Process Control Instrumentation

1
Module I
Introduction to process control process variables degrees of
freedom. Process modelling Liquid level system- Linearization
example Two-tank liquid-level system interacting and non-
interacting systemsThermal process
Mixing processHeat exchangerDistillation column. Dynamics of 1
st
and 2nd
order systems, Batch process and Continuous process. Self-regulation.
Control systems with inverse response.
2
Objectives
Suppressing the influence from external
disturbances
Stability of the process
Optimizing the performance
Safety
Production specifications
Environmental regulations
Operational Constraints
Economics
3
The Block Diagram
4
Process Elements
PROCESS
Flow, Temperature, Pressure, Level, Concentration, etc.
Single Variable, Multi variable
MEASUREMENT
Sensor, Signal Conditioning
ERROR DETECTOR
Both Magnitude and Polarity
CONTROLLER
Operator, Electronic, Pneumatic, Hydraulic, uP, uC, Computers
CONTROL ELEMENT
Direct influence on the process, final control element
Actuators, motors, relays
5
Controlled Variables
Variable chosen to represent the state of the system
Eg : temperature, level, position, pressure, pH, density, moisture content, weight,
and speed
Manipulated Variables
Variable chosen to control the system state
Eg: valve position, motor speed, damper position, or blade pitch
Disturbances
Process Variables
6
Manipulated Variable
Steam inlet flow rate
Controlled Variable
Temperature of the water outlet
Disturbances
Increase / decrease of water inlet
Increase / decrease of water outlet
Process Variables
7
Stability
Steady state
Transient
e(t) = r c(t)
Good steady state
regulation
Best transient
regulation
8
Unstable reactor
9
Unstable reactor
10
Stability
Low yield due to low
temperature
Unsafe for catalysts
Stable / Self
regulating
Unstable
11
Degrees of freedom
The maximum number of independently acting controllers that can
be placed on a process is the degree of freedom of that process
The number of variables that can be independently controlled in a
process
Degrees of freedom = { No.of Variables that describes the system } - { No.of independent
relationship that exist among the variables }
Process Variables Degree of freedom
Train Speed 1
Aeroplane Latitude, longtitude,
Altitude
3
Boat Speed, direction 2
12
Degrees of freedom
VARIABLES
T Outlet water temperature
R1 Steam inlet flow rate
T1 Steam inlet temperature
T2 Steam outlet temperature
T3 Water inlet temperature
R2 Outlet water flow rate
INDEPENDENT RELATIONS
Q = MC T
Degrees of freedom = { 6 } - { 1 } = 5
13
Process Modelling
State Variables
Mass, energy and momentum are characterized by
variables like density, concentration, temperature,
pressure and flow rate.
These characterizing variables are state variables.
The values of S.V define the state of the process.
State Equation
Equation relating state variables to various independent
variables.
14
State Variables and Equations
For a quantity s in a system ,
Accumalation of S = Input of S - Flow of S outside
time time time
+ S generated - S consumed
time time
S can be mass , Total energy or momentum
The state equations with the associated state variables
constitute the mathematical model of a process
This gives the static and Dynamic behavior of the process.
If S.V do not change with time , the process is said to be in
steady state.
15
Modeling - Thermal Process
The fundamental quantities:
Mass of the liquid(m)
Total energy of the material
in the tank
Momentum
Q= M*C*AT
Q= V**C*AT
Q= F**C*AT
D=M/V
16
Modeling - Thermal Process
Step 1:
Momentum = constant
mass = density * volume
state variables = h , T
constant parameters = , A , Cp
and Tref
Step 2:
State equation
17
Modeling - Thermal Process
Step 3:


A dh/dt = Fi - F .........( 1 )
Accumulation of energy / time = (energy (i/p) - energy(o/p) + energy supplied)/time
d/dt(MCT) = FiCpTi - FCpT + Q
d/dt( AhT) = FiCpTi - FCpT + Q
A d/dt ( hT) = FiTi -FT

