Process Systems Analysis And Control
McGraw-HillÕsCHEMICAL ENGINEERING SERIESKey Features:control classesÉthat this is just another mathematics course disguised as an engineering course and Excel have been introduced throughout thebook.dynamics and control and not get bogged down in the mathematical complexities of each problemThe Solutions to the End-of-Chapter Problems are available to Instructors at the textÕs website:www.mhhe.com/coughanowr-leblancElectronic Textbook OptionsThis text is offered through CourseSmart for both instructors and students. CourseSmart is an onlinebrowser where students can purchase access to this and other McGraw-Hill textbooks in a digitalProcess SystemsAnalysis and ControlThird Editionhalf the cost of a traditional text. Purchasing the eTextbook also allows students to take advantage ofsales representative or visit www.CourseSmart.com.ISBN 978-0-07-339789-4MHID 0-07-339789-Xwww.mhhe.comThirdEditionDonald R. CoughanowrSteven E. LeBlancMD DALIM 976649 7/29/08 CYAN MAG YELO BLACKavailable for the course materialCoughanowrLeBlancProcess SystemsAnalysis and ControlProcess Systems Analysis and Control, Third Edition retains the clarity of presentation for whichthis book is well known. It is an ideal teaching and learning tool for a semester-long undergraduatechemical engineering course in process dynamics and control. It avoids the encyclopedic approachof many other texts on this topic. Computer examples using MATLAB and Simulink have beenintroduced throughout the book to supplement and enhance standard hand-solved examples. Thesepackages allow the easy construction of block diagrams and quick analysis of control concepts to enablethe student to explore Òwhat-ifÓ type problems that would be much more difficult and time consumingby hand. New homework problems have been added to each chapter. The new problems are a mixtureof hand-solutions and computational-exercises. One-page capsule summaries have been added to theend of each chapter to help students review and study the most important concepts in each chapter.
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Confirming PagesMcGraw-Hill Chemical Engineering SeriesEditorial Advisory BoardEduardo D. Glandt, Dean, School of Engineering and Applied Science, University ofPennsylvaniaMichael T. Klein, Dean, School of Engineering, Rutgers UniversityThomas F. Edgar, Professor of Chemical Engineering, University of Texas at AustinCoughanowr and LeBlanc:Davis and Davis:de Nevers:de Nevers:Douglas:Edgar, Himmelblau, and Lasdon:Marlin:McCabe, Smith, and Harriott:Murphy:Perry and Green:Peters, Timmerhaus, and West:Smith, Van Ness, and Abbott:cou9789x fm i-xx.indd iiProcess Systems Analysis and ControlFundamentals of Chemical ReactionEngineeringAir Pollution Control EngineeringFluid Mechanics for Chemical EngineersConceptual Design of Chemical ProcessesOptimization of Chemical ProcessesProcess ControlUnit Operations of Chemical EngineeringIntroduction to Chemical ProcessesPerry’s Chemical Engineers’ HandbookPlant Design and Economics forChemical EngineersIntroduction to Chemical EngineeringThermodynamics8/25/08 2:48:39 PM
Confirming PagesThe Founding of a Discipline:The McGraw-Hill Companies, Inc. Series in Chemical EngineeringOver 80 years ago, 15 prominent chemical engineers met in New York to plan a continuing literature for their rapidly growing profession. From industry came such pioneerpractitioners as Leo H. Baekeland, Arthur D. Little, Charles L. Reese, John V. N. Dorr,M. C. Whitaker, and R. S. McBride. From the universities came such eminent educators as William H. Walker, Alfred H. White, D. D. Jackson, J. H. James, Warren K.Lewis, and Harry A. Curtis. H. C. Parmlee, then editor of Chemical and MetallurgicalEngineering, served as chairman and was joined subsequently by S. D. Kirkpatrick asconsulting editor.After several meetings, this committee submitted its report to the