LECTURE ONE

054461 PROCESS CONTROL LAB

054461 Process Control Laboratory

LECTURE 1:
COURSE INTRODUCTION
Daniel R. Lewin
Department of Chemical Engineering
Technion, Haifa, Israel

1-1

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Lecture Objectives
On completing this section, you should:
n Be familiar with the course structure and
objectives.
o Have recalled all of the material you learned in
the introductory control course, and in
particular, be able to:
a. Formulate a linear process model
b. Sketch the response of a linear system
c. Design a simple (PID) feedback controller
using the Root Locus method
1-2

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Daniel R. Lewin, Technion

LECTURE ONE

054461 PROCESS CONTROL LAB

Course Objectives
On completing this course, you should:
n Derive an empirical linear model for a real
process by generating experimental data and its
analysis.
o Design, tune and implement SISO controllers for
a real process. The types of controllers that you
should be able to implement are: simple feedback
(e.g. PID), cascade controllers, IMC and FF.
p Design and implement control system for MIMO
processes.

1-3

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Linear Systems Review + More

n
o
p
q
r

1-4

Modeling process transient behavior

Linearization
Laplace transforms
Linear system response
Root locus design of FB controllers

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Daniel R. Lewin, Technion

LECTURE ONE

054461 PROCESS CONTROL LAB

Modeling - Dead Sea Pond (1)

Feed brine [T/h]

Evap. Rate [T/h]

Brine conc. [kg salt/kg]

Prepare a model describing an evaporating pond in the Dead

Sea Works.
Solution.

Overall mass balance:

rate of accumu- = rate of input rate of out- rate of loss

lation
with feed put with effluent by evaporation
0 = qf q E
Thus,
1-5

q = qf E

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Modeling - Dead Sea Pond (2)

The balance for salt gives:

rate of accumu- = rate of salt rate of salt out-

lation of salt input with feed put with effluent
d
( Vc ) = qfcf qc
dt
Usin g q = qf E, and noting that and V are constant:

dc qfcf c ( qf E )
=

V
dt V
Definin g = V qf :

dc 1 E
= 1c
dt qf
1-6

What is the sign of

(E/qf 1) ?

cf , c ( 0 ) = c0

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Daniel R. Lewin, Technion

LECTURE ONE

054461 PROCESS CONTROL LAB

Linearization (1)
Consider the general SISO nonlinear process:

dx
= f ( x, u )
dt
Linearization around the stationary point (x0, u0) gives
the linear equation:
dx
f
f
f ( x0 , u0 ) +
( x x0 ) +
( u u0 )
dt
x x0 ,u0
u x0 ,u0
dx0
= f ( x0 ,u0 )
But:
dt
Hence: d ( x x0 ) f
f
( x x0 ) +
( u u0 )
x x0 ,u0
u x0 ,u0
dt

dx
dt

1-7

f
x
x x0 ,u0

f
u
u x0 ,u0

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Linearization (2)
Extension to MIMO nonlinear process:
dx
= f ( x,u )
dt
y = g ( x,u )
Linearization around the stationary point (x*, u*) gives
the linear system:
dx
= Ax + Bu
x = x x*
dt
u = u u*
y = Cx + Du
The matrices A,B, C and D are Jacobian matrices, e.g.

A ai,j =
1-8

fi
x j

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Daniel R. Lewin, Technion

LECTURE ONE

054461 PROCESS CONTROL LAB

Linearization Example (1)

Continuing the Dead Sea Ponds example, we have:

dc
E
= f ( c;qf , cf , E ) = 1 q 1c

f
dt

cf , c ( 0 ) = c0

Data: qf = 10 T/h, E = 5 T/h, cf = 0.1 kg salt/kg brine, V = 100 T

At steady state:
dc
= 0 c = cf (1 E qf ) = 0.2 kg salt/kg brine
dt
Stationary point: c* = 0.2; qf* = 10; cf* = 0.1; E* = 5; * = 10 h.
Linearization:

