Designing Controls For The Process Industries

"The book offers a modern, process-oriented approach, emphasizing process control scheme development instead of extended coverage of LaPlace space descriptions of process dynamics. It provides mathematical descriptions to supplement basic concepts. It discusses real-time controllers and higher level automation functions for process and safety applications and shows how to specify simple regulatory and supervisory control strategies and basic safety automation controls and controls for continuous and batch processes. It covers measurement parameters and quantification methods and contains a chapter on control system projects and a recommended lifecycle for plant automation system projects."--Provided by publisher.

Offering a modern, process-oriented approach emphasizing process control scheme development instead of extended coverage of LaPlace space descriptions of process dynamics, Designing Controls for the Process Industries focuses on aspects that are most important for contemporary practical process engineering and reflects the industry’s use of digital distributed control-based systems. The second edition now features 60 tutorial videos demonstrating solutions to most of the example problems. Instead of starting with the controller, the book starts with the process and moves on to how basic regulatory control schemes can be designed to achieve the process objectives while maintaining stable operations. In addition to continuous control concepts, process and control system dynamics are embedded into the text with each new concept presented. The book alsoincludes sections on batch and semi-batch processes and safety automation within each concept area. It discusses the four most common control techniques: control loop feedback, feedforward, ratio, and cascade, and discusses application of these techniques for process control schemes for the most common types of unit operations. It also discusses more advanced andless commonly used regulatory control options such as override, allocation, and split range controllers; includes an introduction to higher-level automation functions; and provides guidance for ways to increase the overall safety, stability, and efficiency for many process applications. It introduces the theory behind the most common types of controllers used in the process industries and provides various additional plant automation-related subjects. The new edition also includes new homework problems and examples, including multiple choice questions for flipped classes, information about statistical process control, and a new case study that documents the development of regulatory control schemes for an entire process area. Aimed at chemical engineering students in process control courses, as well as practicing process and control engineers, this textbook offers an alternative to traditional texts and offers a practical, hands-on approach to design of process controls. PowerPoint lecture slides, multiple-choice quiz questions for each chapter, and a solutions manual are available to qualifying instructors. Tutorial-style videos for most of the text examples are available for all readers to download.

Offering a modern, process-oriented approach emphasizing process control scheme development instead of extended coverage of LaPlace space descriptions of process dynamics, this text focuses on aspects that are most important for process engineering in the 21st century. Instead of starting with the controller, the book starts with the process and moves on to how basic regulatory control schemes can be designed to achieve the process’ objectives while maintaining stable operations. In addition to continuous control concepts, process and control system dynamics are embedded into the text with each new concept presented. The book also includes sections on batch and semi-batch processes and safety automation within each concept area. It discusses the four most common process control loops—feedback, feedforward, ratio, and cascade—and discusses application of these techniques for process control schemes for the most common types of unit operations. It also discusses more advanced and less commonly used regulatory control options such as override, allocation, and split range controllers, includes an introduction to higher level automation functions, and provides guidance for ways to increase the overall safety, stability, and efficiency for many process applications. It introduces the theory behind the most common types of controllers used in the process industries and also provides various additional plant automation-related subjects.

Manufacturing process controls include all systems and software that exert control over production processes. Control systems include process sensors, data processing equipment, actuators, networks to connect equipment, and algorithms to relate process variables to product attributes. Since 1995, the U.S. Department of Energy Office of Industrial Technology 's (OIT) program management strategy has reflected its commitment to increasing and documenting the commercial impact of OIT programs. OIT's management strategy for research and development has been in transition from a "technology push" strategy to a "market pull" strategy based on the needs of seven energy-and waste-intensive industries-steel, forest products, glass, metal casting, aluminum, chemicals, and petroleum refining. These industries, designated as Industries of the Future (IOF), are the focus of OIT programs. In 1997, agriculture, specifically renewable bioproducts, was added to the IOF group. The National Research Council Panel on Manufacturing Process Controls is part of the Committee on Industrial Technology Assessments (CITA), which was established to evaluate the OIT program strategy, to provide guidance during the transition to the new IOF strategy, and to assess the effects of the change in program strategy on cross-cutting technology programs, that is, technologies applicable to several of the IOF industries. The panel was established to identify key processes and needs for improved manufacturing control technology, especially the needs common to several IOF industries; identify specific research opportunities for addressing these common industry needs; suggest criteria for identifying and prioritizing research and development (R&D) to improve manufacturing controls technologies; and recommend means for implementing advances in control technologies.

