CHAPTER 5 : TYPICAL PROCESS SYSTEMS

When I complete this chapter, I want to be able to do the following.

Predict output for typical inputs for common dynamic systems Derive the dynamics for important structures of simple dynamic systems Recognize the strong effects on process dynamics caused by process structures

CHAPTER 5 : TYPICAL PROCESS SYSTEMS

Outline of the lesson.

Common simple dynamic systems

- First order - Dead time - Series - Recycle -Second order - (Non) Self-regulatory - Parallel - Staged

Important structures of simple systems

Workshop

SIMPLE PROCESS SYSTEMS: 1st ORDER

The basic equation is:

dY(t ) + Y ( t ) = K X( t ) dt
Output is smooth, monotonic curve
1.8
tank concentration

K = s-s gain = time constant

1.6 1.4 1.2 1 0.8 0

Maximum slope at t=0

63% of steady-state CA

At steady state Y = K X

20 40 60 time 80 100 120

Would this be easy/difficult to control?

Output changes immediately

2

inlet concentration

1.5

X = Step in inlet variable

1

0.5

20

40

60 time

80

100

120

SIMPLE PROCESS SYSTEMS: 1st ORDER

These are simple first order systems from several engineering disciplines.

SIMPLE PROCESS SYSTEMS: 2nd ORDER

Would this be easy/difficult to control?

The basic equation is:

d 2Y ( t ) dt 2

dY (t ) + 2 + Y (t ) = K X (t ) dt

K = s-s gain , = time constant , = damping factor

overdamped
1 Controlled Variable Controlled Variable 0.8 0.6 0.4 0.2 0 0 10 20 30 40 Time 50 60 70 80 1.5 1

underdamped

0.5

20

40

60

80

100 Time

120

140

160

180

200

1 Manipulated Variable Manipulated Variable 0 10 20 30 40 Time 50 60 70 80 0.8 0.6 0.4 0.2 0

1 0.8 0.6 0.4 0.2 0 0 20 40 60 80 100 Time 120 140 160 180 200

SIMPLE PROCESS SYSTEMS: 2nd ORDER

These are simple second order systems from several engineering disciplines.

SIMPLE PROCESS SYSTEMS: DEAD TIME

= dead time

X out (t ) = X in (t ) X out ( s ) = e s X in ( s )
Would this be easy/difficult to control?

Xout Xin

time

SIMPLE PROCESS SYSTEMS: INTEGRATOR

Level sensor

dV dL =A = Fin Fout dt dt

Liquid-filled tank

Fin (t ) f ( L )
pump valve

Fout (t ) f ( L )

Plants have many inventories whose flows in and out do not depend on the inventory (when we apply no control or manual correction). These systems are often termed pure integrators because they integrate the difference between in and out flows.

SIMPLE PROCESS SYSTEMS: INTEGRATOR

Level sensor

dV dL = A = Fin Fout dt dt

Liquid-filled tank

pump

valve

Plot the level for this scenario Fin Fout

time

SIMPLE PROCESS SYSTEMS: INTEGRATOR

Level sensor

dV dL = A = Fin Fout dt dt

Liquid-filled tank

pump

valve

Level Fin Fout

time

SIMPLE PROCESS SYSTEMS: INTEGRATOR

Level sensor

Liquid-filled tank

pump

valve

Non-self-regulatory variables tend to drift far from desired values. We must control these variables.

Lets look ahead to when we apply control.