1-9

dc f
f
f
f
=
c +
q +
cf +
E
dt c ss
qf ss f
cf ss
E ss

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Linearization Example (2)

dc f
f
f
f
=
c +
qf +
cf +
E
dt c ss
qf ss
cf ss
E ss

f
1 E
= * 1 = 0.05 h-1
c ss * qf*

f
qf

f
cf

c
f
= * = 0.002 T -1
E ss V

=
ss

1
= 0.1 h-1
*

=
ss

cf* c*
= 0.001 T -1
V

dc
= 0.05c 0.001qf + 0.1cf + 0.002E, c ( 0 ) = 0
dt

1-10

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Daniel R. Lewin, Technion

LECTURE ONE

054461 PROCESS CONTROL LAB

Laplace Transforms
General MIMO linear process is:

dx
= Ax + Bu
dt
y = Cx + Du

x = x x*
u = u u*

qf

dc
Example:
= [ 0.05] c + 0.001 0.1 0.002 cf , c ( 0 ) = 0
dt

E
Taking Laplace Transforms (around steady state):
sX ( s ) = AX ( s ) + BU ( s )
Y ( s ) = CX ( s ) + DU ( s )

P(s) transfer

1
Hence: Y ( s ) = C ( sI A) B + D U ( s ) function matrix

relating all inputs

to outputs

1-11

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Laplace Transforms
Analysis of transfer functions: P ( s ) = C ( sI A) B + D
1

The transfer function matrix is composed of elements:

pi,j ( s ) =

bm sm + bm1sm1 + + b1s + b0
an sn + an 1sn 1 + + a1s + a0

A strictly proper system has n > m (physical system).

A proper system has n = m (e.g. PI controller)
Roots of numerator are zeros and roots of denominator
are poles:
zi are zeros
( s z1 )( s z2 ) ( s zm )
pi,j ( s ) =
pi are poles
( s p )( s p ) ( s p )
1

For stability ALL poles must have a negative real part.

Complex poles give oscillatory response.
Zeros shape the response (see later)
1-12

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Daniel R. Lewin, Technion

LECTURE ONE

054461 PROCESS CONTROL LAB

Linear System Response

Response to step
Classification
in OP: --OP PV

Transfer
Function

Kp

Stable selfregulating

p s + 1
Kp s
e
s
Kp
e s
p s + 1

Non selfregulating
Unstable

1-13

e s

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Identification by Step Test

First order response of process, y, to a step change in input, u:
u(t)
u

y(t)
0.623y

Dynamics are approximated by the FOPTD model: p(s) =

Kp
s + 1

e s

with Kp = y u, and and estimated from the trajectory

1-14

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Daniel R. Lewin, Technion

LECTURE ONE

054461 PROCESS CONTROL LAB

Higher Order Responses (1)

p(s) =

Kp

static gain

2s2 + 2s + 1
damping coefficient

natural period

Response of 2nd order transfer function to a unit step:

y(s) =

Kp

s ( s + 2s + 1 )
2 2

Kpp1p2

s ( s p1 )( s p2 )

p1,2 =

2 1

Need to differentiate between three cases: A) > 1

B) = 1
C) < 1

1-15

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Higher Order Responses (2)

A) For > 1, p1 and p2 are real negative roots:
y(t) = Kp (1 A1e p1t A2e p2t )

B) For = 1, p1 = p2 = 1 / :
y(t) = Kp (1 (1 + t ) e t )

1-16

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Daniel R. Lewin, Technion

LECTURE ONE

054461 PROCESS CONTROL LAB

Higher Order Responses (3)

C) For < 1,

2 1 is imaginary, and p1 and p2

2
are complex roots: p1,2 = i 1

1
y(t) = Kp 1
e t sin ( t )

1 2

1 2

= tan 1

1-17

1 2

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Higher Order Responses (4)

Example 1: A processing system with its controller

p (s) =

Kp
C
(s) =
F
( 1s + 1 )( 2s + 1 )

C (s) = P (s)B (s) e (s)

= P ( s ) B ( s ) ( Cs ( s ) C ( s ) )
KcKp

P (s)B (s)
C
=
(s) =
Cs
P ( s ) B ( s ) + 1 1 2 2 1 + 2
s +
s +1
K K + 1
K K + 1
c p

c p

KcKp + 1

1-18

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Daniel R. Lewin, Technion

LECTURE ONE

054461 PROCESS CONTROL LAB

Higher Order Responses (5)

Example 1: A processing system with its controller (Contd)
KcKp

C
K
= 2 2
(s) =
Cs
s + 2s + 1
1 2 2 1 + 2
s +
s+1
K K + 1
K K + 1
c p

c p

KcKp + 1

K=

KcKp
KcKp + 1

1 2
KcKp + 1

1 + 2

2 1 2 KcKp + 1

1. Can C(t) track Cs(t) with no offset?

2. Is the closed-loop response damped or underdamped?
3. Does the closed-loop respond faster or slower than the
open-loop response?
1-19

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Root Locus for Control Design

RL plot shows the location of the closed-loop poles as the
controller gain is increased (i.e., the roots of pc + 1 = 0)
Control design with RL is a polepole-placement technique: Poles
and zeros of the process and the controller are placed on
the complex plane the method permits the manipulation
of the characteristic polynomial to attain design
specifications.
Short-cut method allowing pencil-and-paper design of
control systems
Main disadvantages:
a.

