CHE 185 PROCESS CONTROL AND DYNAMICS

PID ENHANCEMENTS

LIMITATIONS OF CONVENTIAL PID CONTROLLERS

THE PERFORMANCE OF PID CONTROLLERS CAN BE SUBSTANTIALLY LIMITED BY:
PROCESS NONLINEARITY MEASUREMENT DEADTIME PROCESS CONSTRAINTS

THERE ARE SEVERAL APPROACHES FOR PID CONTROLLERS TO HANDLE EACH OF THESE PROBLEMS

INFERENTIAL CONTROL
USES EASILY MEASURE PROCESS VARIABLES (T, P, F) TO INFER MORE DIFFICULT TO MEASURE QUANTITIES SUCH AS COMPOSITIONS AND MOLECULAR WEIGHT. CAN SUBSTANTIALLY REDUCE ANALYZER DELAY. CAN BE MUCH LESS EXPENSIVE IN TERMS OF CAPITAL AND OPERATING COSTS. CAN PROVIDE MEASUREMENTS THAT ARE NOT AVAILABLE ANY OTHER WAY

INFERENTIAL CONTROL
MEASURES A VARIABLE USING AN INDIRECT METHOD USED WHEN
IT IS NOT PRACTICAL TO MEASURE THE TARGET VARIABLE EXCESSIVE COST FOR CONTROL EQUIPMENT TO DIRECTLY MEASURE THE VARIABLE EXCESSIVE DOWNTIME IN A TARGET VARIABLE SENSOR THERE IS AN INFERENTIAL VARIABLE AVAILABLE

INFERENTIAL CONTROL
CHARACTERISTICS OF THE INFERENTIAL VARIABLE IT MUST BE CLOSELY RELATED TO THE TARGET VARIABLE IT MUST NOT BE AFFECTED BY CHANGES IN THE PROCESS CONDITIONS DYNAMICS ARE ADEQUATE FOR FEEDBACK CONTROL

INFERENTIAL CONTROL
CORRECTIONS TO INFERENTIAL CONTROL VARIABLE CAN USE A CASCADE CONTROL SOURCE CAN BE MANUALLY ADJUSTED

INFERENTIAL CONTROL
EXAMPLE USING TEMPERATURE TO CONTROL COMPOSITION FOR ISOBARIC FLASH Vapor
PC

SetPoint Heating or Cooling Media Process Feed Heat Exchange

TC

Product

Flash Tank

LC

Liquid Product

INFERENTIAL CONTROL
EXAMPLE USING TEMPERATURE TO CONTROL COMPOSITION FOR ISOBARIC FLASH CONTROLS COMPOSITION BASED ON FLASH TEMPERATURE DIRECT CONTROLLED VARIABLE IS FLASH PRESSURE LEVEL IS ALSO DIRECTLY CONTROLLED

INFERENTIAL CONTROL
EXAMPLE USING TEMPERATURE TO CONTROL COMPOSITION FOR ISOBARIC FLASH HOW IS THE TEMPERATURE SETTING CHECKED FOR THIS EXAMPLE? MANUAL ANALYSIS CAN BE USED TO ADJUST A FEED FORWARD SIGNAL FROM A PROCESS ANALYZER CAN ALSO BE USED (SEE SKETCH NEXT SLIDE)

INFERENTIAL CONTROL
IT IS ASSUMED THAT THE LAG TIME FOR THE ANALYZER LOOP IS LONGER THAN THAT FOR THE TEMPERATURE LOOP. THIS ALSO WILL TAKE CARE OF ANY STEADY-STATE OFFSET FOR THE TEMPERATURE CONTROL
SetPoint Signal
PC

Vapor Product

AC

Heating or Cooling Media Process Feed Heat Exchange

TC

Flash Tank

LC

Liquid Product

INFERENTIAL TEMPERATURE CONTROL FOR DISTILLATION COLUMNS

REBOILER CONTROL BASED ON TRAY TEMPERATURE

INFERENTIAL TEMPERATURE CONTROL FOR DISTILLATION COLUMNS

CHOOSING A PROPER TRAY TEMPERATURE LOCATION

TRAY TEMPERATURE USED FOR INFERENTIAL CONTROL SHOULD SHOW STRONG SENSITIVITY

INFERENTIAL TEMPERATURE CONTROL FOR FLOW REACTOR

SEE EXAMPLE 13.2 IN TEXT

ARTIFICIAL NEURAL NETWORKS (ANNs)

THESE ARE NON-LINEAR CONTROLLERS THAT ARE USED TO CONTROL NON-LINEAR PROCESSES THE MODEL TAKES INPUT(S) FROM THE SYSTEM AND USES THESE WITH WEIGHTED FUNCTIONS, TO PROVIDE THE OUTPUT FOR THE CONTROLLER

ARTIFICIAL NEURAL NETWORKS (ANNs)

THE WEIGHTING FUNCTIONS ARE REVISED OVER TIME TO OPTIMIZE THE OUTPUT THE ANN IS TUNED BY THE SYSTEM AND ONLY APPLIES TO ONE SYSTEM.