This book presents the most important methods used for the design of digital controls implemented in industrial applications. The best modelling and identification techniques for dynamical systems are presented as well as the algorithms for the implementation of the modern solutions of process control. The proposed described methods are illustrated by various case studies for the main industrial sectors There exist a number of books related each one to a single type of control, yet usually without comparisons for various industrial sectors. Some other books present modelling and identification methods or signal processing. This book presents the methods to solve all the problems linked to the design of a process control without the need to find additional information.

Techniques such as dead time compensation, adaptive control and Kalman filtering have been around for some time, but as yet find little application in industry. This is due to several reasons, including: Articles in the literature usually assume that the reader is familiar with a specific topic and are therefore often difficult for the practicing control engineer to comprehend. Many practicing control engineers in the process industry have a chemical engineering background and did not receive a control engineering education. There is a wide gap between theory and practical implementation, since implementation is primarily concerned with robustness, and theory is not. The user therefore has to build an "expert shell" in order to achieve the desired robustness. Little is published on this issue, however. This book tries to promote the use of advanced control techniques by taking the reader from basic theory to practical implementation. It is therefore of interest to practicing control engineers in various types of industries, especially the process industry. Graduate and undergraduate students in control engineering will also find the book extremely useful since many practical details are given which are usually omitted in books on control engineering. Of special interest are the simulation examples, illustrating the application of various control techniques. The examples are available on a 5-1/4" floppy disk and can be used by anyone who has access to LOTUS 1-2-3. Chapter 1 is the introduction; Chapters 2 through 6 deal with distributed control system networks, computer system software, computer system selection, reliability and security, and batch and continuous control. Chapter 7 gives and introduction to advanced control. Chapters 8 through 11 deal with dead time compensation techniques and model identification. Chapters 12 through 14 discuss constraint control and design, and the adjustment and application of simple process models and optimization. Chapter 15 gives a thorough introduction to adaptive control, and the last two chapters deal with state and parameter estimation. This book is a valuable tool for everyone who realizes the importance of advanced control in achieving improved plant performance. It will take the reader from theory to practical implementation.

Intended for control system engineers working in the chemical, refining, paper, and utility industries, this book reviews the general characteristics of processes and control loops, provides an intuitive feel for feedback control behavior, and explains how to obtain the required control action witho

Process Control details the core knowledge and practical skills that a successful process control practitioner needs. It explains the essential technologies that are in use in current industrial practice or which may be wanting for the future. The book focuses on practical considerations, not only on those that make a control solution work, but also on those that prevent it from failing, especially for complex control loops and plant-wide control solutions. After discussing the indispensable role of control in modern process industries, the authors concentrate on the skills required for process analysis, control design, and troubleshooting. One of the first books to provide a systematic approach and structured methodology for process analysis and control design, Process Control illustrates that methodology with many practical examples that cover process control, equipment control, and control calculations derived from real projects and applications. The book uses 229 drawings and 83 tables to make the concepts it presents more intuitive and its methodology easy to follow. Process Control will help the practising control engineer to benefit from a wealth of practical experience and good ideas on how to make control work in the real world and students training to take up roles in process control are shown the applied relevance of control theory in the efficient functioning of industrial plant and the considerations needed to make it work. Advances in Industrial Control reports and encourages the transfer of technology in control engineering. The rapid development of control technology has an impact on all areas of the control discipline. The series offers an opportunity for researchers to present an extended exposition of new work in all aspects of industrial control.