CHEN502 - 2025 - Advance Process Control - Lecture Slides
CHEN502 - 2025 - Advance Process Control - Lecture Slides
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Process State
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Advanced Process Control (APC)
Advance Process Control (APC, also DCS/ACS) is based on
modern control theory
First usage of APC was in guidance and control of
aircraft/satellites – due to their complexity, PID control was
inadequate.
APC or Automatic control emerged as an interdisciplinary
field.
PID control still dominant in process industries
Digital computer control was required for analysis of the
complex differential equations.
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Feature Classical Control theory Modern Control theory
Domain Frequency domain Time domain
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Challenges of Conventional Control Structure
(Multi-loop PID Control)
Industrial Processes: multivariable (multiple inputs
influence same output) and exhibit strong interaction
among the variables
Conventional Control scheme: Multiple Single
Input Single Output PID controllers used for controlling
plant (Multi-Loop Control)
Consequences: Loop Interactions
–ƒLack of coordination between different PID loops
– ƒNeighboring PID loops can co-operate with
– each other or end up opposing / disturbing each
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Hierarchy of control
system functions
The choice depends on
process complexity,
optimization needs,
and required precision.
Conventional PID Control Strategy
Feedback control strategy works by
studying the downstream data and
then altering the upstream process.
The actions executed are
reactive. For example, if a feed's
temperature is detected to be lower
than desired, then steam can be
used to preheat the feed.
The PID controller calculates the control signal as a sum of its three terms: Proportional, Integral,
and Derivative. This algorithm continuously adjusts the system's input to minimize error over time.
The PID continuously adjusts output based on the error between the desired set-point and actual
system output, they are
• effective in linear, time-invariant systems, ideal for temperature, pressure, or liquid level
regulation
• Ideal for straightforward applications, offering a balance between simplicity and performance.
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Components of PID Control
Proportional (P) Integral (I) Derivative (D)
Reacts to current error; larger error Accumulates past errors to eliminate Predicts future error based on rate
means stronger response. Aims to steady-state error. Can introduce lag of change. Provides damping,
reduce error quickly, but can cause and instability if not tuned carefully. reducing overshoot and improving
steady-state errors or overshoot. stability.
Control Output = P + I + D
𝟏 𝒕 𝒅𝒆(𝒕)
U(t) = K 𝒆 𝒕 + 𝒆 𝝉 𝒅𝝉 + 𝑻𝒅 =P+I+D
𝑻𝒊 𝒅𝒕
where u is the controller output, and e is the error, i.e. the difference between the reference value r (the set
point) and process output y (the measured variable). The control action is thus composed of three terms, one
part (P) is proportional to the error, another (I) is proportional to the integral of the error, and a third (D) is
proportional to the derivative of the error.
On-line Optimization - how advanced models enhance process control
(beyond traditional feedback systems)
Shifts in operational priorities
Example: FCC Unit operated under
simultaneous
ƒ- Maximization of Gasoline /LPG production
ƒ- Maximization of ATF production
ƒ- Maximization of profits
ƒ- Minimization of energy consumption
„
Changes in operating conditions
ƒ- Changes in feed quality (refinery: change in
crude blend)
ƒ- Changes in operating parameters
ƒ- Catalyst degradation
Provides significant benefits for dynamic, nonlinear, and ƒ- Heat-exchanger fouling
constrained processes. ƒ- Changes in separation efficiency
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Key Features & Benefits of APC
Model Predictive Control (MPC) Improved Yield & Capacity
Uses a mathematical model to predict future system Enhances product output and plant operational
behavior and optimize control actions. limits.
Qualitative Qualitative
Transfer Process Fuzzy Logic Black Box Mechanistic Probabilistic Correlation
Functions Descriptions (Empirical)
Lumped Distributed
Linear Non-linear Parameter Parameter
(ODEs) (PDEs)
Transfer Neural
Time Series Time Series Linear Non-Linear Linear Non-Linear
Functions Networks
3 Qualitative Models
For modeling processes not amenable to mathematical 4 Statistical Models
description, using rule-based or fuzzy logic. They are 'rule- Characterize processes using probability and correlation,
based' models that use 'IF-THEN-ELSE‘ constructs to describe important for higher-level decision-making. Widely and
process behavior. Qualitative Transfer Functions (QTFs) interchangeable use in the development of deterministic as
describe relationship between an input and an output variable, well as stochastic digital control algorithms.
- built up of smaller sub-systems and connected together
Models Usage for Process Control
Chemical engineers use detailed models for process design and troubleshooting. Traditional
process control often relies on empirical step-change response models rather than these
fundamental engineering models. This causes 2 issues:
Steady State Limitations Approximations of Reality
Most process models are steady-state, not dynamic. Models are approximations, often with 10%
Developing dynamic models is computationally intensive error. Relying solely on them for control would
and rarely worth the effort, except for some reactor kinetics. lead to unsafe and unprofitable operations.
Due to the inherent limitations of these design models, precise process control is impossible
without measuring and correcting the thermodynamic state. Feedback control provides the
necessary precision that models alone cannot achieve.
