Introduction to Process
Control
Chapter 1
a) prototype system-blending tank
b) feedback control
c) implementation of control
d) justification of control
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Chapter 1
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Chapter 1
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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.
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Chapter 1
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Chapter
Chapter11
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Control Terminology(2)
set-point change - implementing a change in the
operating conditions. The set-point signal is
Chapter 1
changed and the manipulated variable is adjusted
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.
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Chapter 1 Illustrative Example: Blending system
Notation:
• w1, w2 and w are mass flow rates
• x1, x2 and x are mass fractions of component A
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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
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• 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)
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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
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• 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?
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; 11
• 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).
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Chapter 1
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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:
Chapter 1
xSP x1 t
w2 t w1 (1-5)
1 xSP
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• 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.
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Classification of Control Strategies
Table. 1.1 Control Strategies for the Blending System
Method Measured Manipulated Category
Variable Variable
Chapter 1
1 x w2 FB
2 x1 w2 FF
3 x1 and x w2 FF/FB
4 - - Design change
Feedback Control:
• Distinguishing feature: measure the controlled variable
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• 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… 18
Feedforward Control:
Distinguishing feature: measure a disturbance
variable
• Advantage:
Correct for disturbance before it upsets the process.
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• Disadvantage:
Must be able to measure the disturbance.
No corrective action for unmeasured disturbances.
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Closed-loop Artificial Pancreas
glucose u
setpoint
y
r
controller pump patient sensor
measured glucose
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Chapter 1
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Chapter 1
Block diagram for temperature feedback control system
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Chapter 1
Figure 1.6 Block diagram for composition feedback control system
on Fig. 1.4.
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or
pneumatic controller
Chapter 1
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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
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3.2 Economic Incentives - Advanced
Control
Chapter 1
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Chapter 1
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(days-months) 5. Planning and
Scheduling
(hours-days) 4. Real-Time
Optimization
3b. Multiv ariable
Chapter 1
(minutes-hours ) and Constraint
Control
Figure 1.8 Hierarchy of
process control activities.
(seconds-minutes) 3a. Regulatory
Control
2. Saf ety , Env ironment
(< 1 second) and Equipment
Protection
(< 1 second) 1. Measurement
and Actuation
Process
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Chapter 1
Figure 1.10 Major
steps in control
system development
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Chapter 1
Next chapter
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