Applied Process Control: Essential Methods

483 Pages·2016·30.274 MB·English

by  Michael Mulholland

MichaelMulholland
AppliedProcessControl
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Michael Mulholland
Applied Process Control
Essential Methods
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V
Essential Methods Contents
Preface XI
Acknowledgements XIII
Abbreviations XV
Frontispiece XIX
1 Introduction 1
1.1 TheIdeaofControl 1
1.2 ImportanceofControlinChemicalProcessing 3
1.3 OrganisationofThisBook 5
1.4 Semantics 6
References 7
2 Instrumentation 9
2.1 PipingandInstrumentationDiagramNotation 9
2.2 PlantSignalRangesandConversions 11
2.3 ASpecialNoteonDifferentialPressureCells 14
2.4 MeasurementInstrumentation 16
2.4.1 FlowMeasurement 17
2.4.1.1 FlowMeasurementDevicesEmployingDifferentialPressure 17
2.4.1.2 OtherFlowMeasurementDevices 22
2.4.2 LevelMeasurement 22
2.4.2.1 LevelMeasurementbyDifferentialPressure 22
2.4.2.2 OtherLevelMeasurementTechniques 25
2.4.3 PressureMeasurement 25
2.4.4 TemperatureMeasurement 26
2.4.4.1 ThermocoupleTemperatureMeasurement 26
2.4.4.2 MetalResistanceTemperatureMeasurement 28
2.4.4.3 TemperatureMeasurementsUsingOtherPrinciples 28
2.4.5 CompositionMeasurement 29
2.5 Current-to-PneumaticTransducer 31
2.6 FinalControlElements(Actuators) 31
VI EssentialMethodsContents
2.6.1 Valves 32
2.6.1.1 PneumaticallyOperatedGlobeControlValve 32
2.6.1.2 ValveCharacteristics 35
2.6.1.3 ValveC andK 36
V V
2.6.1.4 SpecificationofValvesforInstalledPerformance 37
2.6.1.5 ControlValveHysteresis 39
2.6.1.6 VariousFlowControlDevices 40
2.6.2 SomeOtherTypesofControlActuators 42
2.7 Controllers 42
2.8 Relays,TripsandInterlocks 44
2.9 InstrumentReliability 45
References 51
3 Modelling 53
3.1 GeneralModellingStrategy 54
3.2 ModellingofDistributedSystems 59
3.3 ModellingExampleforaLumpedSystem:ChlorinationReservoirs 61
3.4 ModellingExampleforaDistributedSystem:ReactorCooler 63
3.5 OrdinaryDifferentialEquationsandSystemOrder 67
3.6 Linearity 69
3.7 LinearisationoftheEquationsDescribingaSystem 73
3.8 SimpleLinearisation‘Δ’Concept 75
3.9 SolutionsforaSystemResponseUsingSimplerEquations 77
3.9.1 MathematicalSolutionsforaSystemResponseinthet-Domain 77
3.9.2 MathematicalSolutionsforaSystemResponseinthes-Domain 79
3.9.2.1 ReviewofSomeLaplaceTransformResults 79
3.9.2.2 UseofLaplaceTransformstoFindtheSystemResponse 84
3.9.2.3 Open-LoopStabilityinthes-Domain 95
3.9.3 MathematicalSolutionsforSystemResponseinthez-Domain 97
3.9.3.1 ReviewofSomez-TransformResults 98
3.9.3.2 Useofz-TransformstoFindtheSystemResponse 104
3.9.3.3 EvaluationoftheMatrixExponentialTerms 109
3.9.3.4 ShortcutMethodstoObtainDiscreteDifferenceEquations 110
3.9.3.5 Open-LoopStabilityinthez-Domain 111
3.9.4 NumericalSolutionforSystemResponse 113
3.9.4.1 NumericalSolutionUsingExplicitForms 114
3.9.4.2 NumericalSolutionUsingImplicitForms 115
3.9.5 BlackBoxModelling 117
3.9.5.1 StepResponseModels 117
3.9.5.2 RegressedDynamicModels 122
3.9.6 ModellingwithAutomata,PetriNetsandTheirHybrids 126
3.9.7 ModelsBasedonFuzzyLogic 132
3.10 UseofRandomVariablesinModelling 136
3.11 ModellingofClosedLoops 141
References 142
EssentialMethodsContents VII
4 BasicElementsUsedinPlantControlSchemes 143
4.1 SignalFiltering/Conditioning 143
4.2 BasicSISOControllers 147
4.2.1 BlockDiagramRepresentationofControlLoops 147
4.2.2 ProportionalController 150
4.2.3 Proportional–IntegralController 151
4.2.4 Proportional–Integral–DerivativeController 153
4.2.5 IntegralActionWindup 155
4.2.6 TuningofP,PIandPIDControllers 155
4.2.6.1 StepResponseControllerTuning 158
