m , in such a way as to
reduce the magnitude of the error
4. Implement the change in the manipulated variable through the final control
element (usually a control valve).
5. Repeat 1
Chemical process control [34528] Chapter 6: Introduction to Feedback Control Academic year 2021/22 6
 Concept of feedback control
Equivalent block diagram for a general system under feedback control

d
controller mechanism

ysp + e c Final control m y

-
Controller Process
element

ym Measuring
devide

ysp  set point m  manipulated variable

ym  measured output signal d  disturvance
e  error or deviation ( ysp - ym ) y  output variable
c  controller output signal

Chemical process control [34528] Chapter 6: Introduction to Feedback Control Academic year 2021/22 7
 P&ID Nomenclature

Measurement and
Variable Controller
transmission

Flow FC FT
Pressure PC PT
Liquid level LC LT
Temperature TC TT
Composition CC CT

Chemical process control [34528] Chapter 6: Introduction to Feedback Control Academic year 2021/22 8
 Basic hardware components of a feedback control loop
 Process
The material equipment along with the physical or chemical operation takes place

 Measuring instruments or sensors

These are the devices responsible of measure the controlled output variable (temperature,
pressure, flow, liquid level or composition)

 Transmission lines
Used to carry the measurement signal from the sensor to the controller and the control signal
from the controller to the final control element (pneumatic or electrical)

 Controller
Unit with logic that decides by how much to change the value of the manipulated variable. It also
includes the function of the comparator and requires the specification of the set point

 Final control element

Device that receives the control signal and implements it by physically adjusting the value of the
manipulated variable. Usually, a control valve or a variable‐speed metering pump

Chemical process control [34528] Chapter 6: Introduction to Feedback Control Academic year 2021/22 9
 Basic control modes
PROPORTIONAL CONTROL
The controller output is proportional to the error signal:

c ( t ) = cs + Kc e ( t )
where
Kc  proportional gain of the controller
cs  controller´s bias signal ( steady -state value when e = 0 )

Transfer function
Deviation of the actuating signal: c ' ( t ) = c ( t ) - cs

Then c ' ( t ) = Kc e ( t ) 
¾¾ c ' ( s ) = Kc e ( s )

c' (s )
Gc ( s ) = = Kc
e (s )

Chemical process control [34528] Chapter 6: Introduction to Feedback Control Academic year 2021/22 10
 Basic control modes
PROPORTIONAL CONTROL
Key concepts behind proportional action

 The controller gain can be adjusted to make the controller output changes as sensitive as
desired to deviations (the larger the gain, the higher the sensitivity of controller´s actuating
signal to deviations will be)

 The sign of Kc can be chosen to make the controller output increase (or decrease) as the
error signal increases

 The bias cs must be adjusted so that when e = 0 (steady‐state desired conditions), the
controller output, and consequently, the manipulated variable, are at their nominal steady‐state
values

 When physical limits are included on the controller output, we say that the controller
saturates when the output reaches these bounds
c (t )
cmax

cs
cmin
e (t )
Chemical process control [34528] Chapter 6: Introduction to Feedback Control Academic year 2021/22 11
 Basic control modes
PROPORTIONAL CONTROL
Key concepts behind P‐control

 An inherent disadvantage of P‐only control is that a steady‐state error or offset occurs after
a set point change or a sustained disturbance, regardless of the value of Kc.
In principle, offset can be eliminated by manually resetting either the set point or bias

Chemical process control [34528] Chapter 6: Introduction to Feedback Control Academic year 2021/22 12
 Basic control modes
PROPORTIONAL‐INTEGRAL CONTROL
The controller output is given by:
Kc t
c ( t ) = Kc e ( t ) + ò0 e ( t )dt + cs
where
tI
Kc  proportional gain of the controller
tI  integral time constant or reset time
cs  controller´s bias signal ( steady -state value when e = 0 )

Transfer function
Kc t Kc 1
c ( t ) - cs = c ( t ) = Kc e ( t ) +
'
ò0 e ( t )dt 
¾¾ c ' ( s ) = Kc e ( s ) + e (s )
tI tI s

c' (s )
æ
ç 1 ö÷
Gc ( s ) = = Kc ç 1 + ÷÷
e (s ) ç
è tI s ÷ø

Chemical process control [34528] Chapter 6: Introduction to Feedback Control Academic year 2021/22 13
 Basic control modes
PROPORTIONAL‐INTEGRAL CONTROL
Key concepts behind integral action

 Integral control action (combined with proportional) is widely used because eliminates the
offset

 The controller output changes as long as an error exists in the process output (c ( t ) changes
with time unless e ( t ) = 0 ). Thus, PI‐controller can eliminate even small errors

 If errors cannot be eliminated quickly, and given enough time, integral control action produce
larger and larger values, which in turn keeps increasing the control action until it is saturated
(e.g. the valve completely open or closed). This condition is called integral windup

 The integral action tends to produce oscillatory response of the controlled variable and
reduces the stability of the feedback control system. The undesirable effect of too much
integral action can be avoided by proper tuning of the controller parameters or by including
derivative action, which tends to counteract the destabilizing effects