STRUCTURES OF PROCESS SYSTEMS

NON-INTERACTING SERIES The output from an element does not influence the input to the same element Common example is tanks in series with pumped flow between Block diagram as shown
T

STRUCTURES OF PROCESS SYSTEMS

NON-INTERACTING SERIES The output from an element does not influence the input to the same element Common example is tanks in series with pumped flow between Block diagram as shown
v(s) F0(s) T1(s) T2(s) Tmeas(s)
T

Gvalve(s)

Gtank1(s)

Gtank2(s)

Gsensor(s)

STRUCTURES OF PROCESS SYSTEMS

NON-INTERACTING SERIES
v(s) F0(s) T1(s) T2(s) Tmeas(s)

Gvalve(s)

Gtank1(s)

Gtank2(s)

Gsensor(s)

STRUCTURES OF PROCESS SYSTEMS

NON-INTERACTING SERIES
v(s) F0(s) T1(s) T2(s) Tmeas(s)

Gvalve(s)

Gtank1(s)

Gtank2(s)

Gsensor(s)

In general:

Y (s) n = Gi ( s ) X ( s ) i =1

STRUCTURES OF PROCESS SYSTEMS

NON-INTERACTING SERIES
v(s) F0(s) T1(s) T2(s) Tmeas(s)

Gvalve(s)

Gtank1(s)

Gtank2(s)

Gsensor(s)

In general:

Y (s) n = Gi ( s ) X ( s ) i =1 Y (s) n Ki = X ( s ) i =1 ( i s + 1)

With each element a first order system:

STRUCTURES OF PROCESS SYSTEMS

NON-INTERACTING SERIES
v(s) F0(s) T1(s) T2(s) Tmeas(s)

Gvalve(s)

Gtank1(s)

Gtank2(s)

Gsensor(s)

In general:

Y (s) n = Gi ( s ) X ( s ) i =1 Y (s) n Ki = X ( s ) i =1 ( i s + 1)

overall gain is product of gains no longer first order system slower than any single element

With each element a first order system:

STRUCTURES OF PROCESS SYSTEMS

NON-INTERACTING SERIES
v(s)
0.10/(5s+1)
0 Controlled Variable -1 -2 -3 -4 -5 0 10 20 30 Time 10 Manipulated Variable 8 6 4 2 0 0 10 20 30 Time 40 50 40 50

F0(s)
-1.2/(5s+1)

T1(s)
1/(5s+1)

T2(s)
3.5/(5s+1)

Tmeas(s)

Step Response Looks as though some dead time occurs

60 70 Smooth, monotonic, not first order

Slower than any element K = (Ki)

60 70

STRUCTURES OF PROCESS SYSTEMS

NON-INTERACTING SERIES
v(s) F0(s) T1(s) T2(s) Tmeas(s)

Gvalve(s)

Gtank1(s)

Gtank2(s)

Gsensor(s)

With each element a first order system with dead time:

Guidelines on step response Sigmoidal (S) shaped t63% (i + i) [not rigorous!] K = (Ki) [rigorous!] Usually, some apparent dead time occurs

Kie Y (s) = X ( s ) i =1 ( i s + 1)
n

i s

STRUCTURES OF PROCESS SYSTEMS

Class Exercise: Sketch the step response for the system below.

? =2 =2

STRUCTURES OF PROCESS SYSTEMS

Class Exercise: Sketch the step response for the system below.
5 Controlled Variable 4 3 2 1 0 0 5 10 Time 5 Manipulated Variable 4 3 2 1 0 0 5 10 Time 15 20 25 15 20 25 DYNAMIC SIMULATION

STRUCTURES OF PROCESS SYSTEMS

Class Exercise: Sketch the step response for each of the systems below and compare the results. Case 1

=2 Case 2

=2

=2

=2

=2

=2&=2

=1

=1

Two plants can have different intermediate variables and have the same input-output behavior!
4 case 1 responses 3 2 1 0

Case1

Step
case 2 responses

10 time

12

14

16

18

20

4 3 2 1 0

Case2

10 time

12

14

16

18

20

STRUCTURES OF PROCESS SYSTEMS

PARALLEL STRUCTURES result from more than one causal path between the input and output. This can be a flow split, but it can be from other process relationships.
Example process systems Block diagram

ABC X(s) G1(s) Y(s)

G2(s)

STRUCTURES OF PROCESS SYSTEMS

PARALLEL STRUCTURES G1(s)

X(s)

Y(s)

G2(s) If both elements are first order, the overall model is

Class exercise: Derive this transfer function

K p ( 3 s + 1) Y (s) = X ( s ) ( 1s + 1)( 2 s + 1)

STRUCTURES OF PROCESS SYSTEMS

PARALLEL STRUCTURES can experience complex dynamics. Parameter is the zero in the transfer function.
1.5 4 output variable, Y(t) 1 3 2 1 0.5 0 -1 0 -2

Sample step response at t=0

G1(s) X(s) Y(s)

G2(s)

Which would be difficult/easy to control?