+ Q/ Cp
Ah dT/dt + AT dh/dt = FiTi - FT + Q/ Cp
Ah dT/dt + T (Fi - F ) = FiTi - FT + Q/ Cp
Ah dT/dt = Fi ( Ti - T ) + Q/ Cp ....... ( 2 )
18
Modeling - Thermal Process
Step 4:
State variables : h,T
O/P variables : h,T ( measured )
I/P variables :
Disturbances Ti, Fi
Manipulated variables : Q , F
Parameters : A,Cp, Density
All these combine to give the mathematical model
Solving these equations gives , both steady state and dynamic
behavior
A dh/dt = Fi - F .........( 1 )
Ah dT/dt = Fi ( Ti - T ) + Q/ Cp ....... ( 2 )
19
Steady state and dynamic behavior
Assume, initially tank heater is at steady state
When i/p variables changes, the steady state is disturbed
Solution for the state equations for a step change in T or Fi can
give the dynamic behavior of the system
dh/dt = 0
dT/dt = 0
Fi - Fs = 0 .........( 3 )
Fi ( Ti - T ) + Q/ Cp = 0 ....... ( 4 )
20
Liquid level system
(3) - - - - - - - - - - -
dt
dh
A
R
h
q
get we , 2 and 1 equation Combining
-(2) - - - - - - - - - - - - - - -
R
h
q
(1) - - - - - - -
dt
dh
A ) t ( q ) t ( q
o
o
=
=
=
1 s
R
) s ( Q
) s ( H
(7) - - - - - - - ) s ( AsH ) s ( H
R
1
) s ( Q
get we 6, equation of transform Laplace Taking
-(6) - - - - -
dt
dH
A H
R
1
Q
becomes, 5 Equation
) h h ( H
) q q ( Q
, variables deviation Defining
(5) - - -
dt
) h h ( d
A ) h h (
R
1
) q q (
get we 3, from 4 Subracting
-(4) - - - - - - - - -
dt
dh
A
R
h
q
state, steady at level the Taking
s
s
s
s s
s s
s
+
=
+ =
+ =
=
=

+ =
=

AR =
21
Liquid level system
R
) 1 s (
R
s
s
lim
) s ( sH lim ) t ( H
theorm, value - final Applying
) 1 s (
R
s
1
) s ( H ie;
s
1
Q(s)
) t ( u ) t ( Q
flowrate p i/ the in change step unit a ie; applied, is step unit a If
1 s
R
) s ( Q
) s ( H
0 s
0 s t
=
+
=
=
+
=
=
=
+
=

1 s
1

Q(s)
(s) Q

1 s
R
R
1

) s ( Q
) s ( H
H(s)
(s) Q
Q(s)
(s) Q
ie;
flow, output flow input between relation find To
0
0 0
+
=
+
=
=

AR =
22
Linearization
Analysis of a system represented by nonlinear partial
differential equations, with time varying coefficients is
extremely difficult and requires heavy computations.
There is no general analytic method available for solving
nonlinear systems. Real models usually exhibit non ideal
and nonlinear characteristics.
23
Linearization
Why are linear models useful?
They are easy to compute, understand and visualize.
They give predictable outputs, in time and over iterations
The analysis of linear theory is complete, developed and
efficient
Linear differential equations are easy to solve!
24
Linearization
A function of the general form y = bx + c
A function whose derivative is a constant
A function in which the output is proportional to the input
A straight line? ( this only works in 2D representations)
Intuitively, linearity means proportionality of the output
with respect to a variable. One variable function are most
familiar but functions can be linear in many variables, e.g:
n n n
x b x b x b y + + + =
2 2 1 1
25
Linearization
What makes an equation "linear"?
All variables present only to the first power
No product terms where variables are multiplied (constants
are ok)
No square roots, exponentials, products, etc. involving
variables.
Many of an engineer's tools for analyzing dynamic systems
apply only to linear systems. The Laplace transform, for
instance, only works if the equations to be transformed
are linear.
26
Linearization
27
Linearization
Learning about linear behavior is good, but how useful is it? Is
the real word linear at all? The answer is no most of the time.
Unfortunately, nonlinear dynamics are not fully understood and
the best we can do is simulate the real world with linear or
low-order approximations.
To be more precise, linear behavior is simulated locally, at a
point or along a small interval in space-time, and then the
results are extrapolated about the general domain.
That means that some degree of prediction is possible, but yet,
we do not know everything about nonlinearity.
28
Linearization
Small signal linearization method is the most widely
used
It is in general done with the help of Taylor series.
The Taylor expansion of a function f(x) around a point
is given by:
( )
( ) ( )
) x (
dx
f d
! n
x x
... ) x (
dx
f d
!
x x
) x (
dx
df
x x ) x ( f ) x ( f
n
n
n

