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KKEK 3154
DEPARTMENT OF CHEMICAL
ENGINEERING
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In the chemical industry,
Process Control
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What is the purpose of a control system?
To maintain important process characteristics at
desired targets despite the effects of external
perturbations/disturbances.
Perturbations Process / Plant Control
/disturbances objectives
Market Safety
Economy Make $$$
Climate Product quality
Variations in raw materials Environment...
Control
Process Control
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Example
Disturbances
Temperature variations in
cooling water
Variations in concentrations
of reactants
Operation based on
optimised steady-state
condition (set and forget)
wont work!
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Importance of Process Control
1. Process control improves the safety and reliability of a process
A Control system must provide safe operation, e.g., alarms, safety
constraint control
Stabilise unstable processes, prevent certain important variables from
running away. E.g, temperature control of an exothermic reaction
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Importance of Process Control
3. Can affect how efficient a process is operated more efficient use of
raw materials and energy
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What constitutes a control system?
Control
Combination of process
sensors, actuators and
computer systems
designed and tuned
to orchestrate
safe and profitable
operation.
Plant
Process Control
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Because good control needs understanding of process dynamics, this subject will
cover two major areas:
Process Dynamics:
Study of the transient behavior of processes
Process Control
the use of process dynamics for the
improvement of process operation and
performance
Or
the use of process dynamics to alleviate the
effect of undesirable (unstable) process
behaviors
Process Control
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What do we mean by process?
u
y
P
d
Information Flow
INPUT (manipulated variable) : (u) Something that you can manipulate
DISTURBANCE: (d) Something that comes as a result of some
outside phenomenon but cannot be manipulated
OUTPUT (controlled variable): (y) An observable quantity that we want to
regulate/control
Process Control
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Examples of Process
Examples: Temperature of Stirred Tank
Control Objective
Controlled Variable (CV)
Set Point (SP)
M Controller Output (CO)
Manipulated Variable (MV)
Disturbances (D)
Tin, w
T, w
Q
Inputs Output
Tin
w Process T
Q
Process Control
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Control
Process Control
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Examples: Control of Stirred-Tank Heater
Tin, w
Heater
Q T, w
TC
Thermocouple
Tin, w
Controller Heater T
TR e u y
+ Q
C A P
-
Tank
M
Thermocouple
Process Control
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Examples of Control System
u
glucose
setpoint y
r
Process Control
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Control development is usually carried out following these important
steps
Define objectives
Develop a process
model (KKEK 3152!)
Often an iterative
process, based on Design controller ba sed
performance we may on model
decide to retune,
redesign or remodel a Test by simulation
given control system
Commissioning,
Implement and tune
Monitor performance
Process Control
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Objectives
What are we trying to control?
Process modeling
What do we need?
Mechanistic (first principle) and/or empirical
Controller design
How do we use the knowledge of process behavior to reach our
process control objectives?
What variables should we measure?
What variables should we control?
What are the best manipulated variables?
What is the best controller structure?
Process Control
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Implement and tune the controlled process
Test by simulation
incorporate control strategy to the process hardware
theory rarely transcends to reality
tune and re-tune
Monitor performance
periodic retuning and redesign is often necessary based on
sensitivity of process or market demands
statistical methods can be used to monitor performance
Process Control
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