Chap 04 Marlin 2013

Process Control: Designing Process
and Control Systems for Dynamic

Performance
Chapter 4. Modelling and Analysis for
Process Control
Copyright Thomas Marlin 2013

The copyright holder provides a royalty-free license for use of this
material at non-profit educational institutions
CHAPTER 4 : MODELLING &

ANALYSIS FOR PROCESS CONTROL
When I complete this chapter, I want to be
able to do the following.
Analytically solve linear dynamic models

of first and second order
Express dynamic models as transfer
functions
Predict important features of dynamic
behavior from model without solving

Outline of the lesson.
Laplace transform
Solve linear dynamic models
Transfer function model structure
Qualitative features directly from model
Frequency response
Workshop
WHY WE NEED MORE DYNAMIC MODELLING

I can model this;
what more do
I need?
I would like to
model elements
individually
combine as needed
determine key
dynamic features
w/o solving
T
A
T
A

I would like to
model elements
individually
This will be a
transfer function
Now, I can combine

elements to model
many process
structures
T
A

Now, I can combine
elements to model
many process
structures
Even more amazing,

I can combine to
derive a simplified
model!
THE FIRST STEP: LAPLACE TRANSFORM
st
L( f (t )) f ( s ) f (t )e dt
0
Constant : L(C ) Ce
0
st
C st
dt e
s
t
t 0
Step Change at t=0: Same as constant for t=0 to t=

f(t)=0
t=0
We have seen
this term
often! Its the
step response to
a first order
dynamic system.
st
L( f (t )) f ( s ) f (t )e dt
0
1
e (1/ s )t dt
e (1/ s )t
s 1/
L((1 e t / )) (1 e t / )e st dt e st dt e t / e st dt
1/ s
1
1
1
s s 1 / s s 1 s( s 1)
1
s 1/

Lets learn a new
dynamic response
& its Laplace
Transform
Lets consider plug flow through a pipe. Plug flow has no

backmixing; we can think of this a a hockey puck
traveling in a pipe.
What is the dynamic response of the outlet fluid property

(e.g., concentration) to a step change in the inlet fluid
property?

Lets learn a new
dynamic response
& its Laplace
Transform
What is the value of
dead time for
plug flow?
Xout
= dead time
Xin
time
Y, outlet from dead time
Lets learn a new

dynamic response
& its Laplace
Transform
Is this a
dead time?
0.5
What is the
value?
-0.5
0
5
time
10
5
time
10
X, inlet to dead time
0.5
-0.5
0

Lets learn a new
dynamic response
& its Laplace
Transform
Our plants have
pipes. We will
use this a lot!
The dynamic model for dead time is
X out (t ) X in (t )
The Laplace transform for a variable after dead time is
L( X out (t )) L( X in (t )) e
X in ( s )

I am in desperate
need of examples!
We need the Laplace transform of

derivatives for solving dynamic models.
constant
df (t )
L
sf (s ) f (t ) t 0
dt
First
derivative:
General:
d n f (t )
dt n
constant
s f (s ) s
n 1
f (t ) t 0 s
n 1 df ( t )
dt
....
t 0
d n 1f (t )
dt n 1
t 0
SOLVING MODELS USING THE LAPLACE

TRANSFORM
Textbook Example 3.1: The CSTR (or mixing tank)
experiences a step in feed composition with all other
variables are constant. Determine the dynamic response.
dC' A
V
F(C' A0 C' A ) VkC' A
dt
dC A'
V
F
'
'
C A KC A0 with
and K
dt
F kV
F kV
I hope we get the same
answer as with the
integrating factor!
F
CA0
(Well solve this in class.)
CA
A B
rA kC A

TRANSFORM
Textbook Example 3.2Two isothermal CSTRs are initially
at steady state and experience a step change to the feed
composition to the first tank. Formulate the model for
CA2.
dC' A1
F(C' A0 C' A1 ) V1k1C' A1
dt
dC' A2
V2
F(C' A1 C' A2 ) V2 k 2 C' A2
dt
V1
Much easier than

integrating factor!
F
CA0
dC A' 1
1
C A' 1 K1C A' 0
dt
dC A' 2
2
C A' 2 K 2C A' 1
dt
CA1
V1
CA2
V2
A B
rA kC A

TRANSFORM
Textbook Example 3.5: The feed composition experiences a
step. All other variables are constant. Determine the
dynamic response of CA.
Non-linear!
F
CA0
A B
rA
2
kC A
CA
TRANSFER FUNCTIONS: MODELS VALID FOR

