Process Design and control
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A presentation providing an introduciton to process dynamics and control with the use of real life applications
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Process control
This document provides an introduction to process control. It defines a process as an operation that transforms raw materials into a more useful state. The objectives of process control are to produce desired outputs from inputs in the most economical way. Processes can be described by differential equations and are affected by various internal and external conditions. Effective process control requires maintaining safety, meeting production specifications, and optimizing economics while addressing changing external influences. Examples of processes include unit operations in chemical plants and manufacturing units. The document outlines the basic components of a process control system and loop.
Process dynamics
The document provides an introduction to process control. It defines process control and explains its importance in process industries. It discusses different types of processes like continuous, batch, and their characteristics. It also explains different process control elements like feedback, feedforward, manual and automatic control systems. It distinguishes between feedback and feedforward control schemes. It discusses different process variables involved in control like controlled, manipulated and disturbance variables. Finally, it explains concepts of process dynamics including different dynamic elements like resistance, capacitance, time constant, dead time, and their effect on process response.
Proportional integral and derivative PID controller
The document discusses PID controllers and their origins. It provides information on:
1) The basic components and functions of PID controllers, including proportional, integral and derivative terms that react to error, accumulated error over time, and rate of change of error respectively.
2) The benefits and limitations of proportional, integral and derivative control modes individually and in combination. PID controllers can reduce rise time, settling time and steady state error.
3) Applications of different PID variations and guidelines for controller design depending on process characteristics like temperature, flow or liquid level control.
4) Tips for designing PID controllers including obtaining an open-loop response and adjusting gains to achieve desired closed-loop performance.
PID Control Basics
This document provides an overview of PID control basics and tuning. It begins with explaining why understanding PID is important and then covers common control techniques like manual, on/off, and closed loop control. It defines PID terms like proportional, integral, and derivative control and how they work together. The document discusses process dynamics around dead time and lag. It then provides guidance on manually tuning PID loops and using auto-tune functions. It concludes by listing some Yokogawa products that incorporate PID control capabilities.
PID Tuning
This document provides an overview of knowledge management and PID tuning methods, including:
1) It describes different process characteristics and controller behaviors, and introduces common PID tuning methods like Ziegler-Nichols tuning.
2) It outlines the steps for tuning a PID controller, including understanding the process, selecting a control method, tuning approach, and initially and finely tuning parameters.
3) It details different tuning methods like open-loop, closed-loop, and trial and error, and provides equations and tables for initially setting PID parameters based on these methods.
pid controller
This document provides an overview of PID controllers, including:
- The three components of a PID controller are proportional, integral, and derivative terms.
- PID controllers are widely used in industrial control systems due to their general applicability even without a mathematical model of the system.
- Ziegler-Nichols tuning rules can be used to experimentally determine initial PID parameters to provide a stable initial response for the system. Fine-tuning is then used to optimize the response.
Pid controller
This document provides an overview of PID controllers, including:
- The basic feedback loop and proportional, integral, and derivative algorithms
- Implementation issues like set-point weighing, windup, and digital implementation
- Practical operational aspects like bumpless transfer between manual and automatic modes
Process Control Fundamentals and How to read P&IDs
Types of Process Control, Feedback control, feed-forward control loops, ratio control loop, split range control. How to read Piping and Instrumentation Diagram for Process Engineers
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Process control
This document provides an introduction to process control. It defines a process as an operation that transforms raw materials into a more useful state. The objectives of process control are to produce desired outputs from inputs in the most economical way. Processes can be described by differential equations and are affected by various internal and external conditions. Effective process control requires maintaining safety, meeting production specifications, and optimizing economics while addressing changing external influences. Examples of processes include unit operations in chemical plants and manufacturing units. The document outlines the basic components of a process control system and loop.
Process dynamics
The document provides an introduction to process control. It defines process control and explains its importance in process industries. It discusses different types of processes like continuous, batch, and their characteristics. It also explains different process control elements like feedback, feedforward, manual and automatic control systems. It distinguishes between feedback and feedforward control schemes. It discusses different process variables involved in control like controlled, manipulated and disturbance variables. Finally, it explains concepts of process dynamics including different dynamic elements like resistance, capacitance, time constant, dead time, and their effect on process response.
