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CLL261-Introduction To Process Control: Hariprasad Kodamana Iit Delhi

This document discusses process control and introduces some key concepts. It begins by explaining the need for process control in modern plants due to tighter specifications and integrated processes. The primary objective of process control is to maintain process variables like temperatures and pressures at desired levels. It then discusses process dynamics and introduces the concepts of controlled variables, manipulated variables, and disturbances. An example process is presented and questions are answered to illustrate feedback and feedforward control approaches. Finally, it briefly discusses the development of control systems.

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GARGI SHARMA
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30 views

CLL261-Introduction To Process Control: Hariprasad Kodamana Iit Delhi

This document discusses process control and introduces some key concepts. It begins by explaining the need for process control in modern plants due to tighter specifications and integrated processes. The primary objective of process control is to maintain process variables like temperatures and pressures at desired levels. It then discusses process dynamics and introduces the concepts of controlled variables, manipulated variables, and disturbances. An example process is presented and questions are answered to illustrate feedback and feedforward control approaches. Finally, it briefly discusses the development of control systems.

Uploaded by

GARGI SHARMA
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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CLL261-Introduction to Process Control

Hariprasad Kodamana
IIT DELHI

HK (CHE IITD ) CLL261-PDC 30-SEP-2020 1 / 19


Need of process control

Performance requirements for process plants have become


increasingly difficult to satisfy
Stronger competition, tougher environmental and safety
regulations, and rapidly changing economic conditions have been
key factors in tightening product quality specifications
Modern plants have become more difficult to operate because of
the trend toward complex and highly integrated processes
Further it is difficult to prevent disturbances from propagating
from one unit to other interconnected units
Hence, without computer-based process control systems it would
be impossible to operate modern plants safely and profitably
while satisfying product quality and environmental requirements

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Process control

The primary objective of process control is to maintain a process


at the desired operating conditions, safely and efficiently, while
satisfying environmental and product quality requirements
In large-scale, integrated processing plants such as oil refineries
or ethylene plants, thousands of process variables such as
compositions, temperatures, and pressures are measured and
must be controlled
Feedback control systems compare measurements with their
desired values and then adjust the manipulated variables
accordingly

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Process dynamics and process control

The term process dynamics refers to unsteady-state (or


transient) process behavior
By contrast, most of the chemical engineering curricula
emphasize steady-state and equilibrium conditions in such
courses as material and energy balances, thermodynamics, and
transport phenomena
Transient operation occurs during important situations such as
start-ups and shutdowns, unusual process disturbances, and
planned transitions from one product grade to another
It is important to study/model the process dynamics to perform
process control

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Process
Process: The conversion of feed materials to products using
chemical and physical operations. In practice, the term process
tends to be used for both the processing operation and the
processing equipment
Continuous process

Batch/semi-batch process

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Process variables
Controlled variables (CVs): The process variables that are
controlled. The desired value of a controlled variable is referred
to as its set point
Manipulated variables (MVs): The process variables that can be
adjusted in order to keep the controlled variables at or near their
set points. Typically, the manipulated variables are flow rates
Disturbance variables (DVs): Process variables that affect the
controlled variables but cannot be manipulated. Disturbances
generally are related to changes in the operating environment of
the process: for example, its feed conditions or ambient
temperature.
Some disturbance variables can be measured on-line, but many
cannot
The specification of CVs, MVs, and DVs is a critical step in
developing a control system
HK (CHE IITD ) CLL261-PDC 30-SEP-2020 6 / 19
A motivating example

Notation:
w1 , w2 and w are mass flow rates
x1 , x2 and x are mass fractions of component A
Assumptions
w1 is constant
x2 = constant = 1 (stream 2 is pure A)
Perfect mixing in the tank
Variables
controlled variable: x , the manipulated variable is w2 , and the
disturbance variable is x1
HK (CHE IITD ) CLL261-PDC 30-SEP-2020 7 / 19
A motivating example (Q1)
Q1 Design Problem: If the nominal value ofx1 is x 1 , what nominal
flow rate w 2 is required to produce the desired outlet
concentration, xsp ?
Ans Overall balance

0 = w1 + w2 − w (1)

Component A balance

0 = w1 x 1 + w2 x 2 − w x (2)

As x2 = 1, and x = xsp
xsp − x 1
w2 = w1 (3)
1 − xsp

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A motivating example (Q2)

Q2 Control Problem: Suppose that inlet concentration x1 varies


with time. How can we ensure that the outlet composition x
remains at or near its desired value, xsp ?
Eq. (3) is the design equation at steady state. But what
happens if conditions change? Eg. As a specific example, if
x1 > x 1 , then the outlet composition will also increase due to
the increase in inlet composition , so x > xsp
Possible solutions are:
a Measure x and adjust w2
b Measure x1 and adjust w2
c Measure x , x1 and adjust w2
d Use a larger tank

HK (CHE IITD ) CLL261-PDC 30-SEP-2020 9 / 19


A motivating example (Q2 (a) )
Measure x and adjust w2
Intuitively, if x is too high, we should reduce w2
Manual control vs. automatic control
A simple option: w2 (t) = w + Kc [xsp − x (t)]
Feedback control

HK (CHE IITD ) CLL261-PDC 30-SEP-2020 10 / 19


A motivating example (Q2 (b) )
Measure x1 and adjust w2
Intuitively, if x1 > x 1 is too high, we should reduce w2 so that
w2 < w 2
Rewrite Eq. (3) as
xsp − x1 (t)
w2 (t) = w 1 (4)
1 − xsp
Feed forward control

HK (CHE IITD ) CLL261-PDC 30-SEP-2020 11 / 19


A motivating example (Q2 (c) and (d))

c Measure x , x1 and adjust w2


This approach is a combination of Methods 1 and 2
d 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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Feedback control

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Feedback control (contd..)

glucose u
setpoint
y
r

controller pump patient sensor

measured glucose

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Hierarchy of control

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Economic incentives

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Economic incentives

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Control system development

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Thank you!

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