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INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

CHN-303 Process Dynamics & Control
• Contact Hours:L: 3 T: 1 P: 2/2
• CWS: 15; PRS: 15; MTE: 15; ETE: 40; PRE: 15
PROCESS DYNAMICS & CONTROL S. No. Contents Hours
1. Introduction: The concept of process dynamics and control, 5
Dr. Vimal Chandra Srivastava review of Laplace transform methods, Laplace transform of
G. B. Pant Chair Professor disturbances and building functions, dynamic model building
Head, Department of Chemical Engineering of simple systems.
Indian Institute of Technology Roorkee 2. Linear Open Loop System: Physical examples of first order 8
Roorkee, 247667, Uttarakhand, India
E-mails: [email protected], [email protected] systems and their response for step, impulse and sinusoidal
inputs, linearization of non-linear models, response of first
order system in series, examples of second order systems and
their response, estimation of system parameters.
3. Linear Closed Loop System: The control system and its 8
elements, closed loop transfer functions, transient response of
simple control systems, concept of stability and use of Routh
– Hurwitz test for stability.
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CHN-303 Process Dynamics & Control List of Practicals

S. No. Contents Hours
4. Controllers: Modes of control action, control system and its 3 1. Dynamic Study of Thermometer with and without
closed-loop transfer function. thermo-well
5. Root Locus Method: Root locus treatment, response from root 4
locus and its application to control system design. 2. Dynamic Study of Stirred Tank Heater
6. Frequency Response: Introduction to frequency response, Bode 5 3. McCloyd Gauge and Vacuum System
diagrams of simple systems, Bode stability criterion, control 4. Control valve characteristics
system design by frequency response, use of gain and phase
5. Non-interacting and interacting Systems
margins.
7. Process Application: Controller tuning rules, control of complex 5 6. Heat exchangers
chemical processes and equipment, control valve sizing, 7. Cascade control trainer
introduction to real time computer control of process equipment.
8. Advanced Control Methods: Introduction to state-space method, 4
feed forward and ratio control, inferential control, control using
digital computers-an introduction.
Total 42
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Place of Process Control in a typical Chemical

Suggested Books
Plant

S. Name of Books / Authors Year of

No. Publication
1. Coughanowr D.R. and LeBlanc S. “Process System 2008
Analysis and Control”, 3rd Ed., McGraw Hill.
2. Stephanopoulos G. “Chemical Process Control – An 1990
Introduction to Theory and Practice”, Prentice-Hall
of India.
3. Seborg D. E., Edgar T. F. and Mellichamp D. A., 2004
“Process Dynamics Control”, 2nd Ed., John Wiley.
4. Bequette B. W., “Process Control – Modeling, 2003
Design and Simulation”, Prentice-Hall of India.
5. Ogunnaike B. A. & Ray W. H., “Process Dynamics 1994
Modeling & Control”, Oxford University Press
Luyben (1996)
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Examples of control systems Examples of control systems

Temperature Control System

Speed Control System

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Examples of control systems Need of a Control

Safety:
• Equipment and Personnel
Production Specifications:
• Quality and Quantity
Environmental Regulations:
• Effluents
Operational Constraints:
• Distillation columns (flooding, weeping); Tanks (overflow,
drying), Catalytic reactor (maximum temperature, pressure)
Business Systems Economics:
• Minimum operating cost, maximum profits

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Controlling Temperature in a Stirred Tank Heater

1. Suppressing External Disturbances

2. Ensure the Stability of a Process Objectives: Achieve Set-point
3. Optimization of the Performance T = Ts
h = hs
After reaching steady-state
from start-up, disturbances in
Fi and Ti cause changes in F, T.

How to achieve the objective?

