Index

1. Introduction – Chemical Processes

and Control Objectives
2. Design and Control models
3. Process Dynamics: First, Second,
Higher Order Systems
4. Systems with Challenging Dynamics
5. Basics of Feedback Control Systems
 INDEX

6. Dynamics of Controlled Systems

(Closed Systems)
7. Stability and Control Tuning
8. Control of Unit Operations
9. Design of Direct Synthesis
Controllers
10. Control on MIMO Systems
11. Industrial Application
 LECTURE 3

PROCESS DYNAMICS:
FIRST, SECOND AND
HIGHER ORDER SYSTEMS
 First Order Systems

Time domain Laplace domain

 Examples of First Order Systems

1. The first order processes are characterized by:

• Their capacity to store material, energy, or momentum
(e.g., liquid tank)
• The resistance associated with the flow of mass, energy,
or momentum in reaching the capacity
(e.g., transfer of heat through wall)
 Tank without Heating

R
F = h/R = driving force for flow
/ resistance to flow
dh h
A = F! − F = F! − (h’=h-hs, Fi’=Fi-Fi,s)
dt R
dh !"($) '&
AR
dt
+ h = RF! G(s) = &% "($)
= (& $)*
0 + ℎ" = RF!,$ !! = AR = time constant of the process
dh′ 3! = R = steadystate gain of the process
AR + h′ = RF′!
dt
 Tank with Heating

()
V-.' =Q=/A(0+ − 0)
(*
Dynamic Response to Step Changes

Output is universal.
- scaling output by KP Response looks
identical
- scaling time by τ
 General Remarks
The process “stamp” on the dynamic model
consists of:

The steady state gain The process time constant

Shows how “sensitive” Shows how “quick”

is the system to is the system to
changes changes
 General Remarks 2

• The smaller the process time, τ, the steeper the

initial response (unscaled time).

Process time is a measure on how

quickly the system adjusts to changes.

• For large steady state gains, even small changes

in the input result in large output changes.

Gain is a measure on how important

input changes can be for the system.
 Second Order Systems

Composed of two first order subsystems (G1 and

G2)
F(s)
"! $ "$ $
#! # ! " = #$ # !" =
! !! + ! ! $! +!

F(s)
"! $ " " $ "$
#$ !# = =
(" !! + !)(" " ! + !) " " ! " + "!"! + !
!" + ! !
Where, ! = ! "! ! "#
! !"! !
 Second Order Systems

Time domain Laplace domain

 Remarks

• As damping factor increases, the second order effects are far less

important than the first order effects (i.e., τ2S2 << 2ξ τS).

The system behaves like the first order.

• As time passes by, the second order effect diminishes. (τ2s2 à 0)

The system behaves like the first order.

• The second order dynamics show differences when the second order

effects (τ2s 2 ) are comparable or larger than the first order effect.

Different behavior for small ζ.

 Second Order Response

Step changes in the input.

Overdamped (ξ >1)

Overdamped (ξ >1) and critically Underdamped systems (ξ <1)

damped (ξ =1) systems Overshoot: A/B
Decay ratio: C/A
Period of oscillation: T
Second Order Response – Input step change

For the step changes of F(s) = M/S in the input.

Y(s) = [K / (τ2 S2+2ϛ τ S+1)]·[M / S ]

Second Order Response - Input step change

For the step changes of F(s) = M/S in the input.

Y(s) = [K / (τ2 S2+2ϛ τ S+1)]·[M / S]

Second Order Response - Input step change

Performance characteristics for the step response of

an underdamped process.
Second Order Response - Input step change

For the second order step change:

a. Overshoot
! # %!" $
= "#$ & '
" & %%" ! '
( )

b. Time of first maximum

!"
"! =
"$# !

c. Decay ratio (successive maxima – not min.)

! # %!!" $ "!
= "#$ & '= !
" & %%" ! ' #
( )

d. Period of oscillation
!!"
! =
"$# !
Second Order Systems: Examples
1. Inherently second order
• Manometers

• Pneumatic Valves

• Differential pressure transducers

2. Combinations of the first order systems

• Cascades of Processes

• Coupled systems

3. Systems constructed by humans

• Process control systems
 Jacketed Reactor

What is the dynamic response of T with

changes in Tw?
Jacketed Reactor
 Changes of T with Tw

(Reactor jacket) + (Chemical Reactor)

Second Order System

 Remarks
• Chemical processes often involve combination of
two or more different processes.
• The different systems may

Mutually interact with Support “one-way”

each other interactions
Interacting Non-interacting
capacities capacities
Non interacting capacities

Cascade of agitated tanks (1) and (2)

• (1) feeds (2), but
• (2) does not affect (1)
 Interacting Capacities

• (1) feeds (2)

• (2) resists outflow of (1)

Interacting capacities

Always slower than non-interacting (why?)

Dynamics of Chemical Processes

Dynamics of Chemical Processes: General Case

How does this system behave with respect to the

basic processes?
 Jacketed Reactor

Even if Jacket’s dynamics are extremely fast (i.e., τ1 à 0):

• At best, the process is as slow as the slowest sub-process

(dynamics now determined by the reactor vessel).
• In general, the process is slower than both sub-processes.
• The combined dynamics yield an overdamped response.
Higher Order Systems

Interacting

Or
Non-interacting
Overdamped response
• General curve (non delays)
 Delays on Dynamics

Original signal …. … is equally available,

but only later.

Consequently, the transfer … is equally available, but

function G(s)… with some delay :
 Delays on Dynamics
For example, time delays occur due to:
1. Fluid flowing in a pipe

2. Chemical analysis
- Sampling line delay
- Time required to do the analysis (e.g., on-
line gas chromatograph)
 Delays on Dynamics

Mathematical description:
A time delay, ! , between an input u and an output y
results in the following expression:
! ! "#$ ! < ! "! ! " ! !"
" (! ) = " %&'()* #! !" = $ =
%# ( ! # ! ) "#$ ! $ ! % ! !"
Delays on Combined Processes

Overdamped
response with delay
Process Response: Typical Case

Overdamped with delay First order with delay

Can be developed Simple calculations are Simple model easily

experimentally. only required. available.
Development of Dynamic Model

Step 1: Identify input and output variables.

Step 2: Select an input variable and introduce a step change.

Step 3: Trace its response. (physical experiments, dynamic

simulations)

Step 4: Develop a first order model with delay to

approximate the response.
Distillation Example

Input: reflux R
vapor boilup V

Output: XB, XD

v F: Feed

Develop a dynamic model.

 Input – output model

• Although F is an input (physical input), it does not

describe the control problem and does not appear
here.

• To address the problem, we need:

• An experimental device, or
• A simulation model
 Input – output model

1. Introduce step changes to the reflux R (keep V constant).

2. Trace response of XD.

 Similar Experiments

V vs XD R vs XB V vs XB
Dynamic Model: Compact Form

Output Dynamic Model Input

 Remarks

• Approximate model hides high order dynamics.

• Overdamped response is the most common case,

but not the only one case? (see later)
End of Session 3