Principles and Practice of Automatic Process Control

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1 Principles and Practice of Automatic Process Control Third Edition Carlos A. Smith, Ph.D., P.E. Department of Chemical Engineering University of South Florida Armando B. Corripio, Ph.D., P.E. Gordon A. and Mary Cain Department of Chemical Engineering Louisiana State University WILEY John Wiley & Sons, Inc.

2 1. Introduction A Process Control System Important Terms and Objective of Automatic Process Control Regulatory and Servo Control Transmission Signals, Control Systems, and Other Terms Control Strategies Feedback Control Feedforward Control Background Needed for Process Control Summary 9 Problems Mathematical Tools for Control Systems Analysis The Laplace Transform Definition of the Laplace Transform Properties of the Laplace Transform Solution of Differential Equations Using the Laplace Transform Laplace Transform Solution Procedure Inversion by Partial Fractions Expansion Handling Time Delays Characterization of Process Response Deviation Variables Output Response Stability Response of First-Order Systems Step Response Ramp Response Sinusoidal Response Response with Time Delay Response of a Lead-Lag Unit Response of Second-Order Systems Overdamped Responses Underdamped Responses Higher-Order Responses Linearization Linearization of Functions of One Variable Linearization of Functions of Two or More Variables Linearization of Differential Equations Summary 57 Problems 57

3 3. First-Order Dynamic Systems Processes and Importance of Process Characteristics Mathematical Process Modeling Thermal Process Example Dead Time Transfer Functions and Block Diagrams Transfer Functions Block Diagrams Gas Process Example Chemical Reactors Introductory Remarks Chemical Reactor Example Effects of Process Nonlinearities Additional Comments Summary 98 Problems Higher-Order Dynamic Systems Noninteracting Systems Noninteracting Level Process Thermal Tanks in Series Interacting Systems Interacting Level Process Thermal Tanks with Recycle Nonisothermal Chemical Reaction Response of Higher-Order Systems Other Types of Process Responses Integrating Processes: Level Process Open-Loop Unstable Process: Chemical Reactor Inverse Response Processes: Chemical Reactor Summary Overview of Chapters 3 and Problems Basic Components of Control Systems Sensors and Transmitters Control Valves The Control Valve Actuator Control Valve Capacity and Sizing Control Valve Characteristics Control Valve Gain and Transfer Function Control Valve Summary Feedback Controllers Actions of Controllers Types of Feedback Controllers Modifications to the PID Controller and Additional Comments 186

4 Contents XÜi Reset Windup and Its Prevention Feedback Controller Summary Summary 191 Problems Design of Single-Loop Process Control Systems The Feedback Control Loop Closed-Loop Transfer Function Characteristic Equation of the Loop Steady-State Closed-Loop Response Stability of the Control Loop Criterion of Stability Direct Substitution Method Effect of Loop Parameters on the Ultimate Gain and Period Effect of Dead Time Summary Summary 220 Problems Tuning of Feedback Controllers Quarter Decay Ratio Response by Ultimate Gain Open-Loop Process Characterization Process Step Testing Tuning for Quarter Decay Ratio Response Tuning for Minimum Error Integral Criteria Tuning Sampled-Data Controllers Summary of Controller Tuning Tuning Controllers for Integrating Processes Model of Liquid Level Control System Proportional Level Controller Averaging Level Control Summary of Tuning for Integrating Processes Synthesis of Feedback Controllers Development of the Controller Synthesis Formula Specification of the Closed-Loop Response Controller Modes and Tuning Parameters Summary of Controller Synthesis Results Tuning Rules by Internal Model Control (IMC) Tips for Feedback Controller Tuning Estimating the Reset and Rate Times Adjusting the Proportional Gain Summary 270 Problems Root Locus and Frequency Response Techniques Some Deflnitions Analysis of Feedback Control Systems by Root Locus 280