This highlights why feedback, which reacts to actual measured conditions, is crucial for
maintaining desired process outcomes.
This also highlight why fundamental chemical engineering models are required to directly
control plant operations
Example:
Multi-component Distillation Column Design and Control
An engineer uses her process simulation software to predict that to operate
her multi-component distillation column with a feed rate of 10,000 kg/hr, the
reboiler will require 806 kW of steam for heating.
1. Can she just measure the flow of steam, multiply it by its enthalpy of
vaporization, and control that steam to give us 806 kW of heat?
2. A common control strategy is to use a feedback control mechanism to
control the temperature at the bottom tray (as a good proxy for bottoms
composition) Why is that an acceptable solution?
3. Propose a Feedforward control mechanism and explain why it is a
better control strategy for the column.
Solution:
Multi-component Distillation Column Design and Control
1. The column will eventually need about 806 kW of heating, but when?
At start-up, when the column is cold and the feed is just starting?
30 minutes later?
Will steady state conditions be maintained such that the same heating will
always be required?
This highlights the need for control
The dynamic model required to truly capture all of the possible dynamics of
the distillation column would be a massive computational task, and would
require a set of mass, heat and momentum transfer parameters that no
engineer will ever have from such a simulation.
Solution:
Multi-component Distillation Column Design and Control
2. Why Feedback control is a viable solution
The amount of heat delivered by the steam is readily found in a steam table (for
100 psig steam, the heat of vaporization is 1523 kJ/kgsteam). Dividing the two
𝒌𝑱
𝟐𝟗𝟎 𝒌𝒈𝒇𝒆𝒆𝒅 𝒌𝒈𝒔𝒕𝒆𝒂𝒎
= 𝟎. 𝟏𝟗𝟏 𝒌𝒈𝒇𝒆𝒆𝒅
𝒌𝑱
𝟏𝟓𝟐𝟑 𝒌𝒈𝒔𝒕𝒆𝒂𝒎
knowing the feedrate entering the column (FT-C1F), we can multiply that rate by our model
ratio from Figure MC-DC1, to determine our feedforward flowrate of steam needed by the
reboiler:
𝒌𝒈𝒔𝒕𝒆𝒂𝒎
𝑬𝟐 𝒔𝒕𝒆𝒂𝒎𝒇𝒇 = 𝟎. 𝟏𝟗𝟏 𝒌𝒈𝒇𝒆𝒆𝒅 ∗ (𝑭𝑻 − 𝑪𝟏𝑭)
To use that feedforward signal, we simply add it to the feedback signal generated by
the bottoms tray temperature controller, TC-C1B, before sending it as the remote
setpoint (RSP) to the steam flow controller, i.e.:
Figure MC-DC1b
Multiple-Input Multiple-Output (MultiVariable) Control Systems
f1(s)
G1(s)
f2(s) + y(s)
G2(s) +
. +
.
.
fn(s)
Gn(s)
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Soft sensing
Soft Sensors Work through the following steps:
Data Acquisition: Soft sensors rely on data from existing hardware sensors
that measure process variables like temperature, pressure, flow rates, etc.
Model Development: creating a mathematical model, (often based on
techniques like fuzzy logic, neural networks, or statistical methods), to correlate
the measured variables with the target (hard-to-measure) variable.
Real-Time Estimation: of the desired variable in real-time, using the model
developed based on the available sensor readings (data acquired).
Integration with Control Systems: The estimated values from the soft
sensor can then be integrated into the process control system to adjust process
parameters and maintain desired operating conditions
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Benefits of Soft Sensors
Reduced Costs:
Soft sensors can eliminate the need for expensive or specialized
hardware sensors
Improved Process Understanding:
By providing estimates of difficult-to-measure variables, soft sensors
can offer valuable insights into process behavior
Enhanced Control and Optimization:
Soft sensors enable more precise control of processes, leading to
improved product quality, increased efficiency, and reduced waste
Fault Detection and Diagnosis:
Soft sensors can be used to detect anomalies and faults in the process
by monitoring the estimated values and identifying deviations from
expected behavior 45
Examples of Soft sensors Applications
Chemical and Petrochemical Industries: Estimating product
quality, such as viscosity or composition.
Food Processing: Monitoring ingredient ratios or product
characteristics.
Power Plants: Predicting steam quality or turbine efficiency.
Water Treatment: Estimating pollutant levels or water quality
parameters.
Manufacturing: Optimizing cutting parameters in machining
processes or estimating surface roughness.
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Types of Soft Sensors
Data-Driven (Black-Box) Models:
These models are based solely on historical process data and are useful when
limited process knowledge is available.
First-Principles (White-Box) Models:
These models are based on fundamental laws of physics and chemistry and are
useful when process understanding is strong.
Gray-Box Models:
combine data-driven and first-principles approaches to leverage the strengths of
both.
in essence, soft sensors are a powerful tool for enhancing process control by
providing a cost-effective and reliable way to estimate difficult-to-measure variables,
ultimately leading to improved process efficiency and product quality.
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Identification of Control Process Objectives
and Constraints in Multivariable Systems