McGraw-HillBook Company in September 1925. In the report were detailed specifications for acorrelated series of more than a dozen texts and reference books which became theMcGraw-Hill Series in Chemical Engineering—and in turn became the cornerstone ofthe chemical engineering curricula.From this beginning, a series of texts has evolved, surpassing the scope and longevity envisioned by the founding Editorial Board. The McGraw-Hill Series in Chemical Engineering stands as a unique historical record of the development of chemicalengineering education and practice. In the series one finds milestones of the subject’sevolution: industrial chemistry, stoichiometry, unit operations and processes, thermodynamics, kinetics, and transfer operations.Textbooks such as McCabe et al., Unit Operations of Chemical Engineering,Smith et al., Introduction to Chemical Engineering Thermodynamics, and Peters et al.,Plant Design and Economics for Chemical Engineers have taught to generations ofstudents the principles that are key to success in chemical engineering.Chemical engineering is a dynamic profession, and its literature continues togrow. McGraw-Hill, with its in-house editors and consulting editors Eduardo Glandt(Dean, University of Pennsylvania), Michael Klein (Dean, Rutgers University), andThomas Edgar (Professor, University of Texas at Austin), remains committed to a publishing policy that will serve the needs of the global chemical engineering professionthroughout the years to come.cou9789x fm i-xx.indd iii8/25/08 2:48:39 PM
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Confirming PagesPROCESS SYSTEMSANALYSIS AND CONTROLTHIRD EDITIONSteven E. LeBlancChemical Engineering University of ToledoDonald R. CoughanowrEmeritus Professor, Chemical Engineering Drexel Universitycou9789x fm i-xx.indd v8/25/08 2:48:39 PM
PROCESS SYSTEMS ANALYSIS AND CONTROL, THIRD EDITIONPublished by McGraw-Hill, a business unit of The McGraw-Hill Companies, Inc., 1221 Avenue of the Americas, New York, NY10020. Copyright 2009 by The McGraw-Hill Companies, Inc. All rights reserved. Previous editions 1991 and 1965. Nopart of this publication may be reproduced or distributed in any form or by any means, or stored in a database or retrieval system,without the prior written consent of The McGraw-Hill Companies, Inc., including, but not limited to, in any network or otherelectronic storage or transmission, or broadcast for distance learning.Some ancillaries, including electronic and print components, may not be available to customers outside the United States.This book is printed on acid-free paper.1 2 3 4 5 6 7 8 9 0 DOC/DOC 0 9 8ISBN 978–0–07–339789–4MHID 0–07–339789–XGlobal Publisher: Raghothaman SrinivasanSponsoring Editor: Debra B. HashDirector of Development: Kristine TibbettsDevelopmental Editor: Lorraine K. BuczekSenior Marketing Manager: Curt ReynoldsProject Coordinator: Melissa M. LeickSenior Production Supervisor: Laura FullerDesigner: Laurie B. JanssenCompositor: Laserwords Private LimitedTypeface: 10/12 Times RomanPrinter: R. R. Donnelley Crawfordsville, INLibrary of Congress Cataloging-in-Publication DataCoughanowr, Donald R.Process systems analysis and control.—3rd ed. / Donald R. Coughanowr, Steven E. LeBlanc.p. cm.—(Mcgraw-Hill chemical engineering series)Includes index.ISBN 978–0–07–339789–4—ISBN 0–07–339789–X (hard copy : alk. paper) 1. Chemical process control. I. LeBlanc,Steven E. II. Title.TP155.75.C68 2009660'.2815—dc222008018252www.mhhe.comcou9789x fm i-xx.indd vi8/25/08 2:48:40 PM
Confirming PagesDedicationFor Molly, my children, and grandchildren . . .cou9789x fm i-xx.indd vii8/25/08 2:48:41 PM
