Process Control: Modeling, Design, and Simulation, 2nd Edition

Process Control: Modeling, Design, and Simulation, 2nd Edition

by B. Wayne Bequette
Released August 2023
Publisher(s): Pearson
ISBN: 9780134033846

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Book description

Master Process Control Hands On, through Updated Practical Examples and MATLAB® Simulations

Process Control: Modeling, Design, and Simulation, Second Edition, is a complete introduction to process control and has been fully updated, integrating current software tools to enable professionals and students to master critical techniques hands on through simulations based on modern versions of MATLAB. This revised edition teaches the field's most important techniques, behaviors, and control problems with even more practical examples and exercises. Wide-ranging enhancements include safety considerations, an expanded discussion of digital control, additional process examples, and updates throughout for newer versions of MATLAB and SIMULINK.

  • Fundamentals of process control and instrumentation, including objectives, variables, block diagrams, and process flowsheets

  • Methodologies for developing dynamic models of chemical processes, including compartmental models

  • Dynamic behavior of linear systems: state-space models, transfer function-based models (including conversion to state space), and more

  • Empirical and discrete-time models, including relationships among types of discrete models

  • Feedback control; proportional, integral, and derivative (PID) controllers; and closed-loop stability analysis

  • Frequency response analysis techniques for evaluating the robustness of control systems

  • Improving control loop performance: internal model control (IMC), automatic tuning, gain scheduling, and enhanced disturbance rejection

  • Split-range, selective, and override strategies for switching among inputs or outputs

  • Control loop interactions and multivariable controllers

  • An introduction to model predictive control (MPC), with a new discrete state-space model derivation exercise

Bequette walks step by step through developing control instrumentation diagrams for an entire chemical process, reviewing common control strategies for individual unit operations, then discussing strategies for integrated systems. This edition also includes 16 learning modules demonstrating how to use MATLAB and SIMULINK to solve many key control problems, including new modules on process monitoring and safety, as well as a detailed new study of artificial pancreas systems for Type 1 diabetes.