+ + =
2
2
2
2
x
29
Linearization
Expand in Taylor Series and retain only constant and linear
terms. We have an approximation.
30
Liquid level system
(10) - - -
dt
dh
A h C ) t ( q
9, and 8 equation Combining
(9) - - -
dt
dh
A ) t ( q ) t ( q
(8) - - - - - - - - - h C q
0
0
=
=
=
-(14) - - - ) h h (
R1
1
q q
becomes 13 Equation

2
1
C
2
1
R1
1
Taking
-(13) - - - ) h h )(
2
1
C
2
1
( q q
12, and 11 equation Combining
-(12) - - - - - - - - -
2
1
C
2
1
dh
dq
-(11) - - - ) h h (
dh
dq
q q
terms, linear the Taking
...... ) h h (
dh
q d
) h h (
dh
dq
q q
value, state - steady at expansion series - s Taylor' Applying
applied be cannot transform Laplace and nonlinear is 10 Equation
s s 0 0
s s 0 0
0
s
0
s 0 0
2
s
2
0
2
s
0
s 0 0
+ =
=
+ =
=
+ =
+ + + =
31
Liquid level system
AR1 and
C
h 2
1 R Where
s 1
1 R
1 sAR 1
1 R
) s ( Q
) s ( H
) s ( Q )
R1
1
As )( s ( H
) s ( Q ) s ( H
R1
1
AsH(s)
transform, Laplace taking and hs - h H and qs - q Q Taking
-(16) - - - - - - - - - q q ) h h (
R1
1
dt
dh
A
(15) - - - - - - - - -
dt
dh
A ) h h (
R1
1
- q - q
9, eqn in 14 equation Using
s
s s
s s 0
= =
+
=
+
=
= +
= +
= =
= +
=

Linearization is adequate if the

deviation of height from steady state
is small.
Feedback controllers tries to keep
the level close to steady state.
32
Two tank Liquid level system
Physical systems can be represented by several first order
systems connected in series
Non interacting systems Interacting systems
33
Two tank Liquid level system
Non interacting systems
-(3) - - - - - - - - - - - - -
R
h
q
(2) - - - - - - -
dt
dh
A q q
(1) - - - - - - - -
dt
dh
A q q
1
1
1
2
2 2 1
1
1 1
=
=
=
-(7) - - -
) s 1 (
R
) s 1 (
1
Q(s)
(s) H
function, transfer overall the get we 6, and 5 eqns Combining
A R and h - h H
A R and , q - q Q , q - q Q Where
-(6) - - - - - - -
) s 1 (
R
(s) Q
(s) H
-(5) - - - - - - -
) s 1 (
1
Q(s)
(s) Q
get we variables,
deviation with along 4 and 1,2,3 eqns Combining
-(4) - - - - - - - - - - - - -
R
h
q
2
2
1
2
2 2 2 s 2 2 2
1 1 1 s s 1 1 1
2
2
1
2
1
1
2
2
2
t + t +
=
= t =
= t = =
t +
=
t +
=
=
34
Two tank Liquid level system
Non interacting systems
Here the transfer function is
the product of two single
tank operating (first order
systems) independently.
35
Liquid level system
Several Non interacting First order systems
1 s
k
) s ( X
) s ( X
1 s
k
) s ( X
) s ( X
1 s
k
) s ( X
) s ( X
n
i
1 n
n
2
2
1
2
1
1
0
1
+ t
=
+ t
=
+ t
=

[
=
+ t
=
n
1 i
i
i
0
n
1 s
k
) s ( X
) s ( X
Transfer Lag
36
Two tank Liquid level system
Interacting systems
(4) - - - - - - - - - - - - -
R
h
q
-(3) - - - - - - - - -
R
h h
q
-(2) - - - - -
dt
dh
A q q
(1) - - - - - - -
dt
dh
A q q
2
2
2
1
2 1
1
2
2 2 1
1
1 1
=

