Some Control Strategies for Productivity and Safety

Ratio, Selective,
Override Control
Cheng-Liang Chen
PSE
LABORATORY
Department of Chemical Engineering
National TAIWAN University
Chen CL 1
Typical Computing Relays (Blocks)
Addition/Subtraction:
adding and/or subtracting input signals into output
Multiplication/Division:
multiplying/dividing input signals into output
Square Root:
output is obtained by extracting square root of input
High/Low Selector:
output is the highest or lowest of two or more inputs
High/Low Limiter:
output is the input limited to preset high or low limit
Chen CL 2
Function Generator:
output is a function of input (series of straight lines)
Integrator (totalizer):
output signal is time integral of input signal
Lead/Lag:
(output) =
_

ld
s + 1

lg
s + 1
_
(input)
Dead Time:
output signal is equal to a delayed input signal
Chen CL 3
Computing Blocks
Chen CL 4
Computing Blocks
Chen CL 5
Programming Languages
Chen CL 6
Programming Languages
Chen CL 7
Programming Languages: Mixing Process
Chen CL 8
Programming Languages: Preheater/Reactor
Chen CL 9
Scaling Computing Algorithms (I)
Chen CL 10
Scaling Computing Algorithms (II)
Write equation in engineering units
assign each variable a signal name
Relate each variable to its signal name by a scaled equation
Substitute the set of scaled equations into original equation and
solve for the output signal
Chen CL 11
Gas Mass Flow:
Engineering Equations (step 1)
Mass ow through an orice:
w = K

h
w : mass ow, lb/h
h : dierential pressure across orice, in. H
2
O
: density of gas, lb/ft
3
K : orice coecient, 196.1
lb/h
(in.H
2
O-lb/ft
3
)
1/2
Chen CL 12
Density of gas around operating conditions:
= 0.13 + 0.003(p 30) 0.00013(T 500)
w = K{h[0.13 + 0.003(p 30) 0.00013(T 500)]}
1/2
Ranges of the variables:
signal variable range steady state
S1 h 0 100 in.H
2
O 50 in.H
2
O
S2 T 300 700
o
F 500
o
F
S3 p 0 50 psig 30 psig
S4 w 0 700 lb/h 500 lb/h
Chen CL 13
Gas Mass Flow:
Scaled Signals (step 2)
Signals: 0% 100%
Engineering variables and scaled signals:
S1 =
h 0
100 0
100% h = S1
S2 =
T 300
700 300
100% T = 4S2 + 300
S3 =
p 0
50 0
100% p = 0.5S3
S4 =
w 0
700 0
100% w = 7S4
Chen CL 14
Gas Mass Flow:
Scaled Equation (step 3)
Substituting the scaled equations into engineering equations
= nal scaled equation
w = K{h[0.13 + 0.003(p 30) 0.00013(T 500)]}
1/2
7S4 = 196.1{{S1}[0.13 + 0.003({0.5S3} 30)
0.00013({4S2 + 300} 500)]}
1/2
S4 = 1.085 {S1 [S3 0.35S2 + 44]
. .
S5:addition
. .
multiplication
}
1/2
. .
square root
Chen CL 15
Output of Summation: S5 [0%, 100%] ? Find worst condition
_
p = 40 psig (S3 = 80%)
T = 500
o
F (S2 = 50%)
_
S5 = 107.5%
_
p = 50 psig (S3 = 100%)
T = 300
o
F (S2 = 0%)
_
S5 = 144%
S5 = 144% in worst condition divide S5 by 1.44
S4 = 1.085
_

_
S1
_
S3
1.44
0.35
S2
1.44
+
44
1.44
_
. .
S5:addition
. .
multiplication
_

_
1/2
. .
square root
S4 = 1.302 {S1 [0.694S3 0.243S2 + 30.55]
. .
S5:addition
. .
multiplication
}
1/2
. .
square root
Chen CL 16
Gas Mass Flow:
Implementation (step 4)
Implementation using computing blocks
Summer:
OUT = K
X
X +K
Y
Y +K
Z
Z +B
o
S5 = 0.694(S3) + (0.243)(S2) + 0 + 30.55%
Square root of product block
OUT = (Factor)K
A

