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01_SyllabusCHE461S10 - 1 CHE 461 Process Control Spring...

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Unformatted text preview: 1 CHE 461: Process Control Spring Quarter 2010 School of Chemical, Biological and Environmental Engineering Oregon State University http://classes.engr.oregonstate.edu/cbee/spring2010/che461 CHE 461: 3 cr. LEC. Mon., Wed. 11-11:50am Gleeson Hall Room 200 REC. Fri. 10-11:50am Gleeson Hall Room 200 Instructor: Dr. Keith L. Levien, Room 203 Gleeson Hall 737-3155 Off. Hrs: 3-4pm MWF and by appointment, email = [email protected] Grader/TA: Malachi Bunn, [email protected] , Gleeson 008 Off. Hrs: Thursday 9-11am & Friday 12noon-1pm Textbook: Seborg, Edgar and Mellichamp, Process Dynamics & Control, J. Wiley, 2nd Edition, 2004. ISBN: 0-471-00077-9 (cloth). Other Refs: Process Control: Designing Processes and Control Systems for Dynamic Performance, Marlin, T.E., McGraw-Hill, 1995. Process Dynamics, Modeling and Control, Ogunnaike, B. and W. H. Ray, Oxford Press, 1994. Process Modeling, Simulation and Control for Chemical Engineers, 2nd Ed., W.L. Luyben, W.L., McGraw-Hill, 1990. Principles and Practice of Automatic Process Control, Smith, C.A. and A.B. Corripio, J. Wiley & Sons, 1985. Chemical Process Control: An Introduction to Theory and Practice, Stephanopoulos, G., Prentice-Hall, 1984. Grading: 8 HWs + any labs Project & Instr Eval 3 Exams Final Exam = = = = 20 % HWs due at beginning of class period ! 15 Project completion is REQUIRED to pass this course! 40 Friday 16 Apr (Wk 3), 7 May (Wk 6), 28 May (Wk 9) 25 Wed. June 9, 2010, 2 pm-3:50pm, Gleeson 200 100 % Homework is collected at the beginning of the class period and "locked up". One (1) copy of the solution to each HW will be placed in a 3-ring binder in the bookcase of the Gleeson Student Lounge (1st floor "bay" area). Students must NOT remove these keys – they will not be replaced. 2 COURSE LEARNING OBJECTIVES - At completion of this course, the student will have demonstrated the ability to: 1) Translate a flowsheet or written description of a process into a block diagram, to analyze the relationships among a controller gain, valve position and specified value of the variable to be controlled. (ABET Outcome k) 2) Predict the effect of changing one of the three parameters of an industry standard PID controller on closed loop behavior and relate controller aggressiveness to values of those parameters. (ABET Outcome k) 3) Derive the closed-loop transfer function models given the individual transfer function models that are part of a control loop and analyze the stability of the closed loop using the Routh array, direct substitution method and a Root Locus diagram. (ABET Outcome k) 4) Apply, compare and contrast several analytical design methods for specifying the parameters of PID feedback controllers. (ABET Outcome c) 5) Design and tune a single feedback control loop that includes either a feedforward controller or a cascade controller. (ABET Outcome n) 6) Analyze a MIMO (multi-input/multi-output) system using matrix measures of process interactions and design/tune a two-loop feedback control structure which utilizes two PIDs, a cascade controller and a feedforward controller for a 2-input/2-output process with moderate interactions. (ABET Outcomes c,n) 3 NOTES ON COURSE ADMINISTRATION 1. Exams are scheduled as shown in the syllabus and last 110 minutes. During an exam you may use the SEM2 text, class handouts, your HWs and your class notes - but NO OTHER materials (not allowed = copies of library HW “keys”, old exams, etc) ! It is your responsibility to bring a textbook, a calculator, pencils and paper. If you MUST miss one of these exams for an emergency situation, please let me know as soon as possible. If you oversleep or skip an exam you will not have an opportunity to make it up. If you have a valid (according to me) time conflict and you let me know in advance, there is the possibility of taking an exam early. 2. Exams are graded by KLL, homework by the TA. If you have questions on the grading of HW or addition errors to report, try to see the TA first. If you have questions on the grading of exams or find an addition error, please see me (KLL). 3. On homework assignments you may discuss among yourselves the proper method of solution, but you must not simply copy another person's solution. When there are parts of assignments which require use of the computer I expect each student to do their own work, not copying other people's files! Any instances of dishonesty in any academic work for this course will be treated according to OSU Academic Regulations Article 15: Honesty in Academic Work. Link to Statement of Expectations for Student Conduct, i.e., cheating policies http://oregonstate.edu/admin/stucon/achon.htm 4. All work submitted for a graded evaluation must be done neatly. Homework assignments must have the "cover" page with the student's name neatly written on the upper right hand corner. "All written work in this course should follow the conventions of Standard Written English, which include correct spelling, grammar, punctuation, capitalization, paragraph structure and sentence construction." - OSU Teaching with Writing - Vol.8,#2, Winter '99. 5. Class attendance is required of each student: homework assignments and handouts are distributed during class. Copies of most handouts will be available as pdf files on the class website, but if you miss a class YOU are responsible for obtaining notes from other students. 