Introduction To Process Control

by Romagnoli, Jose A.; Palazoglu, Ahmet

• ISBN13: 9780849334962
• ISBN10: 0849334969
• Format: Hardcover
• Copyright: 2005-07-25
• Publisher: CRC Press

Summary

Improvements in software, instrumentation, and feedback control as well as deepening linkages between fundamental aspects of process technology have vastly changed the practice of industrial process control. Newcomers to the field must have a strong understanding of the new demands and capabilities of modern process control operations. Reflecting these changes, Introduction to Process Control infuses traditional topics with industry-based practices that provide more integrated process operation, control, and information systems. The authors adopt a thoughtfully conceived approach that follows a "Continuing Problem" throughout the text, adding new concepts and strategies to the example, which culminates in a complete control design strategy. This fully realized system is implemented in MATLAB®, with software downloads available from the CRC Web site. This approach not only provides seamless continuity, but also addresses the plantwide control problem and engenders hands-on, step-by-step understanding of how the concepts apply to real processes. The book introduces data processing and reconciliation along with process monitoring as integral components of overall control system architecture. Along with an introduction to modern architectures of industrial computer control systems, Introduction to Process Control offers unique and unparalleled coverage of the expanded role of process control in modern industry, from modeling the process to implementing a plant-wide system.

Table of Contents

Section I Introduction	1	(34)
Chapter 1 Why Process Control?	3	(12)
1.1 Historical Background	4	(1)
1.2 Role of Control in Process Industries	5	(4)
1.2.1 Traditional Role of Process Control	5	(2)
1.2.2 Expanded Role of Process Control	7	(2)
1.3 Objectives of Control	9	(3)
1.3.1 What About Performance?	10	(1)
1.3.2 Economic Benefits of Control	10	(2)
1.4 Summary	12	(1)
Continuing Problem	12	(3)
Chapter 2 Definitions and Terminology	15	(12)
2.1 Concepts and Definitions	15	(3)
2.2 Control Design Problem	18	(3)
2.3 Control System Design	21	(1)
2.4 Control Design Project	22	(3)
2.4.1 Preliminary Engineering	23	(1)
2.4.2 Detailed Engineering	24	(1)
2.4.3 Implementation	24	(1)
2.4.4 Installation	24	(1)
2.4.5 Commissioning	25	(1)
2.4.6 First Production Startup and Turnover	25	(1)
2.4.7 Training	25	(1)
2.5 Summary	25	(1)
Continuing Problem	25	(2)
Section I Additional Reading	27	(2)
Section I Exercises	29	(6)
Section II Modeling for Control	35	(70)
Chapter 3 Basic Concepts in Modeling	37	(14)
3.1 Types of Models	38	(1)
3.2 Classification of Models	38	(4)
3.3 State-Space Models	42	(1)
3.4 Input-Output Models	43	(3)
3.5 Degrees of Freedom	46	(1)
3.6 Models and Control	47	(1)
3.7 Summary	48	(3)
Chapter 4 Development of Models from Fundamental Laws	51	(14)
4.1 Principles of Modeling	51	(1)
4.2 Models Based on Fundamental Laws	52	(6)
4.3 Role of Process Simulators in Modeling	58	(3)
