Applied Process Control Essential Methods 1st Edition Michael Mulholland 2024 Scribd Download
Applied Process Control Essential Methods 1st Edition Michael Mulholland 2024 Scribd Download
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2010
Svrcek, W.Y., Mahoney, D.P., Young, B.R.
Print ISBN: 978-3-527-32552-8
A Real-Time Approach to Process
Buzzi-Ferraris, G., Manenti, F.
Control
3rd Edition
Interpolation and Regression
2014 Models for the Chemical Engineer
Print ISBN: 978-1-119-99388-9 Solving Numerical Problems
2015
Print ISBN: 978-3-527-33275-5
Michael Mulholland
Essential Methods
Author All books published by Wiley-VCH are carefully produced.
Nevertheless, authors, editors, and publisher do not warrant the
Professor Michael Mulholland information contained in these books, including this book, to be
University of KwaZulu-Natal free of errors. Readers are advised to keep in mind that
Chemical Engineering statements, data, illustrations, procedural details or other items
4041 Durban
may inadvertently be inaccurate.
South Africa
Library of Congress Card No.: applied for
Preface XI
Acknowledgements XIII
Abbreviations XV
Frontispiece XIX
1 Introduction 1
1.1 The Idea of Control 1
1.2 Importance of Control in Chemical Processing 3
1.3 Organisation of This Book 5
1.4 Semantics 6
References 7
2 Instrumentation 9
2.1 Piping and Instrumentation Diagram Notation 9
2.2 Plant Signal Ranges and Conversions 11
2.3 A Special Note on Differential Pressure Cells 14
2.4 Measurement Instrumentation 16
2.4.1 Flow Measurement 17
2.4.1.1 Flow Measurement Devices Employing Differential Pressure 17
2.4.1.2 Other Flow Measurement Devices 22
2.4.2 Level Measurement 22
2.4.2.1 Level Measurement by Differential Pressure 22
2.4.2.2 Other Level Measurement Techniques 25
2.4.3 Pressure Measurement 25
2.4.4 Temperature Measurement 26
2.4.4.1 Thermocouple Temperature Measurement 26
2.4.4.2 Metal Resistance Temperature Measurement 28
2.4.4.3 Temperature Measurements Using Other Principles 28
2.4.5 Composition Measurement 29
2.5 Current-to-Pneumatic Transducer 31
2.6 Final Control Elements (Actuators) 31
VI Essential Methods Contents
2.6.1 Valves 32
2.6.1.1 Pneumatically Operated Globe Control Valve 32
2.6.1.2 Valve Characteristics 35
2.6.1.3 Valve CV and KV 36
2.6.1.4 Specification of Valves for Installed Performance 37
2.6.1.5 Control Valve Hysteresis 39
2.6.1.6 Various Flow Control Devices 40
2.6.2 Some Other Types of Control Actuators 42
2.7 Controllers 42
2.8 Relays, Trips and Interlocks 44
2.9 Instrument Reliability 45
References 51
3 Modelling 53
3.1 General Modelling Strategy 54
3.2 Modelling of Distributed Systems 59
3.3 Modelling Example for a Lumped System: Chlorination Reservoirs 61
3.4 Modelling Example for a Distributed System: Reactor Cooler 63
3.5 Ordinary Differential Equations and System Order 67
3.6 Linearity 69
3.7 Linearisation of the Equations Describing a System 73
3.8 Simple Linearisation ‘Δ’ Concept 75
3.9 Solutions for a System Response Using Simpler Equations 77
3.9.1 Mathematical Solutions for a System Response in the t-Domain 77
3.9.2 Mathematical Solutions for a System Response in the s-Domain 79
3.9.2.1 Review of Some Laplace Transform Results 79
3.9.2.2 Use of Laplace Transforms to Find the System Response 84
3.9.2.3 Open-Loop Stability in the s-Domain 95
3.9.3 Mathematical Solutions for System Response in the z-Domain 97
3.9.3.1 Review of Some z-Transform Results 98
3.9.3.2 Use of z-Transforms to Find the System Response 104
3.9.3.3 Evaluation of the Matrix Exponential Terms 109