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Table of contents

  1. Cover Page
  2. About This eBook
  3. Halftitle Page
  4. Title Page
  5. Copyright Page
  6. Pearson’s Commitment to Diversity, Equity, and Inclusion
  7. Dedication Page
  8. Contents
  9. Preface to the Second Edition
  10. About the Author
  11. Chapter 1. Introduction
    1. 1.1 Introduction
    2. 1.2 Instrumentation
    3. 1.3 Process Models and Dynamic Behavior
    4. 1.4 Redundancy and Operability
    5. 1.5 Industrial IoT and Smart Manufacturing
    6. 1.6 Control Textbooks
    7. 1.7 A Look Ahead
    8. 1.8 Summary
    9. References
    10. Student Exercises
  12. Chapter 2. Fundamental Models
    1. 2.1 Background
    2. 2.2 Balance Equations
    3. 2.3 Material Balances
    4. 2.4 Constitutive Relationships
    5. 2.5 Material and Energy Balances
    6. 2.6 Form of Dynamic Models
    7. 2.7 Linear Models and Deviation Variables
    8. 2.8 Summary
    9. Suggested Reading
    10. Student Exercises
  13. Chapter 3. Dynamic Behavior
    1. 3.1 Background
    2. 3.2 Linear State-Space Models
    3. 3.3 Laplace Transforms
    4. 3.4 Transfer Functions
    5. 3.5 First-Order Behavior
    6. 3.6 Integrating Behavior
    7. 3.7 Second-Order Behavior
    8. 3.8 Summary
    9. References
    10. Student Exercises
  14. Chapter 4. Dynamic Behavior: Complex Systems
    1. 4.1 Introduction
    2. 4.2 Poles and Zeros
    3. 4.3 Lead-Lag Behavior
    4. 4.4 Processes with Deadtime
    5. 4.5 Padé Approximation for Deadtime
    6. 4.6 Converting State-Space Models to Transfer Functions
    7. 4.7 Converting Transfer Functions to State-Space Models
    8. 4.8 Matlab and Simulink
    9. 4.9 Summary
    10. Student Exercises
  15. Chapter 5. Empirical and Discrete-Time Models
    1. 5.1 Introduction
    2. 5.2 First-Order + Deadtime
    3. 5.3 Integrator + Deadtime
    4. 5.4 Other Continuous Models
    5. 5.5 Discrete-Time Autoregressive Models
    6. 5.6 Parameter Estimation
    7. 5.7 Discrete Step and Impulse Response Models
    8. 5.8 Converting Continuous Models to Discrete
    9. 5.9 Digital Filtering
    10. 5.10 Summary
    11. References
    12. Student Exercises
    13. Appendix 5.1: Discretization
  16. Chapter 6. Introduction to Feedback Control
    1. 6.1 Motivation
    2. 6.2 Control Block Diagrams
    3. 6.3 Closed-Loop Analysis
    4. 6.4 PID Controller Algorithms
    5. 6.5 Routh Stability Criterion
    6. 6.6 Effect of Tuning Parameters
    7. 6.7 Open-Loop Unstable Systems
    8. 6.8 Simulink Block Diagrams
    9. 6.9 ODEs to Solve PID Problems
    10. 6.10 Summary
    11. References
    12. Student Exercises
  17. Chapter 7. Model-Based Control
    1. 7.1 Introduction
    2. 7.2 Direct Synthesis
    3. 7.3 Internal Model Control
    4. 7.4 IMC-Based PID
    5. 7.5 IMC-Based PID for Time-Delay Processes
    6. 7.6 IMC-Based PID for Unstable Processes
    7. 7.7 Summary
    8. References
    9. Student Exercises
    10. Appendix 7.1: SIMC-Based PID Design
  18. Chapter 8. PID Controller Tuning
    1. 8.1 Introduction
    2. 8.2 Closed-Loop Oscillation-Based Tuning
    3. 8.3 Tuning Rules for First-Order + Deadtime Processes
    4. 8.4 Digital Control
    5. 8.5 Stability of Digital Control Systems
    6. 8.6 Performance of Digital Control Systems
    7. 8.7 Summary
    8. References
    9. Student Exercises
  19. Chapter 9. Frequency-Response Analysis
    1. 9.1 Motivation
    2. 9.2 Bode and Nyquist Plots
    3. 9.3 Effect of Process Parameters on Bode and Nyquist Plots
    4. 9.4 Closed-Loop Stability
    5. 9.5 Bode and Nyquist Stability
    6. 9.6 Robustness
    7. 9.7 Matlab Control Toolbox: Bode and Nyquist Functions
    8. 9.8 Summary
    9. Reference
    10. Student Exercises
  20. Chapter 10. Cascade and Feedforward Control
    1. 10.1 Background
    2. 10.2 Introduction to Cascade Control
    3. 10.3 Cascade-Control Analysis
    4. 10.4 Cascade-Control Design
    5. 10.5 Feedforward Control
    6. 10.6 Feedforward Controller Design