Proportional integral and derivative PID controller
The document discusses PID controllers and their origins. It provides information on:
1) The basic components and functions of PID controllers, including proportional, integral and derivative terms that react to error, accumulated error over time, and rate of change of error respectively.
2) The benefits and limitations of proportional, integral and derivative control modes individually and in combination. PID controllers can reduce rise time, settling time and steady state error.
3) Applications of different PID variations and guidelines for controller design depending on process characteristics like temperature, flow or liquid level control.
4) Tips for designing PID controllers including obtaining an open-loop response and adjusting gains to achieve desired closed-loop performance.
PID Control Basics
This document provides an overview of PID control basics and tuning. It begins with explaining why understanding PID is important and then covers common control techniques like manual, on/off, and closed loop control. It defines PID terms like proportional, integral, and derivative control and how they work together. The document discusses process dynamics around dead time and lag. It then provides guidance on manually tuning PID loops and using auto-tune functions. It concludes by listing some Yokogawa products that incorporate PID control capabilities.
PID Tuning
This document provides an overview of knowledge management and PID tuning methods, including:
1) It describes different process characteristics and controller behaviors, and introduces common PID tuning methods like Ziegler-Nichols tuning.
2) It outlines the steps for tuning a PID controller, including understanding the process, selecting a control method, tuning approach, and initially and finely tuning parameters.
3) It details different tuning methods like open-loop, closed-loop, and trial and error, and provides equations and tables for initially setting PID parameters based on these methods.
pid controller
This document provides an overview of PID controllers, including:
- The three components of a PID controller are proportional, integral, and derivative terms.
- PID controllers are widely used in industrial control systems due to their general applicability even without a mathematical model of the system.
- Ziegler-Nichols tuning rules can be used to experimentally determine initial PID parameters to provide a stable initial response for the system. Fine-tuning is then used to optimize the response.
Pid controller
This document provides an overview of PID controllers, including:
- The basic feedback loop and proportional, integral, and derivative algorithms
- Implementation issues like set-point weighing, windup, and digital implementation
- Practical operational aspects like bumpless transfer between manual and automatic modes
Process Control Fundamentals and How to read P&IDs
Types of Process Control, Feedback control, feed-forward control loops, ratio control loop, split range control. How to read Piping and Instrumentation Diagram for Process Engineers
Cascade control
This document discusses cascade control in a power plant boiler. Cascade control uses two controllers, a master and slave, to more precisely control a process. In a boiler, drum level is controlled using cascade control with drum level as the master controller and feedwater flow as the slave controller. This provides improved control over drum level as steam load changes are compensated for through remote manipulation of the feedwater flow setpoint. Benefits of cascade control include reduced lag time and improved dynamic response, while drawbacks include increased complexity, cost, and controller tuning difficulty.
Introduction of process control
Introduction of process control, Process control, Example of controlled process, Feedback control system, Feed forward control system,Classification of variables in chemical process, Components of control system
process control
This document outlines the details of the Process Dynamics and Control course at UET Lahore Faisalabad Campus. The course code is ChE-411 and it is worth 3 credit hours of theory and 1 credit hour of practical. It will be taught by Dr. Naveed Ramzan and M. Shahzad Zafar. The course covers topics such as feedback and feedforward control, dynamics of first and second order systems, controllers, stability of chemical processes, and frequency response techniques. Main textbooks include books by George Stephanopoulos and Coughanowr and Koppel. The course also includes tutorials, handouts, and a case study developing a control scheme for a complete plant.
Chapter 1 introduction to control system
This chapter introduces control systems and covers the following topics:
1. It defines open-loop and closed-loop control systems, with open-loop systems having no feedback and closed-loop systems using feedback to reduce errors between the output and desired input.
2. It discusses the history of control systems from the 18th century to present day, including developments in areas like stability analysis, frequency response methods, and state-space methods.
3. It compares classical and modern control theory, noting that modern control theory can handle more complex multi-input, multi-output systems through time-domain analysis of differential equations.
Split range control system
In a split range control loop, the output of a controller is split and sent to two or more control valves to control a process. The controller output is sequenced such that one valve controls when the output is 0-50% and the other valve controls when the output is 50-100%. An example is given of controlling hotwell level using a split range strategy with a recirculation valve controlling when the level is below 50% and a deaerator valve controlling when it is above 50%. The strategy allows effective control of a process using multiple final control elements with a single controller output.
