University of Mindanao

College Of Engineering Education

Matina, Davao City

Fundamentals of Process Dynamics and Control:

Modeling and Analysis for Process Controls

Submitted by:
Charlyn M. Cabañog
Bs ChE – 4th

Submitted to:
Engr. Ramiro Emerson C. Amon
Instructor

21 June 2018
 Process dynamics and control is an inter-disciplinary area. Three disciplines, process,
control, and information engineering are of importance. The three disciplines answer
questions such as: for what, why, how, and in which way. Other disciplines are also of
interest like Process engineering, Control engineering, Software engineering, Business
management, Human factors, and Chemical analysis. (Roffel & Betlem, 2006)

Among other things, a process is a system for the transfer of energy. Whenever the
distribution of energy is modified or disturbed, the variables in the system will change value.
It is usually difficult to measure energy directly, but we can use variables that are more
readily measured such as temperature, pressure, and flow. Five processes to control:
temperature, pressure, flow, level, and composition.

A control system has an input, a process, and an output. It can be open loop or closed
loop. Open-loop systems do not monitor or correct the output for disturbances. Closed-loop
systems monitor the output and compare it to the input. If an error is detected, the system
corrects the output and hence corrects the effects of disturbances.
A control system is dynamic: It responds to an input by undergoing a transient
response before reaching a steady-state response that generally resembles the input.
Transient response
In the case of an elevator, a slow transient response makes passengers impatient, whereas
an excessively rapid response makes them uncomfortable. Transient response is also
important for structural reasons: Too fast a transient response could cause physical damage.
Steady-State Response
This response resembles the input and is usually what remains after the transients
have decayed to zero. For example, this response may be an elevator stopped near the fourth
floor. An elevator must be level enough with the floor for the passengers to exit. We define
steady-state errors quantitatively, analyze a system’s steady-state error, and then design
corrective action to reduce the steady-state error.

Control systems are used to maintain process conditions at their desired values by
manipulating certain process variables to adjust the variables of interest. A common example
of a control system from everyday life is the cruise control on an automobile. The purpose of
a cruise control is to maintain the speed of the vehicle (the controlled variable) at the desired
value (the set point) despite variations in terrain, hills, etc. (disturbances) by adjusting the
throttle, or the fuel flow to the engine (the manipulated variable). (Coughanowr & LeBlanc,
2009)
Conceptually we can view the control systems in a following manner (Fig. 1–1)
The controller compares the measurement signal of the controlled variable to the set
point (the desired value of the controlled variable). The difference between the two values is
called the error.

The type of control system shown in Fig. 1–1 is termed a closed-loop feedback
control system. Closed-loop refers to the fact that the controller automatically acts to return
the controlled variable to its desired value. In contrast, an open-loop system would have the
measurement signal disconnected from the controller, and the controller output would have to
be manually adjusted to change the value of the controlled variable. An open-loop system is
sometimes said to be in manual mode as opposed to automatic mode (closed-loop). Negative
feedback is the most common type of signal feedback. Negative refers to the fact that the
error signal is computed from the difference between the set point and the measured signal.
The negative value of the measured signal is “fed back” to the controller and added to the set
point to compute the error. (Coughanowr & LeBlanc, 2009)

Block Diagram
A good overall picture of the relationships among variables in a heated-tank control
system may be obtained by preparing a block diagram as shown in Fig. 1–1. It indicates the
flow of information around the control system and the function of each part of the system.
Particularly significant is the fact that each component of the system is represented by a
block, with little regard for the actual physical characteristics of the represented component
(e.g., the tank or controller). The major interest is in (1) the relationship between the signals
entering and leaving the block and (2) the manner in which information flows around the
system. (Coughanowr & LeBlanc, 2009)
Verbal modeling
Verbal modeling is used for creating and also understanding a process control system.
Verbal modeling consists of first receiving and then gathering information about the process.
A step-by-step process is then used to describe the control systems used to satisfy constraints
and objectives that have been outlined.
There will be five sets of criteria, often coming from different people and institutions.
By gathering all of these criteria you will be able to describe the control system.
Safety
The safe operation of a process is the biggest concern of those working in the plant
and those that live in the surrounding community. The temperatures, pressures, and
concentrations within the system should all fall within acceptable limits. These limits can be
dictated by either government agencies or company policy.
Production Objectives
The production objectives usually include both the amount and purity of the desired
product. This criterion is generally set by the company or customer.
Environmental Regulations
These come in the form of restrictions on the temperature, concentration of chemicals,
and flow rate of streams exiting a plant. State and federal laws, for instance, may dictate the
exit temperature of a cooling water stream into a lake in order to prevent harm to aquatic
wildlife.
Operational Constraints
Equipment found in the plant may have their own unique limitations, such as
temperature or pressure that require proper control and monitoring. For instance, a
thermocouple may be damaged at extremely high temperatures, thus the location of the
thermocouple must be accounted for.
Economics
In general, a company will operate so that its profits are maximized. The process
conditions that maximize these profits are determined by way of optimization. Many costs
must be considered when optimizing process conditions. Some of these costs are fixed, or
will not change with process variables (i.e. equipment costs) and others are variable, or do
depend on process variables (i.e. energy costs). The overall process is usually limited by
certain factors including availability of raw materials and market demand for the final
product. Therefore, the economics of a process must be well understood before process
changes are enforced.

