Principles and Practices of Automatic Process Control,9780471431909

Principles and Practices of Automatic Process Control

by ;
Edition: 3rd
ISBN13: 9780471431909
ISBN10: 0471431907
Format: Hardcover
Pub. Date: 2005-08-05
Publisher(s): WILEY
List Price: $369.36

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Summary

A practical guide for understanding and implementing industrial control strategies. Highly practical and applied, this Third Edition of Smith and Corripio's Principles and Practice of Automatic Process Control continues to present all the necessary theory for the successful practice of automatic process control. The authors discuss both introductory and advanced control strategies, and show how to apply those strategies in industrial examples drawn from their own professional practice. Now revised, this Third Edition features: * Expanded coverage of the development of dynamic balances (Chapter 3) * A new chapter on modeling and simulation (Chapter 13) * More extensive discussion of distributive control systems * New tuning exercises (Appendix D) * Guidelines for plant-wide control and two new design case studies (Appendix B) * New operating case studies (Appendix E) * Book Website containing simulations to practice the tuning of feedback controllers, cascade controllers, and feedforward controllers, and the MATLAB(r) files for simulation examples and problem With this text, you can: * Learn the mathematical tools used in the analysis and design of process control systems. * Gain a complete understanding of the steady state behavior of processes. * Develop dynamic mathematical process models that will help you in the analysis, design, and operation of control systems. * Understand how the basic components of control systems work. * Design and tune feedback controllers. * Apply a variety of techniques that enhance feedback control, including cascade control, ratio control, override control, selective control, feedforward control, multivariable control, and loop interaction. * Master the fundamentals of dynamic simulation of process control systems using MATLAB.

Author Biography

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).