    7. 10.7 Summary of Feedforward Control
    8. 10.8 Combined Feedforward and Cascade
    9. 10.9 Summary
    10. References
    11. Student Exercises
  21. Chapter 11. PID Enhancements
    1. 11.1 Background
    2. 11.2 Antireset Windup
    3. 11.3 Autotuning Techniques
    4. 11.4 Nonlinear PID Control
    5. 11.5 Controller Parameter (Gain) Scheduling
    6. 11.6 Measurement/Actuator Selection
    7. 11.7 Implementing PID Enhancements in Simulink
    8. 11.8 Summary
    9. References
    10. Student Exercises
  22. Chapter 12. Ratio, Selective, and Split-Range Control
    1. 12.1 Motivation
    2. 12.2 Ratio Control
    3. 12.3 Selective and Override Control
    4. 12.4 Split-Range Control
    5. 12.5 Simulink Functions
    6. 12.6 Summary
    7. References
    8. Student Exercises
  23. Chapter 13. Control-Loop Interaction
    1. 13.1 Introduction
    2. 13.2 Motivation
    3. 13.3 The General Pairing Problem
    4. 13.4 The Relative Gain Array
    5. 13.5 Properties and Application of the RGA
    6. 13.6 Return to the Motivating Example
    7. 13.7 RGA and Sensitivity
    8. 13.8 Using the RGA to Determine Variable Pairings
    9. 13.9 Matlab RGA Function File
    10. 13.10 Summary
    11. References
    12. Student Exercises
    13. Appendix 13.1: Derivation of the Relative Gain for an n-Input–n-Output System
    14. Appendix 13.2: m-File to Calculate the RGA
  24. Chapter 14. Multivariable Control
    1. 14.1 Background
    2. 14.2 Zeros and Performance Limitations
    3. 14.3 Scaling Considerations
    4. 14.4 Directional Sensitivity and Operability
    5. 14.5 Block-Diagram Analysis
    6. 14.6 Decoupling
    7. 14.7 Matlab tzero, svd
    8. 14.8 Summary
    9. References
    10. Student Exercises
    11. Appendix 14.1
  25. Chapter 15. Plantwide Control
    1. 15.1 Background
    2. 15.2 Steady-State and Dynamic Effects of Recycle
    3. 15.3 Unit Operations Not Previously Covered
    4. 15.4 The Control and Optimization Hierarchy
    5. 15.5 Further Plantwide Control Examples
    6. 15.6 Simulations
    7. 15.7 Startup, Safety, and the Human-in-the-Loop
    8. 15.8 Summary
    9. References
    10. Student Exercises
    11. Appendix 15.1
  26. Chapter 16. Model Predictive Control
    1. 16.1 Motivation
    2. 16.2 Optimization Problem
    3. 16.3 Dynamic Matrix Control
    4. 16.4 Constraints and Multivariable Systems
    5. 16.5 Other MPC Methods
    6. 16.6 Matlab
    7. 16.7 Summary
    8. References and Relevant Literature
    9. Student Exercises
    10. Appendix 16.1: Derivation of the Step Response Formulation
    11. Appendix 16.2: Derivation of the Least-Squares Solution for Control Moves
    12. Appendix 16.3: State Space Formulation for MPC
  27. Chapter 17. Summary
    1. 17.1 Overview of Topics Covered in This Textbook
    2. 17.2 Process Engineering in Practice
    3. 17.3 Suggested Further Reading
    4. Student Exercises
  28. Module 1. Introduction to Matlab
    1. M1.1 Background
    2. M1.2 Matrix Operations
    3. M1.3 The Matlab Workspace
    4. M1.4 Complex Variables
    5. M1.5 Plotting
    6. M1.6 More Matrix Stuff
    7. M1.7 for Loops
    8. M1.8 m-Files
    9. M1.9 Summary of Commonly Used Commands
    10. M1.10 Frequently Used Matlab Functions
    11. Additional Exercises
  29. Module 2. Introduction to Simulink
    1. M2.1 Background
    2. M2.2 Open-Loop Simulations
    3. M2.3 Feedback-Control Simulations
    4. M2.4 Summary
    5. Additional Exercises
  30. Module 3. Ordinary Differential Equations
    1. M3.1 Matlab ode—Basic
    2. M3.2 Matlab ode—Options
    3. M3.3 Simulink sfun
    4. M3.4 Summary
    5. Additional Exercises
  31. Module 4. Matlab LTI Models
    1. M4.1 Forming Continuous-Time Models
    2. M4.2 Forming Discrete-Time Models
    3. M4.3 Converting Continuous Models to Discrete
    4. M4.4 Converting Discrete Models to Continuous
    5. M4.5 Step and Impulse Responses
    6. M4.6 Summary
    7. Additional Exercises
  32. Module 5. Isothermal Chemical Reactor
