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Advanced Process Control: Instructor: Jayant M Modak Course: CH 246

This document provides an introduction to advanced process control. It discusses key concepts like process variables, control system hardware, control system configurations, and the basic steps for designing a control system. The goal of advanced process control is to efficiently and safely operate chemical processes by meeting production and quality targets while minimizing costs and disturbances.

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Rohit Thakur
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73 views

Advanced Process Control: Instructor: Jayant M Modak Course: CH 246

This document provides an introduction to advanced process control. It discusses key concepts like process variables, control system hardware, control system configurations, and the basic steps for designing a control system. The goal of advanced process control is to efficiently and safely operate chemical processes by meeting production and quality targets while minimizing costs and disturbances.

Uploaded by

Rohit Thakur
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 24

1

ADVANCED PROCESS CONTROL


INTRODUCTION
Instructor: Jayant M Modak
Course: CH 246
Information
2

  Schedule   Book(s)
  M-W-F 12-1 PM   Seborg, D. E., Edgar, T.
  Office: Rm 14 F., & Mellichamp, D. A.
(2004). Process
  Phone: 3108 dynamics and control
  Email: (2nd ed.). New York:
modak@chemeng Wiley Additional
Reliance refinery
3

 27 million tonne refinery at Jamnagar commissioned in 2000


 24 per cent of India’s refining capacity
 World’s largest grassroots refinery and the 5th largest refinery at
any single location.
http://www.relianceinsider.com/2008/06/reliance-jamnagar-petrochemical-refinery-complex/
Hierarchy of process control activities
4

(days-months) 5 Planning and Scheduling

(hours-days) 4 Real-time optimization

(mimutes-hours) 3b Multivariable and constraint control

(seconds-minutes) 3a Regulatory control

(<1 sec) 2 Safety & environmental protection

(< 1 sec) 1 Measurement and actuation

Process
Process control methodologies
5

Linear MPC
Modern advanced control Nonlinear MPC
Statistical control
Feed-forward
Override control
Conventional advanced
Valve position control
control
Analyser feedback
control
Model based control
Regulatory control PID/I-PD control
Technological changes for control engineer
6

PAST CURRENT
Pneumatics Digital
Little overlap in equipment/ Extensive overlap in equipment/
capability capability

Configurable single loop Programmable multifunction


controllers controllers

Stand-alone computers Computer system networks


Human diagnosing hardware Self diagnosing hardware
Large expansion projects Upgrading and modernizing
existing
Industrial scenario
7

Bauer & Craig, Journal of Process Control 18 (2008) 2–18


Industrial scenario
8

Bauer & Craig, Journal of Process Control 18 (2008) 2–18


Course objective
9

  Integrate and apply knowledge from


previous process control courses to learn a
new facet of control
  Topics
 Digitalcontrol
 Multivariable control
 Model predictive control
Course pre-requisite
10

  Fundamental dynamic modeling of lumped-


parameter systems
  Principles of single-loop control, including PID
algorithm and tuning
  Laplace analysis

  Frequency response (calculations and interpretation)


  Stability analysis of lumped-parameter systems
  Classical enhancements such as cascade and
feedforward
  The use of Mathematica/MATLAB/…..
Why control
11

Continuous reactor Batch reactor

Plug flow reactor


Why Do We Need Process Control?
12

  Imperfect process design


  Incorrect
parameter values
  Un-modeled phenomena

  Disturbances
  Feed condition, utility supply pressure / temperature,
catalyst activity, heat transfer efficiency, etc.
  Changes in the operating condition
  Grade transitions (as in polymer plants)
  Real-time optimization (RTP) for economic improvement

  Efficient startup, shutdowns


  Distillation
columns
  Reactors (some with multiple steady states)
Chemical Process
13

  Operate safely.
  Meet the product quality specifications.
  Meet the required production rate(or maximize).
  Minimize operating costs(energy,rawmaterials)
Oil refinery
14

  No explosion, other accidents, or long shutdowns


  Meet the composition spec’s for each stream
  Meet the intended production rate for each stream
  Minimize energy consumption
Operational issues with oil refinery
15

  Production rate possible depends on quality of feed


  Maintaining production rate and product quality is
linked

Petroleum Refining By William L. Leffler


What is process control
16

Chemical processes are, by nature, dynamic


  Dual task of control system
  Monitoring certain process condition indicators
  Inducing changes in appropriate variables in order to
improve process conditions

Process Dynamics and Control is that aspect of


chemical engineering concerned with the
analysis, design, and implementation of control
systems that facilitate the achievement of
specified objectives of process safety, production
rates, and product quality.
Control problem -crude oil furnace heater
17

Deliver crude oil feed to the fractionator at a constant


temperature T*, and flowrate Fo, regardless of all the
factors potentially capable of causing the furnace outlet
temperature T to deviate from this desired value, making
sure that the temperature of the lube surfaces within the
furnace does not, at any time, exceed the value Tm .
Variables of a process
18

  Input variables are those that independently


stimulate the system and can thereby induce change
in the internal conditions of the process.
  Manipulated variables (MV)
  Disturbance variables (DV)

  Output variables are those by which one obtains


information about the internal state of the process.
  Control variables

  State variables are the minimum set of variables


essential for completely describing the internal state
(or condition) of a process.
Variables: crude oil furnace heater
19

y – the ouput variable = [T, F0]

u – the input (manipulated) = [QF, QA]

d – the input (disturbance) = [F,  Ti,  PF,  λF]

x – the state variable


Control system hardware elements
20

  Sensors (↔ vision, hearing, etc.)


  Pressure,
temperature, level, flow, composition
  Thermocouples, differential pressure cells, GC…..

  Transmitter (↔ neurons)
  Air pressure signals, electrical signals
  Controllers (↔ brain)
  Pneumatic, electronic, digital computers
  Final control element (↔ muscles)
  Controlvalves, pumps, compressors, conveyors, relay
switches
Control system configurations
21

Manual control

Feedback control
Control system configurations
22

Feedforward control

Feedforward+Feedback control FF/FB+Cascade control


Summarizing control system design
23

  Step 1. Assess the process and define control objectives.


  Why is there a need for control?
  Can the problem be solved only by control, or is there
another alternative ?
  What do we expect the control system to achieve?

  Step 2. Select the process variables


  Which output variables are
  Which disturbances are most serious?

  Which ones can be measured?

  Which input variables can be manipulated for effective


regulation of the process?
Summarizing control system design
24

  Step 3. Select control structure.


  Step 4. Design controller.

  Obtain a control law by which, given information about


the process (current and past outputs, past inputs and
disturbances, and sometimes even future predictions of
the system output), a control decision is determined
which the controller implements by adjusting the
appropriate manipulated variables accordingly.

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