Chemical process control [34528] Chapter 6: Introduction to Feedback Control Academic year 2021/22 14
 Basic control modes
PROPORTIONAL‐INTEGRAL‐DERIVATIVE CONTROL
The controller output is related to the error by:
Kc t de
c ( t ) = Kc e ( t ) + ò0 e ( t )dt + Kc tD + cs
tI dt
where
Kc  proportional gain of the controller
tI  integral time constant or reset time
tD  derivative time constant or reset time
cs  controller´s bias signal ( steady -state value when e = 0 )

Transfer function
K t de é 1 ù
c ( t ) = Kc e ( t ) + c e ( t )dt + Kc tD ¾¾ c ( s ) = Kc e ( s ) ê 1 +
ê + t Ds ú
'
ò0
' 
tI dt tI s ú
ë û

c' (s )æ
ç 1 ö÷
Gc ( s ) = = Kc ç 1 + + tDs ÷÷
e (s ) ç
è tI s ÷ø

Chemical process control [34528] Chapter 6: Introduction to Feedback Control Academic year 2021/22 15
 Basic control modes
PROPORTIONAL‐INTEGRAL‐DERIVATIVE CONTROL
Key concepts behind derivative action

 With the presence of the derivative term, the controller anticipates what the error will be in
the immediate future by considering the rate of change of the error signal.

 The controller output signal corresponding to the derivative action is equal to the nominal
value as long as the error is constant. That is, if
de
=0
dt
Thus, for a response with constant nonzero error it gives no control action

 The derivative control action tends to stabilize the controlled process. Thus, it is often used to
counteract the destabilizing (oscillatory) tendency of the integral mode.

 Derivative control action also tends to improve the dynamic response of the controlled
variable decreasing the process settling time (time required for the response to reach and
remain the new steady‐state value withing an error of 5%)

 If the process measurement is noisy, then, the derivative of the measured variable will change
widely and derivative action will amplify the noise (unless the measurement is filtered).

Chemical process control [34528] Chapter 6: Introduction to Feedback Control Academic year 2021/22 16
 Basic control modes
PROPORTIONAL‐INTEGRAL‐DERIVATIVE CONTROL
Key concepts behind derivative action

 A sudden change in the set point, and hence in the error e ( t ) = ysp - ym , will cause the
derivative term to become very large for a moment, and thus, provide a derivative kick to the
final control element. This feature, also occurs with the proportional term.

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 Final control elements
Control valves

source: Control Valve Handbook. Emerson Process Management

Chemical process control [34528] Chapter 6: Introduction to Feedback Control Academic year 2021/22 18
 Final control elements
Control valves

source: Control Valve Handbook. Emerson Process Management

Chemical process control [34528] Chapter 6: Introduction to Feedback Control Academic year 2021/22 19
 Final control elements
Control valves – Actuator action

Direct acting: increasing

air pressure pushes down
diaphragm and extends
actuator stem Reverse acting: increasing
air pressure pushes up
diaphragm and retracts
actuator stem

source: Control Valve Handbook. Emerson Process Management

Chemical process control [34528] Chapter 6: Introduction to Feedback Control Academic year 2021/22 20
 Final control elements
Control valves
Air‐to‐open (or fail‐closed)
When the actuating energy source (pneumatic or electric power) fails, the valve will close
Air‐to‐close (or fail‐open)
When the actuating energy source (pneumatic or electric power) fails, the valve will open

Fail Closed Fail Open

Direct acting
actuator

Reverse acting
actuator

Pneumatic signal

Direct acting gate Direct acting gate

valve body valve body
source https://kimray.com/training/should‐my‐valve‐fail‐open‐closed‐or‐place
Chemical process control [34528] Chapter 6: Introduction to Feedback Control Academic year 2021/22 21
 Final control elements
Control valves
‐ Quick Opening: CV % = (V. Opening %)0.5
‐ Linear: CV % = V. Opening %
‐ Equal Percentage: CV % = (V. Opening %)3

Control Valve Flow Characteristics

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 Features of PID control
REVERSE AND DIRECT ACTION

Direct‐acting and reverse‐acting PID controller mode are defined as follows:

The controller gain Kc can be either negative or positive

Proportional control: c ( t ) - cs = Kc e ( t ) ¾¾ c ( t ) - cs = Kc ( ysp - ym ( t ) )

Reverse action c (t )
when Kc > 0 c ( t )  as ym  ( e ) cmax

cs
cmin
when Kc > 0 c ( t )  as ym  ( e )
e (t )

c (t )
Direct action
cmax
when Kc < 0 c ( t )  as ym  ( e ) cs
cmin
when Kc < 0 c ( t )  as ym  ( e ) e (t )

Chemical process control [34528] Chapter 6: Introduction to Feedback Control Academic year 2021/22 23
 Features of PID control ysp

ym
REVERSE AND DIRECT ACTION c
FC
C

Example FT
F

Valve design: air‐to‐open  c ( t )  as flow 

Flow transmitter design: direct acting (most common design)  ym  as flow 

Should the flow controller have direct or

reverse action ?
When ym > ysp (flow rate higher than the set point)  reduce flow by closing the
control valve

For an air‐to‐open valve, the controller output signal c ( t ) should decrease.

Therefore, the controller must be reverse acting flow c (t )

SP

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