LECTURER: Dr. M.W.

Foley
COURSE TITLE: Process Dynamics and Control II
COURSE CODE: CHNG 3003 (formerly CH32B)
LEVEL: 3
SEMESTER: 2
NO. OF CREDITS: 3
PRE-REQUISITE: CHNG 2006
COURSE DESCRIPTION/RATIONALE: The course material extends the basic modelling and
control concepts introduced in CHNG 2006. It comprises the following topics. Analysis and
design of advanced control systems; Feedback control of systems with large deadtime or
inverse response; Control systems with multiple loops; Feedforward and ratio control; Inferential
control systems; Control of multivariable processes; Interaction and decoupling of control loops;
Design of control systems for complete plants; Process control using digital computers;
Transition from continuous to discrete-time systems; Process identification. The main purpose
of CHNG 3003 is to equip students with the practical skills necessary to solve plant process
control problems and recognize opportunities for maximizing plant profitability.
LEARNING OUTCOMES: The student will

develop an appreciation for the architecture of distributed control and plant information
systems as well as the flexibility and functionality of digital feedback controllers

size pneumatic control valves

model the dynamics of chemical processes from first-principles and through regression
of plant step response data

design and simulate control systems with the MATLAB/Simulink and HYSYS.Plant
software packages

predict closed loop stability and performance characteristics from a Bode diagram

tune PID controllers by trial-and-error and using model-based tuning methods to meet
specific performance objectives

apply advanced regulatory schemes such as deadtime compensation and feedforward,

ratio and override control

recognize the potential for loop interaction in the control of multivariate processes such
as distillation columns

pair manipulated and controlled variables in multi-loop PID control schemes using the
Relative Gain Array

derive static and dynamic decoupling elements to reduce loop interaction

LEARNING OUTCOMES (con)

distinguish between energy-balance and material balance distillation control strategies

and invoke design criteria for selecting one approach over the other

examine design procedures which can be used to generate a control system for an
entire plant consisting of many interconnected unit operations.

CONTENT:

Basic Concepts and Terminology (2 hours)

Process dynamics and the reaction curve
Feedback and feedforward control
Analog and digital controllers
Fundamental laws and levels of process control
Approximating high-order dynamics with first-order-plus-deadtime models

Conventional Control Systems and Hardware (6 hours)

Flow, temperature, level and pressure sensors
Control valves: action, sizing and characteristics
Rules of thumb for designing flow, temperature, level and pressure control loops
Trial-and-error tuning of PID controllers
Model-based tuning of PID controllers: Ziegler-Nichols, Cohen-Coon and IMC
methods

Modelling and Control of Surge Tank Levels (2 hours)

Reasons for inventories in plants
Open-loop response of surge tank levels
Theoretical or first-principles models
Empirical or data-based models
Closed-loop response of surge tank levels
Controller selection and tuning for surge tank levels

Automatic Control of Chemical Unit Operations (17 hours)

Heat exchangers
Classification and typical control strategies
Frequency response analysis and the Bode stability criterion
Time delay compensation using the Smith predictor
Feedforward compensation of measured disturbances
Distillation columns
Operability and degrees of freedom
Fundamental variables for composition control
Inferential control
Interaction and decoupling of control loops
Loop pairing using the Relative Gain Array

CONTENT (con)

Modelling the Dynamics of Chemical Processes (8 hours)

Open-loop response of steam heat exchanger
Theoretical model based on dynamic material and energy balances
Linearization using multivariate Taylor series expansion
Open loop response of binary distillation columns
Theoretical models based upon steady-state and dynamic material
balances

Advanced Control Systems (4 hours)

Ratio and override control
Control system design concepts
Plantwide process control design procedure

Computer Simulation (24 hours)

Dynamic simulation of open- and closed-loop systems using MATLAB/ Simulink
and HYSYS.Plant
Frequency response and stability analysis with the MATLAB Control Systems
toolbox.

TEACHING METHODOLOGY: The course content will be delivered by means of three lecturehours per week. In addition, there will be twelve two-hour computer workshops during which
students will be instructed in the use of MATLAB/Simulink and dynamic HYSYS.
ASSESSMENT: The extent to which students demonstrate the desired learning outcomes will
be assessed in the following examinations:

Two-hour computer-based HYSYS midterm (20%)

Two-hour computer-based MATLAB midterm (20%)
Three-hour written final (60%)

REQUIRED READING:
Essential Text:
1.

P.C. Chau, Process Control: A First Course with MATLAB, Cambridge University Press,
2002.

Highly Recommended Texts:

1.

W.B. Bequette, Process Dynamics: Modeling, Analysis and Simulation, Prentice-Hall,

1997.

2.

M.L. Luyben and W.L. Luyben, Essentials of Process Control, McGraw-Hill, 1997.

3.

W.L. Luyben, Plantwide Dynamic Simulators in Chemical Processing and Control,

Marcel-Dekker, 2002.

4.

G. Stephanopoulos, Chemical Process Control, Prentice-Hall, 1984.

Recommended Texts:
1.

K.J. Astrom and L.B. Wittenmark, Computer Controlled Systems (3rd Edition), PrenticeHall, 1997.

2.

W.B. Bequette, Process Control: Modeling, Design and Simulation, Prentice-Hall, 2002.

3.

J.C. Bollinger and N.A. Duffie, Computer Control of Machines and Processes, AddisonWesley, 1988.

4.

D.R. Coughanowr, Process Systems Analysis and Control (2nd Edition), McGraw-Hill,
1991.

5.

J.J. DiStefano, A.R. Stubberud and I.J. Williams, Feedback and Control Systems (2nd
Edition), Schaums Outline Series, McGraw-Hill, 1990.

6.

Glad, T. and L. Ljung, Control Theory: Multivariable and Nonlinear Methods, Taylor and
Francis, 2000.

7.

Ingham, J., I.J. Dunn, E. Heinzle and J.E. Penosil, Chemical Engineering Dynamics: An
Introduction to Modelling and Computer Simulation, Wiley-VCH, 2000.

8.

W. L. Luyben (editor), Practical Distillation Control, Van Nostrand-Reinhold, 1992.

9.

W.L. Luyben, B.D. Tyreus and M.L. Luyben, Plantwide Process Control, McGraw-Hill,
1998.

10. T.E. Marlin, Process Control: Designing Processes and Control Systems for Dynamic
Performance (2nd Edition), McGraw-Hill, 2000.
11. B.A. Ogunnaike and W.H. Ray, Process Dynamics, Modelling and Control, Oxford
University Press, 1994.
12. C.A. Smith and A.B. Corripio, Principles and Practice of Automatic Process Control (3rd
Edition), John Wiley & Sons, 2005.