Department of Chemical Engineering I.I.T.

Bombay, India

CL417: Process Control

Department of Chemical Engineering I.I.T. Bombay, India

Dynamic Analysis

Cause Process Dynamics Effect

Analysis of the influence of a cause on its effect

How does a cause result in an effect ?

How much ?
How quickly?
Department of Chemical Engineering I.I.T. Bombay, India

Control of Process Systems

Design a Process Dynamics Desired
Cause Effect

Manipulation of the cause to yield a desired effect.

Transfer variability from a point where it hurts the most to a point

where it hurts the least Jim Downs, Eastman Chemicals.

Designing a cause => Structuring and facilitating a

control scheme
Department of Chemical Engineering I.I.T. Bombay, India

Transfer of Variability

Fin, Tin

Fout, Tout

Open loop plant Q After Control

Department of Chemical Engineering I.I.T. Bombay, India

Illustrative Example

Cold Stream at Hot Stream at

Flowrate = FC Flowrate = FH
Temperature = TC Temperature = TH

Manipulated Variables enjoy

(We can freely manipulate these)
shower at
Control Objective
Disturbance Variables F = Fsp
T = Tsp
(Beyond our control. Must live with these !!)
Department of Chemical Engineering I.I.T. Bombay, India

Process Control: The act of manipulating certain inputs in order to

meet specific operational objectives even in the
presence of disturbances

In the shower example:

Operational Objectives: We need to enjoy our shower with water at a

specific flow rate and at a specified (comfortable) temperature.

Disturbances: The temperatures of the cold and hot streams. These

temperatures may change depending on the time of the day, season
etc.

Manipulated Variables: We may operate the cold and hot water valves
as per our fancy and meet the operational objectives even if there are:
changes in the cold and/or hot water temperatures
changes in operational objectives
(comfortable temperature may vary from person to person)
Department of Chemical Engineering I.I.T. Bombay, India

In Block Diagram Form

Tout, cold Tin, cold

Disturbance
dynamics

Fin, cold
Mixing Flow
Dynamics +
Temp.
Fin, hot
Note: Process and Disturbance dynamics are negligible
here, but generally they are not and could be different.
Department of Chemical Engineering I.I.T. Bombay, India

Input and Output Variables

Input Variables Cause Variables that influence the effect

variables
Some of these are manipulable manipulative variables
Others are not manipulable disturbance variables

Output Variables are really the effect variables, also called as

Controlled variables
Department of Chemical Engineering I.I.T. Bombay, India

What is the basis for manipulating the cold and hot water valves?
Answer : Look at the deviation from desired value

Step into the shower

Sense the output flow rate and temperature Sensing the variation
(Point of sensing is very important. Disturbance or process variable)

Determine the deviation in the measured flow rate and temperature from
what you wanted them to be (target values or setpoints) Comparison

Adjust the cold and hot water valves suitably Control Action

Notice that the information on the process outputs (flow rate and temperature)
is used to determine the process inputs (valve positions). This is the basic
concept of Feedback Control.
Department of Chemical Engineering I.I.T. Bombay, India

Alternate Scenario

Sense the input flow rates and temperatures Sensing the source of
variation !

Determine if there is any deviation in the expected input flow rates and
temperature Comparison

Adjust the cold and hot water valves suitably Control Action

Notice that the information on the disturbances (input flow rates and
temperature)is used to determine the process inputs (valve positions).
This is the concept of Feedforward Control.
Department of Chemical Engineering I.I.T. Bombay, India

Consider the following scenarios:

What if the disturbances occur frequently? e.g. frequent changes in the

cold and hot water temperatures.

Rather than enjoying the shower, we will end up being busy

changing the valve position all the time

What if my seven year old son wanted to take a shower? the case of
an inexperienced plant operator.

Can he sense, compare and take the appropriate control

action as well as I (the experienced operator) do? He may
need to be constantly supervised pressure on my time

What if my eighty year old grandfather, who is unable to sense

temperatures properly, steps into the shower? personnel safety issue

He may end up scalding himself without realizing it !!

Department of Chemical Engineering I.I.T. Bombay, India

Wouldnt it be rather nice if:

1. We have a control panel where we just input the desired flow rate
and the required temperature, step into the shower and just enjoy !

Sensing, comparison, computation of appropriate control action

(valve positions) are all done automatically by hardware and/or
software.

This leads to automatic process control in contrast to the manual

control (where a human is very actively involved) discussed earlier

2. To handle the safety issues we must ensure that

The desired temperature cannot exceed a certain value (say 40 oC)

or go below a certain value (say 10 oC). These limits should however
be changeable by only the expert operator to handle special
situations
Department of Chemical Engineering I.I.T. Bombay, India

Note that the control system cannot deliver anything that you want

- you cannot ask for a flow rate that exceeds the sum of
maximum possible cold and hot water flow rates

- you cannot ask for a temperature that is above the incoming

hot water stream temperature or one that is below the
incoming cold water temperature.

