Written by an experienced practitioner, this book offers a back-to-basics approach designed specifically for the process industry. The title presents techniques that have an immediate practical application, and in addition to the design methods, it describes any shortcuts that can be taken and explains how to avoid common pitfalls.
Split into two parts, the first covers generic process control techniques, assuming education in mathematics to high school level. The second part of this title is process-specific and requires degree-level knowledge or the equivalent learnt through experience working with the technologies.

This book is progressive and is an introductory, advanced and specialist source of information.

Key features:

•Meets the needs of the process industry, and closes the gap between theory and practice
•Back-to-basics approach, with only the essential mathematics, and a focus on techniques that have an immediate practical application
•Written by an experienced practitioner, highly regarded by major corporations, with over 25 years experience in teaching industry courses

Preface.
About the Author.

1. Introduction.

2. Process Dynamics.

2.1 Definition.

2.2 Cascade Control.

2.3 Model Identification.

2.4 Integrating Processes.

2.5 Other Types of Process.

2.6 Robustness.

2.7 Laplace Transforms for Processes.

References.

3. PID Algorithm.

3.1 Definitions.

3.2 Proportional Action.

3.3 Integral Action.

3.4 Derivative Action.

3.5 Versions of Control Algorithm.

3.6 Interactive PID Controller.

3.7 Proportional-on-PV Controller.

3.8 Nonstandard Algorithms.

3.9 Tuning.

3.10 Ziegler-Nichols Tuning Method.

3.11 Cohen-Coon Tuning Method.

3.12 Tuning Based on Penalty Functions.

3.13 Manipulated Variable Overshoot.

3.14 Lambda Tuning Method.

3.15 IMC Tuning Method.

3.16 Choice of Tuning Method.

3.17 Suggested Tuning Method for Self-Regulating Processes.

3.18 Tuning for Load Changes.

3.19 Tuning for Unconstrained MV Overshoot.

3.20 PI Tuning Compared to PID Tuning.

3.21 Tuning for Large Scan Interval.

3.22 Suggested Tuning Method for Integrating Processes.

3.23 Implementation of Tuning.

3.24 Loop Gain.

3.25 Adaptive Tuning.

3.26 Initialisation.

3.27 Anti-Reset Windup.

3.28 On-Off Control.

3.29 Laplace Transforms for Controllers.

3.30 Direct Synthesis.

References.

4. Level Control.

4.1 Use of Cascade Control.

4.2 Parameters Required for Tuning Calculations.

4.3 Tight Level Control.

4.4 Averaging Level Control.

4.5 Error-Squared Controller.

4.6 Gap Controller.

4.7 Impact of Noise on Averaging Control.

4.8 General Approach to Tuning.

4.9 Three-Element Level Control.

5. Signal Conditioning.

5.1 Instrument Linearisation.

5.2 Process Linearisation.

5.3 Constraint Conditioning.

5.4 Pressure Compensation of Distillation Tray Temperature.

5.5 Pressure Compensation of Gas Flow Measurement.

5.6 Filtering.

5.7 Exponential Filter.

5.8 Higher Order Filters.

5.9 Nonlinear Exponential Filter.

5.10 Averaging Filter.

5.11 Least Squares Filter.

5.12 Control Valve Characterisation.

5.13 Equal Percentage Valve.

5.14 Split-Range Valves.

6. Feedforward Control.

6.1 Ratio Algorithm.

6.2 Bias Algorithm.

6.3 Deadtime and Lead-Lag Algorithms.

6.4 Tuning.

6.5 Laplace Derivation of Dynamic Compensation.

7. Deadtime Compensation.

7.1 Smith Predictor.

7.2 Internal Model Control.

7.3 Dahlin Algorithm.

References.

8. Multivariable Control.

8.1 Constraint Control.

8.2 SISO Constraint Control.

8.3 Signal Selectors.

8.4 Relative Gain Analysis.

8.5 Steady State Decoupling.

8.6 Dynamic Decoupling.

8.7 MVC Principles.

8.8 Parallel Coordinates.

8.9 Enhanced Operator Displays.

8.10 MVC Performance Monitoring.

References.

9. Inferentials and Analysers.

9.1 Inferential Properties.

9.2 Assessing Accuracy.

9.3 Laboratory Update of Inferential.

9.4 Analyser Update of Inferential.

9.5 Monitoring On-stream Analysers.

Reference.

10. Combustion Control.

10.1 Fuel Gas Flow Correction.

10.2 Measuring NHV.

10.3 Dual Firing.

10.4 Inlet Temperature Feedforward.

10.5 Fuel Pressure Control.

10.6 Combustion Air Control.

10.7 Boiler Control.

10.8 Fired Heater Pass Balancing.

11. Compressor Control.

11.1 Polytropic Head.

11.2 Flow Control (Turbo-Machines).

11.3 Flow Control (Reciprocating Machines).

11.4 Anti-Surge Control .

12. Distillation Control.

12.1 Key Components.

12.2 Relative Volatility.

12.3 McCabe-Thiele Diagram.

12.4 Cut and Separation.

12.5 Effect of Process Design.

12.6 Basic Controls.

12.7 Pressure Control.

12.8 Level Control.

12.9 Tray Temperature Control.

12.10 Pressure Compensated Temperature.

12.11 Inferentials.

12.12 First-Principle Inferentials.

12.13 Feedforward on Feed Rate.

12.14 Feed Composition Feedforward.

12.15 Feed Enthalpy Feedforward.

12.16 Decoupling.

12.17 Multivariable Control.

12.18 On-stream Analysers.

12.19 Towers with Sidestreams.

12.20 Column Optimisation.

12.21 Optimisation of Column Pressure.

12.22 Energy/Yield Optimisation.

References.

13. APC Project Execution.

13.1 Benefits Study.

13.2 Benefit Estimation for Improved Regulatory Control.

13.3 Benefits of Closed-Loop Real-Time Optimisation.

13.4 Basic Controls.

13.5 Inferentials.

13.6 Organisation.

13.7 Vendor Selection.

13.8 Safety in APC Design.

13.9 Alarms.

References.

Index.