PROCESS CONTROL Designing Processes and Control Systems for Dynamic Performance Thomas E. Marlin MeMaster University McGraw-Hill, Inc, New York St. Louis San Prancisoo Auckland Bogotd Caracas “Lisbon ‘London Madrid Mexico City Milan Montreal New Delhi San Juan Singapore Sydney Tokyo Toronto“This book was set in Times Roman by Publication Services, Inc. ‘The editors wore BJ. Clark and John M. Morris: the preisction supervisor was Kathryn Pozi. ‘The cover was designed by Initial Graphic Systems, Ic Project supervision was done by Publication Services, Ine. RR, Donnelley & Sons Company was printer and binder. PROCESS CONTROL Designing Processes and Control Systems for Dynamic Performance Copyright ©1995 by McGraw Hil, Ine, Al rights reserved. Printed in the United States of America, Excep as permitted under the United Sites Copyright Act of 1976, no part of thie publication may be reproduced or distributed in any form or by any means, or ‘Stored in a data base or retrieval system, without the proe written permission ofthe pab- lisher. ‘This book is printed on acid-free paper. 4567890 DOCDOC 9098 ISBN 0-07-040491-7, Library of Congress Cataloging-in-Publication Data Matlin, 7. Process con: designing processes and contro systems for dynamic performance / “Thomas Matin, P._ cm-—(McGraw-Hill chemical engineering series) Includes index ISBN 0.07-040491.7 1. Chemical process control. 1. Series TPISS75M365— 1995 6607 2815420 94.45967 ABOUT THE AUTHOR ‘Thomas E. Marlin is Professor of Chemical Engineering at McMaster University, Hamilton, Ontario, Canada, where he holds the NSERC Industrial Research Chair in Process Control. He received his Ph.D. degree in Chemical Engineering from the University of Massachusetts in 1972, after which he applied advanced process con- trol in industry for 15 years. In 1987, he served as the Visiting Fellow for a Warren Centre Study of process automation in Australia that identified potential benefits and. technology needs in a wide range of industries, He is currently Director of the Me- Master Advanced Control Consortium, a group of university personnel and industrial companies collaborating on automation research for the process industries. His re- search interests include real-time advanced control and optimization. In addition to teaching university undergraduate and graduate courses, Dr. Marlin consults widely and teaches numerous industrial short courses on control technology, control benefits analysis, and plant operations optimization, viia CONTENTS Preface Part intro iction 1 Introduction to Process Control 1 12 us 4 15 16 U7 18 19 110 Introduction ‘What Does a Control System Do? Why Is Control Necessary? Why Is Control Possible? How Is Control Done? Where Is Control Implemented? ‘What Does Control Engineering “Engineer”? How Is Process Control Documented” ‘What Are Some Sample Control Strategies? Conclusions 2 Control Objectives and Benefits 24 23 24 25 26 Introduction Control Objectives Determining Plant Operating Conditions Benefits for Controt Importance of Control Engineering Conclusions __Process Dynami: 3 Mathematical Modelling Principles 31 32 33 Introduction A Modelling Procedure Modelling Examples 4 3 3 4 ix