CHEN 5352-04 ADVANCED PROCESS CONTROL Spring 2013

PREREQUISITES: Process Control I (CHEN 4331) or equivalent

Text: Practical Process Control & Hands-on Workshop Series for Loop-Pro 4.x,
Doug Cooper (2005).
Reference:Aspen DMC Plus Version 2.0, Aspen Technology Inc., Cambridge, MA, USA,
(2001)
Chemical & Bio-Process Control," 3rd ed., by J. B. Riggs, Ferret Publishing,
Lubbock, TX (2006). ISBN 0-9669601-4-9
Instructor: D. H. Chen (Lucas 102, Office Hrs. TR 10:45-12:30 or by appointment),
409-880-8786, daniel.chen@lamar.edu)
COURSE OPBECTIVES:
Learn the fundamentals in dynamic model fitting and basic/advanced PID
controller configuration/ tuning with Control Station software.
Learn the fundamentals of dynamic modeling, constraint optimization, and
multivariable control (Linear Algebra, Regression Analysis, and Linear
Programming) and learn to install a multi-loop, constraint controller to control a
process.
COURSE SCHEDULE: TR 12:30 - 1:45 pm, Lucas 110

Week of Chapter/Slides Topic Workshops/Test/Project

Jan. 17- 12-14/ Regulatory Control & Set 1
Feb. 21 ControlA Advanced PID Control/ Set 2
CS d-h Control Station (CS) Workshops
Feb. 26- Apdx.B Piping & Instrumentation Diagram Quiz I
28 ControlD DCS
Mar. 5- 15/ControlC Multivariable Control/
May 2 /DMCa-c MPC Workshop Quiz II
May 8-14 Term Project Report

NOTES
Class participation, group leader, or oral quizzes: up to 3 bonus points semester grade.
Class attendance: 1 pt. semester grade for each unexcused absence; Students fail to
show up for more than a week may be dropped from the class.
Turn in all workshop reports to Blackboard 25%.
Tests 30% +30% =60%; Open book and class notes; Need to show calculation details;
Grades may be curved.
Final project (MPC/DCS/RtOpt/Control Station) ppt presentation & written report 15%;
Control Station Workshops: 7, 8, 11, 12
MPC Exercise: Fractionator, Stabilizer, or Twin Tower
Grade Guideline: A>87, 87>B>75, 75>C>60, 60>D>50, 50>F
Class notes & Handouts are available on-line.
Academic dishonesty will be handled according to Lamar University Student Handbook


CHEN 5352 Adv. PROCESS CONTROL
HOMEWORK LIST

Riggs Chap 12 24, 26, 30 Set 1
Chap 13 18, 21 Set 2
Chap 14 None



Slide Sets

Riggs CascadeRatioFF012412.ppt,InferAdapOverride022012.ppt,BumplessSplitrange2010.ppt,
MultiloopApdxB030512.ppt

CS ControlA011812.ppt, D_Chap69012612.ppt, E_Chap10_012612.ppt,
G_Chap18_Cascade_022112.ppt, H CntlStn_FF_2007.ppt, ControlB.ppt,
ControlStationSlides.ppt,ControlStnQuiz.ppt

MPC LinearAlgebra032612.ppt, ControlC040212.ppt, DMCExWS_040612.ppt
DMC_A2009.ppt, DMC_B_033010.ppt, DMC_C2009.ppt, Optimization.ppt

General ControlSampleTests.ppt, ControlD030110.ppt


Word, Excel, PDF, & Data Files

CS Control Stn Workshop 37- 013112.doc, PPC workshops.doc, ControlStationQuestions.doc,
ControlStnPFD.doc, PPCtextbook.pdf, ControlStationWorkshop.pdf,
ControlStationUserGuide.pdf, CntrlStnPractProcCntrl.pdf, Userguide37.pdf

MPC ModelID_Config_SimuLab042312.doc, DMCworkshopRev1.doc,Fractionator.clc,
LPcostlab.xls,



Assess to Internet
All class materials including syllabus, homework, computer assignments are available and
can be downloaded from Blackboard
https://luonline.blackboard.com/webapps/login/
log in then go to student services
log in Blackboard








Term Project

Select one of the topics (students finished labs earlier get the priority to choose a topic):
1. Control Station 13 & 14
2. Control Station 15 & 16
3. Control Station 9 & 18
4. DMC/RMPCT/ADMC
5. RtOpt/MPC/DCS

Students working on DCS, DMC, RtOpt, MPC, RMPCT, ADMC mainly conduct literature surveys
for the latest technology updates. These groups need to work on MPC tuning (move suppressions)
and what-if scenarios.
Students working on Control Station Exercises mainly follow the earlier workshop format used in
this semester.
Two students form 1 working group and submit only one report. The File name must identify the
brief title and student last names (Up to 10 letters).
Each group needs to upload the power point file before presentation and upload final project report
(Microsoft Word) by the due date. Each presentation takes 15 minutes including questions and
transition.
The group report needs to identify individual contributions (sections responsible in the report)

MPC Workshop (Example)

Descriptions & Data are given in the ModelID_Config_SimuLab042312.doc &
DMC workshop Rev1.doc files. Test data is given in the fractionator.clc file. The LP cost
calculation template is given in an Excel file (LP Cost Lab)
Answer the questions and include your PFD, assembled model, finished LP costs spreadsheet,
controller configuration, and snapshots of a simulated run in a Microsoft Word file.
Two students form 1 working group and submit only one file. The File name must identify the brief
title and student last names.

WS12 Feed Forward Control of the Jacketed Reactor (Example)

Description are given in the course content file PPC Workshops

Work on Steps 1-11. Answer the questions and include your Process Flow Diagram (PFD), Process
& Disturbance model parameters & SSE/R-squared, controller tuning parameters, noise levels, and
dynamic response snapshots in a Microsoft Word file.
Two students form 1 working group and submit only one file. The File name must identify the brief
title and student last names.






DISABILITIES:

Individuals who have any disability, either permanent or temporary, which might affect their ability to perform in
this class are encouraged to inform the instructor timely. Adaptation of methods, materials, or testing may be made
as required to provide for equitable participation


MEASURED OUTCOMES:

(a) Ability to apply knowledge of math, engineering and science in advanced control problems.

Math:
Able to apply the concepts of Linear Algebra, Regression Analysis, and Linear Programming in
Model Predictive Control (MPC).
MPC Exercise/Project: LP Cost, Linear Programming
Engineering:
Able to apply the concepts of feedback control & feedforward control in advanced PID
configuration and tuning.
Control Station: Workshop 11, 12
Advanced PID HW 12.26

(e) An ability to identify, formulate, and solve advanced engineering problems

Students will learn to identify the most appropriate dynamic models involved in MPC.
Identify the model matrix used in MPC (Fractionator Project).

(g) An ability to communicate effectively
A power point oral presentation is required for the MPC/Control Station Projects.

(j) Knowledge of contemporary issues

Examples of override control to address plant safety and environment issues.
Plant Safety: Riggs HW Chap. 13.18, 13.21
Environmental Issues: HW 13.18

(k) Ability to use techniques, skills, and tools in advanced engineering practice

Capable of performing dynamic model fitting, basic/advanced PID controller configuration and
tuning.
Control Station Workshops: 7, 8, 11, and 12

Capable of applying a multi-loop, constraint controller to control a process. Students get exposure
to dynamic modeling, optimization, and multivariable control through the workshop exercises as
well as understanding of fundamentals.
MPC Exercise: Models, LP Costs, and Controller Tuning.