Stirred Tank Heater (Stephanopoulos, 1984)

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Controlling Temperature in a Stirred Tank Heater Ensure the Stability of a Process

Parameters, x (or y) can be anything like T, CA, F;

▪ measure T
x is disturbed at t0 because of which y also gets affected.
▪ compare measured T with
Ts
▪ Compute error:
e = Ts - T
e > 0; Ts > T (increase Fst)
e < 0; Ts < T (reduce Fst)
x returns to steady-state without y never returns to steady-state
an intervention in a self- in three different unstable
Feedback Control in a Stirred Tank Heater regulating process processes (A, B, C)
(Stephanopoulos, 1984)
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Optimization of the Performance of a Batch

Classification of Variables
Reactor
Optimization is a major requirement to achieve maximum profit.
A (feed) → B (desired) → C (undesired); endothermic reaction
Input variables (sometime called as load variables or LV)
Scenarios: Further classified as disturbances and manipulated or control variable.
Steam ▪ Q(t) is given the largest value during
entire TR to favor A → B
▪ Q(t) is given the smallest value Output variables
during entire TR to suppress B→ C Further classified into measured and unmeasured variables
▪ Optimization of Q(t) during TR

Condensate
Often, manipulated variable effects output variable (measured) known
Economic Objective
as controlled variable
Maximize profit = When an output variable is chosen as a manipulated variable, it
ʃ0tR f (A, B, steam) dt becomes an input variable.
A manipulated variable is always an input variable.
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Design Elements in a Control Design Elements in a Control

Define Control Objective: What are the operational

objectives of a control system?
Select Measurements: What variables must be measured h
to monitor the performance of a chemical plant? A F

Select Manipulated Variables: What are the

manipulated variables to be used to control a chemical
Objective: h = hs (Controlled Variable or CV)
process?
Select the Control Configuration: Information
Scenario C. Variable M. Input Output
structure for measured and controlled variables.
Variable Variable Variable
Configurations include feedback control, inferential
1 (shown) h F Fi h
control, feedforward control
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Control Configurations in a Distillation Column

h A
F,
Control Objective Define Control
T (a) T = Ts Objective: 95 % top
(b) h = hs product
Fst Select Measurements:
Input variables Composition of
Fi, Fst, Ti, (F) Distillate
Select Manipulated
Output variables variables: Reflux ratio

h A
F, T, h
F,
Selected Control
T Temperature and level control
Configuration:
Fst in a stirred tank heater
feedback control
(Stephanopoulos, 1984) (Stephanopoulos, 1984)
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Feedforward Control Configuration in a

Inferential Control in a Distillation Column
Distillation Column

Control Objective: xD

Control xD

Unmeasured input =
f (secondary measurements)

(Stephanopoulos, 1984) (Stephanopoulos, 1984)

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Hardware for a Process Control System Process Control and Optimization

• The process (chemical or physical)

• Control and optimization are terms that are many
• Measuring instruments and sensors (inputs, outputs)
What are the sensors for measuring T, P, F, h, x, etc? times erroneously interchanged.
• Transducers (converts measurements to current/ voltage) • Control has to do with adjusting flow rates to
• Transmission lines/ amplifier maintain the controlled variables of the process at
• The controller (intelligence) specified setpoints.
• The final control element
• Recording/ display
• Optimization chooses the values for key setpoints
elements such that the process operates at the “best”
economic conditions.
Recall Process
Instrumentation
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INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

Process Dynamics

• The control of any process needs an understanding of the dynamics

of the process.
– This dynamics can be obtained from principles-based models or
empirical ones.
– Either way, it is necessary to develop a qualitative principles- Laplace Transforms
based models to gain insights of the inputs and its relationships
with the outputs.
• Conservation Equations: Mass, Moles, or Energy Balances

 Rate of   Rate Entering 

 Accumulation = the System −
   
 Rate Leaving   Rate of Generation by 
the System  +  Re action within the System
   
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Method for Solving Linear ODE’s using

Laplace Transforms
Laplace Transforms
• The principles-based models develop differential equations that
should be changed to an algebraic equation for easier manipulation.
sY(s) - y(0) =
Y(s) = H(s)
F(s,Y)
• The Laplace transforms is an operator that converts ODEs to
algebraic equations. Laplace Domain

• Provide valuable insight into process dynamics and the dynamics of Time Domain

feedback systems.
• Provide a major portion of the terminology of the process control dy/dt = f(t,y) y(t) = h(t)
profession.

