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Chapter1 PDF
Chapter1 PDF
hardware elements.
inferential control.
Textbook:
1. Seborg, D. E., Edgar, T.F., Mellichamp, D. A., (2004), Process
Dynamics and Control, 2nd edition, John Wiley
Chapter 1
Reference Books:
1. Karim, M.N., Riggs, J. B. (2006), Chemical and Bio-Process
Control, 3rd edition, Prentice Hall
2. Marlin, T. (2000), Process Control: Designing Processes and
Control Systems for Dynamic Performance, McGraw Hill
Course Website:
http://teacher.buet.ac.bd/shoukat/
Then click courses Æ Process Control
Dr. M. A. A. Shoukat Choudhury 4
Chapter 1
Dr. M. A. A. Shoukat Choudhury 6
A Career in Process Control
- Requires that engineers use all of their chemical
engineering training (i.e., provides an excellent
technical profession that can last an entire career)
- Allows engineers to work on projects that can result
Chapter 1
Dr. M. A. A. Shoukat Choudhury 7
What is a Process?
Process:
- A Heat Exchanger (heating/cooling)
- A Chemical/Biological Reactor (make
Chapter 1
Dr. M. A. A. Shoukat Choudhury 8
Chemical Process Industries (CPI)
Hydrocarbon fuels
Chemical products
Chapter 1
Dr. M. A. A. Shoukat Choudhury 9
Bio-Process Industries
Pharmaceutical industry
Ethanol from grain industry
Dr. M. A. A. Shoukat Choudhury 10
Chapter 1
Dr. M. A. A. Shoukat Choudhury 11
Chapter 1
Dr. M. A. A. Shoukat Choudhury 12
CONTROL
Chapter 1
Empty vessel
adjustment
anywhere
• Safe location
• History of past
operation
Outputs
Inputs
Chapter 1
(effects)
(cause)
Process
Output:
“off-specification”
Consequence:
Less profit!
Dr. M. A. A. Shoukat Choudhury 16
Benefits of Improved Control
New Controller
Old Controller
Concentration
Limit
Concentration
Limit
Impurity
Impurity
Chapter 1
Time Time
Improved Performance
Concentration
Limit
Impurity
Time
Dr. M. A. A. Shoukat Choudhury 17
Objectives of Process Control
– Maintain a stable process operation
– Appropriate instruments/sensors are to be
implemented to operate under “fail/safe”
conditions.
Chapter 1
Process Control
Objective: to maintain or operate a process at the desired
operating conditions safely and efficiently, while satisfying
environmental and product quality requirements.
a) Large scale, continuous processes:
i. Oil refinery, ethylene plant, pulp mill
ii. Typically, 1000 – 5000 process variables are measured.
1. Most of these variables are also controlled.
Dr. M. A. A. Shoukat Choudhury 20
Process Control (cont’d.)
Dr. M. A. A. Shoukat Choudhury 22
1.1 Illustrative Example: Blending system
Chapter 1
Notation:
• w1, w2 and w are mass flow rates
• x1, x2 and x are mass fractions of component A
Dr. M. A. A. Shoukat Choudhury 23
Assumptions:
1. w1 is constant
2. x2 = constant = 1 (stream 2 is pure A)
3. Perfect mixing in the tank
Control Objective:
Chapter 1
Terminology:
• Controlled variable (or “output variable”): x
• Manipulated variable (or “input variable”): w2
• Disturbance variable (or “load variable”): x1
Dr. M. A. A. Shoukat Choudhury 24
Design Question. What value of w2 is required to have
x = xSP ?
Overall balance:
0 = w1 + w2 − w (1-1)
Chapter 1
Component A balance:
w1 x1 + w2 x2 − wx = 0 (1-2)
xSP − x1 ( t )
w2 ( t ) = w1 (1-5)
1 − xSP
1 x w2 FBa
2 x1 w2 FF
3 x1 and x w2 FF/FB
4 - - Design change
Feedback Control:
• Distinguishing feature: measure the controlled variable
the disturbance.
¾ Reduces sensitivity of the controlled variable to
disturbances and changes in the process (shown later).
• Disadvantages:
¾ No corrective action occurs until after the disturbance
has upset the process, that is, until after x differs from
xsp.
¾ Very oscillatory responses, or even instability…
Dr. M. A. A. Shoukat Choudhury 34
Feedforward Control:
¾ Distinguishing feature: measure a disturbance
variable
• Advantage:
¾ Correct for disturbance before it upsets the process.
Chapter 1
• Disadvantage:
¾ Must be able to measure the disturbance.
¾ No corrective action for unmeasured disturbances.
Dr. M. A. A. Shoukat Choudhury 35
The key elements and principles of a feedback loop
– Cause and Effect
Exercise: The key
elements and
principles of a
feedback loop
Chapter 1
pump valve
Dr. M. A. A. Shoukat Choudhury 36
The key elements and principles of a feedback
loop – Cause and Effect
Exercise: You want to control the level, but you can
only measure the flow in. What is your
strategy? Are you using feedback?
Chapter 1
sensor F
valve
pump
pump valve
Dr. M. A. A. Shoukat Choudhury 37
The key elements and principles of a feedback
loop – Cause and Effect
Exercise: The key elements and principles of a
feedback loop
What is being measured?
Chapter 1
Empty vessel
v8
F2 F5
v3
T5 P1
T4
F1 T1 T3 F3 T6 F4
L1
v1 v5 v6 L2
T7
v2 v7
T2 T8
T9 F6
Hot Oil Hot Oil
F2 F5
v3
T5 P1
T4
F1 T1 T3 F3 T6 F4
L1
v1 v5 v6 L2
T7
v2 v7
T2 T8
T9 F6
Hot Oil Hot Oil
v4
We want to
control the hot
outlet
temperature.
TC
Dr. M. A. A. Shoukat Choudhury 45