Process control ch 1
This document provides an introduction to process control. It discusses the importance of precise control of variables like temperature, pressure, and flow in process industries. Process control is necessary to reduce variability, increase efficiency, and ensure safety. Key terms are defined, like process variable, set point, error, and load disturbance. The components of control loops like transducers, transmitters, and different signal types are also explained.
Lecture 2 transfer-function
This document provides an overview of transfer functions and stability analysis of linear time-invariant (LTI) systems. It discusses how the Laplace transform can be used to represent signals as algebraic functions and calculate transfer functions as the ratio of the Laplace transforms of the output and input. Poles and zeros are introduced as important factors for stability. A system is stable if all its poles reside in the left half of the s-plane and unstable if any pole resides in the right half-plane. Examples are provided to demonstrate calculating transfer functions from differential equations and analyzing stability based on pole locations.
PID controller
A PID controller is a control mechanism widely used in industrial systems that attempts to correct the error between a measured process variable and desired setpoint. It does this by calculating and outputting a corrective action based on proportional, integral, and derivative terms that can rapidly adjust the process and keep the error minimal. The weighted sum of these three terms is used to control an element like a valve or heating element position. Tuning the gains of each term provides control tailored to the specific process requirements.
Process control examples and applications
Process control involves maintaining the output of a process within a desired range through mechanisms and algorithms. For example, controlling the temperature of a chemical reactor to maintain consistent product output. There are different types of process control including regulatory control to maintain performance at a certain level, feedforward control which anticipates disturbances to compensate before they affect the process, and adaptive control where the controller modifies its own parameters based on dynamic process conditions. Discrete control systems make event-driven or time-driven changes to processes.
Cascade control presentation
Cascade control involves using two or more control loops, with one controller acting as the primary/outer loop that sets the setpoint for the secondary/inner loop controller. This cascade structure allows the overall control to respond faster to disturbances and provide more consistent performance compared to a single control loop. However, it requires an additional measurement and controller that adds complexity.
Industrial process control
This file will be soon on filepost.com for download
Thanks to all references used in collecting data.
Control system
This document provides an overview of control systems. It defines a control system as a device or collection of devices that manage the behavior of other devices. It describes distributed control systems (DCS) which have controllers distributed throughout a machine instead of a central controller. The document then discusses the basics of control systems, including feedback and feedforward control. It provides examples of early control systems and describes the development of control theory over time. Finally, it discusses different types of modern control systems including open loop, closed loop, supervisory, direct digital, and hierarchy control systems.
Modern Control - Lec 03 - Feedback Control Systems Performance and Characteri...
The document summarizes key concepts about feedback control systems including:
- It defines the order of a system as the highest power of s in the denominator of the transfer function. First and second order systems are discussed.
- Standard test signals like impulse, step, ramp and parabolic are introduced to analyze the response of systems.
- The time response of systems has transient and steady-state components. Poles determine the transient response.
- For first order systems, the responses to unit impulse, step, and ramp inputs are derived. The step response reaches 63.2% of its final value after one time constant.
- For second order systems, the natural frequency, damping ratio, and poles are defined.
DCS - Distributed Control System
The document discusses distributed control systems (DCS), including their evolution, architecture, components, and applications in power plants. A DCS decentralizes control of an entire plant or manufacturing system across multiple controllers that communicate with each other. It allows for monitoring and control of all processes, identification of faults, and improved safety. A typical DCS architecture includes servers to collect and share data, archives for data storage, operator stations to monitor processes and alarms, engineering stations to configure the system, master controllers to supervise devices and modules, and field devices where the actual processes take place. DCS systems are hierarchical with lower-level controllers handling basic functions and higher-level controllers coordinating plant-wide control.
Class 14 summary – basics of process control
This document summarizes key concepts from a course on process instrumentation and control. It discusses servo and regulatory control, distinguishing between responses to setpoint changes versus disturbances. It also contrasts continuous versus batch processes. Continuous processes have constant inputs and outputs, while batch processes involve discrete batches undergoing separate processing stages. The document provides examples and compares characteristics of batch and continuous processes. Finally, it defines self-regulating versus non-self-regulating processes, using a water tank example to illustrate inherent feedback in self-regulating systems.
