Lecture 1 PDF

054461 PROCESS CONTROL LAB LECTURE ONE
Daniel R. Lewin, Technion 1

Course Introduction PROCESS CONTROL LAB - (c) Daniel R. Lewin 1-1
054461 Process Control Laboratory
LECTURE 1:
COURSE INTRODUCTION
Daniel R. Lewin
Department of Chemical Engineering
Technion, Haifa, Israel
Lecture Objectives
Be familiar with the course structure and
objectives.
Have recalled all of the material you learned in
the introductory control course, and in
particular, be able to:
a. Formulate a linear process model
b. Sketch the response of a linear system
c. Design a simple (PID) feedback controller
using the Root Locus method
On completing this section, you should:
Course Objectives
Derive an empirical linear model for a real
process by generating experimental data and its
analysis.
Design, tune and implement SISO controllers for
a real process. The types of controllers that you
should be able to implement are: simple feedback
(e.g. PID), cascade controllers, IMC and FF.
Design and implement control system for MIMO
processes.
On completing this course, you should:
Linear Systems Review + More
Modeling process transient behavior
Linearization
Laplace transforms
Linear system response
Root locus design of FB controllers
Modeling - Dead Sea Pond (1)
Prepare a model describing an evaporating pond in the Dead
Sea Works.
Feed brine [T/h]
Brine conc. [kg salt/kg]
Evap. Rate [T/h]
Solution.
rate of accumu- rate of input rate of out- rate of loss
by evaporation lation with feed put with effluent
f
0 q q E
( ( ( (
=

=
Overall mass balance:
f
Thus, q q E =
Modeling - Dead Sea Pond (2)
( )
rate of accumu- rate of salt rate of salt out-
lation of salt input with feed put with effluent
f f
d
Vc q c qc
dt
( ( (
=

=
The balance for salt gives:
f
Using q q E, and noting that and V are constant: =
( )
1
,
0 f
f
dc
E
1 c c c 0 c
q
dt
| |
| |
|
|
+ |
|
| |
\ . \ .
= =
( )
f f f
c q E q c dc
V V dt

=

f
Defining V q : =
What is the sign of
(E/q
f
1) ?
Linearization (1)
Consider the general SISO nonlinear process:
( )
dx
f x, u
dt
=
Linearization around the stationary point (x
0
, u
0
) gives
the linear equation:
( ) ( ) ( )
0 0 0 0
0 0 0 0
x ,u x ,u
dx f f
f x , u x x u u
dt x u

+ +

But: ( )
0
0 0
dx
f x , u
dt
=
Hence: ( )
( ) ( )
0 0 0 0
0 0 0 0
0
0 0
x ,u x ,u
x ,u x ,u
d x x f f
x x u u
dt x u
dx f f
x u
dt x u

+

+


Linearization (2)
Extension to MIMO nonlinear process:
( )
( )
dx
f x, u
dt
y g x, u
=
=
Linearization around the stationary point (x
*
, u
*
) gives
the linear system:

dx
Ax Bu
dt
y Cx Du
= +
= +
i
i,j
j
f
A a
x
The matrices are Jacobian matrices, e.g. A, B, C and D
*
*
x x x
u u u
=
=

Linearization Example (1)
( ) ( )
1
,
0 f f f
f
dc
E
f c;q , c , E 1 c c c 0 c
q
dt
| |
| |
|
|
+ |
|
| |
\ . \ .
= = =
Continuing the Dead Sea Ponds example, we have:

Data: q
f
= 10 T/h, E = 5 T/h, c
f
= 0.1 kg salt/kg brine, V = 100 T
At steady state:
( ) = = =
f f
dc
0 c c 1 E q 0.2 kg salt/kg brine
dt
Stationary point: c
*
= 0.2; q
f*
= 10; c
f*
= 0.1; E
*
= 5;
*
= 10 h.
Linearization:
f f
ss ss f f
ss ss
dc f f f f
c q c E
dt c q c E