3.9.3.4 Shortcut Methods to Obtain Discrete Difference Equations 110
3.9.3.5 Open-Loop Stability in the z-Domain 111
3.9.4 Numerical Solution for System Response 113
3.9.4.1 Numerical Solution Using Explicit Forms 114
3.9.4.2 Numerical Solution Using Implicit Forms 115
3.9.5 Black Box Modelling 117
3.9.5.1 Step Response Models 117
3.9.5.2 Regressed Dynamic Models 122
3.9.6 Modelling with Automata, Petri Nets and Their Hybrids 126
3.9.7 Models Based on Fuzzy Logic 132
3.10 Use of Random Variables in Modelling 136
3.11 Modelling of Closed Loops 141
References 142
Essential Methods Contents VII
9 Optimisation 409
9.1 Introduction 409
9.2 Aspects of Optimisation Problems 409
9.3 Linear Programming 412
9.4 Integer Programming and Mixed Integer Programming (MIP) 418
9.5 Gradient Searches 421
9.5.1 Newton Method for Finding a Minimum or a Maximum 421
9.5.2 Downhill Simplex Method 422
9.5.3 Methods Based on Chosen Search Directions 423
9.5.3.1 Steepest Descent Method 425
9.5.3.2 Conjugate Gradient Method 427
9.6 Nonlinear Programming and Global Optimisation 429
9.6.1 Global Optimisation by Branch and Bound 429
9.7 Combinatorial Optimisation by Simulated Annealing 432
9.8 Optimisation by Evolutionary Strategies 434
9.8.1 Reactor Design Example 435
9.8.2 Non-dominated Sorting Genetic Algorithm (NSGA) 437
9.9 Mixed Integer Nonlinear Programming 441
9.9.1 Branch and Bound Method 442
9.9.2 Outer Approximation Method (OA) 443
9.9.3 Comparison of Other Methods 444
9.10 The GAMS Modelling Environment 444
9.11 Real-Time Optimisation of Whole Plants 449
References 454
Index 457
XI
Preface
Material in this book is sequenced for the process engineer who needs ‘some’ background in process
control (Chapters 1–5) through to the process engineer who wishes to specialise in advanced pro
cess control (Chapters 1–9). The theory needed to properly understand and implement the methods
is presented as succinctly as possible, with extensive recourse to linear algebra, allowing multi-input,
multi-output problems to be interpreted as simply as single-input, single-output problems.
Before moving on to the more advanced algorithms, an essential practical background is laid out
on plant instrumentation and control schemes (Chapters 2, 4 and 5). Chapter 3 builds modelling
abilities from the simplest time-loop algorithm through to discrete methods, transfer functions,
automata and fuzzy logic. By the end of Chapter 5, the engineer has the means to design simple
controllers on the basis of his or her models, and to use more detailed models to test these control
lers. Moreover, ability has been developed in the use of the multi-element control schemes of
‘advanced process control’.
Chapter 6 focuses on observation. Whereas Chapter 3 reveals the tenuous chain of preparation of
plant signals, Chapter 6 aims to make sense of them. Important issues on the plant are signal con
ditioning, data reconciliation, identification of model parameters and estimation of unmeasured
variables.
Chapter 7 addresses more advanced control algorithms, drawing on a wide range of successful
modern methods. To a large extent, continuous and discrete versions of an algorithm are presented
in parallel, usually in multi-input, multi-output formats – which simply devolve to the single-input,
single-output case if required. State–space, input–output, fuzzy, evolutionary, artificial neural
network and hybrid methods are presented. There is a strong emphasis on model predictive control
methods which have had major industrial benefits.