Override control system
This document discusses override control systems. An override control system allows one controller to override another by selecting the most critical process value. It describes a system that uses override control to protect a water pump. A level controller overrides a pressure controller to slow the pump speed if the well level drops too low, preventing the pump from running dry while still maintaining some water pressure. This provides a "soft constraint" with moderated action as well as a backup "hard constraint" shutdown for additional safety. Integral windup must be managed when controllers are overridden to prevent control issues.
Dcs lec01 - introduction to discrete-time control systems
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- Examples of digitally controlled systems like vehicle speed regulation, autopilots, pharmaceutical processes and robotics.
- The components of a digital control system, including analog-to-digital converters, digital controllers implemented in software, and digital-to-analog converters.
- Advantages of digital control systems like easy modification, consistent performance, and lower cost compared to analog controllers. Disadvantages include potential degradation from sampling and quantization.
PROCESS CONTROL.pdf
This document provides an introduction to process control. It discusses the importance of process control for reducing variability, increasing efficiency, and ensuring safety. Precise control of process variables like temperature, pressure, and flow is important for process industries. The document outlines the basic components of a control loop, including sensors, controllers, and final control elements. It also describes different types of controllers and their algorithms, including proportional, integral, and derivative control modes. Controller tuning aims to determine the magnitude, duration, and speed of corrective actions.
In Apc Training Presentation
The document provides an overview of advanced process control (APC), including its definition, applications, advantages, and limitations. It discusses how APC builds on basic process control techniques by using process models and optimization to enhance plant operation and profitability. Examples are given of APC applications in petrochemical plants and semiconductor manufacturing. The benefits of APC include improved yield, quality, energy efficiency, and responsiveness. However, APC implementations are also complex, time-consuming, and require specialized expertise and resources.
Floating mode controller
This document describes floating control mode in industrial processes. In floating control mode, the controller output does not have a unique value determined by the error - it "floats" at its current setting when error is zero. There are two main types: single speed, where the output changes at a fixed rate when error exceeds the neutral zone, and multiple speed, where the output rate increases as deviation exceeds certain limits. Equations are provided to model the behavior of single and multiple speed floating control modes.
Process Dynamics and Control
Process Dynamics and Control (2007 Edition) (Hardbound)
By K. T. Jadhav
Size : B5, Pages: 428; Price : Rs. 390.00
Buy this book from : www.chinttanpublications.in
Process dynamics and control
This document outlines a plan to restructure a company's operations to improve efficiency and reduce costs. Key points include consolidating three regional offices into one central location, eliminating redundant roles and functions across departments, and reducing headcount through a voluntary buyout program. The changes are expected to result in annual savings of $5 million once fully implemented over the next 18 months.
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Cascade control
This document discusses cascade control in a power plant boiler. Cascade control uses two controllers, a master and slave, to more precisely control a process. In a boiler, drum level is controlled using cascade control with drum level as the master controller and feedwater flow as the slave controller. This provides improved control over drum level as steam load changes are compensated for through remote manipulation of the feedwater flow setpoint. Benefits of cascade control include reduced lag time and improved dynamic response, while drawbacks include increased complexity, cost, and controller tuning difficulty.
Introduction of process control
Introduction of process control, Process control, Example of controlled process, Feedback control system, Feed forward control system,Classification of variables in chemical process, Components of control system
process control
This document outlines the details of the Process Dynamics and Control course at UET Lahore Faisalabad Campus. The course code is ChE-411 and it is worth 3 credit hours of theory and 1 credit hour of practical. It will be taught by Dr. Naveed Ramzan and M. Shahzad Zafar. The course covers topics such as feedback and feedforward control, dynamics of first and second order systems, controllers, stability of chemical processes, and frequency response techniques. Main textbooks include books by George Stephanopoulos and Coughanowr and Koppel. The course also includes tutorials, handouts, and a case study developing a control scheme for a complete plant.
Chapter 1 introduction to control system
This chapter introduces control systems and covers the following topics:
1. It defines open-loop and closed-loop control systems, with open-loop systems having no feedback and closed-loop systems using feedback to reduce errors between the output and desired input.
2. It discusses the history of control systems from the 18th century to present day, including developments in areas like stability analysis, frequency response methods, and state-space methods.
3. It compares classical and modern control theory, noting that modern control theory can handle more complex multi-input, multi-output systems through time-domain analysis of differential equations.