1.) Describe the Process

A brief description of the general process is needed while not dwelling on the
details and calculations involved. The major steps of the process, as well as inputs
and outputs of the process, should be stated. A simple diagram should be provided
detailing the chemical process to help visualize the process.
2.) Identify Process Objectives and Constraints
The objectives and constraints of the process must be identified before
process control actions can be performed. The process objectives include the type,
quantity, and quality of the product that is to be produced from the process. The
economic objectives, such as the desired levels of raw material usage, costs of
energy, costs of reactants, and price of products, should also be identified.
3.) Identify Significant Disturbances
Disturbances, in the sense of process description, are defined as inputs or
external conditions from the surrounding environment that have certain properties
that cannot be controlled by the plant personnel. Examples of disturbances include
ambient air temperature, feed temperature, feed flow rate, feed composition, steam
pressure changes, and cooling water temperature changes. Disturbances can
drastically affect the operation of a unit. A control system should be able to
effectively handle all process disturbances. As such, all possible disturbances must
be identified and these disturbances need to be accounted for by the development of
contingency plans within the process.
4.) Determine Type and Location of Sensors
A proper design must ensure that adequate measurements of the system are
obtained to monitor the process. To meet this goal, sensors must be chosen to
accurately, reliably, and promptly measure system parameters. Such parameters
include temperature, flow rate, composition, and pressure. Placement of sensors is
important both in the usefulness of measurements as well as the cost of the system.
Sensors should be placed such that the measured quantities are appropriate in
addressing control objectives.
5.) Determine the Location of Control Valves
Valves must be placed in a location to control variables that impact the control
objectives. For example, control of the temperature of a reactor could be obtained by
placing a valve on either the stream of heating / cooling fluids or by placing a valve
on the feed stream to the reactor. One must determine which streams should be
manipulated to meet process objectives.
6.) Perform a Degree of Freedom Analysis
The degrees of freedom in a system are equal to the number of manipulated
streams (Determined in step 5) minus the number of control objectives and control
restraints (Determined in step 2). A degree of freedom analysis is used to determine
if a system is being under- or over-specified by the process objectives. The degrees
of freedom come from the number of known and unknown that are specified within
the system. If there are extra degrees of freedom present in a system, unused
manipulated variables can be used to optimize the process. If there are negative
degrees of freedom, a system is over specified because more objectives and
restraints exist than manipulated streams. In this case, all objectives cannot
necessarily be met simultaneously and the least important objectives must be
neglected. A system with zero degrees of freedom is fully specified.
All objectives can be met, but there is no room for optimization.
7.) Energy Management
In any system with exothermic or endothermic reactions, distillation columns,
or heat exchangers, energy management becomes a factor that must be accounted
for. Heat must be removed from exothermic reactions in order to prevent reactor
runaway, and heat must be supplied to endothermic reactions to ensure desired
production rates. Strategies such as pre-heating feed streams with the excess heat
from a product stream are helpful in maintaining efficient usage of energy; however,
they also result in more complex processes that may require more intricate control
systems.
8.) Control Process Production Rate and Other Operating Parameters
The production rate can be controlled by a variety of manipulated variables.
One manipulated variable may be the feed rate. The plant feed rate can be changed
and each subsequent unit can use its controls to accommodate this change,
ultimately resulting in a change in the final production rate. Other manipulated
variables may also include reactor conditions, such as temperature and pressure.
Temperature and pressure affect reaction rates and can be used to alter the final
production rate. It is important to choose the most suitable manipulated variable to
control production rate.
9.) Handle Disturbances and Process Constraints
The effects of disturbances should be minimized as much as possible, in
order to maintain the system at desired conditions and meet all process objectives
and constraints.
Feedback or feedforward are specific control techniques and are common
ways to overcome disturbances. A feedback control works by studying the
downstream data and then altering the upstream process.
Additionally, if constraints are reached during the process, controls should be
implemented to avoid safety, operational, or environmental hazards. This can also
be done with feedback and feedforward controls on manipulated variables.
10.) Monitor Component Balances
Every component within a process, whether it is inert or not, should be
accounted for at every step of the system in order to prevent accumulation. This step
is more crucial in processes that involve recycle streams. If such a stream is present,
a purge stream is often necessary to remove unwanted components. In addition,
component balances are used to monitor yield and conversion or reveal locations in
the process where loss may be occurring. In order to monitor component balances,
composition sensors are used.
11.) Control Individual Unit Operations
Most systems used today in industry employ the use of multiple unit
operations. Each of these unit operations, however, needs to be fully controllable in
the sense that it has a control system that can adjust manipulated variables in order
to maintain other parameters. For instance, a crystallizer. The refrigeration load of
the crystallizer must be controllable in order to control the temperature.
12.) Optimize the Process
In most cases, there will be certain aspects of a process that will not be
dictated to a designer and can be changed to make the overall process more
economical for the company. These are referred to as "unaccounted for" degrees of
freedom and can be implemented as new control valves or adjustable controller set
points.
Works Cited
Coughanowr, D., & LeBlanc, S. (2009). Process Systems Analysis and Control. New York: McGraw-Hill.

O'Connor, D. (2000). A Process Control Primer. Illinois: Honeywell.

Roffel, B., & Betlem, B. (2006). Process Dynamics and Control: Modeling for Control and Prediction.
John Wiley & Sons Ltd.