-0.5 0

5 time

10

STRUCTURES OF PROCESS SYSTEMS

PARALLEL STRUCTURE Class exercise: Explain the dynamics of the outlet temperature after a change to the flow ratio, with the total flow rate constant.

STRUCTURES OF PROCESS SYSTEMS

PARALLEL STRUCTURES: Explain the dynamics of the outlet temperature after a step change to the flow ratio.
93 mixing temperature 92 91 90 89 0 93 92 91 90 89 0

Why an overshoot?

10 time

15

20

25

senor output

10 time

15

20

25

0.7 fraction by-pass

0.6

0.5

T
0.4 0 5 10 time 15 20 25

STRUCTURES OF PROCESS SYSTEMS

PARALLEL STRUCTURE Class exercise: Explain the dynamics of the outlet concentration after a step change to the solvent flow rate.

reactant

FA CA0

solvent

FS CAS=0

CA1

V1 CA2 V2

STRUCTURES OF PROCESS SYSTEMS

PARALLEL STRUCTURE Class exercise: Explain the dynamics of the outlet concentration after a step change to the solvent flow rate.
0.43 0.42 0.41 0.4 0.39 tank 2 concentration

Why an inverse response?

10

20

30

40

50

60

0.1 0.09 solvent flow 0.08 0.07 0.06 0.05 0 10 20 30 time 40 50 60

STRUCTURES OF PROCESS SYSTEMS

RECYCLE STRUCTURES result from recovery of material and energy. They are essential for profitable operation, but they strongly affect dynamics.
Process example T0 Block diagram

T3 T4

STRUCTURES OF PROCESS SYSTEMS

RECYCLE STRUCTURES
T1(s) T0(s) T3(s)

GH1(s)
T2(s)

GR(s)

T4(s)

GH2(s)

GR ( s )GH 1 ( s ) T 4( s ) = T 0( s ) 1 GR ( s )GH 2 ( s )

STRUCTURES OF PROCESS SYSTEMS

RECYCLE STRUCTURES Class exercise: Determine the effect of recycle on the dynamics of a chemical reactor (faster or slower?).
T0

Exothermic reaction
T3 T4

feed/effluent preheater

GH 1 ( s ) = 0.40 K / K GH 2 ( s ) = 0.30 K / K GR ( s ) = 3 /(10 s + 1)

STRUCTURES OF PROCESS SYSTEMS

Class exercise: Determine the effect of recycle on the dynamics of a chemical reactor (faster or slower?).
T4 is a deviation variable 2.5 T4 without recycle 2 1.5 1 0.5 0 0 5 10 15 20 25 time

Without recycle, faster and smaller effect

30 35 40 45 50

25 T4 with recycle 20 15 10 5 0 0 50 100 150 200 250 time 300 350 400 450 500

With recycle, slower and larger effect

Different scales!

STRUCTURES OF PROCESS SYSTEMS

STAGED STRUCTURES Liquid
xD FR

Vapor

FV

Tray n

xB

Liquid

Vapor

STRUCTURES OF PROCESS SYSTEMS

STAGED STRUCTURES
0.99 0.985 XD (mol frac) 0.98 0.975 0.97 0.965 0 10 20 30 40 Time (min) 50

XB (mol frac)

Steps because analyzer provides new measurement only every 2 mintes.