Split range control system
In a split range control loop, the output of a controller is split and sent to two or more control valves to control a process. The controller output is sequenced such that one valve controls when the output is 0-50% and the other valve controls when the output is 50-100%. An example is given of controlling hotwell level using a split range strategy with a recirculation valve controlling when the level is below 50% and a deaerator valve controlling when it is above 50%. The strategy allows effective control of a process using multiple final control elements with a single controller output.
Process control ch 1
This document provides an introduction to process control. It discusses the importance of precise control of variables like temperature, pressure, and flow in process industries. Process control is necessary to reduce variability, increase efficiency, and ensure safety. Key terms are defined, like process variable, set point, error, and load disturbance. The components of control loops like transducers, transmitters, and different signal types are also explained.
Lecture 2 transfer-function
This document provides an overview of transfer functions and stability analysis of linear time-invariant (LTI) systems. It discusses how the Laplace transform can be used to represent signals as algebraic functions and calculate transfer functions as the ratio of the Laplace transforms of the output and input. Poles and zeros are introduced as important factors for stability. A system is stable if all its poles reside in the left half of the s-plane and unstable if any pole resides in the right half-plane. Examples are provided to demonstrate calculating transfer functions from differential equations and analyzing stability based on pole locations.
PID controller
A PID controller is a control mechanism widely used in industrial systems that attempts to correct the error between a measured process variable and desired setpoint. It does this by calculating and outputting a corrective action based on proportional, integral, and derivative terms that can rapidly adjust the process and keep the error minimal. The weighted sum of these three terms is used to control an element like a valve or heating element position. Tuning the gains of each term provides control tailored to the specific process requirements.
Process control examples and applications
Process control involves maintaining the output of a process within a desired range through mechanisms and algorithms. For example, controlling the temperature of a chemical reactor to maintain consistent product output. There are different types of process control including regulatory control to maintain performance at a certain level, feedforward control which anticipates disturbances to compensate before they affect the process, and adaptive control where the controller modifies its own parameters based on dynamic process conditions. Discrete control systems make event-driven or time-driven changes to processes.
Cascade control presentation
Cascade control involves using two or more control loops, with one controller acting as the primary/outer loop that sets the setpoint for the secondary/inner loop controller. This cascade structure allows the overall control to respond faster to disturbances and provide more consistent performance compared to a single control loop. However, it requires an additional measurement and controller that adds complexity.
Industrial process control
This file will be soon on filepost.com for download
Thanks to all references used in collecting data.
Control system
This document provides an overview of control systems. It defines a control system as a device or collection of devices that manage the behavior of other devices. It describes distributed control systems (DCS) which have controllers distributed throughout a machine instead of a central controller. The document then discusses the basics of control systems, including feedback and feedforward control. It provides examples of early control systems and describes the development of control theory over time. Finally, it discusses different types of modern control systems including open loop, closed loop, supervisory, direct digital, and hierarchy control systems.
Modern Control - Lec 03 - Feedback Control Systems Performance and Characteri...
The document summarizes key concepts about feedback control systems including:
- It defines the order of a system as the highest power of s in the denominator of the transfer function. First and second order systems are discussed.
- Standard test signals like impulse, step, ramp and parabolic are introduced to analyze the response of systems.
- The time response of systems has transient and steady-state components. Poles determine the transient response.
- For first order systems, the responses to unit impulse, step, and ramp inputs are derived. The step response reaches 63.2% of its final value after one time constant.
- For second order systems, the natural frequency, damping ratio, and poles are defined.
DCS - Distributed Control System
The document discusses distributed control systems (DCS), including their evolution, architecture, components, and applications in power plants. A DCS decentralizes control of an entire plant or manufacturing system across multiple controllers that communicate with each other. It allows for monitoring and control of all processes, identification of faults, and improved safety. A typical DCS architecture includes servers to collect and share data, archives for data storage, operator stations to monitor processes and alarms, engineering stations to configure the system, master controllers to supervise devices and modules, and field devices where the actual processes take place. DCS systems are hierarchical with lower-level controllers handling basic functions and higher-level controllers coordinating plant-wide control.