Table of Contents

Introduction
1(10)
A Process Control System
1(2)
Important Terms and Objective of Automatic Process Control
3(1)
Regulatory and Servo Control
4(1)
Transmission Signals, Control Systems, and Other Terms
5(1)
Control Strategies
6(3)
Feedback Control
6(1)
Feedforward Control
7(2)
Background Needed for Process Control
9(1)
Summary
9(2)
Problems
10(1)
Mathematical Tools for Control Systems Analysis
11(50)
The Laplace Transform
11(8)
Definition of the Laplace Transform
11(3)
Properties of the Laplace Transform
14(5)
Solution of Differential Equations Using the Laplace Transform
19(7)
Laplace Transform Solution Procedure
19(1)
Inversion by Partial Fractions Expansion
20(4)
Handling Time Delays
24(2)
Characterization of Process Response
26(7)
Deviation Variables
26(1)
Output Response
27(6)
Stability
33(1)
Response of First-Order Systems
33(8)
Step Response
35(1)
Ramp Response
36(1)
Sinusoidal Response
36(2)
Response with Time Delay
38(1)
Response of a Lead-Lag Unit
39(2)
Response of Second-Order Systems
41(9)
Overdamped Responses
42(3)
Underdamped Responses
45(4)
Higher-Order Responses
49(1)
Linearization
50(7)
Linearization of Functions of One Variable
51(2)
Linearization of Functions of Two or More Variables
53(1)
Linearization of Differential Equations
54(3)
Summary
57(4)
Problems
57(4)
First-Order Dynamic Systems
61(46)
Processes and Importance of Process Characteristics
61(2)
Mathematical Process Modeling
63(4)
Thermal Process Example
67(8)
Dead Time
75(2)
Transfer Functions and Block Diagrams
77(8)
Transfer Functions
77(2)
Block Diagrams
79(6)
Gas Process Example
85(5)
Chemical Reactors
90(4)
Introductory Remarks
90(1)
Chemical Reactor Example
91(3)
Effects of Process Nonlinearities
94(2)
Additional Comments
96(2)
Summary
98(9)
Problems
99(8)
Higher-Order Dynamic Systems
107(47)
Noninteracting Systems
107(8)
Noninteracting Level Process
107(6)
Thermal Tanks in Series
113(2)
Interacting Systems
115(18)
Interacting Level Process
115(5)
Thermal Tanks with Recycle
120(2)
Nonisothermal Chemical Reaction
122(11)
Response of Higher-Order Systems
133(2)
Other Types of Process Responses
135(12)
Integrating Processes: Level Process
135(4)
Open-Loop Unstable Process: Chemical Reactor
139(6)
Inverse Response Processes: Chemical Reactor
145(2)
Summary
147(1)
Overview of Chapters 3 and 4
147(7)
Problems
148(6)
Basic Components of Control Systems
154(42)
Sensors and Transmitters
154(2)
Control Valves
156(17)
The Control Valve Actuator
157(2)
Control Valve Capacity and Sizing
159(5)
Control Valve Characteristics
164(6)
Control Valve Gain and Transfer Function
170(3)
Control Valve Summary
173(1)
Feedback Controllers
173(18)
Actions of Controllers
174(1)
Types of Feedback Controllers
175(11)
Modifications to the PID Controller and Additional Comments
186(3)
Reset Windup and Its Prevention
189(2)
Feedback Controller Summary
191(1)
Summary
191(5)
Problems
192(4)
Design of Single-Loop Process Control Systems
196(33)
The Feedback Control Loop
196(16)
Closed-Loop Transfer Function
199(5)
Characteristic Equation of the Loop
204(5)
Steady-State Closed-Loop Response
209(3)
Stability of the Control Loop
212(8)
Criterion of Stability
213(1)
Direct Substitution Method
214(3)
Effect of Loop Parameters on the Ultimate Gain and Period
217(1)
Effect of Dead Time
218(2)
Summary
220(1)
Summary
220(9)
Problems
220(9)
Tuning of Feedback Controllers
229(50)
Quarter Decay Ratio Response by Ultimate Gain
230(4)
Open-Loop Process Characterization
234(17)
Process Step Testing
236(6)
Tuning for Quarter Decay Ratio Response
242(3)
Tuning for Minimum Error Integral Criteria
245(5)
Tuning Sampled-Data Controllers
250(1)
Summary of Controller Tuning
251(1)
Tuning Controllers for Integrating Processes
251(7)
Model of Liquid Level Control System
252(2)
Proportional Level Controller
254(2)
Averaging Level Control
256(2)
Summary of Tuning for Integrating Processes
258(1)
Synthesis of Feedback Controllers
258(9)
Development of the Controller Synthesis Formula
258(1)
Specification of the Closed-Loop Response
259(1)
Controller Modes and Tuning Parameters
260(3)
Summary of Controller Synthesis Results
263(2)
Tuning Rules by Internal Model Control (IMC)
265(2)
Tips for Feedback Controller Tuning
267(3)
Estimating the Reset and Rate Times
268(2)
Adjusting the Proportional Gain
