G784
Process Dynamics and
Control
Degree in Chemical Engineering
University of Cantabria
Introduction to Process
Control
Chapter 1
Introduction to Process
Control
Chapter 1.
Chapter 1
- Introduction to process control.
- Classification of process variables in control
schemes
- Process control stretagies: feedback vs.
Feedforward
Textbook
Process Dynamics and Control, 4th Ed. Seborg et al.
Wiley 2017 (or previous editions)
Chapter 1
Chapter 1
Chapter 1
Chapter 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
Chapter 1
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 (or “output variable”): x
• Manipulated variable (or “input variable”): w2
• Disturbance variable (or “load variable”): x1
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:
w1x1 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
xSP x1
w2 w1 (1-3)
1 xSP
• Equation 1-3 is the design equation for the blending
system.
Chapter 1
• If our assumptions are correct, then this value of w2 will keep x
at xSP . But what if conditions change?
Control Question. Suppose that the inlet concentration x1
changes with time. How can we ensure that x remains at or near
the set point xSP ?
As a specific example, if x1 x1 and w2 w2, then x > xSP.
Chapter 1
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
Chapter 1
• Proportional feedback control law,
w2 t w2 Kc 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 (error) from the set point, xSP – x(t).
Chapter 1
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:
Chapter 1
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.
Chapter 1
Classification of Control Strategies
Table. 1.1 Control Strategies for the Blending System
Method Measured Manipulated Category
Variable Variable
1 x w2 FeedBack (FB)
Chapter 1
2 x1 w2 FeedForward
(FF)
Feedback Control:
• Distinguishing feature: measure the controlled variable
• Advantages:
Corrective action is taken regardless of the source of the disturbance.
• 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… (let’s think about the
origin of instability)
Feedforward Control:
Distinguishing feature: measure a disturbance
variable
• Advantage:
Correct for disturbance before it upsets the process.
Chapter 1
• Disadvantage:
Must be able to measure the disturbance.
No corrective action for unmeasured disturbances.
Control Terminology
controlled variables - these are the variables which
quantify the performance or quality of the final
product, which are also called output variables.
Chapter 1
manipulated variables - these input variables are
adjusted dynamically to keep the controlled variables
at their set-points.
disturbance variables - these are also called "load"
variables and represent input variables that can
cause the controlled variables to deviate from their
respective set points.
Check what you have learned
1. Can you define Feedback control?
2. Can you identify the characteristic and
Chapter 1
distinguishing feature of feedforward control?
3. Do you know the difference between “controlled
variable” and “manipulated variable”?
4. What is the “set-point”?
5. Say examples in which you can identify
disturbances.
Study on your own
Stirred tank heater:
What is the function of the process?
What process variables can you
identify?
Chapter 1
Which one is the controlled variable,
linked to the process function?
Is there any other controlled variable,
related to the operation of the unit
operation?
What external factors influence the
operation of the heater?
Propose two different control strategies
in order to cancel the effect of the
external disturbances on the process.