=
=
=
1 s ) R A ( s
R
) s ( Q
) s ( H
get we H1, and Q2 Q1, g Eliminatin
(12) - - - - - - - (s) H ) s ( Q R
(11) - - - - - - - (s) H - (s) H ) s ( Q R
(10) - - - - - - - (s) sH A ) s ( Q - ) s ( Q
(9) - - - - - - - - - (s) sH A ) s ( Q - Q(s)
solving, and transform Laplace Taking
-(8) - - - - - - - - - - - - - - -
R
H
Q
-(7) - - - - - - - - - - -
R
H H
Q
(6) - - - - - - - - -
dt
dh
A Q - Q
(5) - - - - - - - - -
dt
dh
A Q - Q
variables deviation with Solving
2 1 2 1
2
2 1
2 2
2 2 2
2 1 1 1
2 2 2 1
1 1 1
2
2
2
1
2 1
1
1
1 2 1
1
1 1
+ + t + t + t t
=
=
=
=
=
=

=
=
=
37
Interacting systems
) 1 s 62 . 2 )( 1 s 38 . 0 (
1
) s ( Q
) s ( Q
g, Factorisin
1 s 3 s
1
) s ( Q
) s ( Q
A A
, g min Assu
2
2 2
2
2 1
2 1
+ t + t
=
+ t + t
=
t = t = t
=
t t
+ =
62 . 2 / t 38 . 3 / t
2
e 17 . 1 e 17 . 0 1 (t) Q
change, step unit a For
Two tank Liquid level system
38
Mixing Process
Streams 1 and 2 are
mixed in a well stirred
tank, producing product
stream 3.
Feed streams are of A
and B, with
concentration of
cA1,cB1 and cA2,cB2
respectively.
F1,F2 and F3 are the
volumetric flow rates,
T1,T2 and T3 are the
corresponding
temperatures
39
Modeling the Mixing Process
The fundamental quantities of the mixing process are
Total mass in the tank
Amounts of A and B in the tank
Total energy
Momentum of the material in the tank ( does not change so neglected)
STEP 1
Total Mass Balance
) 2 ( F ) F F (
dt
dh
A
dt
dV
becomes, (1) eqn hence ,
same be to assumed are ) densities( simplicity for
) 1 ( F ) F F ( ) V (
dt
d
time
mass of o/p
time
mass of i/p
time
Mass of Total Acc.
3 2 1
3 2 1
3 3 2 2 1 1
+ = =
= = =
+ =
=



40
Modeling the Mixing Process
STEP 2
Mass Balance on component A
) 3 ( ) cA cA ( F ) cA cA ( F
dt
) cA ( d
V
) cA cA ( F ) cA cA ( F ) cA cA ( F
dt
) cA ( d
V
F cA F cA F cA cAF cAF cAF
dt
) cA ( d
V
cA cA
F cA ) F cA F cA ( ] F ) F F [( cA
dt
) cA ( d
V
F cA ) F cA F cA (
dt
) V ( d
cA
dt
) cA ( d
V
F cA ) F cA F cA (
dt
) cAV ( d
time
A of P / O
time
A of P / I
time
A of . Acc
3 2 2 3 1 1
3
3 3 3 3 2 2 3 1 1
3
3 3 2 2 1 1 3 2 1
3
3 3 2 2 1 1 3 2 1
3 3 2 2 1 1
3 3 2 2 1 1
+ =
+ =
+ = + +
=
+ = + +
+ = +
+ =
=
41
Modeling the Mixing Process
STEP 3
Total Energy balance
E=U (internal) + K (kinetic) + P (potential)
Since tank is stationary, rate of change of both kinetic and
potential energies are assumed to be negligible.
42
Self regulation
Controlled variable (H)
Manipulated or controlling
variable (Q)
43
Feedback control
Controlled variable
(T)
Manipulated or
controlling variables
(F, S)
To maintain T=Ts ,
when Fi , Ti changes
r = Ts
e = Ts - T
44
Feed Forward control
Frequent
disturbances
Controlled variable
(T)
Manipulated or
controlling variables
(F, S)
To maintain T=Ts ,
when Fi , Ti changes
r = Ts
e = Ts - T