Automated Continuous Process Control

CARLOS A. SMITH is Professor of Chemical Engineering and Associate Dean of Academics in the College of Engineering, University of South Florida, Tampa. He not only teaches students but also teaches numerous short courses on process control to professionals. He is the coauthor of the bestselling textbook Principles of Automatic Process Control (Wiley).

• Preface xi1 Introduction 11-1 Process Control System 11-2 Important Terms and Objective of Automatic Process Control 31-3 Regulatory and Servo Control 41-4 Transmission Signals, Control Systems, and Other Terms 51-5 Control Strategies 61-5.1 Feedback Control 61-5.2 Feedforward Control 81-6 Summary 92 Process Characteristics 112-1 Process and Importance of Process Characteristics 112-2 Types of Processes 132-3 Self-Regulating Processes 142-3.1 Single-Capacitance Processes 142-3.2 Multicapacitance Processes 242-4 Transmitters and Other Accessories 282-5 Obtaining Process Characteristics from Process Data 292-6 Questions When Performing Process Testing 322-7 Summary 33Reference 33Problems 343 Feedback Controllers 383-1 Action of Controllers 383-2 Types of Feedback Controllers 403-2.1 Proportional Controller 403-2.2 Proportional–Integral Controller 443-2.3 Proportional–Integral–Derivative Controller 483-2.4 Proportional–Derivative Controller 503-3 Reset Windup 503-4 Tuning Feedback Controllers 533-4.1 Online Tuning: Ziegler–Nichols Technique 533-4.2 Offline Tuning 543-5 Summary 60References 60Problems 604 Cascade Control 614-1 Process Example 614-2 Implementation and Tuning of Controllers 654-2.1 Two-Level Cascade Systems 654-2.2 Three-Level Cascade Systems 684-3 Other Process Examples 694-4 Closing Comments 724-5 Summary 73References 735 Ratio, Override, and Selective Control 745-1 Signals and Computing Algorithms 745-1.1 Signals 745-1.2 Programming 755-1.3 Scaling Computing Algorithms 765-1.4 Significance of Signals 795-2 Ratio Control 805-3 Override, or Constraint, Control 885-4 Selective Control 925-5 Designing Control Systems 955-6 Summary 110References 111Problems 1126 Block Diagrams and Stability 1276-1 Block Diagrams 1276-2 Control Loop Stability 1326-2.1 Effect of Gains 1376-2.2 Effect of Time Constants 1386-2.3 Effect of Dead Time 1386-2.4 Effect of Integral Action in the Controller 1396-2.5 Effect of Derivative Action in the Controller 1406-3 Summary 141Reference 1417 Feedforward Control 1427-1 Feedforward Concept 1427-2 Block Diagram Design of Linear Feedforward Controllers 1457-3 Lead/Lag Term 1557-4 Extension of Linear Feedforward Controller Design 1567-5 Design of Nonlinear Feedforward Controllers from Basic Process Principles 1617-6 Closing Comments on Feedforward Controller Design 1657-7 Additional Design Examples 1677-8 Summary 172References 173Problem 1738 Dead-time Compensation 1748-1 Smith Predictor Dead-Time Compensation Technique 1748-2 Dahlin Controller 1768-3 Summary 179References 1799 Multivariable Process Control 1809-1 Pairing Controlled and Manipulated Variables 1819-1.1 Obtaining Process Gains and Relative Gains 1869-1.2 Positive and Negative Interactions 1899-2 Interaction and Stability 1919-3 Tuning Feedback Controllers for Interacting Systems 1929-4 Decoupling 1949-4.1 Decoupler Design from Block Diagrams 1949-4.2 Decoupler Design from Basic Principles 1969-5 Summary 197References 197Problem 198Appendix A Case Studies 199Case 1: Ammonium Nitrate Prilling Plant Control System 199Case 2: Natural Gas Dehydration Control System 200Case 3: Sodium Hypochlorite Bleach Preparation Control System 201Case 4: Control System in the Sugar Refining Process 202Case 5: Sulfuric Acid Process 204Case 6: Fatty Acid Process 205Reference 207Appendix B Processes For Design Practice 208Installing the Programs 208Process 1: NH 3 Scrubber 208Process 2: Catalyst Regenerator 211Process 3: Mixing Process 213Index 215

"...explains the practical design and operation of process control systems..." (SciTech Book News, Vol. 26, No. 2, June 2002) “…a book worth adding to any process control library shelf…” (Measurement & Control, April 2003)