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Confirming PagesCONTENTSPreface to the Third EditionChapter 11.11.2Introductory Concepts1Why Process Control?Control Systems11PART I MODELING FOR PROCESS DYNAMICSChapter 2 Modeling Tools for Process Dynamics2.12.22.3Chapter 33.13.2Appendix 3A:911Process Dynamics—A Chemical Mixing ScenarioMathematical Tools for ModelingSolution of Ordinary Differential Equations (ODEs)111826Inversion by Partial Fractions32Partial FractionsQualitative Nature of SolutionsFurther Properties of Transforms and Partial Fractions324349PART II LINEAR OPEN-LOOP SYSTEMSChapter 4 Response of First-Order Systems4.14.24.34.44.54.64.7xvTransfer FunctionTransient ResponseForcing FunctionsStep ResponseImpulse ResponseRamp ResponseSinusoidal Response697171777879848787ixcou9789x fm i-xx.indd ix8/25/08 2:48:41 PM
Confirming PagesxCONTENTSChapter 55.15.2Chapter 66.16.26.3Chapter 77.17.2Physical Examples of First-Order SystemsExamples of First-Order SystemsLinearization99109Response of First-Order Systems in Series123Introductory RemarksNoninteracting SystemInteracting System123123128Higher-Order Systems: Second-Orderand Transportation Lag137Second-Order SystemTransportation Lag137153PART III LINEAR CLOSED-LOOP SYSTEMSChapter 8 The Control System163165IntroductionComponents of a Control SystemBlock DiagramDevelopment of Block Diagram165165166168Controllers and Final Control Elements1869.19.2Appendix 9A:MechanismsIdeal Transfer FunctionsPiping and Instrumentation Diagram Symbols187190203Chapter 10Block Diagram of a Chemical-ReactorControl System205Description of SystemReactor Transfer FunctionsControl ValveMeasuring ElementControllerController TransducerTransportation LagBlock Diagram206206209210211212212212Closed-Loop Transfer Functions218Standard Block-Diagram SymbolsOverall Transfer Function for Single-Loop SystemsOverall Transfer Function for Multiloop Control Systems2182192248.18.28.38.4Chapter 910.110.210.310.410.510.610.710.8Chapter 1111.111.211.3cou9789x fm i-xx.indd x998/25/08 2:48:41 PM
Confirming PagesCONTENTSChapter 1212.112.212.312.412.5Chapter 1313.113.213.313.4Chapter 1414.1Transient Response of SimpleControl SystemsProportional Control for Set Point Change(Servo Problem—Set Point Tracking)Proportional Control for Load Change (RegulatorProblem—Disturbance Rejection)Proportional-Integral Control for Load ChangeProportional-Integral Control for Set Point ChangeProportional Control of System with Measurement Lag15.115.215.3Chapter 1616.116.216.316.4cou9789x fm i-xx.indd xi229234236241243252Concept of StabilityDefinition of Stability (Linear Systems)Stability CriterionRouth Test for Stability252254254258Root Locus269Concept of Root Locus269285287Substitution RuleBode DiagramsAppendix—Generalization of Substitution Rule287300316Control System Design by Frequency Response323Tank Temperature Control SystemThe Bode Stability CriterionGain and Phase MarginsZiegler-Nichols Controller Settings323326327335PART V PROCESS APPLICATIONSChapter 17 Advanced Control Strategies17.117.217.317.417.5228StabilityPART IV FREQUENCY RESPONSEChapter 15 Introduction to Frequency ResponseCascade ControlFeedforward ControlRatio ControlDead-Time Compensation (Smith Predictor)Internal Model Controlxi3513533533613703733788/25/08 2:48:42 PM
Confirming PagesxiiCONTENTSChapter 18Controller Tuning and Process Identification39118.118.218.3Controller TuningTuning RulesProcess Identification391394Chapter 19Control Valves423Control Valve ConstructionValve SizingValve CharacteristicsValve Positioner423425427438Theoretical Analysis of Complex Processes443Control of a Steam-Jacketed KettleDynamic Response of a Gas AbsorberDistributed-Parameter Systems44345345819.119.219.319.4Chapter 2020.120.220.3PART VI STATE-SPACE METHODSChapter 21 State-Space Representation of Physical Systems47521.121.2Appendix 21A:IntroductionState VariablesElementary Matrix Algebra477477490Chapter 22Transfer Function Matrix498Transition MatrixTransfer Function Matrix499502Multivariable Control512Control of Interacting SystemsStability of Multivariable Systems51452522.122.2Chapter 2323.123.2PART VII NONLINEAR CONTROLChapter 24 Examples of Nonlinear Systems24.124.224.324.424.5Chapter 2525.125.2cou9789x fm i-xx.indd xii410477531533Definition of a Nonlinear SystemThe Phase PlanePhase-Plane Analysis of Damped OscillatorMotion of a PendulumA Chemical Reactor533534535543547Examples of Phase-Plane Analysis553Phase SpaceExamples of Phase-Plane Analysis5535618/25/08 2:48:42 PM
