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IPC - Lectures 6-11 (Introductory Concepts)

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25 views20 pages

IPC - Lectures 6-11 (Introductory Concepts)

Uploaded by

Hafsa Imran
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Instrumentation and Process

Control
Lectures 6-11

1
Application of Instrumentation and
Process Control
•Food processing
•Water treatment plants
•Pharmaceutical and biotechnology
•Oil, chemical, mineral processing,
metallurgical
•Detergent, power generation
•Paint, plastics and cosmetics industries

2
Illustrative Example: Blending system

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

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
4
• Disturbance variable (or “load variable”): x1
Design Question. What value of w2 is required to have
x  xSP ?

Overall balance:
0  w1  w2  w (1-1)

Component A balance:

w1x1  w2 x2  wx  0 (1-2)

(The overbars denote nominal steady-state design values.)

• At the design conditions, x  xSP. Substitute Eq. 1-2, x  xSP and


x2  1 , then solve Eq. 1-2 for w2 :
xSP  x1
w2  w1 (1-3)
1  xSP
5
• Equation 1-3 is the design equation for the blending
system.
• If our assumptions are correct, then this value of w2 will keep x
at xSP . But what if conditions change?

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; 6
• Manual control vs. automatic control
• Proportional feedback control law,
w2  t   w2  Kc  xSP  x  t  (1-4)

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).

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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:

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

9
10
• 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.

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.

11
Classification of Control Strategies

Table. 1.1 Control Strategies for the Blending System


Method Measured Manipulated Category
Variable Variable
1 x w2 FB
2 x1 w2 FF
3 x1 and x w2 FF/FB
4 - - Design change

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Feedback Control:
• Distinguishing feature: measure the controlled variable

• Advantages:
 Corrective action is taken regardless of the source of
the disturbance.
• 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…

13
Feedforward Control:
 Distinguishing feature: measure a disturbance
variable
• Advantage:
 Correct for disturbance before it upsets the process.
• Disadvantage:
 Must be able to measure the controlled variables.
 No corrective action for unmeasured disturbances.

14
Controlled and manipulated variables for a typical distillation column

15
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Figure 1.6 Block diagram for composition feedback control system
on Fig. 1.4.

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Block diagram for temperature feedback control system

19
Justification of Process Control

Specific Objectives of Control


1. Increased product throughput
2. Increased yield of higher valued products
3. Decreased off-spec product
4. Decreased energy consumption
5. Decreased pollution
6. Increased Safety
7. Extended life of equipment
8. Improved Operability
9. Decreased production labor

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