Theoretical Background : Module I Furnace Transient Response Analysis

Transient Response Analysis

Fundamental Modeling

Empirical Modeling

Based process knowledge such (i.e. material and E. balances, momentum transfer, chemical kinetics, thermodynamics and physical property relationships) Complex and difficult to develop

Based on experimental data (i.e. response curve) to explain the observed response Lacks fundamental correctness Should be used with caution

Theoretical Background : Modeling Furnace FOTD

FOTD

Few experimental step responses seldom exhibit first order behavior Time-delay term can be included to account for higher order dynamics and can improve the agreement between model and experimental responses Graphical method to model FOTD

Theoretical Background : Empirical Method Graphical Method

FOTD

Steady-State Gain

Dead Time

Time Constant

Theoretical Background : Module II Steady-state Feedback Control

Controller

Process
Error Signal:
(1) Sensor measures the controlled variable before being transmitting the signal to the controller (1) Controller then compares this measurement with the set point. (2) Deviation cause controller to take corrective actions to reduce or eliminate the deviation by sending a signal to the final control element (3) Manipulated variable is adjusted accordingly to bring the controlled variable back to the set point

Theoretical Background : Module II Steady-state Feedback Control

Controller

P Controller

PI Controller

High Kc results in large change in controller output for a given error signal But, High Kc can cause the system to become unstable, due to presence of oscillation. Small Kc makes the controller less responsive to large error signal, due to a smaller output response for a given error signal

Addition of integral element, which is a summation of instantaneous error over time Aims to eliminate offset and cause controller output to change continuously until the steadystate error zero is achieved Low I allows for steady-state error zero to be achieved faster Too low I causes the output response to be more oscillatory, and prevent system from reaching steady state Increasing I suppresses the oscillatory response but increases the settling time

Theoretical Background : Module III Steady-state Feed Forward Control

(1) Sensor measures a distrubance in the control systems external environment using a sensor (2) Information is transmitted to the feedforward controller (3) Feedforward controller measures the change required in the manipulated variable such that the change will perfectly offset the disturbance

Theoretical Background : Module III Steady-state Feed Forward Control

Model for Feed Forward control:

The controller is physically realizable only if p < d If p > d, one can use an approximate dynamic compensation by using a lead-lag element as shown below:

Theoretical Background : Module III Steady-state Feed Forward Control

To solely use Feed Forward as a controller:

All disturbances must be measurable

Very accurate model is needed to account for all the disturbances

=> In reality, some of these requirements may be difficult to obtain or even cannot obtain

Feedback Controller + Feed-forward Controller

Error Analysis

Determined by drawing a maximum slope at the inflexion point

Graphical method was used to determine the gain, dead time and time constant
Point of inflexion was hard to be determined

Error Analysis

Affect calculations of process/ disturbance gain, time constant and dead time values

Process and disturbance models derived from graphs were noisy

Human judgment was needed to choose the new steady state baseline (due to presence of fluctuations)

Error Analysis

Measurement and valve dynamics were not taken into consideration

Measurement and valve dynamics affect Bode stability analysis, and limit the speed of response of the controlled process

Result in potential deviations in simulated response from reality

Error Analysis

Assumption: TF for fuel gas flow, air flow, hydrocarbon flow and fuel gas purity were linearly independent

May not be necessarily true in an actual furnace environment

Result in possible deviation in the results from reality