Introduction to Process
Control
Chapter 1
Prototype system-blending tank
Feedback control
Implementation of control
Justification of control
Process Dynamics
a) Refers to unsteady-state or transient behavior
b) Steady-state vs. unsteady-state behavior
i. Steady state: variables do not change with time
ii. But on what scale? cf., noisy measurement
c) ChE curriculum emphasizes steady-state or equilibrium
situations
i. Examples: mass and energy balance, thermodynamics, unit
operation, process design, etc.
d) Continuous processes: Transient operations include
i. Start up & shutdown
ii. Grade changes
iii. Major disturbance: e.g., refinery during stormy or hurricane
conditions
iv. Equipment or instrument failure (e.g., pump or sensor failure)
Chapter 1
e) Batch processes
i. Inherently unsteady-state operation
ii. Example: batch reactor
1. Composition changes with time
2. Other variables such as temperature could be constant
Process Control
a) Process: the conversion of feed materials to products using
chemical and physical operations
b) Large scale, continuous processes
i. Oil refinery, ethylene plant, pulp mill
ii. Typically, 1000 ~ 5000 process variables (PVs) are measured.
1. Most of these variables are also controlled.
Process Control (contd.)
iii. Examples of process variables: flow rate, T, P, liquid level,
composition
iv. Sampling rates
1. Process variables: A few seconds to minutes
2. Quality variables: once per 8 hr shift, daily, or weekly
c) Manipulated variables
i. We implement process control by manipulating process
variables, usually flow rates.
1. Examples: feed rate, cooling rate, product flow rate, etc.
ii. Typically, several thousand manipulated variables in a large
continuous plant
Process Control (contd.)
d) Batch processes:
i. Used in many process industries, including
microelectronics, pharmaceuticals, specialty chemicals,
and fermentation
ii. Provide needed flexibility for multiproduct plants
iii. Smaller plants in most industries
1. Exception: microelectronics (200 300 processing
steps).
iv. But still large numbers of measured variables.
e) Question: How do we control processes?
i. We will consider an illustrative example.
Control Terminology
Controlled variables (CV) - these are the variables
which quantify the performance or quality of the final
Chapter 1
product, which are also called output variables.
Manipulated variables (MV) - these input variables
are adjusted dynamically to keep the controlled
variables at or near their set-points.
Disturbance variables (DV) - these are also called
"load" variables and represent input variables that
can cause the controlled variables to deviate from
their respective set points.
8
Control Terminology(2)
Set-point tracking - implementing a change in the
operating conditions. The set-point signal is
Chapter 1
changed and the manipulated variable is adjusted
appropriately to achieve the new operating
conditions. Also called servomechanism (or "servo")
control.
Disturbance rejection - the process transient
behavior when a disturbance enters, also called
regulatory control or load change. A control system
should be able to return each controlled variable
back to its set-point.
1.1 Illustrative Example: Blending System
Notation:
w1, w2 and w are mass flow rates
x1, x2 and x are mass fractions of component A
Assumptions:
1. w1 is constant
2. x2 = constant = 1 (stream 2 is pure A)
3. Perfect mixing in the tank
Control Objective:
Keep x at a desired value (or set point) xsp, despite variations in x1(t). Flow
rate w2 can be adjusted for this purpose.
Terminology:
Controlled variable (CV or output variable): x
Manipulated variable (MV or input variable): w2
Disturbance variable (DV or load variable) process variables that affect
the controlled variables but cannot be manipulated: x1
Design Question. What value of w2 is required to have
x xSP ?
Overall balance:
0 w1 w2 w (1-1)
Component A balance:
w1 x1 w2 x2 wx 0 (1-2)
(The overbars denote nominal steady-state design values.)
At the design conditions, x xSP . Substitute Eq. 1-2, x xSP and
x2 1 , then solve Eq. 1-2 for w2 :
xSP x1
w2 w1 (1-3)
1 xSP
Equation 1-3 is the design equation for the blending system.
If our assumptions are correct, then this value of w2 will keep x
at x SP . But what if conditions change?
x S P
Control Question. Suppose that the inlet concentration x1 changes
with time. How can we ensure that x remains at or near the set point?
As a specific example, if x1 x1 and w2 w2 , then x > xSP.
Some Possible Control Strategies:
Method 1. Measure x and adjust w2.
Intuitively, if x is too high, we should reduce w2
Manual control vs. automatic control
Proportional feedback control law,
w2 t w2 K c xSP x t (1-4)
1. where Kc is called the controller gain.
2. w2(t) and x(t) denote variables that change with time t.
3. The change in the flow rate, w2 t w2 , is proportional to the
deviation from the set point, xSP x(t).
Method 2. Measure x1 and adjust w2.
Thus, if x1 is greater than x1 , we would decrease w2 so that
w2 w2 ;
One approach: Consider Eq. (1-3) and replace x1 and w2 with x1(t)
and w2(t) to get a control law:
xSP x1 t
w2 t w1 (1-5)
1 xSP
Because Eq. (1-3) applies only at steady state, it is not clear how
effective the control law in (1-5) will be for transient conditions.
Method 3. Measure x1 and x, adjust w2.
This approach is a combination of Methods 1 and 2.
Method 4. Use a larger tank.
If a larger tank is used, fluctuations in x1 will tend to be damped out
due to the larger capacitance of the tank contents.
However, a larger tank means an increased capital cost.
1.2 Classification of Control Strategies
Table. 1.1 Control Strategies for the Blending System
Method Measured Manipulated Category
Variable Variable
1 x w2 FB
2 x1 w2 FF
3 x1 and x w2 FF/FB
4 - - Design change
Feedback Control
Distinguishing feature: measure the controlled variable
It is important to make a distinction between negative feedback and
positive feedback.
Engineering usage vs. social sciences
Advantages:
Corrective action is taken regardless of the source of the
disturbance.
Reduces sensitivity of the controlled variable to disturbances
and changes in the process (shown later).
Disadvantages:
No corrective action occurs until after the disturbance has
upset the process, that is, until after x differs from xsp.
Very oscillatory responses, or even instability
Feedforward Control
Distinguishing feature: measure a disturbance variable
Advantage:
Correct for disturbance before it upsets the process.
Disadvantage:
Must be able to measure the disturbance.
No corrective action for unmeasured disturbances.
A process model is required.
Closed-loop Artificial Pancreas
glucose u
setpoint y
r
Chapter 1
controller pump patient sensor
measured glucose
22
Chapter 1
Figure 1.6 Block diagram for composition feedback control system
on Fig. 1.4.
23
Chapter 1
24
Chapter 1 Chapter 1
26
25
Justification of Process Control
Specific Objectives of Control
Increased product throughput
Increased yield of higher valued products
Decreased energy consumption
Decreased pollution
Decreased off-spec product
Increased safety
Extended life of equipment
Improved operability
Decreased production labor
3.2 Economic Incentives - Advanced Control
(days-months ) 5. Planning and
Scheduling
(hours-days ) 4. Real-Time
Optimization
3b. Multivariable
(minutes-hours ) and Constraint
Control
Figure 1.7 Hierarchy of
process control activities.
(seconds-minutes ) 3a. Regulatory
Control
2. Safety, Environment
(< 1 second ) and Equipment
Protection
(< 1 second ) 1. Measurement
and Actuation
Process
Chapter 1
Figure 1.8 Major
steps in control
system development
31