Class 14 summary – basics of process control
This document summarizes key concepts from a course on process instrumentation and control. It discusses servo and regulatory control, distinguishing between responses to setpoint changes versus disturbances. It also contrasts continuous versus batch processes. Continuous processes have constant inputs and outputs, while batch processes involve discrete batches undergoing separate processing stages. The document provides examples and compares characteristics of batch and continuous processes. Finally, it defines self-regulating versus non-self-regulating processes, using a water tank example to illustrate inherent feedback in self-regulating systems.
Override control system
This document discusses override control systems. An override control system allows one controller to override another by selecting the most critical process value. It describes a system that uses override control to protect a water pump. A level controller overrides a pressure controller to slow the pump speed if the well level drops too low, preventing the pump from running dry while still maintaining some water pressure. This provides a "soft constraint" with moderated action as well as a backup "hard constraint" shutdown for additional safety. Integral windup must be managed when controllers are overridden to prevent control issues.
Dcs lec01 - introduction to discrete-time control systems
Digital control systems implement control laws using digital devices like microcontrollers. They are now common in automotive, aerospace, manufacturing and other industries. This lecture discusses the basics of digital control systems, including:
- Examples of digitally controlled systems like vehicle speed regulation, autopilots, pharmaceutical processes and robotics.
- The components of a digital control system, including analog-to-digital converters, digital controllers implemented in software, and digital-to-analog converters.
- Advantages of digital control systems like easy modification, consistent performance, and lower cost compared to analog controllers. Disadvantages include potential degradation from sampling and quantization.
PROCESS CONTROL.pdf
This document provides an introduction to process control. It discusses the importance of process control for reducing variability, increasing efficiency, and ensuring safety. Precise control of process variables like temperature, pressure, and flow is important for process industries. The document outlines the basic components of a control loop, including sensors, controllers, and final control elements. It also describes different types of controllers and their algorithms, including proportional, integral, and derivative control modes. Controller tuning aims to determine the magnitude, duration, and speed of corrective actions.
In Apc Training Presentation
The document provides an overview of advanced process control (APC), including its definition, applications, advantages, and limitations. It discusses how APC builds on basic process control techniques by using process models and optimization to enhance plant operation and profitability. Examples are given of APC applications in petrochemical plants and semiconductor manufacturing. The benefits of APC include improved yield, quality, energy efficiency, and responsiveness. However, APC implementations are also complex, time-consuming, and require specialized expertise and resources.
Floating mode controller
This document describes floating control mode in industrial processes. In floating control mode, the controller output does not have a unique value determined by the error - it "floats" at its current setting when error is zero. There are two main types: single speed, where the output changes at a fixed rate when error exceeds the neutral zone, and multiple speed, where the output rate increases as deviation exceeds certain limits. Equations are provided to model the behavior of single and multiple speed floating control modes.
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Process Dynamics and Control
Process Dynamics and Control (2007 Edition) (Hardbound)
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Size : B5, Pages: 428; Price : Rs. 390.00
Buy this book from : www.chinttanpublications.in
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This document outlines a plan to restructure a company's operations to improve efficiency and reduce costs. Key points include consolidating three regional offices into one central location, eliminating redundant roles and functions across departments, and reducing headcount through a voluntary buyout program. The changes are expected to result in annual savings of $5 million once fully implemented over the next 18 months.
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13200836 solution-manual-process-dynamics-and-control-donald-r-coughanowr-130...
This document contains solutions to selected problems in process systems analysis and control. It is divided into three parts:
Part 1 contains solutions to selected problems involving block diagrams, Laplace transforms, and partial fraction expansions. Sample problems include drawing a block diagram for a human steering a car and using partial fractions to solve differential equations.
Part 2 will list useful books related to the subject.
Part 3 will provide links to useful websites with additional information on process systems analysis and control.
