Process Control

Process Control Using Process Simulator

Riezqa Andika
 Simulation/Process Simulation?

▪ Simulation
Use of a computer program to quantitatively model
the characteristic equations of a process.

▪ Process Simulation
Apply Simulation to Chemical Process
- Steady State .vs. Dynamic state
- Design, Operation
▪ Model
A Model is an Abstraction of Reality that we use to
help gain understanding of an entity.
 Principle

“All models are wrong

– but some are useful”

W. Edwards Deming
George Box
 Steady and Dynamic Simulation
⚫ Steady-State Modeling: Input – Output = 0

FV Solution Space
x F(x) •Design
F •Operation
xs •Optimization
xi
F(x)=0
FL
F = FV + FL 0 Simulation Taken Time
or Number of Iteration

⚫ Dynamic Modeling: Input – Output = Accumulation

x
FV
F PC •Design Verification
•Operation Analysis
LC •Control Strategy
FC
•Operator Training
FL
0 Time
dV / dt = F − ( FV + FL )
 Dynamic Modeling

▪ Basic requirements for Dynamic modeling:

- Size equipment
- Define pressure flow specifications
- Add strip charts and controllers
- Run a simple Dynamic simulation and observe the role of
the various controllers

▪ Examines the process of changing from Steady State

simulation into Dynamic model
 Transition from Steady State to Dynamic

▪ Equipment Sizing is a very important step in Dynamic

modeling

▪ Remember to pay attention to the pressure drop across

the plant
- NO PRESSURE DROP = NO FLOW
- POSITIVE PRESSURE GRADIENT = NEGATIVE FLOW

▪ Think like it is a real plant

 Size Matters in Dynamic!

Large tanks can mitigate disturbances

 Transition from Steady State to Dynamic

The Procedure for moving from a Steady State case to a Dynamic

one follows:
▪ Adding Valves to the simulation.
• Valves are use to control the flow in streams. They are often not
required in Steady State cases but are key operations in Dynamic
cases.
▪ Equipment Sizing
• All unit operations in the simulation need to be sized using actual
plant equipment . Vessels should be sized to accommodate actual
plant flowrates and pressure while maintaining acceptable residence
time.
▪ Adding Controllers.
• PID controllers are used to control the simulation.
▪ Defining the Pressure-Flow Relationship in the process.
▪ Adding Stripcharts to monitor process variables.
 Equipment Sizing

Rating/Dynamics Tab

▪ Sizing the Valves

• Valve type
• Normal valve opening position
• Pressure drop across the valve
• Current flow rate

▪ Sizing the separator (3000 ft3) (85 m3)

▪ Sizing the heat exchanger (1165 ft3; 315 ft3) (33m3; 9m3)

▪ Sizing the heater (1165 ft3) (33m3)

 Sizing
Height/Length?
Diameter? Cv?
Volume?
etc.?

Tray Spacing?
Diameter?
Internals
(ex:Weir
Height)?
etc.? Cv? ? Cv?

Cv?

Cv?
Heuristics/Rule of Thumb
Heuristics/Rule of Thumb
Heuristics/Rule of Thumb
 Pressure Flow Specs

Pressure-flow relationships solutions

▪ Material Streams
• Pressure specification
• Flow specification

▪ Equipment
• Fixed Pressure drop
• Pressure/Flow equation
• Resistance calculation (for valves)
• Conductance Calculation (for process equipment)
 Process Control

Designing Controller

Riezqa Andika
 How to Make Pairing?

TT

Which one more suitable to control reboiler duty? A tray temperature, steam
flow, or else?
 How to Make Pairing?

FT

Which one more suitable to control reboiler duty? A tray temperature, steam
flow, or else?
 How to Make Pairing?

FT

Which one more suitable to control reboiler duty? A tray temperature, steam
flow, or else?
 How to Make Pairing?