= + + +

Linearization Example (2)
-1 *
* ss f*
E f 1
1 0.05 h
c q
| |
= =
|

\ .
-1 * f*
f
ss
c c f
0.001 T
q V

= =

-1
* f
ss
f 1
0.1 h
c
= =

-1 *
ss
c f
0.002 T
E V
= =

( ) f
f
dc
0.05c 0.001q 0.1c 0.002E, c 0 0
dt
= + + =
f f
ss ss f f
ss ss
dc f f f f
c q c E
dt c q c E

= + + +

Laplace Transforms
General MIMO linear process is:

dx
Ax Bu
dt
y Cx Du
= +
= +
*
*
x x x
u u u
=
=
Example:
| |
( )
f
f
q
dc
0.05 c 0.001 0.1 0.002 c , c 0 0
dt
E
(
(
(
= + = (
(

(

Taking Laplace Transforms (around steady state):
( ) ( ) ( )
( ) ( ) ( )
sX s AX s BU s
Y s CX s DU s
= +
= +
Hence: ( ) ( ) ( )
1
Y s C sI A B D U s
(
= +

P(s) transfer
function matrix
relating all inputs
to outputs
Laplace Transforms
A strictly proper system has n > m (physical system).
A proper system has n = m (e.g. PI controller)
Roots of numerator are zeros and roots of denominator
are poles:
Analysis of transfer functions: ( ) ( )
1
P s C sI A B D
= +
The transfer function matrix is composed of elements:
( )
m m 1
m m 1 1 0
i,j n n 1
n n 1 1 0
b s b s bs b
p s
a s a s a s a
+ + + +
=
+ + + +
z
i
are zeros
( )
( ) ( ) ( )
( ) ( ) ( )
1 2 m
i,j
1 2 n
s z s z s z
p s
s p s p s p

=

p
i
are poles
For stability ALL poles must have a negative real part.
Complex poles give oscillatory response.
Zeros shape the response (see later)
Response to step
in OP: --OP PV
Classification
Transfer
Function

Stable self-
regulating
s
p
p
e
1 s
K

+

Non self-
regulating
s
p
e
s
K

Unstable
s
p
p
e
1 s
K

+

Linear System Response
Identification by Step Test
First order response of process, y, to a step change in input, u:
Dynamics are approximated by the FOPTD model:
p s
K
p(s) e
s 1

=
+
p
with K y u, and and estimated from the trajectory =
u(t)
y(t)
u
0.623y
y
Higher Order Responses (1)
p
2 2
K
p(s)
s 2 s 1
=
+ +
Response of 2
nd
order transfer function to a unit step:
( )
( ) ( )
= =
+ +
p p 1 2
2 2
1 2
K K p p
y(s)
s s p s p s s 2 s 1

=

2
1,2
1
p
Need to differentiate between three cases:
static gain
damping coefficient
>
=
<
A) 1
B) 1
C) 1
natural period
>
1 2
A) For 1, p and p are real negative roots:
( )

=
1 2
p t p t
p 1 2
y(t) K 1 Ae A e
= = =
1 2
B) For 1, p p 1/ :
( ) ( )

= +
t
p
y(t) K 1 1 t e
<
2
1 2
C) For 1, 1 is imaginary, and p and p
are complex roots:
( )
t
p
2
1
y(t) K 1 e sin t
1

| |
= |
|

\ .
=
2
1,2
p i 1

=
2
1
( )
=
1 2
tan 1
Example 1: A processing system with its controller
( ) ( )
( ) ( )
p
1 2
K
C
p s s
F s 1 s 1
= =
+ +
( ) ( ) ( ) ( )
( ) ( ) ( ) ( ) ( )
s
C s P s B s e s
P s B s C s C s
=
=
( )
( ) ( )
( ) ( )
c p
c p
1 2 1 2
c p c p
s
2
K K
K K 1
K K 1 K K 1
P s B s C
s
C P s B s 1
s s 1
+
+
+ +
= =
+ | | | |
+ +
| |
| |
\ . \ .
( )
+
+
+ +
= =
+ + | | | |
+ +
| |
| |
\ . \ .
c p
c p
1 2 1 2
c p c p
2 2
s
2
K K
K K 1
K K 1 K K 1
C K
s
C s 2 s 1
s s 1
=
+
c p
c p
K K
K
K K 1