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Instrumentation and process control fundamentals
Basic course covers:
-Basic understanding of process control
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Process Design and control
- 1. Process Design and Control Dr. Eng. Rami Bechara 1
- 2. Personal Information • 27 years old • Degree in chemical engineering from Ecole Centrale Paris, 2011 • Doctorate from Université Lyon I, School of chemistry, 2015- Thesis realized in IFPEN and EPFL – Specialization in Process Engineering • Thesis entitled: “Methodology for optimal process design: Application to sugarcane conversion processes” 2
- 3. Syllabus • Theoretical model of Chemical processes • Laplace Transforms, Transfer Functions and State-Space Models • Dynamic Behavior of First-Order and Second-Order Systems • Open-Loop and Closed-Loop Stability Analysis • PID Controller Design, Analysis and Tuning • Feed Forward, Cascade, Internal Model Control, Smith Predictor and Multiloop Control • Overview of Advanced control: Model Predictive Control and Optimization 3
- 4. Summary • Introduction to process control • Feedback control • Case studies • Feedback control strategies - PID • Future courses 4
- 5. Introduction to Process control • Objective: Obtain and maintain desired operating conditions • Compositions, pressures, temperatures • By manipulating selected variables • Flow rates • By virtue of control valves 5
- 6. Control Strategies • Feedback Control • Mix of Feedback and Feedforward • Dampening or Design modifications 6
- 7. Control Strategies Feedback control • Output signal is used to control input variable • Advantages: Corrective action occurs regardless of disturbance • Present in most industrial systems 7
- 8. Feedback control strategies Feedback type • Positive feedback or direct acting • Controller output increases with error • Case: Flow rate ↗ if leak ↗ • Vicious cycle: Boiler turned on if room T ↗ • Not commonly encountered • Negative feedback or reverse acting • Controller output decreases with error • Case: Boiler turned off if room T ↗ • Most common • Regulatory control or Disturbance rejection • Servo control: track changing set-point 8
- 9. Case study I Gravity Drained Tanks 9 • Case for positive feedback & Disturbance rejection • Problem: How can disturbance changes be countered?
- 10. Case study II Heat exchanger • Case for negative feedback & set point tracking • How can new set points be achieved? 10
- 11. Feedback control strategies ON/OFF variables • Equation • Response Diagram • Case for a thermostat not applicable to precise process control 11 0if, 0if, )( min max eCO eCO tCO
- 12. Feedback control strategies Proportional (P) response • Equation • Response Diagram 12 )()( 0 teKCOtCO C CO0 controller bias KC controller gain KC > 0 KC < 0
- 13. Feedback control strategies P response • Advantages • Offset is reduced (↗ KC ) • Rather simple tuning • Problems: • Greater Overshooting (↗ KC ) • Offset cannot be eliminated Introduction of integral control 13
- 14. Feedback control strategies Proportional Integral (PI) response • Equation • Response Diagram (P vs. PI) 14 t I C tteteKCOtCO 0 0 d)( 1 )()( I =integral time (>0) (also called reset time) Integral action contribution
- 15. Feedback control strategies PI vs. P 15
- 16. Feedback control strategies PI response • Advantages • Offset can be eliminated • Problems: • Harder tuning – 2 parameters • Oscillatory response Instability • Integral controller saturation Windup • Unable to counter fast deviations Introduction of derivative action 16
- 17. Feedback control strategies PI Derivative (PID) response • Equation • Response Diagram 17 t te tteteKCOtCO D t I C d )(d d)( 1 )()( 0 0 D (>0) derivative time Derivative action contribution
- 18. Feedback control strategies PID response • Advantages: • Oscillations dampened • Process response speeded up • Counters fast deviations • Problems: • Harder tuning – 3 parameters • Noise amplification - Unable to handle noisy measurements 18
- 19. P vs. PI vs. PID 19
- 20. Feedback control PID Uses • P-only controller: used when steady state offsets can be tolerated-Liquid level loops • PI – controller: used when offsets need to be eliminated and no need for fast response - Large proportion of feedback loops • PID: used when need for fast response, and process signal is noise-free – Temperature control 20
- 21. Future courses • Concerning feedback control • Different PID configurations • Strategies for parameter tuning • Controller Characterization • Selection of manipulated/measured variables • Concerning other control strategies • Disadvantage of feedback: First must allow a deviation or error to appear before it can take action • Solution: Inclusion of Feed Forward Control 21
- 22. References • Textbook: Seborg, Dale E., et al. Process dynamics and control. John Wiley & Sons, 2010 – Chapter 7 • http://controlguru.com/: Dr. Douglas Cooper, Direct Chemical and Biochemical Engineering department, University of Connecticut • Further Coursework: Barry Johnston. 10.450 Process Dynamics, Operations, and Control, Spring 2006. (Massachusetts Institute of Technology: MIT OpenCourseWare), http://ocw.mit.edu 22
- 23. 23