ANY INPUT FUNCTION
Lets rearrange the Laplace transform of a dynamic model
Y(s) = G(s) X(s)
X(s)
G(s)
Y(s)
A TRANSFER FUNCTION is the output variable, Y(s),

divided by the input variable, X(s), with all initial
conditions zero.
G(s) = Y(s)/X(s)

ANY INPUT FUNCTION
G(s) = Y(s)/ X(s)
X(s)
How do we achieve zero initial

conditions for every model?
We dont have primes on the
variables; why?
Is this restricted to a step input?
What about non-linear models?
How many inputs and outputs?
G(s)
Y(s)

ANY INPUT FUNCTION
G(s) = Y(s)/ X(s)
X(s)
Some examples:
C A (s)
Mixing tank :
G( s ) ?
C A0 ( s )
C A2 ( s )
Two CSTRs :
G( s ) ?
C A0 ( s )
G(s)
Y(s)

ANY INPUT FUNCTION
G(s) = Y(s)/ X(s)
X(s)
G(s)
Y(s)
Why are we doing this?

To torture students.
We have individual models that we can
combine easily - algebraically.
We can determine lots of information
about the system without solving the
dynamic model.
I chose the
first answer!

ANY INPUT FUNCTION
Lets see how to
combine models
3
F0 ( s )
m
/s
Gvalve ( s )
.10
% open
v( s)
T ( s)
G tank1 ( s ) 1
F0 ( s )
1.2 K
m 3 /s
250 s 1
Tmeasured ( s )
Gsensor ( s )
T2 ( s )
Gtank2 ( s )
T2 ( s ) 1.0 K / K
T1 ( s )
300 s 1
1 .0 K / K
10 s 1
(Time in seconds)

ANY INPUT FUNCTION
The BLOCK DIAGRAM
v(s)
F0(s)
Gvalve(s)
T1(s)
Gtank1(s)
T2(s)
Gtank2(s)
Its a picture of the model equations!

Individual models can be replaced easily
Helpful visualization
Cause-effect by arrows
Tmeas(s)
Gsensor(s)

ANY INPUT FUNCTION
Combine using BLOCK DIAGRAM ALGEBRA
v(s)
F0(s)
Gvalve(s)
T1(s)
T2(s)
Gtank1(s)
v(s)
Gtank2(s)
G(s)
Tmeas(s)
Gsensor(s)
Tmeas(s)
T1 ( s ) F0 ( s )
F0 ( s ) v( s )
Gs ( s )GT 2 ( s )GT 1 ( s )Gv ( s )
Tmeas ( s )
Tmeas ( s )
G( s )
v( s )
T2 ( s )
T2 ( s )
T1 ( s )

ANY INPUT FUNCTION
Key rules for BLOCK DIAGRAM ALGEBRA
QUALITATIVE FEATURES W/O SOLVING

FINAL VALUE THEOREM: Evaluate the final valve of the
output of a dynamic model without solving for the entire
transient response.
Y (t ) t lim sY(s)
s
Example for first order system
C A (t ) |t lim s
s 0
C A0 K p
s( s 1)
C A0 K p

What about dynamics
can we determine
without solving?
We can use partial fraction

expansion to prove the following
key result.
Y(s) = G(s)X(s) = [N(s)/D(s)]X(s) = C1/(s- 1) + C2/(s- 2) + ...

With i the solution to the denominator of the transfer
function being zero, D(s) = 0.
1t
Y (t ) A0 A1e
2t
A2 e
... ( B0 B1t B2t ..)e

qt
... [C1 cos(t ) C2 sin(t )]e

Real, distinct i
pt
Complex i
q is Re( i)
...
Real, repeated i

With i the solutions to D(s) = 0, which is a polynomial.
1t
Y (t ) A0 A1e
2t
A2 e
pt
... ( B0 B1t B2t ..)e

qt
... [C1 cos(t ) C2 sin(t )]e
...
1. If all i are ???, Y(t) is stable

If any one i is ???, Y(t) is unstable
2. If all i are ???, Y(t) is overdamped
(does not oscillate)
If one pair of i are ???, Y(t) is
underdamped
Complete statements
based on equation.

With i the solutions to D(s) = 0, which is a polynomial.
1t
Y (t ) A0 A1e
2t
A2 e
pt
... ( B0 B1t B2t ..)e

qt
... [C1 cos(t ) C2 sin(t )]e
...
1. If all real [ i] are < 0, Y(t) is stable

If any one real [ i] is 0, Y(t) is unstable
2. If all i are real, Y(t) is overdamped (does not
oscillate)
If one pair of i are complex, Y(t) is underdamped

1
dC A' 1
C A' 1 K1C A' 0
dt
dC A' 2
2
C A' 2 K 2C A' 1
dt
A B
rA kC A
F
CA0
CA1
V1
CA2
V2
1. Is this system stable?