Can only deal with deadtime systems by Pad

approximation

b. Is useful only for SISO control systems

1-20

10

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Daniel R. Lewin, Technion

LECTURE ONE

054461 PROCESS CONTROL LAB

Root Locus for Control Design

The Rules:
1. The open-loop transfer function is expressed in the form:
( s z1 )( s z2 ) ( s zm )
pc ( s ) = K
( s p1 )( s p2 ) ( s pn )
2. The root loci start (at K = 0) at the poles of pc(s) and end
(K = ) at the zeros of pc(s) or at
3. On the real axis of the complex plane, the RL is
constructed from right to left, according to the total poles
and zeros (pz) met along the way:

If K > 0, draw the RL if pz is odd

If K < 0, draw the RL if pz is even
4. The number of loci = order of the system = number of
poles of pc(s). The complex loci always appear as complex
conjugates (mirror image either side of the real axis).
1-21

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Root Locus for Control Design

The Rules (Contd):
5. The angle of the asymptotes of the loci (as K ) is:

180 (2k 1 )
nm
180 (2k )

k = 0,1, ,n m 1 (K > 0)

k = 0,1, ,n m 1 (K < 0)
nm
where n and m are the number of poles and zeros of pc(s).
6. The asymptotes are centered at = ( pi zi ) (n m )
where pi and zi are the locations of poles and zeros of
pc(s), respectively.

1-22

11

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Daniel R. Lewin, Technion

LECTURE ONE

054461 PROCESS CONTROL LAB

Root Locus for Control Design

Example 3

p (s) =

( s + 1 )( s + 3)
3

, c ( s ) = Kc

Im(s)

2
1
-5

-4

-3

-2

Re(s)

-1
-1
-2
-3

1-23

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Root Locus for Control Design

Example 4

p (s) =

( s + 1 )( s + 3)
3

, c ( s ) = Kc (1 + 1 Ts
i )

Im(s)

2
1

-5

-4

-3

-2

-1

Re(s)

-1
-2
-3
1-24

12

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Daniel R. Lewin, Technion

LECTURE ONE

054461 PROCESS CONTROL LAB

Root Locus for Control Design

Example 5

p (s) =

1
e s , c ( s ) = Kc (1 + 1 Ts
i )
( s + 1)
3

Im(s)

2
1
-5

-4

-3

-2

-1

Re(s)

-1
-2
-3
1-25

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Design Specifications for RL

The desired closed loop response is:
y
1
(s) = 2 2
ys
s + 2s + 1
The response to a unit step in ys is:
1
y(t) = 1
e t sin ( t )
1 2
The analytical response is used to estimate desired overshoot
and settling time.

Overshoot:

OS = exp

1 2

(loge OS )
2
(loge OS) + 2
2

Thus:
1-26

13

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Daniel R. Lewin, Technion

LECTURE ONE

054461 PROCESS CONTROL LAB

Design Specifications for RL

Settling Time: To settle to within a
fraction x of the set point at time t = ts:
1
1
x=
e ts sin ( ts )
e ts
2
1
1 2

Hence, to meet the settling time constraint:

ts loge x 1 2

To meet desired OS:

(loge OS )
2
(loge OS) + 2
2

1-27

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Design Specifications for RL

Example:

Specifications met for the range Km K K*. Stable for K < Ku

1-28

14

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Daniel R. Lewin, Technion

LECTURE ONE

054461 PROCESS CONTROL LAB

Summary
n Modeling process transient behavior
Generating models in standard form:
x = f ( x,u ) , y = g ( x, u )

o
p
q
r

Linearization
Laplace transforms
Linear system response
Root locus design of FB controllers
Use of approximate specifications in design

1-29

15

PROCESS CONTROL LAB - (c) Daniel R. Lewin

Course Introduction

Daniel R. Lewin, Technion