Introduction to Process Control: (Chemical Industries)

Introduction to Process Control, Second Edition provides a bridge between the traditional view of process control and the current, expanded role by blending conventional topics with a broader perspective of more integrated process operation, control, and information systems. Updating and expanding the content of its predecessor, this second edition addresses issues in today’s teaching of process control. Teaching & Learning Principles Presents a concept first followed by an example, allowing students to grasp theoretical concepts in a practical manner Uses the same problem in each chapter, culminating in a complete control design strategy Includes 50 percent more exercises Content Defines the traditional and expanded roles of process control in modern manufacturing Introduces the link between process optimization and process control (optimizing control), including the effect of disturbances on the optimal plant operation, the concepts of steady-state and dynamic backoff as ways to quantify the economic benefits of control, and how to determine an optimal transition policy during a planned production change Incorporates an introduction to the modern architectures of industrial computer control systems with real case studies and applications to pilot-scale operations Discusses the expanded role of process control in modern manufacturing, including model-centric technologies and integrated control systems Integrates data processing/reconciliation and intelligent monitoring in the overall control system architecture Web Resource The book’s website offers a user-friendly software environment for interactively studying the examples in the text. The site contains the MATLAB® toolboxes for process control education as well as the main simulation examples from the book. Access the site through the authors’ websites at www.pseonline.net and www.chms.ucdavis.edu/research/web/pse/ahmet/ Drawing on the authors’ combined 50 years of teaching experiences, this classroom-tested text is designed for chemical engineering students but is also suitable for industrial practitioners who need to understand key concepts of process control and how to implement them. The authors help readers see how traditional process control has evolved into an integrated operational environment used to run modern manufacturing facilities.

Table of Contents:
INTRODUCTION Why Process Control? Historical Background Role of Control in Process Industries Objectives of Control Summary Continuing Problem References Definitions and Terminology Concepts and Definitions Control Design Problem Control System Design Control Design Project Summary Continuing Problem References MODELING FOR CONTROL Basic Concepts in Modeling Why Is Process Modeling Necessary? Classification of Models Types of Models Degrees of Freedom Models and Control Summary References Development of Models from Fundamental Laws Principles of Modeling Models Based on Fundamental Laws Modeling of Processes Involving Chemical Reactions Modeling of Complex Systems Distributed Parameter Systems Numerical Solution of Model Equations Summary Continuing Problem References Input–Output Models: The Transfer Function Linear (Linearized) Model Concept of Transfer Function Transfer Functions of Single-Input Single-Output Processes Properties of Transfer Functions Nonrational Transfer Functions Summary Continuing Problem Models from Process Data Development of Empirical Models Model Structures Process Reaction Curve Method Regression in Modeling Summary Continuing Problem References PROCESS ANALYSIS Stability Stability of Linear Systems Input–Output Stability Routh’s Criterion Root-Locus Method Direct Substitution Method Summary References Dynamic Performance Input Types First-Order Processes Second-Order Processes Multicapacity Processes Effect of Zeros Effect of Time Delays Summary Continuing Problem Frequency Response What Is Frequency Response? Complex Numbers in Polar Coordinates Construction of Frequency Response Evaluation of Frequency Response Frequency Response of Common Systems Bode Diagrams Nyquist Diagrams Systems in Series Summary Continuing Problem FEEDBACK CONTROL Basic Elements of Feedback Control Feedback Control Problem Control Law Closed-Loop Transfer Functions Analysis of Individual Terms in PID Controllers Practical Issues in PID Design Summary Continuing Problem Reference Stability Analysis of Closed-Loop Processes Closed-Loop Stability Routh’s Criterion Root-Locus Method Modeling Errors Frequency Response Methods Summary Continuing Problem Feedback Control Design Design Objectives Controller Tuning Techniques Comparing the Methods Summary Continuing Problem References MODEL-BASED CONTROL Model-Based Control Feedforward Control Delay Compensation (Smith Predictor) Internal Model Control Summary Continuing Problem References Model Uncertainty and Robustness IMC Structure with Model Uncertainty Description of Model Uncertainty IMC Design under Model Uncertainty Summary References Model Predictive Control General Principles Dynamic Matrix Control Process Constraints State-Space Formulation of MPC Summary Continuing Problem References MULTIVARIABLE CONTROL Multivariable Systems: Special Cases Cascade Control Ratio Control Split-Range Control Override Control Summary Continuing Problem References Multivariable Systems Characteristics of Multivariable Processes Modeling of Multivariable Processes Transfer Functions of Multivariable Processes Multivariable Feedback Control Structure Summary Continuing Problem References Design of Multivariable Controllers Multiple-Input–Multiple-Output Feedback Analysis RGA Interaction Measure Multiloop Controller Design Design of Noninteracting Control Loops: Decouplers Summary Continuing Problem References CONTROL IN MODERN MANUFACTURING Practical Control of Nonlinear Processes Operating Regime Modeling Approach Gain-Scheduling Controller Multimodel Controller Design Summary References Process Optimization and Control Process Optimization Optimizing Control of Disturbances Dynamic Optimization and Transition Planning Summary References Industrial Control Technology Evolution of Industrial Control Technology Generic Industrial Control Systems Architecture Summary Continuing Problem References Role of Process Control in Modern Manufacturing Expanded Role of Control in Modern Manufacturing Model-Centric Technologies Integrated Control Systems Summary References Data Processing and Reconciliation Dealing with Missing Points Outliers Characterizing Process Data Modeling Process Data Data Reconciliation Issues in Data Reconciliation Process Monitoring Process Monitoring Statistical Process Control Principal Component Analysis Multivariate Performance Monitoring Fault Diagnosis and Classification Controller Performance Monitoring Summary References Appendix A: Linearization Appendix B: Laplace Transformation Appendix C: Matrix Operations Appendix D: Basic Statistics Index Additional Reading and Exercises appear at the end of each section.