2. Is this system over- or underdamped?
Without
solving!
3. What is the order of the system?

(Order = the number of derivatives
between the input and output variables)
4. What is the steady-state gain?

FREQUENCY RESPONSE:The response to a sine input of
the output variable is of great practical importance. Why?
Sine inputs almost never occur. However, many

periodic disturbances occur and other inputs can be
represented by a combination of sines.
For a process without control, we want a sine input to
have a small effect on the output.

Amplitude ratio = |Y(t)| max / |X(t)| max
Phase angle = phase difference between
input and output
P
output
Y, outlet from system
0.4
0.2
0
-0.2
-0.4
X, inlet to system
3
time
3
time
input
0.5
0
-0.5
-1

Amplitude ratio = |Y(t)| max / |X(t)| max
Phase angle = phase difference between
input and output
For linear systems, we can evaluate directly using transfer function!
Set s = j, with = frequency and j = complex variable.
Amp. Ratio AR G ( j ) Re(G ( j )) 2 Im(G ( j )) 2

Im(G ( j ))
Re(G ( j ))
Phase angle G ( j ) tan 1
These calculations are tedious by hand but easily performed in

standard programming languages.

Example 4.15 Frequency response of mixing tank.
Time-domain
behavior.
Bode Plot - Shows

frequency response for
a range of frequencies
Log (AR) vs log()
Phase angle vs log()

CA2
F
CA0
CA1
Sine disturbance with
V1
CA2
V2
Must have
fluctuations
amplitude = 1 mol/m3
frequency = 0.20 rad/min
Data from 2 CSTRs
< 0.050 mol/m3
Using equations for the frequency response amplitude ratio

Kp
| C A2 |
| G ( j ) |
| C A0 |
(1 2 2 )
| C A 2 || C A0 |
Kp
(1 2 2 )
| C A 2 | (1.0)(0.12) 0.12 0.050
Not acceptable. We need

to reduce the variability.
How about feedback
control?
OVERVIEW OF ANALYSIS METHODS

Transfer function and block diagram
We can determine
individual models
and combine
1. System order
2. Final Value
3. Stability
4. Damping
5. Frequency response
We can determine
these features without
solving for the
entire transient!!
Flowchart of Modeling Method

Goal:
Assumptions:
Data:
Combining Chapters 3
and 4
Variable(s): related to goals

System : volume within which variables are indepen dent of position
Fundam ental Ba lance: e.g. material, energy
DOF = 0
Is model linear?
Yes
Check
D.O.F.
No
DOF 0
Anothe r equa tion:
-Fundament al balance
-Constitutive equations
Expand in Taylor Series
Express in deviation var iables
Group param eter s to evalua te [ga ins (K), time-constants (), dead-times()]
Take Laplace transform
Substitute specific input, e.g.,
step, and solve for output
Ana lytical solution

(ste p)
Num erical solution
Ana lyze the m odel for:

- causality
- order
- stability
- damping
Combine severa l m odels into

integrated system
We can use a
standard modelling
procedure to
focus our
creativity!
Too small to read here - check it out in the textbook!
CHAPTER 4: MODELLING & ANALYSIS WORKSHOP 1
Example 3.6 The tank with a drain has a continuous flow in

and out. It has achieved initial steady state when a step
decrease occurs to the flow in. Determine the level as a
function of time.
Solve the linearized model using Laplace transforms
T
A
1. System order
2. Final Value
3. Stability
4. Damping
5. Frequency response
The dynamic model for a nonisothermal CSTR is derived in

Appendix C. A specific example
has the following transfer
function.
T (s)
( 6.07 s 45.83)
2
Fc ( s ) ( s 1.79 s 35.80)
Determine the features
in the table for this
system.

Answer the following using the MATLAB program
S_LOOP.
Using the transfer function derived in Example 4.9,
determine the frequency response for CA0 CA2. Check one
point on the plot by hand calculation.
F
CA0
CA1
V1
CA2
V2

We often measure pressure for process monitoring and control.
Explain three principles for pressure sensors, select one for P1
and explain your choice.
T6
Feed
T1
T2
T5
F1
T4
T3
F2
P1
L1
F3
Process Steam
fluid
Vapor
product
A1
L. Key
Liquid
product

When I complete this chapter, I want to be
able to do the following.
Analytically solve linear dynamic models of first

and second order
Express dynamic models as transfer functions
Predict important features of dynamic behavior

from model without solving
Lots of improvement, but we need some more study!