270(1)
Summary
270(9)
Problems
271(8)
Root Locus and Frequency Response Techniques
279(31)
Some Definitions
279(1)
Analysis of Feedback Control Systems by Root Locus
280(3)
Plotting Root Locus Diagrams
283(1)
Analysis of Control Systems by Frequency Response
284(22)
Bode Plots
291(7)
Frequency Response Stability Criterion
298(8)
Summary
306(4)
Problems
307(3)
Cascade Control
310(16)
A Process Example
310(3)
Stability Considerations
313(2)
Implementation and Tuning of Controllers
315(3)
Two-Level Cascade Systems
315(2)
Three-Level Cascade Systems
317(1)
Other Process Examples
318(2)
Final Comments
320(2)
Summary
322(4)
Problems
322(4)
Ratio, Override, and Selective Control
326(47)
Signals, Software, and Computing Algorithms
326(7)
Signals
326(1)
Programming
327(4)
Scaling Computing Algorithms
331(2)
Ratio Control
333(7)
Override, or Constraint, Control
340(4)
Selective Control
344(2)
Designing Control Systems
346(14)
Summary
360(13)
Problems
361(12)
Feedforward Control
373(36)
The Feedforward Concept
373(2)
Block Diagram Design of Linear Feedforward Controllers
375(8)
Lead-Lag Element
383(2)
Back to the Previous Example
385(4)
Design of Nonlinear Feedforward Controllers from Basic Process Principles
389(4)
Some Closing Comments and Outline of Feedforward Controller Design
393(3)
Three Other Examples
396(6)
Summary
402(7)
Problems
403(6)
Multivariable Process Control
409(43)
Loop Interaction
409(4)
Pairing Controlled and Manipulated Variables
413(11)
Calculating the Relative Gains for a 2 x 2 System
417(5)
Calculating the Relative Gains for an n x n System
422(2)
Decoupling of Interacting Loops
424(12)
Decoupler Design from Block Diagrams
425(7)
Decoupler Design for n x n Systems
432(2)
Decoupler Design from Basic Principles
434(2)
Multivariable Control versus Optimization
436(1)
Dynamic Analysis of Multivariable Systems
437(5)
Dynamic Analysis of a 2 x 2 System
437(4)
Controller Tuning for Interacting Systems
441(1)
Design of Plantwide Control Systems
442(6)
Summary
448(4)
Problems
449(3)
Dynamic Simulation of Control Systems
452(39)
Uses and Tools of Dynamic Simulation
452(3)
Uses of Dynamic Simulation
453(1)
Tools for Dynamic Simulation
453(2)
Simulation of Linear Transfer Functions
455(2)
Process Simulation
457(7)
Simulation of Control Instrumentation
464(14)
Control Valve Simulation
465(2)
Simulation of Feedback Controllers
467(4)
Simulation of Sensors-Transmitters
471(1)
Simulation of Lead-Lag Dynamic Compensation
472(6)
Other Simulation Aspects
478(7)
Summary
485(6)
Problems
485(6)
A. Instrumentation Symbols and Labels
491(7)
B. Design Case Studies
498(16)
Case 1. Methanol Synthesis Process
503(2)
Case 2. Hydrocarbon Process
505(1)
Case 3. Fatty Acid Process
506(2)
Case 4. Control Systems in the Sugar-Refining Process
508(1)
Case 5. Sulfuric Acid Process
509(2)
Case 6. Ammonium Nitrate Prilling Plant Control System
511(1)
Case 7. Natural Gas Dehydration Control System
512(2)
C. Sensors, Transmitters, and Control Valves
514(24)
Pressure Sensors
514(1)
Flow Sensors
514(5)
Level Sensors
519(1)
Temperature Sensors
520(3)
Composition Sensors
523(1)
Transmitters
523(2)
Pneumatic Transmitters
523(1)
Electronic Transmitters
524(1)
Types of Control Valves
525(4)
Reciprocating Stem
525(4)
Rotating Stem
529(1)
Control Valve Actuators
529(1)
Pneumatically Operated Diaphragm Actuators
529(1)
Piston Actuators
529(1)
Electrohydraulic and Electromechanical Actuators
529(1)
Manual-Handwheel Actuators
530(1)
Control Valve Accessories
530(2)
Positioners
530(2)
Boosters
532(1)
Limit Switches
532(1)
Control Valves---Additional Considerations
532(4)
Viscosity Corrections
532(1)
Flashing and Cavitation
533(3)
Summary
536(2)
D. Tuning Case Studies
538(10)
Process 1. Regenerator Feedback
538(2)
Process 2. Regenerator Cascade
540(1)
Process 3. Paper-Drying Process
541(2)
Process 4. HCI Scrubber
543(1)
Process 5. Mixing Process
544(3)
Process 6. Reactor Process
547(1)
Process 7. Distillation Process
547(1)
E. Operating Case Studies
548(11)
Operating Case Study 1: HCI Scrubber
548(2)
Operating Case Study 2: Water Treatment unit
550(3)
Operating Case Study 3: Catalyst Regenerator
553(2)
Operating Case Study 4: Baby Back Ribs
555(1)
Operating Case Study 5: Paper Drying Unit
556(3)
Index 559

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