A Real-Time Approach to Process Control

Throughout the chemical industry, ever more emphasis is being placed upon extracting increasingly greater value from existing plant equipment. Improved process control is almost unique in its ability to deliver substantial operational improvements with little or no additional capital investment. As such, process control has rapidly become one of the most important and sought-after skills within the chemical industry.

Preface.

Acknowledgements.

Endorsement.

About the authors.

1 A brief history of control and simulation.

1.1 Control.

1.2 Simulation.

1.3 References.

2 Process control hardware fundamentals.

2.1 Control system components.

2.2 Primary elements.

2.3 Final control elements.

2.4 References.

3 Fundamentals of single input−single output systems.

3.1 Open-loop control.

3.2 Disturbances.

3.3 Feedback control overview.

3.4 Feedback control: a closer look.

3.5 Process attributes: capacitance and dead time.

3.6 Process dynamic response.

3.7 Process modelling and simulation.

3.8 References.

4 Basic control modes.

4.1 On−off control.

4.2 Proportional (P-only) control.

4.3 Integral (I-only) control.

4.4 Proportional plus integral (PI) control.

4.5 Derivative action.

4.6 Proportional plus derivative (PD) controller.

4.7 Proportional integral derivative (PID) control.

4.8 Choosing the correct controller.

4.9 Controller hardware.

4.10 References.

5 Tuning feedback controllers.

5.1 Quality of control and optimisation.

5.2 Tuning methods.

5.3 References.

6 Advanced topics in classical automatic control.

6.1 Cascade control.

6.2 Feedforward control.

6.3 Ratio control.

6.4 Override control (auto selectors).

6.5 References.

7 Common control loops.

7.1 Flow loops.

7.2 Liquid pressure loops.

7.3 Liquid level control.

7.4 Gas pressure loops.

7.5 Temperature control loops.

7.6 Pump control.

7.7 Compressor control.

7.8 Boiler control.

7.9 References.

8 Distillation column control.

8.1 Basic terms.

8.2 Steady-state and dynamic degrees of freedom.

8.3 Control system objectives and design considerations.

8.4 Methodology for selection of a controller structure.

8.5 Level, pressure, temperature and composition control.

8.6 Optimizing control.

8.7 Distillation control scheme design using steady-state models.

8.8 Distillation control scheme design using dynamic models.

8.9 References.

9 Using steady-state methods in a multi-loop control scheme.

9.1 Variable pairing.

9.2 The relative gain array.

9.3 Niederlinski index.

9.4 Decoupling control loops.

9.5 Tuning the controllers for multi-loop systems.

9.6 Practical examples.

9.7 Summary.

9.8 References.

10 Plant-wide control.

10.1 Short-term versus long-term control focus.

10.2 Cascaded units.

10.3 Recycle streams.

10.4 General considerations for plant-wide control.

10.5 References.

Appendices.

1 P&ID symbols.

2 Glossary of terms.

A2.1 Reference.

Workshops.

1 Learning through doing.

2 Feedback control loop concepts.

3 Process capacity and dead time.

4 Feedback control.

5 Controller tuning for capacity and dead time processes.

6 Topics in advanced control.

7 Distillation control.

8 Plant operability and controllability.

Index.

What is included with this book?

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A Real-Time Approach to Process Control

Summary

Table of Contents

Supplemental Materials