Read the textbook
Review the notes, especially learning goals and workshop
Try out the self-study suggestions
Naturally, well have an assignment!
LEARNING RESOURCES
SITE PC-EDUCATION WEB

- Instrumentation Notes
- Interactive Learning Module (Chapter 4)
www.pc-education.mcmaster.ca/
- Tutorials (Chapter 4)
Software Laboratory
- S_LOOP program
SUGGESTIONS FOR SELF-STUDY

1. Why are variables expressed as deviation variables when
we develop transfer functions?
2. Discuss the difference between a second order reaction
and a second order dynamic model.
3. For a sine input to a process, is the output a sine for a
a. Linear plant?
b. Non-linear plant?
4. Is the amplitude ratio of a plant always equal to or
greater than the steady-state gain?
SUGGESTIONS FOR SELF-STUDY

5. Calculate the frequency response for the model in
Workshop 2 using S_LOOP. Discuss the results.
6. Decide whether a linearized model should be used for
the fired heater for
PIC
1
a. A 3% increase in the
fuel flow rate.
b. A 2% change in the
feed flow rate.
c. Start up from ambient
temperature.
d. Emergency stoppage
of fuel flow to 0.0.
feed
AT
1
FT
1
PI
4
TI
1
PI
5
TI
5
TI
2
TI
6
PT
1
TI
3
TI
7
TI
4
TI
9
TI
8
FT
2
PI
2
air
TI
10
FI
3
PI
3
TI
11
PI
6
fuel

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Process Control: Designing Process

and Control Systems for Dynamic

Copyright Thomas Marlin 2013

CHAPTER 4 : MODELLING &

Analytically solve linear dynamic models

CHAPTER 4 : MODELLING &

WHY WE NEED MORE DYNAMIC MODELLING

WHY WE NEED MORE DYNAMIC MODELLING

Now, I can combine

WHY WE NEED MORE DYNAMIC MODELLING

Even more amazing,

THE FIRST STEP: LAPLACE TRANSFORM

Step Change at t=0: Same as constant for t=0 to t=

THE FIRST STEP: LAPLACE TRANSFORM

THE FIRST STEP: LAPLACE TRANSFORM

Lets consider plug flow through a pipe. Plug flow has no

What is the dynamic response of the outlet fluid property

THE FIRST STEP: LAPLACE TRANSFORM

THE FIRST STEP: LAPLACE TRANSFORM

Y, outlet from dead time

Lets learn a new

X, inlet to dead time

THE FIRST STEP: LAPLACE TRANSFORM

The dynamic model for dead time is

THE FIRST STEP: LAPLACE TRANSFORM

We need the Laplace transform of

SOLVING MODELS USING THE LAPLACE

(Well solve this in class.)

SOLVING MODELS USING THE LAPLACE

Much easier than

(Well solve this in class.)

SOLVING MODELS USING THE LAPLACE

(Well solve this in class.)

TRANSFER FUNCTIONS: MODELS VALID FOR

A TRANSFER FUNCTION is the output variable, Y(s),

TRANSFER FUNCTIONS: MODELS VALID FOR

How do we achieve zero initial

TRANSFER FUNCTIONS: MODELS VALID FOR

TRANSFER FUNCTIONS: MODELS VALID FOR

Why are we doing this?

TRANSFER FUNCTIONS: MODELS VALID FOR

TRANSFER FUNCTIONS: MODELS VALID FOR

Its a picture of the model equations!

TRANSFER FUNCTIONS: MODELS VALID FOR

TRANSFER FUNCTIONS: MODELS VALID FOR

QUALITATIVE FEATURES W/O SOLVING

Example for first order system

QUALITATIVE FEATURES W/O SOLVING

We can use partial fraction

Y(s) = G(s)X(s) = [N(s)/D(s)]X(s) = C1/(s- 1) + C2/(s- 2) + ...

... ( B0 B1t B2t ..)e

... [C1 cos(t ) C2 sin(t )]e

QUALITATIVE FEATURES W/O SOLVING

... ( B0 B1t B2t ..)e

... [C1 cos(t ) C2 sin(t )]e

1. If all i are ???, Y(t) is stable

QUALITATIVE FEATURES W/O SOLVING

... ( B0 B1t B2t ..)e

... [C1 cos(t ) C2 sin(t )]e

1. If all real [ i] are < 0, Y(t) is stable

QUALITATIVE FEATURES W/O SOLVING

C A' 1 K1C A' 0

1. Is this system stable?

3. What is the order of the system?