A review of the classical methods of stability analysis is delayed until Chapter 8. This has been
kept brief, in line with reduced application in the processing industries. One recognises that stability
criteria, such as pole locations, do underlie some of the design techniques of Chapter 7. Certainly,
frequency domain concepts are part of the language of control theory, and essential for advanced
investigation. But with the slower responses and inaccurate models of processing plants, controllers
are not predesigned to ‘push the limits’ and tend to be tuned up experimentally online.
A review of a range of optimisation techniques and concepts is given in Chapter 9. Although not a
deep analysis, this imparts a basic working knowledge, enabling the development of simple applica
tions, which can then later be built upon. Topics covered include linear, integer, mixed, and non
linear programming, search techniques, global optimisation, simulated annealing, genetic algorithms
and multi-objective optimisation. These methods, and dynamic programming, underlie the
XII Preface
predictive control and optimal scheduling topics in Chapter 7, and are also important as static opti
misers in such applications as supply chain, product blending/distribution and plant economic
optimisers.
This book tries to make the methods practically useful to the reader as quickly as possible. How
ever, there is no shortcut to reliable results, without a basic knowledge of the theory. For example,
one cannot make proper use of a Kalman filter, without understanding its mechanism. Complex
multi-input, multi-output applications will require a good theoretical understanding in order to
trace a performance problem back to a poorly calibrated input measurement. Hence, an adequate
theoretical background is provided.
A few distinctions need to be clarified:
1) Modelling is a particular strength of the process engineer, and is a basis of all of the algorithms
– especially model predictive control. The reader needs to distinguish state-based models ver
sus input–output models. The state-based models can predict forward in time knowing only
the initial state and future inputs. Some algorithms rely on this. In contrast, input–output
models will need additional information about past inputs and outputs, in order to predict
future outputs. To use state-based algorithms on these, a state observer algorithm (e.g. Kal
man filter) will be required to estimate the states.
2) The forward shift operator z = eTs is used to relate discrete versions of systems to their transfer
function forms G(s) in the s (Laplace/frequency) domain. In a lot of what follows, this theoret
ical connection is not significant, and the data sampling shift parameter q could be used, but
sometimes it is not in this text.
3) The text consistently uses bold characters to signify matrices [A], vectors [x] and matrix trans
fer functions [G(s), G(z)]. Non-bold characters are used for scalars.
A number of examples are presented in this book in order to clarify the methods. In addition, the
separate accompanying book Applied Process Control: Efficient Problem Solving presents 226 solved
problems, using the methods of this text. These often make use of MATLAB code which is
arranged in obvious time loops, allowing easy translation to the real-time environment. There will,
however, be the challenge to provide additional routines such as matrix inversion.
A simple interactive simulator program has been made available at https://sourceforge.net/
projects/rtc-simulator/. It includes 20 different applications for such aspects as PID and DMC con
troller tuning, advanced level control, Smith prediction, Kalman filtering and control strategies for a
furnace, a boiler and a hybrid system. No support is available for the simulator.
Although I have personally used a variety of methods on industrial and research applications, in
writing this book I have been fascinated to discover the brilliant ideas of many other workers in the
field. To all of those people who get excited about process control, I wish you an optimal trajectory.
Acknowledgements
Many of the problems in this book are dealt with using the MATLAB program, which is distrib
uted by the MathWorks, Inc. They may be contacted at
The MathWorks, Inc.
3 Apple Hill Drive
Natick, MA 01760–2098, USA
Tel: 508-647-7000
Fax: 508-647-7001
E-mail: [email protected]
Web: mathworks.com
How to buy: http://www.mathworks.com/store
A few problems are dealt with in the GAMS optimisation environment, distributed by
GAMS Development Corporation
1217 Potomac Street, NW
Washington, DC 20007, USA
General Information and Sales: (+1) 202 342-0180
Fax: (+1) 202 342-0181
Contact: [email protected]
Some problems make use of the LPSOLVE mixed integer linear programming software which is
hosted on the SourceForge Web site at
http://sourceforge.net/projects/lpsolve/
XV
Abbreviations
Language: English
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