4.2.6.2 FrequencyResponseControllerTuning 159
4.2.6.3 Closed-LoopTrial-and-ErrorControllerTuning 160
4.2.7 FeedforwardControl 160
4.2.8 OtherSimpleControllers 162
4.2.8.1 On/OffDeadbandControl 162
4.2.8.2 SimpleNonlinearandAdaptiveControllers 162
4.3 CascadeArrangementofControllers 163
4.4 RatioControl 164
4.5 SplitRangeControl 165
4.6 ControlofaCalculatedVariable 165
4.7 UseofHighSelectororLowSelectoronMeasurementSignals 168
4.8 Overrides:UseofHighSelectororLowSelectoronControl
ActionSignals 168
4.9 Clipping,Interlocks,TripsandLatching 170
4.10 ValvePositionControl 171
4.11 AdvancedLevelControl 172
4.12 CalculationofClosed-LoopResponses:ProcessModelwith
ControlElement 173
4.12.1 Closed-LoopSimulationbyNumericalTechniques 174
4.12.2 Closed-LoopSimulationUsingLaplaceTransforms 176
References 177
5 ControlStrategyDesignforProcessingPlants 179
5.1 GeneralGuidelinestotheSpecificationofanOverallPlantControlScheme 180
5.2 SystematicApproachestotheSpecificationofanOverallPlantControlScheme 180
5.2.1 StructuralSynthesisofthePlantControlScheme 181
5.2.2 ControllabilityandObservability 184
5.2.3 MorariResiliencyIndex 188
5.2.4 RelativeGainArray(BristolArray) 191
5.3 ControlSchemesInvolvingMoreComplexInterconnectionsofBasicElements 193
5.3.1 BoilerDrum-LevelControl 193
5.3.1.1 NoteonBoilerDrum-LevelInverseResponse 194
5.3.2 FurnaceFullMeteringControlwithOxygenTrimControl 195
5.3.3 FurnaceCross-LimitingControl 196
References 198
VIII EssentialMethodsContents
6 EstimationofVariablesandModelParametersfromPlantData 199
6.1 EstimationofSignalProperties 199
6.1.1 CalculationofCross-CorrelationandAutocorrelation 199
6.1.2 CalculationofFrequencySpectrum 202
6.1.3 CalculationofPrincipalComponents 203
6.2 Real-TimeEstimationofVariablesforWhichaDelayedMeasurementIs
AvailableforCorrection 205
6.3 PlantDataReconciliation 208
6.4 RecursiveStateEstimation 211
6.4.1 DiscreteKalmanFilter 213
6.4.2 ContinuousKalman–BucyFilter 220
6.4.3 ExtendedKalmanFilter 222
6.5 IdentificationoftheParametersofaProcessModel 225
6.5.1 ModelIdentificationbyLeast-SquaresFittingtoaBatchof
Measurements 227
6.5.2 ModelIdentificationUsingRecursiveLeastSquaresonMeasurements 229
6.5.3 SomeConsiderationsinModelIdentification 233
6.5.3.1 TypeofModel 233
6.5.3.2 ForgettingFactor 239
6.5.3.3 Steady-StateOffset 240
6.5.3.4 ExtractionofPhysicalParameters 241
6.5.3.5 TransportLag(DeadTime) 243
6.6 CombinedStateandParameterObservationBasedonaSystemofDifferential
andAlgebraicEquations 243
6.7 NonparametricIdentification 246
6.7.1 ImpulseResponseCoefficientsbyCross-Correlation 246
6.7.2 DirectRLSIdentificationofaDynamicMatrix(StepResponse) 247
References 250
7 AdvancedControlAlgorithms 251
7.1 Discretez-DomainMinimalPrototypeControllers 251
7.1.1 SetpointTrackingDiscreteMinimalPrototypeController 251
7.1.2 SetpointTrackingandLoadDisturbanceSuppressionwithaDiscrete
MinimalPrototypeController(Two-Degree-of-FreedomController) 255
7.2 Continuouss-DomainMIMOControllerDecouplingDesignbyInverse
NyquistArray 256
7.3 Continuouss-DomainMIMOControllerDesignBasedonCharacteristicLoci 259
7.4 Continuouss-DomainMIMOControllerDesignBasedonLargestModulus 260
7.5 MIMOControllerDesignBasedonPolePlacement 261
7.5.1 Continuouss-DomainMIMOControllerDesignBasedonPolePlacement 261
7.5.2 Discretez-DomainMIMOControllerDesignBasedonPolePlacement 264
7.6 State-SpaceMIMOControllerDesign 266
7.6.1 ContinuousState-SpaceMIMOModalControl:ProportionalFeedback 266
7.6.2 DiscreteState-SpaceMIMOModalControl:ProportionalFeedback 267
7.6.3 ContinuousState-SpaceMIMOControllerDesignBasedon‘Controllable
System’PolePlacement 267