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Dynamic Behaviour

In analysing process dynamic and process control systems, it is important to know

how the process responds to changes in the process inputs.

Process inputs falls into two categories:

1. Inputs that can be manipulated to control the process
2. Inputs that are not manipulated, classified as disturbance variables.

Process output
A dependent variable to be maintained at a desired value (set point) e.g control
variable in a process

A number of standard types of input changes are widely used for two reasons:
1. They are representative of the type of changes that occur in plants.
2. They are easy to analyse mathematically.

e.g. stirred tank

Inputs: Any variable effects the output
(e.g. flow rate of the stream flow into tank)
Output: the mass fraction (x) of the
effluent stream 3
STANDARD
PROCESS
INPUTS

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Standard Process Inputs

There are six important types of input changes used in industrial practise: Step, Ramp,
Rectangular pulse, sinusoidal, impulse, random.

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Step Input

• Sudden changes and sustained input changes

E.g. reactor feedstock may be change quickly from one supply to another supply causing
a corresponding change in important input variables such as feed concentration and feed
temperature.

• Such change can be approximated by the step change.

M , Magnitude of change
t, time
Us(t), deviation variable (change from the normal steady state)
S(t), unit step function

Example:
Suppose the heat input to a stirred tank heating unit
suddenly changed from 8000 to 10,000 kcal/h by changing
the electrical heater input.

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Ramp Input

• Inputs that drifts- gradually change upward and downward for some period of time
with a roughly constant slope.

E.g. ambient conditions (air temperature and relative humidity) can change slowly
during the day so that the plant cooling tower temperature change slowly.

A, constant
t, time
uR(t), deviation variable (change from the normal steady state)

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Rectangular Pulse

• Sudden step change that then returns to its original value.

E.g.
1. Feed reactor is shut off for certain period of time.
2. A natural gas fired furnace experiences a brief interruption in fuel gas.

tw, pulse width

t, time
h, pulse magnitude
uRP(t), deviation variable

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Sinusoidal Input

• Input that vary periodically

E.g.
1. The drift in cooling tower temperature can often be closely tied to diurnal (day to
night to day) fluctuation in ambient temperature. Cyclic process changes within 24
hours period often are cause by variations in cooling water temperature.

2. On a shorter time scale, high frequency disturbances are associated with mixing and
pumping operations, and with 60-Hz electrical rise arising from AC electrical
equipment and instrumentation.

A, amplitude of sinusoidal function

t, time
ω, angular frequency (radians/time)
P= 2π/ω (period)
usin(t), deviation variable

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 TYPE
OF RESPONSE
IN PROCESS

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Process response

• Time response of a dynamic system

response to an input express as a
function of time.

• Time response of any system has two

components
1. Transient response
2. Steady state response

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Time response of control systems

• When the response of the systems is changed from rest or equilibrium it takes some
time to settle down.

• Transient response is the response of a system from rest or equilibrium to steady state.

• The response of the system after the transient response is called steady state
response.

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Terminology

Process response curve: the trend of process measurement.

The period of time taken by the process to

reach the set point

The process response (PV) surpasses the

set point

The time interval between two successive

peaks.

The process response (PV) goes below

the set point

The period of time taken by the process to

reach stability 13
Terminology

Ideal response : the desired process response is achieved at an instantaneous time.

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Terminology

Stable : the process response stabilized at (near) the set point.

Unstable: the process response could not stabilized at the set point.

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Terminology

Quality Limits: A range, set values above and below the set point, whereby the process is
allowed to oscillate. Product quality is acceptable within these limits.

Note:
LCL: Lower control limit (quality)
UCL: Upper control limit (quality)

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Various shapes of process responses under automatic control

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Terminology

Settling criteria: a response curve that meet any of the following criteria is considered settle:

1. Response time
2. Setting time
3. Rise time
4. Quarter amplitude damping (QAD)
5. Quality Limits
6. No overshoot or under no undershoot (BEST for temperature and pH control)
7. Minimum IAE, ITSE etc.

