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INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

CHN-303 Process Dynamics & Control
• Contact Hours: L: 3 T: 1 P: 2/2
• CWS: 15; PRS: 15; MTE: 15; ETE: 40; PRE: 15
PROCESS DYNAMICS & CONTROL S. No. Contents Hours
1. Introduction: The concept of process dynamics and control, 5
Dr. Vimal Chandra Srivastava review of Laplace transform methods, Laplace transform of
G. B. Pant Chair Professor disturbances and building functions, dynamic model building
Department of Chemical Engineering of simple systems.
Indian Institute of Technology Roorkee 2. Linear Open Loop System: Physical examples of first order 8
Roorkee, 247667, Uttarakhand, India
E-mails: vimal.srivastava@iitr.ac.in, vimalcsr@yahoo.co.in systems and their response for step, impulse and sinusoidal
inputs, linearization of non-linear models, response of first
order system in series, examples of second order systems and
their response, estimation of system parameters.
3. Linear Closed Loop System: The control system and its 8
elements, closed loop transfer functions, transient response of
simple control systems, concept of stability and use of Routh
– Hurwitz test for stability.
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CHN-303 Process Dynamics & Control List of Practicals

S. No. Contents Hours
4. Controllers: Modes of control action, control system and its 3 1. Dynamic Study of Thermometer with and without
closed-loop transfer function. thermo-well
5. Root Locus Method: Root locus treatment, response from root 4
locus and its application to control system design. 2. Dynamic Study of Stirred Tank Heater
6. Frequency Response: Introduction to frequency response, Bode 5 3. McCloyd Gauge and Vacuum System
diagrams of simple systems, Bode stability criterion, control 4. Control valve characteristics
system design by frequency response, use of gain and phase
5. Non-interacting and interacting Systems
margins.
7. Process Application: Controller tuning rules, control of complex 5 6. Heat exchangers
chemical processes and equipment, control valve sizing, 7. Cascade control trainer
introduction to real time computer control of process equipment.
8. Advanced Control Methods: Introduction to state-space method, 4
feed forward and ratio control, inferential control, control using
digital computers-an introduction.
Total 42
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Suggested Books Process

S. Name of Books / Authors Year of • A process denotes an operation or series of operations on fluid or
No. Publication solid materials during which the materials are placed in a more
1. Coughanowr D.R. and LeBlanc S. “Process System 2008 useful state
Analysis and Control”, 3rd Ed., McGraw Hill.
2. Stephanopoulos G. “Chemical Process Control – An 1990 Objectives of process
Introduction to Theory and Practice”, Prentice-Hall • The objective of a process is to convert certain raw materials (input
of India. feedstock) into desired products (output) using available sources of
3. Seborg D. E., Edgar T. F. and Mellichamp D. A., 2004 energy in the most economical way.
“Process Dynamics Control”, 2nd Ed., John Wiley.
• A process can be described either by an ordinary differential
4. Bequette B. W., “Process Control – Modeling, 2003
equation (lumped parameter system) or by partial differential
Design and Simulation”, Prentice-Hall of India.
equation (distributed parameter system).
5. Ogunnaike B. A. & Ray W. H., “Process Dynamics 1994
Modeling & Control”, Oxford University Press

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Requirements of Process

• Unit process may involve either a change of • A process must satisfy several requirements imposed by its
designers and the general technical, economic and social conditions
chemical state or a change in physical state in the presence of ever-changing external influences (disturbances).
• Many external and internal conditions affect the
performance of a process. The Requirements
• These conditions may be expressed in terms of • Safety of men and machine
• Environmental regulations
process variables such as temperature, pressure,
• Production specifications
flow, liquid level, dimension, weight, volume, etc.
• Operational constructions and economics

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Examples of Process Control

By process it is meant either • The term control means methods to force parameters in
the environment to have specific values
❖ Unit process like Example
• an alkylation reactor ❖ This can be as simple as making the temperature in a
❖ Unit operation like room stay at 25 Degree Celsius or
• Evaporator, ❖As complex as manufacturing an integrated circuit or
guiding a spacecraft to Jupiter.
• Distillation column or
❖ In general, all of the elements necessary to accomplish
• Storage vessel. the control objective are described by the term control
system