=
+
1 2
c p
K K 1
( )
+
=
+
1 2
1 2 c p
2 K K 1
1. Can C(t) track C
s
(t) with no offset?
2. Is the closed-loop response damped or underdamped?
3. Does the closed-loop respond faster or slower than the
open-loop response?
Example 1: A processing system with its controller (Contd)
Root Locus for Control Design
RL plot shows the location of the closed-loop poles as the
controller gain is increased (i.e., the roots of pc + 1 = 0)
Control design with RL is a pole pole- -placement placement technique: Poles
and zeros of the process and the controller are placed on
the complex plane the method permits the manipulation
of the characteristic polynomial to attain design
specifications.
Short-cut method allowing pencil-and-paper design of
control systems
Main disadvantages:
a. Can only deal with deadtime systems by Pad
approximation
b. Is useful only for SISO control systems
1. The open-loop transfer function is expressed in the form:
The Rules:
2. The root loci start (at K = 0) at the poles of pc(s) and end
(K = ) at the zeros of pc(s) or at
3. On the real axis of the complex plane, the RL is
constructed from right to left, according to the total poles
and zeros (pz) met along the way:
If K > 0, draw the RL if pz is odd
If K < 0, draw the RL if pz is even
4. The number of loci = order of the system = number of
poles of pc(s). The complex loci always appear as complex
conjugates (mirror image either side of the real axis).
( )
( ) ( ) ( )
( ) ( ) ( )
1 2 m
1 2 n
s z s z s z
pc s K
s p s p s p

=


5. The angle of the asymptotes of the loci (as K ) is:
The Rules (Contd):
( )
( )
180 2k 1
k 0,1, ,n m 1 (K 0)
n m
180 2k
k 0,1, ,n m 1 (K 0)
n m
= >
= <
where n and m are the number of poles and zeros of pc(s).

6. The asymptotes are centered at
where p
i
and z
i
are the locations of poles and zeros of
pc(s), respectively.
( ) ( )
i i
p z n m =

( )
( ) ( )
( )
c
1
p s , c s K
s 1 s 3
= =
+ +
Example 3
1 2 -1 -2 -3 -4
-1
-2
1
2
Re(s)
Im(s)
3
-3
-5

( )
( ) ( )
( ) ( )
c i 2
1
p s , c s K 1 1 Ts
s 1 s 3
= = +
+ +
Example 4
1 2 -1 -2 -3 -4
-1
-2
1
2
Re(s)
Im(s)
3
-3
-5

2

( )
( )
( ) ( )
s
c i
1
p s e , c s K 1 1 Ts
s 1

= = +
+
1 2 -1 -2 -3 -4
-1
-2
1
2
Re(s)
Im(s)
3
-3
-5
Example 5

Design Specifications for RL
The desired closed loop response is:
2 2
s
y 1
(s)
y s 2 s 1
=
+ +
( )
t
2
1
y(t) 1 e sin t
1

=

The response to a unit step in y
s
is:
The analytical response is used to estimate desired overshoot
and settling time.
Overshoot:
2
OS exp 1
(
=

Thus:
( )
( )
2
e
2
2
e
log OS
log OS

+
Settling Time: To settle to within a
fraction x of the set point at time t = t
s
:
( )
s s
t t
s
2 2
1 1
x e sin t e
1 1

=

Hence, to meet the settling time constraint:
( )
( )
2
e
2
2
e
log OS
log OS

+
( )
2
s e
t log x 1
(

(

To meet desired OS:
Specifications met for the range K
m
K K*. Stable for K < K
u
Example:
Summary
Linearization
Laplace transforms
Linear system response
Root locus design of FB controllers
Use of approximate specifications in design
( ) ( ) = =
x f x, u , y g x, u
Modeling process transient behavior
Generating models in standard form:

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054461 PROCESS CONTROL LAB LECTURE ONE

Daniel R. Lewin, Technion 1

Course Introduction PROCESS CONTROL LAB - (c) Daniel R. Lewin 1-8

The matrices are Jacobian matrices, e.g. A, B, C and D

054461 PROCESS CONTROL LAB LECTURE ONE

Continuing the Dead Sea Ponds example, we have:

Course Introduction PROCESS CONTROL LAB - (c) Daniel R. Lewin 1-22

where n and m are the number of poles and zeros of pc(s).

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