4.3.1 New Trends in Process Simulations	59	(2)
4.4 Summary	61	(1)
Continuing Problem	62	(3)
Chapter 5 Input-Output Models: The Transfer Function	65	(18)
5.1 Linear (Linearized) Model	65	(5)
5.1.1 Deviation Variables	66	(2)
5.1.2 Higher Dimensional Equations	68	(1)
5.1.3 Linear State-Space Model	69	(1)
5.2 Concept of Transfer Function	70	(1)
5.3 Transfer Functions of SISO Processes	71	(3)
5.3.1 Asymptotic Theorems	73	(1)
5.4 Properties of Transfer Functions	74	(2)
5.5 Nonrational Transfer Functions	76	(2)
5.6 Summary	78	(1)
Continuing Problem	79	(4)
Chapter 6 Models from Process Data	83	(12)
6.1 Development of Empirical Models	83	(3)
6.1.1 Performing the Experiments	84	(1)
6.1.2 Developing the Model	85	(1)
6.1.3 Evaluating the Model	85	(1)
6.2 Process Reaction Curve	86	(4)
6.3 Linear Regression in Modeling	90	(4)
6.4 Summary	94	(1)
Section II Additional Reading	95	(2)
Section II Exercises	97	(8)
Section III Process Analysis	105	(52)
Chapter 7 Stability	107	(12)
7.1 Stability of Linear Systems	107	(4)
7.2 Input-Output Stability	111	(2)
7.3 Routh's Criterion	113	(3)
7.4 Root-Locus Method	116	(1)
7.5 Summary	117	(2)
Chapter 8 Dynamic Performance	119	(20)
8.1 First-Order Processes	119	(4)
8.2 Second-Order Processes	123	(4)
8.3 Multi-Capacity Processes	127	(6)
8.4 Effect of Zeros	133	(3)
8.5 Effect of Time Delays	136	(1)
8.6 Summary	137	(2)
Chapter 9 Frequency Response	139	(12)
9.1 What is Frequency Response?	139	(1)
9.2 Complex Numbers in Polar Coordinates	140	(1)
9.3 Construction of the Frequency Response	141	(2)
9.4 Evaluation of the Frequency Response	143	(2)
9.5 Bode Diagrams	145	(2)
9.6 Nyquist Diagrams	147	(3)
9.7 Summary	150	(1)
Section III Additional Reading	151	(2)
Section III Exercises	153	(4)
Section IV Feedback Control	157	(60)
Chapter 10 Basic Elements of Feedback Control	159	(18)
10.1 Feedback Control Problem	159	(3)
10.2 Control Law	162	(3)
10.2.1 Proportional Mode	162	(2)
10.2.2 Integral Mode	164	(1)
10.2.3 Derivative Mode	164	(1)
10.2.4 Three-Mode Controller (PID)	164	(1)
10.3 Closed-Loop Transfer Functions	165	(2)
10.4 Closed-Loop Performance	167	(6)
10.4.1 Proportional Mode	167	(2)
10.4.2 Integral Mode	169	(2)
10.4.3 Derivative Mode	171	(1)
10.4.4 Integral Windup	172	(1)
10.5 Summary	173	(1)
Continuing Problem	173	(4)
Chapter 11 Stability Analysis of Closed-Loop Processes	177	(14)
11.1 Closed-Loop Stability	177	(2)
11.2 Routh's Criterion	179	(1)
11.3 Root-Locus Method	180	(4)
11.4 Frequency Response Methods	184	(3)
11.5 Summary	187	(1)
Continuing Problem	188	(3)
Chapter 12 Feedback Control Design	191	(20)
12.1 Design Objectives	191	(3)
12.1.1 Error-Based Criteria	192	(2)
12.2 Open-Loop Tuning (Cohen-Coon) Method	194	(1)
12.3 Closed-Loop Tuning (Ziegler-Nichols) Method	195	(5)
12.4 Autotuning (Relay) Controller	200	(4)
12.5 Practical Issues in PID Design	204	(4)
12.5.1 Direct and Reverse Action	205	(1)
12.5.2 Bumpless Transfer	206	(1)
12.5.3 PID Equation Forms	206	(2)
12.6 Summary	208	(1)
Continuing Problem	209	(2)
Section IV Additional Reading	211	(2)
Section IV Exercises	213	(4)
Section V Multivariable Control	217	(62)