5 8-3 Plotting Root Locus Diagrams Analysis of Control Systems by Frequency Response Bode Plots Frequency Response Stability Criterion Summary 306 Problems Cascade Control A Process Example Stability Considerations Implementation and Tuning of Controllers Two-Level Cascade Systems Three-Level Cascade Systems Other Process Examples Final Comments Summary 322 Problems Ratio, Override, and Selective Control Signals, Software, and Computing Algorithms Signals Programming Scaling Computing Algorithms Ratio Control Override, or Constraint, Control Selective Control Designing Control Systems Summary 360 Problems Feedforward Control The Feedforward Concept Block Diagram Design of Linear Feedforward Controllers Lead-Lag Element Back to the Previous Example Design of Nonlinear Feedforward Controllers from Basic Process Principles Some Closing Comments and Outline of Feedforward Controller Design Three Other Examples Summary 402 Problems Multivariable Process Control Loop Interaction Pairing Controlled and Manipulated Variables Calculating the Relative Gains for a 2 x 2 System Calculating the Relative Gains for annxn System 422

6 Contents xv 12-3 Decoupling of Interacting Loops Decoupler Design from Block Diagrams Decoupler Design for n x n Systems Decoupler Design from Basic Principles Multivariable Control versus Optimization Dynamic Analysis of Multivariable Systems Dynamic Analysis of a 2 x 2 System Controller Tuning for Interacting Systems Design of Plantwide Control Systems Summary 448 Problems Dynamic Simulation of Control Systems Uses and Tools of Dynamic Simulation Uses of Dynamic Simulation Tools for Dynamic Simulation Simulation of Linear Transfer Functions Process Simulation Simulation of Control Instrumentation Control Valve Simulation Simulation of Feedback Controllers Simulation of Sensors-Transmitters Simulation of Lead-Lag Dynamic Compensation Other Simulation Aspects Summary 485 Problems 485 A. Instrumentation Symbols and Labels 491 B. Design Case Studies 498 Case 1. Methanol Synthesis Process 503 Case 2. Hydrocarbon Process 505 Case 3. Fatty Acid Process 506 Case 4. Control Systems in the Sugar-Refining Process 508 Case 5. Sulfuric Acid Process 509 Case 6. Ammonium Nitrate Prilling Plant Control System 511 Case 7. Natural Gas Dehydration Control System 512 C. Sensors, Transmitters, and Control Valves 514 C-l Pressure Sensors 514 C-2 Flow Sensors 514 C-3 Level Sensors 519 C-4 Temperature Sensors 520 C-5 Composition Sensors 523 C-6 Transmitters 523 C-6.1 Pneumatic Transmitters 523 C-6.2 Electronic Transmitters 524 C-7 Types of Control Valves 525

7 C-7.1 Reciprocating Stern 525 C-7.2 Rotating Stern 529 C-8 Control Valve Actuators 529 C-8.1 Pneumatically Operated Diaphragm Actuators 529 C-8.2 Piston Actuators 529 C-8.3 Electrohydraulic and Electromechanical Actuators 529 C-8.4 Manual-Handwheel Actuators 530 C-9 Control Valve Accessories 530 C-9.1 Positioners 530 C-9.2 Boosters 532 C-9.3 Limit Switches 532 C-10 Control Valves Additional Considerations 532 C-10.1 Viscosity Corrections 532 C-10.2 Flashing and Cavitation 533 C-ll Summary 536 D. Urning Case Studies 538 Process 1. Regenerator Feedback 538 Process 2. Regenerator Cascade 540 Process 3. Paper-Drying Process 541 Process 4. HCl Scrubber 543 Process 5. Mixing Process 544 Process 6. Reactor Process 547 Process 7. Distillation Process 547 E. Operating Case Studies 548 Index 559 Operating Case Study 1: HCl Scrubber 548 Operating Case Study 2: Water Treatment unit 550 Operating Case Study 3: Catalyst Regenerator 553 Operating Case Study 4: Baby Back Ribs 555 Operating Case Study 5: Paper Drying Unit 556

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