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Process Control Development of Process Control

➢The process may be controlled by measuring a • During the first industrial revolution the work
variable representing the desired state of the done by human muscle was gradually replaced by
product and automatically adjusting one of the the power of machine.
other variables of the process. • During second industrial revaluation the routine
➢In process control, the basic objective is to functions of human mind and need for continuous
regulate the value of some quantity. presence of human observer was also taken care
➢To regulate means to maintain that quantity at by Machine Process.
some desired value (reference value or set point) • Control made optimization and there by beginning
regardless of external influences. of third industrial revolution.

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Definition of Process Control Block Diagram of Process Control Loop

• Process Control System is the arrangement of Physical

Components and devices connected to regulate the
Quantity of interest at some desired value regardless of
external Influences.

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Variables Variables

Controlled Variable Set Point Variable

• Controlled variable is the one that must be maintained precisely as • Set point variable is the one that is set by
the set point. • operator, master controller or computer
• Typically the variable choosing to represent the state of the system • as a desired value for a controlled variable.
is termed the controlled variable. • • It is also called reference value.
Manipulated Variable Load variable
• Manipulated variable is the one that can be changed in order to • Load variables are those variables that cause disturbances in the
maintain the controlled variable at the set point. process.
• In other words the variable chosen the control system state is • They are also called as load disturbance.
termed as manipulated variable
• The load variable may change either

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Examples of the controlled and manipulated

Transient and Steady-State Response Analyses
variables
• The first step in analyzing a control system is to derive a mathematical model of
Controlled Variables Manipulated Variable the system.
a) Temperature • Coolant flow • Once such a model is obtained, various methods are available for the analysis of
system performance.
b) Pressure • Fuel flow
• In practice, the input signal to a control system is not known ahead of time but is
c) Flow rate • Feed water flow random in nature, and the instantaneous input cannot be expressed analytically.
d) Level • Steam flow • Only in some special cases is the input signal known in advance and expressible
analytically or by curves.
e) Displacement
• In analyzing and designing control systems, we must have a basis of comparison
f) Concentration of performance of various control systems.
g) Density • This basis may be set up by specifying particular test input signals and by
h) Viscosity comparing the responses of various systems to these input signals.
• Many design criteria are based on the response to such test signals or on the
i) pH response of systems to changes in initial conditions (without any test signals).
j) Humidity The use of test signals can be justified because of a correlation existing between
the response characteristics of a system to a typical test input signal and the
capability of the system to cope with actual input signals.
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Typical Test Signals Transient Response and Steady-State Response

• The commonly used test input signals are step functions, ramp functions,
acceleration functions, impulse functions, and sinusoidal functions. • The time response of a control system consists of two parts: the
• With these test signals, mathematical and experimental analyses of control transient response and the steady-state response.
systems can be carried out easily, since the signals are very simple functions of • By transient response, we mean that which goes from the initial
time.
state to the final state.
• Which of these typical input signals to use for analyzing system characteristics
may be determined by the form of the input that the system will be subjected to • By steady-state response, we mean the manner in which the system
most frequently under normal operation. output behaves as t approaches infinity.
– If the inputs to a control system are gradually changing functions of time, then
a ramp function of time may be a good test signal.
– Similarly, if a system is subjected to sudden disturbances, a step function of
time may be a good test signal; and for a system subjected to shock inputs, an
impulse function may be best.
• Once a control system is designed on the basis of test signals, the performance of
the system in response to actual inputs is generally satisfactory.
• The use of such test signals enables one to compare the performance of many
systems on the same basis.
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Absolute Stability, Relative Stability, and Steady- Absolute Stability, Relative Stability, and Steady-
State Error State Error
• The most important characteristic of the dynamic behavior of a control system is • Important system behavior (other than absolute stability) to which we must give
absolute stability—that is, whether the system is stable or unstable. careful consideration includes relative stability and steady-state error.
• A control system is in equilibrium if, in the absence of any disturbance or input, • Since a physical control system involves energy storage, the output of the system,
the output stays in the same state. when subjected to an input, cannot follow the input immediately but exhibits a
– A linear time-invariant control system is stable if the output eventually comes transient response before a steady state can be reached.
back to its equilibrium state when the system is subjected to an initial • The transient response of a practical control system often exhibits damped
condition. oscillations before reaching a steady state.
– A linear time-invariant control system is critically stable if oscillations of the • If the output of a system at steady state does not exactly agree with the input, the
output continue forever. system is said to have steady-state error. This error is indicative of the accuracy of
– It is unstable if the output diverges without bound from its equilibrium state the system.
when the system is subjected to an initial condition. • In analyzing a control system, we must examine transient-response behavior and
• Actually, the output of a physical system may increase to a certain extent but may steady-state behavior.
be limited by mechanical “stops,” or the system may break down or become
nonlinear after the output exceeds a certain magnitude so that the linear
differential equations no longer apply.

