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Introduction To Process Control

This document provides an introduction to process control concepts. It discusses controlled and manipulated variables, feedback and feedforward control strategies, and justification for control. It uses an example of controlling the composition of a blending tank. Control methods discussed include measuring the composition (x) and adjusting the flow (w2), measuring the inlet composition (x1) and adjusting the flow, or measuring both x1 and x to determine w2. Feedback control measures the controlled variable while feedforward also measures disturbances. Process control is justified for benefits like increased throughput, yield, safety and equipment life.

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Fajar Adityadarma
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46 views28 pages

Introduction To Process Control

This document provides an introduction to process control concepts. It discusses controlled and manipulated variables, feedback and feedforward control strategies, and justification for control. It uses an example of controlling the composition of a blending tank. Control methods discussed include measuring the composition (x) and adjusting the flow (w2), measuring the inlet composition (x1) and adjusting the flow, or measuring both x1 and x to determine w2. Feedback control measures the controlled variable while feedforward also measures disturbances. Process control is justified for benefits like increased throughput, yield, safety and equipment life.

Uploaded by

Fajar Adityadarma
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
You are on page 1/ 28

Introduction to Process

Control
Chapter 1

a) prototype system-stirred tank heater


b) feedback control
c) implementation of control
d) justification of control
Chapter 1
Chapter 1
Control Terminology
controlled variables - these are the variables which
quantify the performance or quality of the final
product, which are also called output variables.
Chapter 1

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.
Chapter 1
Chapter
Chapter11
Control Terminology(2)

set-point change - implementing a change in the


operating conditions. The set-point signal is
changed and the manipulated variable is adjusted
Chapter 1

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.
Chapter 1 1.1 Illustrative Example: Blending system

Notation:
w1, w2 and w are mass flow rates

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


Chapter 1

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


Design Question. What value of w2 is required to have
x xSP ?

Overall balance:
0 w1 w2 w (1-1)
Chapter 1

Component A balance:

w1 x1 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
Equation 1-3 is the design equation for the blending
system.
If our assumptions are correct, then this value of w2 will keep x
atxSP . But what if conditions change?
Chapter 1

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;


Manual control vs. automatic control
Proportional feedback control law,
w2 t w2 K c xSP x t (1-4)

1. where Kc is called the controller gain.


Chapter 1

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).
Chapter 1
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:
Chapter 1

xSP x1 t
w2 t w1 (1-5)
1 xSP
Chapter 1
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.


Chapter 1

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.
1.2 Classification of Control Strategies

Table. 1.1 Control Strategies for the Blending System


Method Measured Manipulated Category
Variable Variable
Chapter 1

1 x w2 FBa
2 x1 w2 FF
3 x1 and x w2 FF/FB
4 - - Design change
FB = feedback control; FF = feedforward control; FF/FB = feedforward control and
feedback control

Feedback Control:
Distinguishing feature: measure the controlled variable
It is important to make a distinction between negative feedback
and positive feedback.
Engineering Usage vs. Social Sciences
Advantages:
Corrective action is taken regardless of the source of
Chapter 1

the disturbance.
Reduces sensitivity of the controlled variable to
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
Feedforward Control:
Distinguishing feature: measure a disturbance
variable
Advantage:
Correct for disturbance before it upsets the process.
Chapter 1

Disadvantage:
Must be able to measure the disturbance.
No corrective action for unmeasured disturbances.
Chapter 1
Chapter 1
Chapter 1
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
3.2 Economic Incentives - Advanced
Control
Chapter 1
Chapter 1
(days-months ) 5. Planning and
Scheduling

(hours-days ) 4. Real-Time
Optimization

3b. Multivariable
(minutes-hours)
Figure 1.7 Hierarchy of
Chapter 1

and Constraint
Control
process control activities.
(seconds-minutes) 3a. Regulatory
Control

2. Safety, Environment
(< 1 second) and Equipment
Protection

(< 1 second) 1. Measurement


and Actuation

Process
Chapter 1

Figure 1.9 Major


steps in control
system development
Chapter 1

Next chapter

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