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 RESPONSE
OF
FIRST-ORDER PROCESS

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General First Order Transfer Function

K = steady state gain

τ = time constant
U(s) = inputs
Y(s) = Outputs

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Step Response
For step input of magnitude M, U(t)= M for t≥0, thus U(s) = M/s

Laplace domain Time domain

• the proses does not respond instantaneously to

a sudden change in its input.
• When t=τ, the process respond only at 63.2%
• The t only can reach steady state when t≈ 5τ
Note: Large τ means slow response 21
Example 1:

A stirred tank heating system is used to preheat a reactant containing a suspended solid
catalyst at a constant flow rate of 1000 kg/h. the volume in the tank is 2 m3, and the
density and specific heat of the suspended mixture are 900 kg/m3 and 1 cal/g·°C,
respectively. The process initially is operating with inlet and outlet temperatures of 100
and 130°C, respectively. The steady state energy input is 3x 107. The transfer function is

a) What are the values of K and τ?

b) If the heater input is suddenly increased by +30%, how long will it take for the tank
temperature to achieve 99% of the final temperature change?

c) If the inlet temperature is increased suddenly from 100 to 120°C, how long will it take
before the outlet temperature changes from 130 to 135°C?

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Solution
a) What are the values of K and τ?

Notes:
‘m’ is mass (g). How to determine the value of ‘m’ ?
‘w’ is mass flowrate (g/h)
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Solution
b) If the heater input is suddenly increased by +30%, how long will it take for the tank
temperature to achieve 99% of the final temperature change?

Step:
1. Refer to the table.
2. Determine t at y(t)/KM ≈99%
3. Determine the change in T due to the
change of Q

Answer:
Time required to attain the 99% response
following a step change of any magnitude in
heater input will be 5τ that is 9h

Notes:
What is the final Temperature after the change of Q?

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Solution
c) If the inlet temperature is increased suddenly from 100 to 120°C, how long will it take
before the outlet temperature changes from 130 to 135°C?

Step:
1. Refer to the response
graph.
2. Use time domain
equation to solve the
required time.
3. Determine the gain and
time constant based on
the transfer function
equation (highlighted
with red box.

Notes:
What is the value of M?
How to determine y(t)?
What is the value of K? 27
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Effect of parameter on the response of first order process
Suppose two first order processes have same static gain but different time constant.

verify:

Note:
Double time constant increase the time to reach steady state. τ = 1, t≈5 while τ=2, t≈10.
But both reach at the same final value y(t)=1 (steady state) 29
Effect of parameter on the response of first order process
Suppose two first order processes have different static gain but same time constant.

verify:

Note:
Increase the gain, increase the final value y(t).
At K=1 and τ=1, t≈5 and y(t)=1 (steady state)
and K=1.2 and τ=1, t≈5 and y(t)=1.2 (steady state) 30
Determine the gain and time constant using process curve
An open loop test can be performed starting from the reference steady state:
1. Step the input to the process
2. Record the time profile of the measured output until reach new steady state is
approached.
3. Check if this profile resemble
4. If so, calculate Kp as:
Note: A is magnitude (M)

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Transient response specification
1. Time constant, τ
2. Rise time, tr
3. Settling time, ts

Note:

a is 1/τ

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Example 2:

Note:

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Derive expression for the response in some of particular inputs.

Ramp Response
For ramp input U(s) = a/s2

General first order Laplace domain Time domain

Note:

• Ramp input yields a ramp output with

slope equal to Ka, but shift in time by the
process time constant, τ.

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Derive expression for the response in some of particular inputs.
3. Sinusoidal Response
For sinusoidal input U(s) = ω/(S2+ω)

General first Laplace domain Time domain

order

Note:

• The exponential term goes to zero as t

approaches to ∞ leaving pure sin
response.

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Example 3:

A liquid surge tank has a transfer function model of :

Where h is the tank level (m), qi is the flow rate (m3/s), the gain is 10 s/m2 and the time
constant is 50s. The system is operating at steady state with q=0.4m3/s and h=4m when
the sinusoidal perturbation in inlet flow rate begins with amplitude=0.1m3/s and a cyclic
frequency of 0.002 cycles/s. The response of the process is shown by the following
equations:

a) What are the maximum and minimum values of the tank level after the flow rate
disturbances has occurred for 6 mi or more?

b) What are the largest level perturbations expected as a result of this sinusoidal variation
in flow rate?

c) What is the effect of high-frequency variations, e.g 0.2 cycles/s?

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Solution
a. What are the maximum and minimum values of the tank level after the flow rate
disturbances has occurred for 6 mi or more?

