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2nd Edition
Thomas E. Marlin
McMaster University
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PROCESS CONTROL
DESIGNING PROCESSES ANDCONTROL SYSTEMS FORDYNAMIC PERFORMANCE
International Editions 2000
Exclusive rights byMcGraw-Hill Book Co - Singapore, for manufiicture and export This book cannot be
re-exported from the country to which it is sold by McGraw-Hill. The International Edition is not
available in North America.
Copyright 2000,1995 by The McGraw-Hill Companies, Inc. All rights reserved. Except as permitted
under the United States Copyright Act of 1976, no part of this publication may be reproduced or
distributed in any form orby any means, orstored in a data base orretrieval system, without the prior
written permissionof the publisher.
Some ancillaries, including electronic and print components, may not be available to customers outside
the United States.
10 09 08 07 06 05 04 03 02
20 09 08 07 06 05 04 03 02 01
PMP BJE
ISBN 0-07-039362-1
Marlin, Thomas E.
Process control: designing processes and control systems fordynamic performance /
Thomas E. Marlin. -2nd ed.
p. cm.
Includes index.
ISBN 0-07-039362-1
1. Chemical process control. I. Title.
TP155.75.M365 2000
660\2815-dc21 99-026739
Printed in Singapore
About the
Author
Automation via feedback is not new. Early application of automatic control prin
ciples appeared in antiquity, and widespread use of automation began in the nine
teenth century when machinery was becoming the dominant method for manu
facturing goods. Great advances have been made in theory and practice so that
automation is now used in systems as commonplaceas room heatingand as excit
ing as the navigation of interplanetary exploration and telecommunications. The
great change over the recent years is the integralat times essentialrole of au
tomation in our daily lives and industrial systems.
Process control is a sub-discipline of automatic control that involves tailoring
methods for the efficient operation of chemical processes. Proper application of
process control can improve the safety and profitability of a process, while main
taining consistently high product quality. The automation of selected functions
has relieved plant personal of tedious, routine tasks, providing them withtime and
data to monitor andsupervise operations. Essentially every chemical engineer de
signing or operating plants is involved with and requires a background in process
control. This book provides an introduction to process control with emphasis on
topics that are of useto the general chemical engineer as well as the specialist.
The intent of this book is to present fundamental principles with clear ties to
applications and with guidelines on their reduction to practice. The presentation
is based on four basic tenets.
vn
viii Fundamentals
Preface
First,engineers should master control technology fundamentals, since there is no
set of heuristics or guidelines that can serve them through their careers. Since
these fundamentals must be presented with rigor, needed mathematical tools are
presentedto assistthe student. It maybe worthrecallingthat these principles were
selected because they provide the simplest approaches for solving meaningful
problems.
Practice
Second, we are not efficient if we "start from scratch" every time we encounter
a problem; similar situationscan be analyzed to develop guidelines for a defined
set of applications. Also, the fundamental concepts can be best reinforced and
enriched through the presentation of good engineering practice. With this per
spective, important design guidelines and enhancements are presented as logical
conclusions and extensions to the basic principles. Coverage of implementation
issuesincludes pitfalls with thestraightforward "textbook" approaches alongwith
modifications for practical application.
Complexity
Third, the presentation in this book follows the guideline"Everythingshould be
made as simple as possible, and no simpler." Naturally, many issues are easily
resolved using straightforward analysismethods. However, the engineer must un
derstand the complexity of automating a system, even when a closed-form solution
does not exist at the present time.
Design
Fourth, designis a capstone topic thatenables engineers to specify, buildandoper
ate equipment that satisfiespredeterminedgoals. Currently, closed-form solutions
do not exist for this activity; thus, a comprehensive design method for managing
the numerous interlocking designtasks is presented along with a step-by-step ap
proach to guide the engineer through problem definition, preliminary analysis of
degreesof freedomandcontrollability, andselectingprocessand control structures.
Many guidelines,checklists,and examplesaid the student in making well-directed
initial decisions and refining themthrough iterations to achievethe design goals.
THE READERS
Hopefully, readers with different backgrounds will find value in this treatment of
process control. A few comments are now addressed to the three categories of
likely readers of this book: university students, instructors, and practitioners.
Students
Many students find process control to be one of the most interesting and enjoyable
courses in the curriculum, because they apply the skills built in fluid mechanics,
heat transfer, thermodynamics, masstransfer, andreactordesign.This presentation