    1. M5.1 Background
    2. M5.2 Model
    3. M5.3 Steady-State and Dynamic Behavior
    4. M5.4 Closed-Loop Control
    5. Reference
    6. Additional Exercises
  33. Module 6. Biochemical Reactors
    1. M6.1 Background
    2. M6.2 Steady-State and Dynamic Behavior
    3. M6.3 Stable Steady-State Operating Point
    4. M6.4 Unstable Steady-State Operating Point
    5. M6.5 Simulink Model File
    6. Reference
    7. Additional Exercises
  34. Module 7. CSTR
    1. M7.1 Background
    2. M7.2 Simplified Modeling Equations
    3. M7.3 Example Chemical Process—Propylene Glycol Production
    4. M7.4 Effect of Reactor Scale
    5. M7.5 For Further Study: Detailed Model
    6. M7.6 Other Considerations
    7. M7.7 Summary
    8. References
    9. Additional Exercises
    10. Appendix M7.1
  35. Module 8. Steam Drum Level
    1. M8.1 Background
    2. M8.2 Process Model
    3. M8.3 Feedback Controller Design
    4. M8.4 Feedforward Controller Design
    5. M8.5 Three-Mode Level Control
    6. Appendix M8.1: Simulink Diagram for Feedforward/Feedback Control of Steam Drum Level
    7. Appendix M8.2: Simulink Diagram for Three-Mode Control of Steam Drum Level
  36. Module 9. Surge Vessel Level Control
    1. M9.1 Background
    2. M9.2 Process Model
    3. M9.3 Controller Design
    4. M9.4 Numerical Example
    5. M9.5 Summary
    6. Reference
    7. Additional Exercises
    8. Appendix M9.1: The Simulink Block Diagram
  37. Module 10. Batch Reactor
    1. M10.1 Background
    2. M10.2 Batch Model 1: Jacket Temperature Manipulated
    3. M10.3 Batch Model 2: Jacket Inlet Temperature Manipulated
    4. M10.4 Batch Model 3: Cascade Control
    5. M10.5 Summary
    6. Reference
    7. Additional Exercises
  38. Module 11. Biomedical Systems
    1. M11.1 Overview
    2. M11.2 Pharmacokinetic Models
    3. M11.3 Intravenous Delivery of Anesthetic Drugs
    4. M11.4 Blood Glucose Control in ICU Patients
    5. M11.5 Critical Care Patients
    6. M11.6 Summary
    7. References
    8. Additional Exercises
  39. Module 12. Automated Insulin Delivery
    1. M12.1 Background: Physiology of Blood Glucose Regulation
    2. M12.2 Type 1 Diabetes
    3. M12.3 Closed-Loop Components and Diagram
    4. M12.4 Simulation Model
    5. M12.5 Open-Loop Responses to Meal and Insulin
    6. M12.6 Closed-Loop Responses
    7. M12.7 Summary
    8. References
    9. Suggested Further Study
    10. Additional Exercises
  40. Module 13. Distillation Control
    1. M13.1 Description of Distillation Control
    2. M13.2 Open-Loop Behavior
    3. M13.3 SISO Control
    4. M13.4 RGA Analysis
    5. M13.5 Multiple SISO Controllers
    6. M13.6 Singular Value Analysis
    7. M13.7 Nonlinear Effects
    8. M13.8 Other Issues in Distillation Column Control
    9. M13.9 Summary
    10. References
    11. Additional Exercises
  41. Module 14. Case Study Problems
    1. M14.1 Background
    2. M14.2 Reactive Ion Etcher
    3. M14.3 Rotary Lime Kiln Temperature Control
    4. M14.4 Fluidized Catalytic Cracking Unit
    5. M14.5 Anaerobic Sludge Digester
    6. M14.6 Suggested Case Study Schedule
    7. M14.7 Summary
    8. Additional Exercises
  42. Module 15. Process Monitoring
    1. M15.1 Concise Review of Probability
    2. M15.2 Statistical Process Control
    3. M15.3 Characteristic Process Noise
    4. M15.4 Filtering and Smoothing
    5. M15.5 Data Reconciliation
    6. M15.6 Gross Error Detection
    7. M15.7 Summary
    8. References
    9. Additional Exercises
    10. Appendix M15.1
  43. Module 16. Safety
    1. M16.1 Overview
    2. M16.2 Chemical Process Disasters
    3. M16.3 Aircraft Disasters
    4. M16.4 Fault Detection Algorithms and Safety Science
    5. M16.5 Summary
    6. References
    7. Additional Exercises
  44. Index
  45. Code Snippets

Product information

  • Title: Process Control: Modeling, Design, and Simulation, 2nd Edition
  • Author(s): B. Wayne Bequette
  • Release date: August 2023
  • Publisher(s): Pearson
  • ISBN: 9780134033846