Step:
1. Calculate the exponential
value. ( to neglect the first
term.
2. Calculate amplitude cause by
perturbation.
3. Calculate min and max tank
level.

Notes:
What is amplitude perturbation?

What is actual tank level varies from max to min?

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Solution
b) What are the largest level perturbations expected as a result of this sinusoidal variation
in flow rate?

Step:
1. Calculate ±KA
2. Calculate min max level
pertubation

Notes:

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Solution
c) What is the effect of high-frequency variations, e.g 0.2 cycles/s?

Verify:

Notes:

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First Order Plus Dead Time (FOPTD)

K = steady state gain

τ = time constant
t° = dead time
X(s) = inputs
Y(s) = Outputs

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 RESPONSE
OF
SECOND ORDER PROCESS

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Second Order Transfer Function

When two first order process are connected in series, the process can be represented by
second order transfer function.

e.g.
Two stirred tank blending process, each with a first order transfer function relating inlet to
outlet mass fraction, might be physically connected so that the outlet stream of the first
tank is used as the inflow stream of the second tank.

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Second Order Transfer Function

The type of behaviour that occurs depends on the numerical value of damping coefficient:

It is convenient to consider three types of behaviour:

Note: the characteristic polynomial is the denominator of the transfer function.

What about if damping coefficient <0? Unstable response 47

Second Order Transfer Function

Compare denominator for general and two first order systems:

Expanding the right side

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Example 4:

An overdamped system consists of two first order process operating in series (τ1=4 τ2=1).
Find the equivalent values of τ and ζ for this system.

Solution:

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Step Response
For step input of magnitude M, U(s) = M/s

Laplace domain Time domain

Overdamped (ζ>1)

Critically damped (ζ=1)

Underdamped (0≤ζ<1)

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 Underdamped response

Notes:

Overdamped

Notes:

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Example 5:

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Example 6:

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Characteristic of the step response (underdamped process):

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Example 7:

A stirred tank reactor has an internal cooling coil to remove heat liberated in the reaction.
A proportional controller is used to regulate coolant flow rate so as to keep the reactor
temperature essentially constant. The controller has been designed so that the controlled
reactor exhibit typical underdamped second order temperature response characteristics
whe it is disturbed, either by feed flow rate or by coolant temperature changes.

a) The feed flowrate to the reactor changes suddenly from 0.4 to 0.5 kg/s and the
temperature of the reactor contents, initially at 100C, changes eventually to 102C.
What is the gain of the transfer function (under feedback control) that relates changes
in the reactor temperature to changes in feed flow rate?

b) The operator notes that the resulting response is slightly oscillatory with maxima
estimated to be 102.5 and 102C occurring at times 1000 and 3060s after the change
initiated. What is the complete process transfer function?

c) The operator failed to note the rise time, predict tr based on the result in a) and b).

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Solution:
a) The feed flowrate to the reactor changes suddenly from 0.4 to 0.5 kg/s and the
temperature of the reactor contents, initially at 100C, changes eventually to 102C.

What is the gain of the transfer function (under feedback control) that relates changes in
the reactor temperature to changes in feed flow rate?

Step:
1. Determine gain by dividing the steady state
change in temperature by the feed flow rate

Notes:

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Solution:
b) The operator notes that the resulting response is slightly oscillatory with maxima
estimated to be 102.5 and 102C occurring at times 1000 and 3060s after the change
initiated.

Step:
1. Determine the τ and ζ using second order process characteristic.
2. Substitute the value into general second order transfer function

Notes:
What is the complete process transfer function?

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Solution:
c) The operator failed to note the rise time, predict tr based on the result in a) and b).

Step:
1. Tr can be determine from underdamped
equation.
2. When t=tr,(yt) is equal to steady state
value KM. Neglect bracketed quantity.
3. When y(t)=KM, it has multiple value of t,
n =1,2,….
4. The rise time correspond to the first time
(n=1) y(t)=KM=y(∞)
5. Substitute in equation and determine tr

Notes:
What is the value of tr?
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 TYPE
OF SYSTEMS

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 Type of systems

1. Self regulating and non self regulating systems

2. Interacting and non interacting systems.

1) Self regulating 2) non self regulating 3) noninteracting (above)

4) interacting (below 67
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