Introduction to Process Control

*Modern plants have become more difficult to operate because of

trend toward complex and highly integrated process.
Process Dynamics
Introduction

-unsteady-state (transient) process behavior

-ChE curricula emphasize steady-state or equilibrium
conditions
Process Control
-the primary objective is to maintain a process a the desired
operating conditions, safely and efficiently, while satisfying
environmental and product quality requirements
-process variables such temperature, pressure, composition..
-feedback control system
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 Introduction to Process Control
Introduction

Process-the conversion of feed materials to products using

physical and chemical operations. The term tend to be
used for both the processing operation and the processing
equipment
Three types of common processes:
(1) Batch
(2) Semi-Batch
(3) Continuous

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 Introduction to Process Control
CONTINUOUS Process
Introduction

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Introduction
Chapter 1

Kappa Number
-measures the lignin content of cellulosic fibers. Controlled
to certain value by controlling digester T, P or cycle time.

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 Introduction

5
 Introduction

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 Control Terminology
Controlled variables - these are the variables which
quantify the performance or quality of the final
product, which are also called output variables. The
Introduction

desired value is called setpoint.

Manipulated variables - these input variables are
adjusted dynamically to keep the controlled variables
at their set-points.
Disturbance variables - these are also called "load"
variables and represent input variables that can
cause the controlled variables to deviate from their
respective set points.

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 Control Terminology(2)

Set-point change - implementing a change in the

Introduction

operating conditions. The set-point signal is

changed and the manipulated variable is adjusted
appropriately to achieve the new operating
conditions. Also called servomechanism (or "servo")
control.
Disturbance change - the process transient
behavior when a disturbance enters, also called
regulatory control or load change. A control system
should be able to return each controlled variable
back to its set-point.

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 Illustrative Example: Blending system
Introduction

Design Question. What value of w2 is required to have

x  xSP ?
Notation:
• w1, w2 and w are mass flow rates
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• x1, x2 and x are mass fractions of component A
 Assumptions:
1. w1 is constant
2. x2 = constant = 1 (stream 2 is pure A)
3. Perfect mixing in the tank
Introduction

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 equation for the blending system.
• If our assumptions are correct, then this value of w2 will keep xSP
at x . But what if conditions change?
Introduction

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; 12
 • Manual control vs. automatic control
• Proportional feedback control law or control algorithm,
w2  t   w2  Kc  xSP  x  t  (1-4)
Introduction

1. where Kc is called the controller gain.

2. w2(t) and x(t) denote variables that change with time t.
3. The change in the flow rate, w2  t   w2 , is proportional to
the deviation from the set point, xSP – x(t). Example of
proportional control.

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 Introduction

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 Method 2. Measure x1 and adjust w2.
• Thus, if x1 is greater than x1, we would decrease w2 so that
w2  w2 ;

• One approach: Consider Eq. (1-3) and replace x1 and w2 with

x1(t) and w2(t) to get a control law:
Introduction

xSP  x1  t 
w2  t   w1 (1-5)
1  xSP

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 Introduction

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 Chapter 1

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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.

• This approach is a combination of Methods 1 and 2.
Introduction

Method 4. Use a larger tank.

• If a larger tank is used, fluctuations in x1 will tend to be damped
out due to the larger capacitance of the tank contents.
• However, a larger tank means an increased capital cost.

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 Classification of Control Strategies

Table. 1.1 Control Strategies for the Blending System

Method Measured Manipulated Category
Variable Variable
Introduction

1 x w2 FB
2 x1 w2 FF
3 x1 and x w2 FF/FB
4 - - Design change

Feedback Control:
• Distinguishing feature: measure the controlled variable
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 Draw a distillation column with the corresponding parts and
system control.
Problem Statement

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 The distillation column shown in the drawing is used to distill a binary
mixture. Symbols x, y, and z denote mole fractions of the more volatile
component, while B, D, R, and F represent molar flow rates. It is desired
Problem Statement

to control distillate composition y despite disturbances in feed flow rate F.

All flow rates can be measured & manipulated with the exception of F,
which can only be measured. A composition analyzer provides
measurements of y.
(a)Propose a feedback control method and sketch the schematic diagram.
(b)Suggest a feedforward control method and sketch the schematic
diagram.

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 • It is important to make a distinction between negative feedback
and positive feedback.

Negative Feedback Control

refers to the corrective action taken by the controller forces the
Introduction

controlled variable toward the setpoint.

Positive Feedback Control

the controller makes things worse by forcing the controlled
variable farther away from the setpoint.

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 FEEDBACK CONTROL
•Advantages:
 Corrective action is taken regardless of the source of
the disturbance.
 Reduces sensitivity of the controlled variable to
Introduction

disturbances and changes in the process (shown later).

•Disadvantages:
 No corrective action occurs until after the disturbance
has upset the process, that is, until after x differs from
xsp.
 Very oscillatory responses, or even instability…

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 Feedforward Control:
 Distinguishing feature: measure a disturbance
variable
• Advantage:
 Correct for disturbance before it upsets the process.
Introduction

• Disadvantage:
 Must be able to measure the disturbance.
 No corrective action for unmeasured disturbances.

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 Closed-loop Artificial Pancreas
glucose u
setpoint
y
r

controller pump patient sensor

measured glucose

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 Introduction

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Chapter 1

Block diagram for temperature feedback control system

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Chapter 1

Figure 1.6 Block diagram for composition feedback control system

on Fig. 1.4.

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 or
pneumatic controller
Chapter 1

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 Justification of Process Control

Specific Objectives of Control

• Increased product throughput
Chapter 1

• Increased yield of higher valued products

• Decreased energy consumption
• Decreased pollution
• Decreased off-spec product
• Increased Safety
• Extended life of equipment
• Improved Operability
• Decreased production labor

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 3.2 Economic Incentives - Advanced
Control
Chapter 1

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 (da ys-month s) 5. P l ann in g an d
S ch edu l in g

(ho urs-day s) 4. Rea l-T im e

Opti miza tio n

3b . Mu lti vari abl e

Chapter 1

(min utes-ho urs) and Co nstrai nt

Co ntro l
Figure 1.8 Hierarchy of
process control activities.

(se con ds-mi nutes

) 3a . Re gul a to ry
Co ntro l

2. S afety, E n viron ment

(< 1 se con d) a nd E qu ip ment
P rotecti on

(< 1 se con d) 1. Mea sure ment

a nd A ctua ti on

P ro ces s
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Chapter 1

Figure 1.10 Major

steps in control
system development

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 QUIZ#1
1.True or False
A.Feedback and feedforward control both require a measured
variable.
Chapter 1

B.Feedforward can provide perfect control; that is, the output can be
kept at its desired value, even with an imperfect process model.
C.The process variable to be controlled is measured in feedback
control.
D.Feedforward control can be perfect in the theoretical sense that
the controller can take action via the manipulated variable even
while the controlled variable remains equal to its desired value.
E.Feedback control will always take action regardless of the
accuracy of any process model that was used to design it and the
source of a disturbance.

Next chapter
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 2. Consider a heat exchange system, where steam is supplied
to heat oil flowing in a tube. Draw a schematic diagram for
this system. Identify the controlled variable, manipulated
variable and disturbance variable.
Chapter 1

Next chapter
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 Two flow control loops are shown in the drawing. Indicate
whether each system is either a feedback or a feedforward
control system. Justify your answer. It can be assumed that
the distance between the flow transmitter (FT) and the
Chapter 1

control valve is quite small in each system.

Next chapter
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