Course Title : Process Control

Code 70480
Course Year 3rd year
Term 2018・1st semester
Class day & Period Wednesday・2nd Period
Location W201/The 1st seminar room
Credits 2
Restriction No Restriction
Lecture Form(s) Lecture
Language Japanese
Instructor Graduate School of Engineering, Professor Shinji Hasebe, Professor Masahiro Ohshima, Assistant Professor, Sanghong Kim

Course Description

Process control is used for operating the production processes in chemical and the steel industries. Pressure, temperature, liquid level and flow rate are major process variables to be controlled automatically (i.e., computers). Understanding the process dynamics is the first step to develop a good control system. Then, as the second step, the optimal selection and manipulation of the process input variables has to be determined. The class teaches to derive the physico-chemical dynamic models of chemical processes and transfer function models, which are obtained by taylor expansion of the physico-chemical models. Then, the design scheme of controller is described. To make the understanding easier, computer simulation exercises using Matlab and Simulink are offered. 1.

Grading

The score is determined by considering the quality of homeworks, midterm exam, term-end exam and final project.

Course Goals

The goal of the class is to educate the students to be able to develop the dynamic process model, design the process controller and to analyze the control performance so as to design the optimal process control systems.

Course Topics

Theme Class number of times Description
Introduction of Process Control 1 Showing several examples, the necessity, objectives and importance of process control are described. Then, the concepts of feedback and feed-forward controls and technical terms on process control are explained. Some issues on process control design are explained. The basic design procedure of the control system for solving the issues is explained.
Development of Dynamic Models 1 The first step for developing better process control systems is to understand the dynamic behaviors of the process to be controlled. The modeling method using the material and heat balance equations is lectured to construct the model showing the dynamic behavior of the process appropriately. Then, how to derive the linear transfer model using Taylor expansion of the first principle model is explained.
Laplace transform and Transfer function 1 The Laplace transform is revisited first. Then, how to derive the transfer function from the linearized dynamic model among the input and the output variables is lectured. How to obtain the linear model from the step response is also taught.
Exercise with Matlab for learning dynamic behavior 1 [Exercise] After learning the basics of Matlab and Simulink, the dynamic behaviors of some typical dynamic systems such as the first-order lag system and the second-order lag system are simulated. Then, for a given process, the exercise on developing the model and executing the simulation is executed.
PID Control 1 The most popular controller in process industries is PID (Proportional, Integral, and Derivative) controller. The basic features of three elements (P, I, D) are explained. Then, after explaining the basic feature of PID controller, how to adjust the control parameters is taught.
Dynamics of controlled system 1 The relationship between the pole of the transfer function and the stability is lectured. Then, the basic feature, the steady-state characteristics, and the stability of the feedback control system are explained.
Mid-term exam 1 To know the level of understanding, the mid-term examination is conducted.
Frequency response 1 The relationship between the sine wave input and the output (the frequency response), and how to detect the stability from the frequency response are lectured. The features of various filters are also explained.
PID control system design 1 The adjusting method of PID parameters based on the IMC control procedure is explained. Then, several revised controllers of the basic PID controller for improving the performance are lectured.
Exercise of control system design 1 [Exercise] For a given process, the exercise of tuning the control parameters and verifying the performance under the developed system using Matlab/Simulink is executed.
Cascade control and Multi-loop control 1 The concept of cascade control is explained. Then, as a control system dealing with the two-input and two-output process, the multi-loop control system is introduced, and how to remove the interaction among the control loops is explained.
Exercise of multi-loop control 1 [Exercise] For a given process, the exercise of developing a controller for a two-input and two-output process is executed.
Equipment for control 1 The equipment used for the real process control system are explained. The concept of proportional band and the reason why non-dimensional system is used are explained.
Overall exercise of process control design 1 [Exercise] Starting with the construction of the first principle model of a chemical/bio process, a two-input and two-output control system (multi-loop controller) is designed and the parameters are tuned by using Matlab and Simulink
Feed-back time The question and answer to the final exercise, and the whole of the lectures are conducted.

Textbook

Process Control Engineering, Hashimoto, Hasebe, Kano, Asakura book store,

Textbook(supplemental)

Process Control System, Ohshima, CORONA Publishing

Prerequisite(s)

Basic understanding of linear algebra, ordinal differential equations and Laplace transform

The final term project will be given.

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Additional Information