6. The course syllabus is provided as a guide to your reading of the textbook material about subjects discussed in class. You are responsible for at least a preliminary reading of the material prior to the class times listed. You should not expect that all details of the material will be presented with examples during the lecture/recitation periods. For example some points may be made only through homework problems. In that case you are responsible for working out the example and seeing the result of your analysis !! WARNING - students CANNOT adequately learn the principles of this class by simply copying the problem solutions and studying them prior to exams - you must work on the problems yourself to see the principles and relationships involved. 4 7. MATLAB/SIMULINK software. This software is state-of-the-art for process control design and simulation and is used by engineers in many industries to perform process control tasks (from control of refineries by Shell Oil, Houston, Texas, to control of CD optical reader heads by Philips Electronics N.V., Netherlands). This is not the only package available to aid in these tasks, but it is the most widely used one and others are very similar in capabilities and somewhat similar in use (interface). By an agreement with The MathWorks, developers of the software, we are allowed to use it on the OSU campus and our VPN computers, subject to a maximum number of simultaneous users (200 for S10), but not allowed to distribute the software for home use. A student version is available from the bookstore at reasonable ( ~ $100 ) cost. Several good reference books on MATLAB are available at the OSU book store, including the textbook used for CHE\BIOE\ENVE 102 = MATLAB - An Introduction with Applications, 3rd. Ed., by Amos Gilat, John Wiley & Sons, 2008. 8. In a memo dated Dec. 13, 1995 the Office of the Dean of Students recommended the following to be added to each course syllabus and reviewed the first day of classes: "Behaviors which are disruptive to the learning environment will not be tolerated, and will be referred to the Office of the Dean of Students for disciplinary action. Behaviors which create a hostile, offensive or intimidating environment based on gender, race, ethnicity, color, religion, age, disability, marital status or sexual orientation will be referred to the Affirmative Action Office." Web link : http://oregonstate.edu/admin/stucon/index.htm 9. Statement Regarding Students with Disabilities http://oregonstate.edu/ap/curriculum/policies/S_syllabus.html "Accommodations are collaborative efforts between students, faculty and Disability Access Services (DAS). Students with accommodations approved through DAS are responsible for contacting the faculty member in charge of the course prior to or during the first week of the term to discuss accommodations. Students who believe they are eligible for accommodations but who have not yet obtained approval through DAS should contact DAS immediately at 737-4098." 5 “Tentative” Schedule for Weeks 1-2 of CHE461 – S10 Week 1 Date Mon 29 Mar Wed 31 Mar Fri 2 April 2 Mon 5 April Wed 7 April Fri 9 April Topics Review of dynamic models, transfer functions G(s) models, block diagrams, "identification" and interactions Closed-loop control problems - servo and regulatory, PID controllers - time domain concepts PID controllers - Laplace Domain, block diagrams for equipment Laplace Domain analysis of “Smart Operator” Case of PI controller with firstorder process in 3 block diagram: servo Laplace and time domain calculations in servo and regulatory performance – process output and process input calculations Chap 11.1-11.2 Real Loops SEM2 Readings / Assignments CHE 361: Chaps 1-8,13 CHE 361 Outline Review MATLAB/Simulink Fundamental Feedback Control Handouts = 2 of them Chapter 8 SEM2 for PID equations in time HW 1 DUE Chapter 8 SEM2 review Fund. Feedback Handout 2/2 Rules of Thumb Handout Chap 9 for "real" equipment (Ch10 = “later,system design”) Fig. 11.8 6-block diagram 6 Review of Chemical Process Dynamics I. A. B. C. D. E. F. MODELING EQUATIONS - ODEs for Mass and Energy Balances Develop equations: rate of accumulation and other rates Linearization Operating point: steady-state and deviation variables Laplace transforms Concept of a transfer function Solution of ODE models using numerical methods: Euler, Runge-Kutta and integration packages linear vs. non-linear models. The "state-space" formulation for dynamics: state derivatives x = f ( x , u ) nonlinear ≈ A x + B u linear ODEs outputs y = g ( x ) nonlinear ≈ C x + D d linear combination II. A. B. C. D. E. III. A. B. C. D. IV. A. B. C. D. E. PROCESS CHARACTERIZATION Classical first-order systems {Kp, τp, θ} and time behavior Classical second-order systems {Kp, τ, ζ, θ} underdamped, critically damped and overdamped and time behavior - overshoot and period of oscillation for underdamped system Block diagram relationships: Overall transfer function, interacting systems Concepts of poles and zeros in the complex plane, RHP vs LHP, Im and Re axes. slow vs. fast poles, "effective" second or first order systems via dominant dynamics or pole/zero "cancellation" Time delay and the Pade' approximation, lead-lag elements FREQUENCY RESPONSE G(s) to G(jω) short-cut method for Re + (Im) j to calculate amplitude ratio (AR) and phase angle (φ) AR and φ equations for common G(s) systems Asymptotic behavior of AR, φ at low and high frequencies Physical significance of frequency response PROCESS IDENTIFICATION / BEHAVIOR Fit step response data: first-order plus time-delay 1. 63.2 % Δy' method 2. initial nonzero slope = KM / τ 3. ln ( ysteady-state - y ) vs. t plot with slope of -1/τ 4. inflection point or Sundaresan and Krishnaswamy 2pt fit (35.3 and 85.3 % choices) Second-order step response: after effect of time delay is removed Smith's method First over second-order response: nonlinear least-squares fit with step2g.m MATLAB file Pulse testing to obtain Bode plot and identification of G(s) model from Bode plot ODE(s) from poles + zeros + gain or Bode plot ...
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