Chapter 13 Multivariable Systems: Special Cases	219	(18)
13.1 Cascade Control	219	(4)
13.2 Ratio Control	223	(4)
13.2.1 Ratio Computation	223	(1)
13.2.2 Set-Point Computation	223	(4)
13.3 Override Control	227	(3)
13.4 Summary	230	(1)
Continuing Problem	231	(6)
Chapter 14 Multivariable Systems: General Concepts	237	(14)
14.1 Characteristics of Multivariable Processes	237	(1)
14.2 Modeling of Multivariable Processes	238	(2)
14.3 Transfer Functions of Multivariable Processes	240	(5)
14.3.1 Poles and Zeros of MIMO Systems	242	(3)
14.4 Multivariable Feedback Control Structure	245	(4)
14.4.1 Closed-Loop Poles and Zeros	246	(1)
14.4.2 Stability of MIMO Closed-Loop Systems	247	(2)
14.5 Summary	249	(2)
Chapter 15 Design of Multivariable Controllers	251	(22)
15.1 MIMO Feedback Analysis	251	(5)
15.2 RGA Interaction Measure	256	(4)
15.2.1 Selection of Loops	258	(2)
15.3 Multiloop Controller Design	260	(1)
15.4 Design of Noninteracting Control Loops: Decouplers	261	(4)
15.5 Summary	265	(1)
Continuing Problem	265	(8)
Section V Additional Reading	273	(2)
Section V Exercises	275	(4)
Section VI Model-Based Control	279	(86)
Chapter 16 Model-Based Control	281	(26)
16.1 Feedforward Control	281	(3)
16.1.1 Feedforward-Feedback Control Strategy	283	(1)
16.2 Delay Compensation (Smith Predictor)	284	(3)
16.3 Internal Model Control (IMC) Structure	287	(8)
16.3.1 Concept of Perfect Control	289	(1)
16.3.2 IMC Design Procedure	290	(4)
16.3.3 PID Tuning using IMC Rules	294	(1)
16.4 Summary	295	(1)
Continuing Problem	296	(11)
Chapter 17 Model Uncertainty and Robustness	307	(12)
17.1 IMC Structure with Model Uncertainty	307	(1)
17.2 Description of Model Uncertainty	308	(3)
17.2.1 Additive Uncertainty	308	(1)
17.2.2 Multiplicative Uncertainty	309	(1)
17.2.3 Estimation of Uncertainty Bounds	309	(2)
17.3 IMC Design Under Model Uncertainty	311	(6)
17.3.1 Robust Stability	312	(1)
17.3.2 Robust Performance	313	(4)
17.4 Summary	317	(2)
Chapter 18 Model Predictive Control (MPC)	319	(22)
18.1 General Principles	319	(4)
18.1.1 Model Forms	321	(2)
18.2 Dynamic Matrix Control	323	(4)
18.2.1 SISO Unconstrained DMC Problem	325	(1)
18.2.2 Controller Tuning	326	(1)
18.3 Treatment of Process Constraints	327	(4)
18.4 State-Space Formulation of MPC	331	(3)
18.4.1 Infinite Horizon Problem	332	(2)
18.5 Summary	334	(1)
Continuing Problem	335	(6)
Chapter 19 Practical Control of Nonlinear Processes	341	(24)
19.1 Operating Regime Modeling Approach	341	(5)
19.1.1 Global Model Structure	343	(3)
19.2 Gain-Scheduling Controller	346	(6)
19.2.1 Determination of Process Gains	349	(1)
19.2.2 Gain-Scheduling Implementation	349	(3)
19.3 Multimodel Controller Design	352	(5)
19.3.1 Multimodel MPC	354	(3)
19.4 Summary	357	(2)
Section VI Additional Reading	359	(2)
Section VI Exercises	361	(4)
Section VII Control in Modern Manufacturing	365	(118)
Chapter 20 Plantwide Process Control	367	(26)
20.1 Fundamentals of Plantwide Control	368	(5)
20.1.1 Material Recycle	369	(1)
20.1.2 Energy Integration	369	(1)
20.1.3 Chemical Component Inventories	370	(3)
20.2 Plantwide Control Design Procedure	373	(4)
