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Introduction to
Chemical Process Dynamics,
Instrumentation & Control
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Chapter Objectives
End of this chapter, you should be able to:
1.
2.
3.
4.
5.
6.
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How to control?
A thermocouple is inserted in a thermowell in
the exit oil pipe.
Thermocouple wires are connected to a
temperature transmitter that converts the
millivolt output into a 4- to 20 mA signal.
A sensor
A transmitter
A controller
A final control element
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Block diagram
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Continuous Processes
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Process variables
Three important types: (Control Terminology)
1. Controlled variables - these are the variables which
quantify the performance or quality of the final
product, which are also called output variables.
2. Manipulated variables - these input variables are
adjusted dynamically to keep the controlled
variables at their set-points.
3. 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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Process variables
Specification of controlled variables,
manipulated variables and disturbance
variables is a critical step in developing a
control system
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Control problems
Batch or semi-batch reactor: The reactor temperature
is controlled by manipulating a coolant flow rate.
Batch digester: The end point of the chemical reaction
is indicated by Kappa number, a measure of lignin
content. It is controlled to a desired value by adjusting
the digester temperature, pressure, and/or cycle time.
Plasma etcher: The unwanted material on a layer of a
microelectronics circuit is selectively removed by
chemical reactions. The temperature, pressure and
flow rates of etching gases to the reactor are
controlled by adjusting electrical heaters and control
valves.
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Control problems
Kidney dialysis unit: The blood flow rate is
maintained by a pump, and ambient
conditions, such as temperature of the unit,
are controlled by adjusting a flow rate.
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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 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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Illustrative Example:
Blending system
Notation:
Assumptions:
w1 is constant
x2 = const. = 1 (stream 2 is pure A
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Blending system
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 ?
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Overall balance:
0 w1 w2 w
(1-1)
Component A balance:
w1x1 w2 x2 wx 0
(1-2)
xSP x1
w2 w1
1 xSP
(1-3)
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w2 t w2 Kc xSP x t
(1-4)
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Control Method 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
xSP x1 t
1 xSP
(1-5)
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Control Method 2
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Control 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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Method
Measured
Variable
Manipulated
Variable
Category
w2
FB
x1
w2
FF
x1 and x
w2
FF/FB
Design
change
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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 the disturbances.
Reduces sensitivity of the controlled variable
to disturbances and changes in the process.
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Feedback Control
Disadvantages:
No corrective action occurs until after the
disturbance has upset the process, that is,
until after x differs from xsp.
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Feedforward Control
Distinguishing feature:
Measure a disturbance variable
Advantage:
Correct for disturbance before it upsets the
process.
Disadvantage:
Must be able to measure the disturbance
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(ho urs-day s)
5. P l ann in g a nd
S ch edu li ng
3b . Mu lti vari ab le
and Cons trai nt
Co ntro l
3a . Re gul atory
Co ntro l
(< 1 se con d)
(< 1 se con d)
1. Mea suremen t
a nd A ctuatio n
P ro ces s
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Conclusions
You have been introduced to:
1. the role of process dynamics and control in
industry
2. general concepts of process control
3. classification of variables
4. the purpose of process control
5. control aspects of complete chemical plant
6. hardware for process control system
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