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CHEP8004 - Automatic Process Control

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Title:Automatic Process Control
Long Title:Automatic Process Control
Module Code:CHEP8004
 
Duration:1 Semester
Credits: 5
NFQ Level:Advanced
Field of Study: Chemical & Process Eng
Valid From: Semester 1 - 2018/19 ( September 2018 )
Module Delivered in 2 programme(s)
Module Coordinator: NIALL MORRIS
Module Author: Roisin Foley
Module Description: Students learn about closed-loop transfer functions, stability, feedback control, feed forward control and advanced singe-loop applications. Students then learn how to analyse and design multiple-input multiple-output control systems and how to apply this knowledge to automatic control systems.
Learning Outcomes
On successful completion of this module the learner will be able to:
LO1 Analyse, interpret and predict the stability of open and closed-loop systems and then characterise the dynamic behaviour of open-loop processes with a view to tuning simple Single-Input Single-Output systems.
LO2 Devise complex Process Control systems to improve the dynamic behaviour of difficult processes.
LO3 Manipulate control system simulation software using a sequence of self-study exercises.
LO4 Analyse Multiple-Input Multiple-Output systems
LO5 Design systems to control process equipment and utility plant.
Pre-requisite learning
Module Recommendations
This is prior learning (or a practical skill) that is strongly recommended before enrolment in this module. You may enrol in this module if you have not acquired the recommended learning but you will have considerable difficulty in passing (i.e. achieving the learning outcomes of) the module. While the prior learning is expressed as named CIT module(s) it also allows for learning (in another module or modules) which is equivalent to the learning specified in the named module(s).
None
Incompatible Modules
These are modules which have learning outcomes that are too similar to the learning outcomes of this module. You may not earn additional credit for the same learning and therefore you may not enrol in this module if you have successfully completed any modules in the incompatible list.
None
Co-requisite Modules
No Co-requisite modules listed
Requirements

This is prior learning (or a practical skill) that is mandatory before enrolment in this module is allowed. You may not enrol on this module if you have not acquired the learning specified in this section.

No requirements listed
 

Module Content & Assessment

Indicative Content
1. Closed-Loop Behaviour:
Transfer functions; Laplace transforms and deviation variables; block diagrams open-loop & closed-loop transfer functions; open-loop & closed-loop steady-state input-output equation; P-I-D controller.
2. Stability and Characteristic Equation:
Poles and zeros; stability criterion; the Characteristic Equation (CE); plotting roots of CE on the complex plane; Right Hand Plane (RHP) zeros - inverse response; dead-time processes; Pade approximation;
3. Process Characterisation & Controller Tuning:
Process characterisation; Ziegler-Nichols closed-loop test method; Tyreus-Luyben empirical correlations; “step test”; Process Reaction Curve (PRC); FOPDT model approximation; minimum error integral criteria;
4. Frequency Response Analysis:
Frequency response concept; Bode stability criterion; Bode diagrams; gain and phase margin; Nyquist stability criterion; “non-minimum phase” concepts.
5. Alternate Feedback Schemes:
Cascade control; override control; selective control; split-range control; inferential control; adaptive control; case studies to include simplified P&IDs.
6. Feedforward-Feedback Control:
Ratio control; feedforward control; the static compensator; the lead-lag unit; the dead time compensator; the summation unit; feedforward-feedback control case studies to include simplified P&IDs.
7. Controller Synthesis
Controller synthesis to produce desired controller response trajectory; IMC based controllers and “physical realisability”; systems that exhibit inverse response; IMC empirical correlations.
8. Multiple-Input Multiple-Output Systems:
Degrees of freedom analysis; concept of interaction; relative-gain; Bristol Relative-Gain Array (RGA); pairing rules to minimise interaction; design of decouplers.
9. Control of Utility Plant:
Steam distribution systems; cooling water systems; pumps; refrigeration systems; case studies and analysis; design and critique of P&IDs; operating strategies.
10. Batch Process Control:
Fermenter and reactor temperature control including utilities; endpoint control of fermenters and batch reactors; control of highly exothermic reactions; wastewater control; downstream processes; case studies - analysis and criticism; design and critique of P&IDs; operating strategies; future trends in process control.
11. Process Analytical Technology:
Benefits of Process Analytical Technology (PAT); overview of on-line measurement techniques used in the process industries - temperature, moisture content, dissolved oxygen, near IR, particle size; applications of PAT to the process industries; case study options for on-line measurement including direct measurement and inferential techniques.
Assessment Breakdown%
Course Work30.00%
End of Module Formal Examination70.00%
Course Work
Assessment Type Assessment Description Outcome addressed % of total Assessment Date
Practical/Skills Evaluation Lab based examination - devise and simulate a control system. 1,2,3,4 15.0 Every Second Week
Short Answer Questions Class examination based on lecture material. 1,2 15.0 Week 8
End of Module Formal Examination
Assessment Type Assessment Description Outcome addressed % of total Assessment Date
Formal Exam End-of-Semester Final Examination 1,2,3,4,5 70.0 End-of-Semester
Reassessment Requirement
Repeat examination
Reassessment of this module will consist of a repeat examination. It is possible that there will also be a requirement to be reassessed in a coursework element.

The institute reserves the right to alter the nature and timings of assessment

 

Module Workload

Workload: Full Time
Workload Type Workload Description Hours Frequency Average Weekly Learner Workload
Lecture Lectures/discussions/ case studies/class problem solving/ class software exercises. 3.0 Every Week 3.00
Lab Control simulation laboratory 2.0 Every Second Week 1.00
Independent & Directed Learning (Non-contact) Study/solving tutorial sheets/ solving past-paper problems 3.0 Every Week 3.00
Total Hours 8.00
Total Weekly Learner Workload 7.00
Total Weekly Contact Hours 4.00
This module has no Part Time workload.
 

Module Resources

Recommended Book Resources
  • Smith, C.A., Corripio, A.B. 2015, Principles and Practice of Automatic Process Control, 3rd Edn Ed., Wiley New York [ISBN: 9788126557417]
  • Dale Seborg, Thomas F Edgar & Duncan Mellichamp 2011, Process Dynamics & Control, 3rd Ed., Wiley [ISBN: 8126508345]
Supplementary Book Resources
  • William L. Luyben 2013, Distillation Design and Control Using Aspen Simulation, 2nd Edition, 2nd Ed., Wiley [ISBN: 9781118411438]
  • Myke King, 2016, Process Control, Wiley [ISBN: 978-0-470-97587-9]
  • Shinskey, F.G. 1996, Process Control Systems; Application, Design and Tuning, 4th Edn Ed., McGraw-Hill New York
This module does not have any article/paper resources
Other Resources
 

Module Delivered in

Programme Code Programme Semester Delivery
CR_ECPEN_8 Bachelor of Engineering (Honours) in Chemical and Biopharmaceutical Engineering 8 Mandatory
CR_EMENG_9 Master of Engineering in Mechanical Engineering 2 Group Elective 1

Cork Institute of Technology
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