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Laplace Transforms Definition

• Important analytical method for solving linear ordinary

differential equations. The Laplace transform of a function, f(t), is defined as
• Application to nonlinear ODEs? Must linearize first. 
F ( s ) = L  f (t )  =  f ( t ) e − st dt (3-1)
0
• Laplace transforms play a key role in important process control
concepts and techniques. where F(s) is the symbol for the Laplace transform, L is the
Laplace transform operator, and f(t) is some function of time, t.
• Examples:
• Transfer functions
The L operator transforms a time domain function f(t) into an s
• Frequency response domain function, F(s).
• Control system design s is a complex variable: s = a + bj,
• Stability analysis

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Inverse Laplace Transform, L-1 Important Properties of Laplace and Inverse Laplace

Both L and L-1 are linear operators. Thus,

By definition, the inverse Laplace transform L  ax ( t ) + by ( t )  = aL  x ( t )  + bL  y ( t ) 

operator, L-1, converts an s-domain function = aX ( s ) + bY ( s ) (3-3)
back to the corresponding time domain where:

function: - x(t) and y(t) are arbitrary functions

f ( t ) = L−1  F ( s )  - a and b are constants
X ( s ) L  x ( t )  and Y ( s ) L  y ( t )

Similarly,
L−1  aX ( s ) + bY ( s )  = ax ( t ) + b y ( t )

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Laplace Transforms of Common Functions Laplace Transforms of Common Functions

Constant Function Step Function

Let f(t) = a (a constant) The unit step function is widely used in the analysis of process
control problems. It is defined as:

Then, from the definition of the Laplace transform 0 for t  0

S (t )  (3-5)
1 for t  0

 a  a a
L ( a ) =  ae− st dt = − e− st = 0−−  = (3-4) Because the step function is a special case of a “constant”, it
0 s  s s follows that
0

1
L  S ( t )  = (3-6)
s

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Laplace Transforms of Common Functions

Exponential Functions Find the Laplace of following:

Consider f ( t ) = e−bt where b > 0. Then, • e-at
  − b+ s t
L e−bt  =  e−bt e− st dt =  e ( ) dt • t e-at
  0 0
1  −( b+ s )t  1 • sin ꞷt
= −e = (3-16)
b+s  0 s+b • cosh ꞷt

• e-at (sin ꞷt)

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Laplace Transforms of Common Functions Laplace Transforms of Common Functions

Derivatives Where, n is an arbitrary positive integer

dk f
f ( ) ( 0)
This is a very important transform because derivatives appear in k
the ODEs we wish to solve. dt k t =0

 df  Special Case: All Initial Conditions are Zero

L   = sF ( s ) − f ( 0 ) (3-9)
 dt  f ( 0 ) = f ( ) ( 0 ) = ... = f ( ) ( 0 ) .
Suppose 1 n−1

initial condition at t = 0
dn f 
Similarly, for higher order derivatives: L  n  = sn F ( s )
 dt 
dn f  n − 2 (1)
 = s F ( s ) − s f (0) − s f (0) −
n n −1 In process control problems, we usually assume zero initial conditions.
L n
 dt  Reason: This corresponds to the nominal steady state when “deviation
−... − sf ( ) 0 − f ( ) 0 variables” are used.
n−2 n −1
( ) ( ) (3-14)

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Partial-Fraction Expansion

where ak (k=1, 2,p , n) are constants. The coefficient ak is called the

residue at the pole at s=–pk.

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Partial-Fraction Expansion

• Find the inverse Laplace transform of

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SOLUTION OF ORDINARY DIFFERENTIAL

EQUATIONS (ODEs)

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SOLUTION OF DIFFERENTIAL
EQUATIONS
• Find the Laplace transform of the function x ( t ) that satisfies the
differential equation and initial conditions

• Use has been made of the linearity property and of the fact that only
positive values of t are of interest. Inserting the initial conditions
and solving for x(s), we have

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To find A, multiply both sides of Eq. by s and then set s=0

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Inversion of a transform that has complex roots in the

denominator

• Solve

• Multiplying by s, and putting s=0.