X Y Z +B
o
S4 = 1.302
_
(S1) (S5) + 0%
Note: two inputs Factor = 1
Chen CL 17
S5 = 0.694(S3) + (0.243)(S2) + 0 + 30.55%
S4 = 1.302
_
(S1) (S5) + 0%
Chen CL 18
Gas Mass Flow:
Validation (step 5)
Steady-state signals
S1 = 50% S2 = 50% S3 = 60% S4 = 71.4%
Steady-state mass ow from scaled equation:
S4 = 1.302{50[0.694(60) 0.243(50) + 30.5]}
1/2
= 71.3% 71.4%
Chen CL 19
Blending Control of Two Liquid Streams
Chen CL 20
Ratio Control of Blending Systems
Chen CL 21
Ratio Control of Blending Systems: One Wild Flow
(a) is a more linear system (preferred)
F
set
B
= R F
A
R = F
B
/F
A
F
set
B
F
A
= R
R
F
A
=
F
B
F
2
A
=
R
F
A
Chen CL 22
Ratio Control of Blending Systems: One Wild Flow
Chen CL 23
Air/Fuel Ratio Control for A Boiler
Chen CL 24
Air/Fuel Ratio Control for A Boiler
Chen CL 25
Air/Fuel Ratio Control for A Boiler
Chen CL 26
Air/Fuel Ratio Control for A Boiler
Chen CL 27
Air/Fuel Ratio Control for A Boiler
Chen CL 28
Air/Fuel Ratio Control for A Boiler
Chen CL 29
Air/Fuel Ratio Control for A Boiler
Chen CL 30
Air/Fuel Ratio Control for A Boiler
Chen CL 31
Air/Fuel Ratio Control for A Boiler
Chen CL 32
Air/Fuel Ratio Control for A Boiler
Chen CL 33
Air/Fuel Ratio Control for A Boiler
Chen CL 34
Air/Fuel Ratio Control for A Boiler
Chen CL 35
Feedback Trim Enhances Ratio Control
Adding 20% NaOH to a
varying ow of water to
produce 5% NaOH
The multiplier is scaled for
twice the product of the A
and B function to obtain a
FB controller output of 0.5
(midscale)
allow FB trim to adjust
ratio equally well up or down
from the normal value
FB trim can be introduced with a summer, adding to or subtracting from the
FF (?) calculation
Additive or Multiplicative ? a matter of minimizing FB correction
Chen CL 36
Tank and Flow Control Loop
Simple Feedback Control
Chen CL 37
Tank and Flow Control Loop
Override Control Scheme
Chen CL 38
Override Control Scheme
Controllers with Reset Feedback (RFB)
Chen CL 39
Heater Temperature Control System
Simple Feedback Control
Chen CL 40
Heater Temperature Control System
Override Control Scheme
Chen CL 41
A Plug Flow Reactor
Simple Temperature Control
Chen CL 42
A Plug Flow Reactor
Selective Control
Chen CL 43
A Hot Oil System
Feedback/Cascade Control
Chen CL 44
A Hot Oil System
Selective/Valve-Position Control
Chen CL 45
Designing Control Systems: An Exothermic Reactor
Consider a reactor, where the exothermic reaction A+B C takes place. The
diagram shows the control of the temperature in the reactor by manipulating the
cooling water valve.
Chen CL 46
1. Design a control scheme to control the ow of reactants to the reactor. The
ows of reactants A and B should enter the reactor at a certain ratio, R, that
is, R = F
B
/F
A
. Both ows can be measured and controlled.
2. Operating experience has shown that the inlet cooling water temperature varies
somewhat. Because of the lags in the system this disturbance usually results in
cycling of the temperature in the reactor. The engineer in charge of this unit
has been wondering whether some other control scheme can help in improving
the temperature control. Design a control scheme to help him.
3. Operating experience has also shown that under some infrequent conditions the
cooling system does not provide enough cooling. In this case the only way to
control the temperature is by reducing the ow of reactants. Design a control
scheme to do this automatically. The scheme must be such that when the
cooling capacity returns to normal the scheme of previous part is reestablished.
Chen CL 47
Designing Control Systems: An Exothermic Reactor
Chen CL 48
Designing Control Systems: An Exothermic Reactor
Chen CL 49
Designing Control Systems: An Exothermic Reactor
Chen CL 50
Designing Control Systems: An Exothermic Reactor
Chen CL 51
Designing Control Systems: An Exothermic Reactor
Chen CL 52
Designing Control Systems: An Exothermic Reactor
Chen CL 53
Designing Control Systems: An Exothermic Reactor
Chen CL 54
Designing Control Systems: An Exothermic Reactor
Chen CL 55
Designing Control Systems: An Exothermic Reactor
Chen CL 56
Designing Control Systems: An Exothermic Reactor
Chen CL 57
Designing Control Systems: An Exothermic Reactor
Chen CL 58
Designing Control Systems: An Exothermic Reactor
Chen CL 59
Designing Control Systems: An Exothermic Reactor
Chen CL 60
Designing Control Systems: An Exothermic Reactor
Chen CL 61
Design Control System: An Endothermic Reactor
Consider the reactor, where stream A reacts with water. Stream A can be
measured but not manipulated. This stream is the by-product of another unit.
The water enters the reactor in two dierent forms, as liquid and as steam. The
steam is used to heat the reactor contents. It is necessary to maintain a certain
ratio, R, between the total water and stream A into the reactor. It is also
necessary to control the temperature in the reactor. It is important to maintain
the ratio of total ow of water to ow of stream A below a value Y : otherwise, a
very thick polymer may be produced plugging the reactor.
Chen CL 62
A situation has occurred several times during extended periods of time in which
the ow of stream A reduces signicantly. In this case the control scheme totally
cuts the liquid water ow to the reactor to maintain the ratio. However, the steam
ow to the reactor, to maintain temperature, still provides more water than
required, and thus the actual ratio of water to stream A entering the reactor
dangerously approaches Y . Design a control scheme to control the temperature in
the reactor, and another scheme to maintain the ratio of total water to stream A,
while avoiding reaching the value of Y even if it means that the temperature
deviates from set point.
Chen CL 63
Design Control System: An Endothermic Reactor
Chen CL 64
Design Control System: An Endothermic Reactor
Chen CL 65
Design Control System: An Endothermic Reactor