- also, only certain combinations of the flow rate and the

temperature may be attainable.

for example, if the maximum hot water flow rate is 1 m3 / min

and if the temperature of the cold and hot streams are 30 oC &
40 oC respectively, the system cannot deliver a flow rate of
1.5 m3 / min and a shower tempertaure equal to 40 oC.

No super-operator or advanced control system can overcome

the limitations posed by a poorly designed process
Department of Chemical Engineering I.I.T. Bombay, India

Typical Control Examples

1. Driving your car

Objectives: Go from point A to point B safely (for you and everyone

else) and in a reasonable amount of time

Sense: Position of the automobile, speed of the car (measurable outputs

related to the objective)

Disturbances: curves and bumps on the road, position of other cars,

changing speed limits, ..

Manipulated Variables: Steering wheel, Brake pedal, Accelerator pedal

Must maintain safe & acceptable position, speed of the car by manipulating
the SW, BP and AP despite disturbances such as curves, bumps etc.
Department of Chemical Engineering I.I.T. Bombay, India

Typical Control Examples

2. Composition in a Distillation Column
Objectives: Maintain top and bottom streams at specified values
Sense: Composition (Temperature) of the top trays
Disturbances: Feed flowrates, compositions, .
Manipulated Variable: Boil-up rates and condenser duty

Qc
D,xd
F,z

Qh
B,xb
Department of Chemical Engineering I.I.T. Bombay, India

Bringing in a new concept: Dynamics

I am driving a car on a highway. I
hit the brakes. Does the car
come to an immediate
Q, T1
(instantaneous) halt?
A certain government introduces
a financial stimulus package to
revive a sagging economy. Will
the effects be immediately felt by Q, T2
the common man?
I open the steam valve of the

Condensate
stirred tank heater system by
10% Will the temperature T2
reach a new steady value
immediately? Steam
Department of Chemical Engineering I.I.T. Bombay, India

The answer to the above questions is No. Do you know why?

Systems have Inertia or Capacitance. This means that changes

evolve over time Process Dynamics

Final Value of T2

12oC New Steady

Dynamics
Initial Value State
of T2

Final Valve Opening

10%

Initial Valve
Time
Opening
Department of Chemical Engineering I.I.T. Bombay, India

Why would knowledge of process dynamics improve in our

ability to control?

Why not work with just steady state information?

Knowledge of Steady-state effects is certainly important (and

perhaps even the most important information about the process)

To improve the sagging economy, a certain government would consider

tax cuts rather than impose new taxes (tax cut is manipulated variable)

If I open the steam valve by 10%, the increase in temperature T2 is

approximately 12oC. So, a change of 1% in the valve opening will affect
the temperature T2 by approximately 1.2oC
However, .
Department of Chemical Engineering I.I.T. Bombay, India

Temperature Control Problem

B C

Temperature
A

0 time 3

Which is most appropriate ?

Plan A : Sluggish Control Depends on:
Plan B : Aggressive Control Thermal sensitivity
Plan C : Without Control Time for rejection
Department of Chemical Engineering I.I.T. Bombay, India

Complex Interactions in a Distillation Column

L
C

From desorbent
stripper level.
L
C

11th tray

T
C

21st tray

Feed Complex interplay between

enthalpy and inventory
Department of Chemical Engineering I.I.T. Bombay, India

Complex Interactions in a Distillation Column

Ignoring dynamics may lead to sustained oscillations due to complex

interactions.
Department of Chemical Engineering I.I.T. Bombay, India

Components of a Feedback Control System

Remember, the process is the centerpiece. A badly designed
process cannot be well controlled even with the most advanced
instrumentation and control system.

Sensor to measure the output variable (Controlled Variable). The

value of the controlled output is utilized by the controller to compute
the appropriate value of the input variable (Manipulated Variable)

Comparator compares the set point and the measured values of the
controlled variable. Computes the error signal [E = SP PV]

Controller uses the error signal E to compute an appropriate

controller output signal usually an electronic or pressure signal

Final Control Element In most process control applications, the FCE

is a valve. The valve responds to the controller output signal and the
valve stem either moves up or down effectively altering a flow
variable (i.e. the manipulated variable)
Department of Chemical Engineering I.I.T. Bombay, India

Components of a Feedback Control System

Notes:

1. The controller can either be a human operator or a computing device

2. The comparator is often included within the controller so it is not

often seen separately

3. The control algorithm can either be simple or complex

CO = + K if E > e and K if E < -e (On/Off Control)

CO = Kc * E (where Kc is the controller gain)
CO = Kc * ( E + KI E dt) (KI is the integral gain)
etc.