TT

Which one more suitable to control reboiler duty? A tray temperature, steam
flow, or else?
 An Equipment Scale Pairings (Distillation Column)

▪ Controller outputs – xD, xB, P, hD, hB

▪ Manipulated inputs – D, B, R, QD, QB
▪ Best pairings not obvious
▪ Number of possible pairings = n! = 5! = 120
▪ Need efficient method to screen possible pairings
 Open-Loop and Closed-Loop

▪ Open-loop (non-feedback system)

▪ Closed-loop control (feedback system)

Open-loop control

Closed-loop control
 The Relative Gain

▪ Quantifies the change in steady-state gain between an input-output pair that

occurs when other control loops are closed
▪ Provides a measure of steady-state process interactions from only gain
information
▪ Relative gain between input j and output i
𝜕𝑖 /𝜕𝑗
𝑢
λ𝑖𝑗 = 𝑖, 𝑗𝜖 1, 𝑛
𝜕𝑖 /𝜕𝑗
𝑦

where:
𝜕𝑖 /𝜕𝑗 is the open-loop gain with all other control loop open
𝑢
𝜕𝑖 /𝜕𝑗 is the closed-loop gain with all other control loop closed
𝑢
 Relative Gain Calculation for 2×2 System

▪ Steady-state model
y1 = K11u1 + K12u2 y2 = K21u1 + K22u2

▪ Open-loop gain
𝜕𝑖 /𝜕𝑗 = 𝐾11
𝑢2 =0

▪ Closed-loop gain
𝐾
𝑦2 = 0 ➔ 𝑢2 = − 𝐾21 𝑢1
22
𝐾12 −𝐾21 𝜕𝑦1 𝐾12 −𝐾21
𝑦1 = 𝐾11 1 − 𝑢1 ➔ = 𝐾11 1 −
𝐾11 𝐾22 𝜕𝑢1 𝑦 =0 𝐾11 𝐾22
2

▪ Relative gain
𝜕𝑦1 /𝜕𝑢1 𝑢2 =0 𝐾11 1
λ11 = = 𝐾 −𝐾 = 𝐾 −𝐾
𝜕𝑦1 /𝜕𝑢1 𝑦2 =0 𝐾11 1− 𝐾12 𝐾 21 1− 𝐾12 𝐾 21
11 22 11 22
 The Relative Gain Array

▪ Definition

▪ Each row and column of the RGA must sum to unity

 Input-Output Pairings: 2×2 Case

▪ RGA

▪ Five possible cases

a. λ = 1: open-loop and closed-loop gains are identical; pair u1 and y1
b. λ = 0: open-loop gain is zero; do not pair u1 and y1
c. 0 < λ < 1: closed-loop gain is larger than the open-loop gain; pair u1 and y1 if λ
is “close” to 1
d. λ > 1: closed-loop gain is smaller than the open-loop gain; pair u1 and y1 if λ is
“close” to 1
e. λ < 0: open-loop and closed-loop gains have opposite signs; do not pair u1
and y1
 Input-Output Pairings: General Case

▪ RGA

▪ Pairing rules
a. λij = 1: pair u1 and y1
b. λij < 0: do not pair u1 and y1
c. λij = 0: do not pair u1 and y1
d. 0 < λij < 1: pair u1 and y1 if λij is “close” to 1
e. λij > 1: pair u1 and y1 if λij is “close” to 1
▪ Caveat
RGA is based only on steady-state information and neglects process dynamics

Further reading: http://homepages.ed.ac.uk/jwp/control06/controlcourse/restricted/course/advanced/module6.html

Examples (1)
 Examples (2)
2×2 Systems
1
Y1 = K11U1 + K12U 2 11 = , 12 = 1 − 11 =  21
K12K 21
1−
Y2 = K 21U1 + K 22U 2 K11K 22
Example:
K K12   2 1.5
K =  11  = 
K 21 K 22  1.5 2 
 2.29 − 1.29 
 = 
Recommended pairing is Y1
−  and U1, Y2 and U2.
 1.29 2.29 
Example:

− 2 1.5 0.64 0.36 

K=    = 0.36 0.64 
1.5 2   
Recommended pairing is Y1 with U1, Y2 with U2.
Examples with MATLAB
Process Control

PID Control

Riezqa Andika
Flowchart for Controller Selection
Controller Library
 PID Controller

Proportional
E SP
= Set point
MV + Integral
+
= controller output - CV =
Derivative Controlled
variable
Note: Error = E  SP - CV sensor
Final
Process
element
variable
PROCESS
 Basic of the PID Controller

▪ The PID controller is the most used controller in the

process industries
▪ The basic PID equation is:
OP(t) = Kc E(t) + Kc/τi ∫(E(t)dt + Kc τd dE(t)/dt
P – Proportional I - Integral D - Derivative

where:
OP(t) = controller output value
E(t) = error between controller setpoint and process variable

and the tuning parameters are:

Kc = controller gain
τi = controller integral reset
τd = controller derivative constant
Key Input for the PID Controller Model
 PID Tuning Method

▪ Ziegler-Nichols
▪ Tyerus-Luyben
▪ Cohen-Coon
▪ Ciancone and Marline
▪ Etc.
 Controller Tuning - Recommendations

The values below are recommended starting points for

tuning control loops (from Aspen).