ARTIFICIAL NEURAL NETWORKS (ANNs)

SOFT SENSORS BASED ON NEURAL NETWORKS NEURAL NETWORK (NN) PROVIDES NONLINEAR CORRELATION. WEIGHTS ARE ADJUSTED UNTIL NN AGREES WITH PLANT DATA NN-BASED SOFT SENSORS ARE USED TO INFER NOX LEVELS IN THE FLUE GAS FROM POWER PLANTS.

SCHEDULING CONTROLLER TUNING

THIS IS A METHOD TO COMPENSATE FOR PROCESS NON-LINEARITY THAT CAN AFFECT CONTROL RESPONSE THE BASIC TECHNIQUE IS TO TUNE THE CONTROLLER BASED ON EMPIRICAL DATA
OPTIMUM TUNING DATA IS OBTAINED OVER A RANGE OF PROCESS SETTINGS.

SCHEDULING CONTROLLER TUNING

THE TUNING DATA IS THEN CONVERTED INTO PROPORTIONAL, INTEGRAL AND DERIVATIVE RESET FUNCTIONS OF THE MANIPULATED VARIABLE. THIS METHOD IS SIMILAR TO ANN EXCEPT IT ONLY LOOKS AT ONE INPUT VARIABLE AND RESULTS IN CLEARLY DEFINED FUNCTIONS

SCHEDULING CONTROLLER TUNING

ADJUST TUNING OF HEAT EXCHANGER CONTROL FOR VARIOUS FEED RATES LINK TUNING PARAMETERS TO THE FLOW RATES

SCHEDULING CONTROLLER TUNING

TYPICAL OPEN LOOP RESPONSE

SCHEDULING CONTROLLER TUNING

CLOSE LOOP RESPONSE WITH SCHEDULING

SCHEDULING CONTROLLER TUNING

CLOSE LOOP RESPONSE WITH SCHEDULING

SCHEDULING CONTROLLER TUNING

IMPLEMENTATION CAN TAKE THE FORM OF ADJUSTMENT OF PI GAIN AND INTEGRAL TIME USING THE TUNING FACTORS FOR EXAMPLE USING ZEIGLER-NICHOLS (EQUATION 9.11.2):

OVERRIDE/SELECT CONTROL
THIS METHOD EMPLOYS A SELECTION AMONG MULTIPLE INPUTS
IT CAN BE APPLIED TO ROUTINE CONTROL IT CAN BE USED TO IMPLEMENT EMERGENCY CONTROL

UNDER NORMAL OPERATION A LOW SELECT OR A HIGH SELECT METHOD IS USED BY THE CONTROLLER TO ADJUST THE MANIPULATED VARIABLE

OVERRIDE/SELECT CONTROL
INPUT COMES FROM TWO OR MORE CONTROLLERS TO A SECOND IN A CASCADE CONFIGURATION THE COMPARISON CONTROLLER CHOOSES THE LOWEST OR HIGHEST TO SEND TO THE ACTUATOR CONSIDER A REACTOR WITH COOLING FOR TEMPERATURE CONTROL

OVERRIDE/SELECT CONTROL
THE LOW SELECTOR TAKES THE LOWER VALUE FROM THE COMPOSITION ANALYZER AND THE REACTOR TEMPERATURE SENSOR THE LOWER VALUE IS SELECTED BECAUSE THIS ASSURES THE HIGHEST COOLING FLOW TO THE UNIT.
LS AC TC

ISOTHERMAL CSTR

OVERRIDE/SELECT CONTROL
TEXT PROVIDES SEVERAL OTHER EXAMPLES BASED ON HIGH, LOW AND COMBINED SELECTION NOTE THAT IT IS IMPORTANT FOR THE OPERATOR TO KNOW WHICH SIGNAL IS BEING USED BY THE CONTROLLER. MAY BE USED FOR LOW AND HIGH LEVEL ALARM ACTIONS
ALERTS OPERATOR TO OUT-OF-RANGE AND INITIATES CORRECTION WITHIN THE LOOP NOT INTENDED TO REPLACE SEPARATE HI-HI AND LO-LO ALARMS

COMPUTED MANIPULATED VARIABLE CONTROL

THESE ARE APPLIED MASS BALANCES, ENERGY BALANCES OR REACTION MODELS THAT ARE USED TO SPECIFY OPERATING SET POINTS. CAN BE USED FOR COMPLICATED SYSTEMS THAT CAN BE CONVENIENTLY MODELED TYPICALLY USED AS A SECONDARY SET POINT GENERATOR MAY BE LINKED TO SIMULATORS

COMPUTED MANIPULATED VARIABLE CONTROL

COMPUTED REBOILER DUTY CONTROL

COMPUTED MANIPULATED VARIABLE CONTROL

INTERNAL REFLUX CONTROL