(Later, we will study about control algorithms in detail)

Department of Chemical Engineering I.I.T. Bombay, India

Components of a Feedback Control System

Notes:

4. Sensors are one of the most crucial components of the feedback

control system. Sensors are required to measure a variety of
process variables such as flow rate, temperature, pressure, level
and composition.

Even to measure temperature, there are many choices available

thermocouples, thermistors, bimetallic, resistance temperature
detectors, filled systems and pyrometers.

The choice depends on the required accuracy, range, dynamics

(speed of response) and the cost.
Department of Chemical Engineering I.I.T. Bombay, India

Components of a Feedback Control System

Notes:

5. Control Valves (Final Control Element)

The most common method for influencing the behavior of chemical

processes is through the flow rate of process streams.

Usually, a valve with a variable opening in the pipe is manipulated

to influence the flow rate and achieve the desired process behavior.

Again, various types of valves are available. The appropriate valve is

chosen on the basis of the required size, maximum pressure,
temperature of the fluid, required trim characteristic etc.
Department of Chemical Engineering I.I.T. Bombay, India

Components of a Feedback Control System

Notes:

6. Besides the components mentioned above, various signal processing

devices such as transmitters, transducers, multiplexers, demultiplexers
etc. are needed.

We may have a controller that outputs a current or voltage signal

but the control valve may be a pneumatic valve and can only be driven
by a pressure signal. A E/P or I/P transducer is needed to convert
the current or voltage signal into an equivalent pressure signal.

Multiplexer is a device that combines multiple inputs into an aggregate

signal to be transported via a single transmission channel.

Remember that control involves lots of data processing and communication

Department of Chemical Engineering I.I.T. Bombay, India

Why are Chemical & Environmental Systems Controlled?

Safety and protection of plant personnel, environment

and equipment
Smooth operation and production
Keeping consistent product quality
Minimize the operating cost (utility charges, prolonging
catalyst life, .)

To ensure safe and profitable plant operation

Department of Chemical Engineering I.I.T. Bombay, India

Setpoint 100
Limit
98
Setpoint moved
X 96
closer to limit
94 APC online
Before APC
92
0 500 1000 1500 2000 2500 3000 3500

300
Before APC 250
APC online 300
Setpoint @ limit
200
200 200
150

100
100 100
50

0 0 0
94 96 98 95 96 97 98 99 100
X 95.98 ; X 0.83 X 95.99 ; X 0.23 X 98.99 ; X 0.24
Department of Chemical Engineering I.I.T. Bombay, India

Multivariate (Multivariable) Systems

u1 y1
u2 Process y2
u3 y3

Almost all systems are multivariable in nature

Eg. Driving car: What are the inputs and outputs?

Attending CL358 course: What are the inputs and outputs?
Department of Chemical Engineering I.I.T. Bombay, India

Issues in Multivariate Control

1. Loop Pairing: To control y1, would you use u1 or u2 or u3?

Similarly for y2 & y3

Steering
Wheel
Speed
Gas Pedal
Process
Brakes Position
Gear

Question: Can we manipulate steering wheel to control the speed?

Department of Chemical Engineering I.I.T. Bombay, India

Issues in Multivariate Control

2. Number of independent control objectives vs. number of manipulated variables

u1 y1
Process y2
u2 y3

The process operation team has given us 3 independent control

objectives: desired values specified for y1, y2 and y3
The process design group has provided us two manipulated variables
u1 and u2

It is possible to satisfy the specifications on y1, y2 and y3?

Department of Chemical Engineering I.I.T. Bombay, India

3. Centralized or De-centralized control?

De-Centralized (Multi-Loop) Design

+
C1 Y1,SP
-
u1
y1
Process
u2
y2

- +
C2 Y2,SP
Department of Chemical Engineering I.I.T. Bombay, India

Centralized (Multivariable) Design

Y1,SP

u1 +
-
y1
Multivariable
Controller
Process
u2 y2 -

+
Y2,SP

The multivariable controller simultaneously determines what u1 and u2 are!

Considers all relationships between the us and the ys simultaneously
Department of Chemical Engineering I.I.T. Bombay, India

Summary (1)

Sensors Process
Knowledge
Ingredients needed
Choosing
to reap maximum
Valves the best
benefits from
operating point
APC implementation

Safety Control
Issues Algorithms

A responsive plant designed with dynamic considerations

Department of Chemical Engineering I.I.T. Bombay, India

Summary (2)
Can APC alone make the plant safe and profitable?

Safety must be everyones concern

Plant profit determined by
Business Aspects (Does demand exist? Are profit margins big? .)
Plant Design (good chemistry, efficient design with dynamics in mind, )
Selection of operating conditions (Safety limits, change operating conditions
depending on feed composition to improve profit, .)
Process Control (will implement the recommended operating conditions)
Logistics (Production Schedule, Distribution Network, .)
Marketing Strategies product positioning, customer service etc.
Process Control does contribute to the overall health of your (current
employer / future employer) business. It helps to learn about this
subject !!