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Process Control: Blending System Overview

This document provides an introduction to process control. It discusses different types of control strategies including feedback control and feedforward control. It uses an example of controlling the concentration in a blending tank to illustrate these concepts. Feedback control measures the controlled variable to make adjustments, while feedforward control measures disturbances before they impact the process. The document also discusses control terminology, justifications for control, and the major steps in developing a control system.

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Salih Ahmed Obeid
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27 views29 pages

Process Control: Blending System Overview

This document provides an introduction to process control. It discusses different types of control strategies including feedback control and feedforward control. It uses an example of controlling the concentration in a blending tank to illustrate these concepts. Feedback control measures the controlled variable to make adjustments, while feedforward control measures disturbances before they impact the process. The document also discusses control terminology, justifications for control, and the major steps in developing a control system.

Uploaded by

Salih Ahmed Obeid
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd

Introduction to Process

Control
Chapter 1

a) prototype system-blending tank


b) feedback control
c) implementation of control
d) justification of control
Chapter 1
Chapter 1
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.
Chapter 1
Chapter
Chapter11
Control Terminology(2)

set-point change - 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 change - 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.
Chapter 1 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
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
• 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 xSP . But what if conditions change?
Chapter 1

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.

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  Kc  xSP  x  t  (1-4)

1. where Kc is called the controller gain.


Chapter 1

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).
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
Chapter 1
• 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.
Chapter 1

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
Chapter 1

1 x w2 FBa
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
Chapter 1

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.
Chapter 1

• Disadvantage:
 Must be able to measure the disturbance.
 No corrective action for unmeasured disturbances.
Closed-loop Artificial Pancreas
glucose u
setpoint
y
r

controller pump patient sensor

measured glucose

Bob Parker has integrated this example throughout his course (different levels
of modeling, etc.
Chapter 1
Chapter 1
Chapter 1
Justification of Process Control

Specific Objectives of Control


• Increased product throughput
Chapter 1

• 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
Chapter 1
Chapter 1
(days-months) 5. Planning and
Scheduling

(hours-days) 4. Real-Time
Optimization

3b. Multiv ariable


Chapter 1

(minutes-hours) and Constraint


Control
Figure 1.7 Hierarchy of
process control activities.

(seconds-minutes) 3a. Regulatory


Control

2. Saf ety , Env ironment


(< 1 second) and Equipment
Protection

(< 1 second) 1. Measurement


and Actuation

Process
Chapter 1

Figure 1.9 Major


steps in control
system development
Chapter 1

Next chapter

Common questions

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Set-point change involves adjusting the operating conditions by altering the set-point signal of controlled variables, prompting adjustments in manipulated variables to achieve the new conditions. In process control systems, this is crucial for adaptive operations, allowing systems to respond to changing production requirements or objectives. It is also known as servomechanism or 'servo' control, emphasizing its role in maintaining desired performance levels amidst operational changes .

In response to changes in inlet concentration (x1), the blending system adjusts the flow rate of component A (w2) to maintain the mass fraction x at the set-point xSP. If x1 increases, w2 is reduced to compensate and achieve balance, as dictated by the control law. This method ensures that output quality remains consistent despite variations in input parameters, exemplifying practical application of process control principles to achieve stability .

Feedback control has the advantage of taking corrective actions regardless of the disturbance's source and reducing the controlled variable's sensitivity to changes in the process. However, it responds only after the disturbance affects the process, potentially leading to oscillatory behaviors or instability. Conversely, feedforward control adjusts for disturbances before they affect the process, enhancing proactive response. Its disadvantage lies in the requirement that the disturbance must be measurable, and it offers no corrective action for unmeasured disturbances .

Using a larger tank in a blending system increases the system's capacitance, which helps dampen fluctuations in disturbance variables like inlet concentration (x1). However, while this approach enhances process stability by reducing sensitivity to disturbances, it also incurs higher capital costs. Therefore, the decision involves a trade-off between improved stability and increased investment .

In process control systems, controlled variables represent the output variables that measure the performance or quality of the final product. Manipulated variables are input variables that are dynamically adjusted to maintain the controlled variables at their desired set-points. Disturbance variables, also known as load variables, are input variables that can cause deviations in the controlled variables from their set points. This trichotomy is crucial for designing control systems that can respond effectively to changes and disturbances to maintain optimal operation .

In a proportional feedback control system, the controller gain (Kc) determines how much the manipulated variable will change in response to a deviation of the controlled variable from its set point. Specifically, the change in the manipulated variable (w2) is proportional to the magnitude of deviation (xSP - x(t)), with Kc acting as the proportionality factor. A higher Kc leads to larger adjustments, potentially increasing responsiveness but also the risk of instability .

Justifying the implementation of process control systems involves evaluating their contributions towards increased product throughput, enhanced yield of valuable products, reduced energy consumption, and minimized pollution levels. Additionally, factors such as improved safety, extended equipment life, decreased off-spec production, and reduced labor costs can significantly weigh in favor of implementing advanced process control systems .

The interplay between process control and economic incentives centers around optimizing operational efficiency and reducing costs. Advanced process control techniques improve throughput, product quality, and yield, directly enhancing revenue. They also decrease energy consumption and waste, leading to significant cost savings and environmental compliance. Ultimately, the strategic application of process control is pivotal for achieving competitive advantage and financial sustainability .

Developing an effective control system involves several critical steps: measurement and actuation, implementing safety, environmental and equipment protection measures, ensuring robust regulatory control, facilitating real-time optimization, and integrating planning and scheduling. This hierarchical approach ensures comprehensive management from immediate control actions to long-term production plans .

Implementing advanced control strategies can significantly enhance process efficiency and economic performance. Benefits include increased product throughput and yield of higher-valued products, decreased energy consumption, and reduced pollution. Advanced control also minimizes production of off-spec products, increases safety, and extends equipment life, leading to improved operability and reduced production labor .

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