System Kc τi (minutes) τd (minutes)

Flow 0.1 0.2 0
Level 2 10 0
Pressure 2 2 0
Temperature 1 20 0
 Zeigler-Nichols Tuning

▪ John G. Zeigler and Nathaniel B. Nichols are the

fathers of scientific tuning methods
In 1942, they published two loop tuning
techniques that addressed the question of
how an engineer can determine the values of
Kp, Ti, and Td

▪ ¼ Wave decay concept

Criticism is that it will not give robust
controller performance and the process
borders on instability
Zeigler-Nichols Tuning
 Zeigler-Nichols Tuning Method

1) Zeigler-Nichols Continuous Cycling Method

▪ This is a trial and error method conducted while a
control loop is in automatic mode (closed loop
systems)

2) Zeigler-Nichols Step Method

▪ Uses a reaction curve to perform calculations
▪ Used for stable open loop systems (manual
mode)
 Zeigler-Nichols Continuous Steps

Step 1
With the loop in automatic mode, enter a new set point a small amount
above or below the set point at which you want to tune. Allow the loop to
stabilize.

Step 2
Place the loop in manual mode, the loop must continue to be stable.

Step 3
Turn off integral and derivative action (set them to zero), and set
proportional to a small value.

Step 4
Place the controller in automatic mode.
 Zeigler-Nichols Continuous Steps

Step 5
Change the set point (SP) to your operating set point, an offset should occur
in the process variable (PV).

Step 6
Increase the gain until the loop starts oscillating.

Step 7
Record the gain as your ultimate gain (Ku).

Step 8
Record the resulting period as the ultimate period (Pu).
 Zeigler-Nichols Continuous Steps

Step 9
Calculate Kp, Ti, and Td using the following table:

Kp Ti Td

P 0.50 KU — —
PI 0.45 KU Pu /1.2 —

PID 0.60 KU Pu /2 Pu /8
Ultimate Gain and Ultimate Period
 Ultimate Gain and Ultimate Period

Ultimate Gain: It's the gain when the system starts to oscillate.
 Zeigler-Nichols Continuous Steps

Even though this method is frequently used, it has the following

disadvantages:
▪ It can be time consuming if several trials are required and the
process dynamics are slow.
▪ Introducing oscillations into a process is in many cases not desirable.
▪ Will not work for an integrating process.
Some processes where the streams are comprised of gases,
liquids, powders, slurries and melts do not naturally settle out at
a steady state operating level. Process control practitioners
refer to these as non-self regulating, or more commonly, as
integrating processes.
▪ Will not work for dead time dominant processes.
Dead time is the delay from when a controller output (CO) signal
is issued until when the measured process variable (PV) first
begins to respond. The presence of dead time, Өp, is never a
good thing in a control loop.
▪ Requires proper manipulation of the bias value by the controller or
the person doing the tuning.
 Zeigler-Nichols Step Method

Step 1
Create a disturbance (ΔCV) -- Step Function the system input

Step 2
Record this on a Reaction Curve (Graph)

Step 3
Draw a line tangent to the rising part of the response curve. This line defines
the lag time (L) and rise time (T) values.
Lag time is the time delay between the controller output and the CV
response
 Zeigler-Nichols Step Method

Step 4
Calculate the slope of the curve (Refer to example on next few slides)

Step 5
Calculate the PID constants (Refer to example on next few slides)
 Zeigler-Nichols Step Method

L = 0.2 s (lag time)

T = 0.9 s (rise time)

ΔPV = 7% (change in process variable from sensor)

ΔCV = 10% (step change of controlled variable from
controller)
 Zeigler-Nichols Step Method

N = slope of response curve

L = 0.2 s (lag time)
T = 0.9 s (rise time)
ΔPV = 7% (change in process variable from sensor)
ΔCV = 10% (step change of controlled variable from
controller)

N = (ΔPV)/T = 7%/.9 s = 7.8%/s

Kp = (1.2 Δ CV)/NL = (1.2*10%)/(7.8%/s*0.2 s) = 7.7
Ti = 1/2L = 1/(2*0.2 s) = 2.5/s
Td = 0.5L = 0.5*2 s = 0.1 s