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INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

Order of Control Systems

• A first order control system is defined as a type of

control system whose input-output relationship
(also known as a transfer function) is a first-order
FIRST-ORDER SYSTEMS differential equation.
–A first-order differential equation contains a
first-order derivative, but no derivative higher
than the first order.
• The order of a differential equation is the order
of the highest order derivative present in the
equation.
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Example of Mercury Thermometer for development

RESPONSE OF FIRST-ORDER SYSTEMS
of the transfer function for a first-order system

• It is necessary to become familiar with the responses of • Consider the thermometer to be located in a flowing stream of fluid
some of the simple, basic systems that often are the for which the temperature x varies with time. It is aimed to calculate
the response or the time variation of the thermometer reading y for a
building blocks of a control system.
particular change in x.
• First we will study, in detail the behavior of several basic
systems and show that a great variety of physical systems
can be represented by a combination of these basic
systems.
• Some of the terms and conventions that have become well
established in the field of automatic control will also be
introduced.

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Following assumptions will be used in this analysis

• All the resistance to heat transfer resides in the film surrounding the
bulb (i.e., the resistance offered by the glass and mercury is
neglected).
• All the thermal capacity is in the mercury. Furthermore, at any
instant the mercury assumes a uniform temperature throughout.
• The glass wall containing the mercury does not expand or contract
during the transient response. (In an actual thermometer, the
expansion of the wall has an additional effect on the response of the
thermometer reading. The glass initially expands and the cavity
containing the mercury grows, resulting in a mercury reading that
initially falls. Once the mercury warms and expands, the reading
increases.
• This is an example of an inverse response. Inverse responses will be
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Transfer Function

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Liquid Level Systems – Resistance & Capacitance

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Liquid Level Systems – Resistance & Capacitance Liquid Level Systems – Resistance & Capacitance

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Liquid Level Systems – Development of model Liquid Level Systems – Development of model

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Transient Response of First Order Systems –

Liquid Level Systems – Development of model
Step Response

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Transient Response of First Order Systems – Transient Response of First Order Systems –
Step Response Step Response

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Transient Response of First Order Systems –

Impulse Response

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Transient Response of First Order Systems – Transient Response of First Order Systems –
Ramp response Sinusoidal Response

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Transient Response of First Order Systems – Transient Response of First Order Systems –
Sinusoidal Response Sinusoidal Response

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Transient Response of First Order Systems – Transient Response of First Order Systems –
Sinusoidal Response Sinusoidal Response

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Transient Response of First Order Systems –

Sinusoidal Response

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Linearization Linearization

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Linearization Linearization

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Linearization Linearization

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Linearization

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Thank you

E-mail: vimalcsr@yahoo.co.in, vimal.srivastava@ch.iitr.ac.in

Webpages:
• http://www.iitr.ac.in/~CH/vimalfch
• https://publons.com/researcher/1442249/vimal-chandra-srivastava/
• http://www.researcherid.com/rid/B-4455-2008
• http://orcid.org/0000-0001-5321-7981
• https://scholar.google.com/citations?user=vXB9eOwAAAAJ&hl=en
• http://www.scopus.com/authid/detail.url?authorId=35565811700
• http://inae.in/expert-search/index.php/vimal-chandra-srivastava

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