20.3 Importance of Simulations for Plantwide Control	377	(6)
20.4 Targeting Economics and Environment	383	(6)
20.4.1 Economically Conscious Processes	383	(1)
20.4.2 Environmentally Conscious Processes	383	(1)
20.4.3 Process Integration for Economic and Environmental Improvement	384	(1)
20.4.4 Plantwide Control of Integrated Processes	385	(4)
20.5 Summary	389	(4)
Chapter 21 Industrial Control Technology	393	(18)
21.1 Evolution of Industrial Control technology	393	(1)
21.2 Generic Industrial Control Systems Architecture	394	(11)
21.2.1 Supervisory Environment	394	(2)
21.2.2 Control Environment	396	(1)
21.2.3 Communication Environment	396	(1)
21.2.4 Data Exchange	397	(8)
21.3 Summary	405	(1)
Continuing Problem	405	(6)
Chapter 22 Role of Process Control in Modern Manufacturing	411	(18)
22.1 Expanded Role of Control in Modern Manufacturing	411	(8)
22.2 Integrated Control Systems	419	(6)
22.3 Summary	425	(4)
Chapter 23 Data Processing and Reconciliation	429	(20)
23.1 Dealing with Missing Points	429	(3)
23.2 Outliers	432	(2)
23.3 Characterizing Process Data	434	(3)
23.4 Modeling Process Data	437	(2)
23.4.1 Model Fitting Based on Least-Squares Estimation	438	(1)
23.5 Data Reconciliation	439	(3)
23.6 Issues in Data Reconciliation	442	(6)
23.6.1 Process Model	442	(2)
23.6.2 Classification of Process Variables	444	(1)
23.6.3 Linear Data Reconciliation with Unmeasured Variables	445	(1)
23.6.4 Gross Errors	446	(2)
23.7 Summary	448	(1)
Chapter 24 Process Monitoring	449	(28)
24.1 Statistical Process Control	449	(4)
24.1.1 Control Charts	450	(1)
24.1.2 Control Chart Interpretation	451	(1)
24.1.3 Multivariate Charts	452	(1)
24.2 Principal Component Analysis (PCA)	453	(5)
24.2.1 Calculation of PCA	453	(5)
24.3 Multivariate Performance Monitoring	458	(5)
24.3.1 Elliptical Normal Operation region	460	(2)
24.3.2 T² and SPE Charts	462	(1)
24.3.3 Contribution Plots	463	(1)
24.4 Fault Diagnosis and Classification	463	(7)
24.5 Controller Performance Monitoring (CPM)	470	(5)
24.5.1 State Classification	472	(1)
24.5.2 Model Validation	472	(1)
24.5.3 Stochastic Performance Monitoring	473	(1)
24.5.4 Controller Oscillation Assessment	474	(1)
24.6 Summary	475	(2)
Section VII Additional Reading	477	(2)
Section VII Exercises	479	(4)
Appendix A Linearization	483	(8)
A.1 Basic Steps in Linearization	483	(3)
A.2 Linearization Generalized	486	(5)
Appendix B Laplace Transformation	491	(8)
B.1 Definition	491	(1)
B.2 Laplace Transform of Some Typical Functions	491	(2)
B.3 Some Useful Properties of the Laplace Transform	493	(2)
B.4 Partial Fraction Expansion	495	(4)
Appendix C Matrix Operations	499	(8)
C.1 Vectors and Matrices	499	(1)
C.1.1 Special Matrices	500	(1)
C.2 Determinant and Inverse	500	(2)
C.3 Eigenvalue Decomposition	502	(1)
C.4 Singular-Value Decomposition	503	(1)
C.5 Vector and Matrix Norms	504	(3)
Appendix D Basic Statistics	507	(8)
D.1 Sample Mean and Standard Deviation	507	(1)
D.2 Random Variables and Probability Distributions	508	(1)
D.3 Gaussian (Normal) Distribution	509	(2)
D.4 Correlations and Covariance	511	(1)
D.5 χ² and F Distributions	512	(3)
Index	515