0.025 0.02 0.015 0.01 0.005

Complex structure, smooth dynamics

0 x 10
4

10

20

30 40 Time (min)

50

8532.5 8532 R (mol/min) 8531.5 8531 8530.5 8530 0 10 20 30 40 Time (min) 50 V (mol/min)

1.37 1.365 1.36 1.355 1.35

10

20

30 40 Time (min)

50

OVERVIEW OF PROCESS SYSTEMS

Even simple elements can yield complex dynamics when combined in typical process structures.
We can Estimate the dynamic response based on elements and structure Recognize range of effects possible Apply analysis methods to yield dynamic model

CHAPTER 5: PROCESS SYSTEMS WORKSHOP 1

Four systems experienced an impulse input at t=2. Explain what you can learn about each system (dynamic model) from the figures below.
(a) 3 3 2 2 output output 1 0 0 -1 (b)

10

15 (c)

20

25

30

10

15 (d)

20

25

30

3 2 output 1 0 -1 output 0 5 10 15 time 20 25 30

2.5 2 1.5 1 0.5 0

10

15 time

20

25

30

CHAPTER 5: PROCESS SYSTEMS WORKSHOP 2 Using the guidelines in this chapter, sketch the response of the measured temperature below to a +5% step to the valve.
F0 (s ) m 3 / min = .10 G valve (s ) = % open v (s )
T1 (s ) 1.2 K /(m 3 / min) G tank1 (s ) = = F0 (s ) 250s + 1

Gsensor ( s ) =

Tmeasured ( s ) T2 ( s ) 1.0 K / K 10s + 1

Gtank2 ( s ) =

T2 ( s ) 1.0 K / K = T1 ( s ) 300s + 1

(Time in seconds)

CHAPTER 5: PROCESS SYSTEMS WORKSHOP 3 Sensors provide an estimate of the true process variable because the measurement is corrupted by errors. Discuss sources of noise in a measurement. Define the following terms for a sensor - Accuracy - Reproducibility Explain some process measurements needing (a) good accuracy and (b) good reproducibility Suggest an approach for operating a process when a key material property (composition, etc.) cannot be measured using an onstream analyzer.

CHAPTER 5: PROCESS SYSTEMS WORKSHOP 4 We are designing the following reactor with recycle. We have two choices for the conversion in the reactor. Will the plant dynamics be affected by the selection? Pure product

Fresh feed flow is constant X = 50% X = 95%

Pure, unreacted feed

CHAPTER 5 : TYPICAL PROCESS SYSTEMS

When I complete this chapter, I want to be able to do the following. Predict output for typical inputs for common dynamic systems Derive the dynamics for important structures of simple dynamic systems Recognize the strong effects on process dynamics caused by process structures

Lots of improvement, but we need some more study! Read the textbook Review the notes, especially learning goals and workshop Try out the self-study suggestions Naturally, well have an assignment!

CHAPTER 5: LEARNING RESOURCES

SITE PC-EDUCATION WEB - Instrumentation Notes - Interactive Learning Module (Chapter 5) - Tutorials (Chapter 5) Software Laboratory - S_LOOP program Textbook - Chapter 18 on level modelling and control - Appendix I on parallel structures

CHAPTER 5: SUGGESTIONS FOR SELF-STUDY 1. Extend textbook Figure 5.1 for new input functions (additional rows): impulse and ramp. 2. Determine which of the systems in textbook Figure 5.3 can be underdamped. 3. Explain the shape of the amplitude ratio as frequency increases for each system in textbook Figure 5.1. 4. Discuss the similarity/dissimilarity between self regulation and feedback. 5. Explain textbook Figure 5.5. 6. Discuss the similarity between recycle and feedback.

CHAPTER 5: SUGGESTIONS FOR SELF-STUDY 7. Discuss how the dynamics of the typical process elements and structures would affect our ability to control a process. Think about driving an automobile with each of the dynamics between the steering wheel and the direction that the auto travels. 8. Formulate one question in each of three categories (T/F, multiple choice, and modelling) with solution and exchange them with friends in your study group.