• Application of the Laplace transform yields

• The quadratic term in the denominator may be factored by use of

the quadratic formula. The roots are found to be -1- j and -1+ j.
• If we use these complex roots in the partial fraction expansion, the
algebra can get quite tedious.
• We can use an alternate form of the partial fraction expansion.
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• Remember that for a perfect square, the quadratic must have the form

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The steps in this method for inverting quadratic terms with Exceptional case - the denominator of x(s) has
complex roots while avoiding the use of complex algebra repeated roots
• Solve

• Final solution

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Partial-Fraction Expansion when F(s) Involves Partial-Fraction Expansion when F(s) Involves
Multiple Poles Multiple Poles

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Partial-Fraction Expansion when F(s) Involves Partial-Fraction Expansion when F(s) Involves
Multiple Poles Multiple Poles

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QUALITATIVE NATURE OF SOLUTIONS QUALITATIVE NATURE OF SOLUTIONS

• If we are interested only in the form of the solution x(t), which is • Location of typical roots of characteristic equation
often the case in our work, this information may be obtained
directly from the roots of the denominator of x(s).

• s in the denominator of x(s) will give rise to a constant in x(t).

• Qualitative nature of the solution x(t) can be related to the location
of the roots of the denominator of x(s) in the complex plane.
• These roots are the roots of the characteristic equation, and the roots
of the denominator of the transformed forcing function.

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QUALITATIVE NATURE OF SOLUTIONS

• Nature of terms in the solution x(t) based on roots in the

denominator of X(s)

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FINAL-VALUE and INITIAL VALUE THEOREMS Questions

• Final value theorem • Find the final value of the function x(t) at infinity for which the
Laplace transform is

Solution:

• Initial value theorem Note: If this transform was inverted

which approaches unity as t approaches infinity.

• Note that since the denominator of s.x(s) can be factored to (s+1)3,
the conditions of the theorem are satisfied; that is, (s+1)3 is not
equal to zero unless s=-1.

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Questions Questions

• Find the final value of the function x(t) at infinity for which the
• Find the initial value x (0) of the function that has the transform
Laplace transform is

Solution:
Solution

Since this becomes infinite, for s=1 and s=2, the conditions of the
theorem are not satisfied.
• Inverted form of the transform is:

• This function continues to grow exponentially with t and, as

expected, does not approach a limit.
• Thus, if any roots of the denominator have positive real parts, the
final-value theorem does not apply.
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TRANSLATION OF TRANSFORM TRANSLATION OF TRANSFORM

• A primary use for this theorem is in the inversion of transforms.

Proof:

Question:

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TRANSLATION OF FUNCTION

• Relationship between f(t-t0) and f(t).

This is done for an arbitrary function
f ( t ) in Fig.
It can be seen that f(t-t0) is simply
translated horizontally from f(t)
through a distance t0.

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TRANSFORM OF THE UNIT-IMPULSE

Question
FUNCTION
• If we allow h to shrink to zero, we obtain a new function which is
zero everywhere except at the origin, where it is infinite. However,
it is important to note that the area under this function always
remains equal to unity. We call this new function δ(t), and the fact
that its area is unity means that:

• The graph of δ(t) appears as a line of infinite height at the origin.

• The function δ(t) is called the unit-impulse function or,
alternatively, the delta function.

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TRANSFORM OF AN INTEGRAL &

DERIVATIVE

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Questions

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Question Question

• Solve • Solve

• Final solution

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Thank you

E-mail: [email protected], [email protected]

Webpages:
• http://www.iitr.ac.in/~CH/vimalfch
• https://publons.com/researcher/1442249/vimal-chandra-srivastava/
• http://www.researcherid.com/rid/B-4455-2008
• http://orcid.org/0000-0001-5321-7981
• https://scholar.google.com/citations?user=vXB9eOwAAAAJ&hl=en
• http://www.scopus.com/authid/detail.url?authorId=35565811700
• http://inae.in/expert-search/index.php/vimal-chandra-srivastava

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