Confirming PagesCONTENTSPART VIII COMPUTERS IN PROCESS CONTROLChapter 26 Microprocessor-Based Controllersand Distributed Control26.126.226.326.426.5cou9789x fm i-xx.indd xiiixiii579581Historical BackgroundHardware ComponentsTasks of a Microprocessor-Based ControllerSpecial Features of Microprocessor-Based ControllersDistributed 08 2:48:42 PM
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Confirming PagesPREFACE TO THE THIRD EDITIONIt has been over 17 years since the second edition of this book was published. The second edition, which was written by Dr. Donald R. Coughanowr in 1991, contained manychanges and new topics to bring the book up to date at the time of publication. The thirdedition has been a number of years in the making. I would like to thank Dr. Coughanowrfor the opportunity to work on this project and help update this excellent work, whichhe first published in 1965 with Dr. Lowell B. Koppel. As an undergraduate, I learnedprocess control from the first edition of this text over 30 years ago. It was an excellentbook then, and it still is. I’ve used a number of other books over the years as a studentand as a professor, but I kept coming back to this one. I felt that it was the best bookto learn from. Is it an all-encompassing, totally comprehensive process dynamics andcontrol book? No, but it is not intended to be. It is a clearly written book that is gearedtoward students in a first process dynamics and control course. Many control bookson the market contain more material than one could ever hope to cover in a standardundergraduate semester-long class. They can be overwhelming and difficult to learnfrom. I have always felt that one of the strengths of this book, from both the student’sand professor’s point of view, was the relatively short, easy-to-read chapters that can becovered in one to two lectures. An additional strength of this text has been its uniqueability to be a teaching and learning text. I hope that in this current revision, I have beenable to retain that style and flavor, while introducing some new material and examplesto update the text.OBJECTIVES AND USES OF THE TEXTThis text is intended for use in an introductory one-semester-long undergraduate process dynamics and control course. It is intended to be not a comprehensive treatise onprocess control, but rather a textbook that provides students with the tools to learnthe basic material and be in a position to continue their studies in the area if they sochoose. Students are expected to have a background in mathematics through differential equations, material and energy balance concepts, and unit operations. After thefirst 13 chapters, the instructor may select from the remaining chapters to fit a courseof particular duration and scope. A typical one-semester 15-week course, for example,may include Chapters 1 through 19 and 26.Features of the third edition A capsule summary of the important points at the end of each chapter Restructuring of the initial chapters to reduce the impression that students frequently have regarding control classes—that this is just another mathematicscourse disguised as an engineering course Integration of MATLAB, Simulink, and Excel throughout the text: To reduce the tedium of solving problems so that students may concentratemore on the concepts of dynamics and control and not get bogged down in themathematical complexities of each problemxvcou9789x fm i-xx.indd xv8/25/08 2:48:42 PM
Confirming PagesxviPREFACE TO THE THIRD EDITION To give students the tools to be able to ask (and more easily answer) “what if . . .?”type of questions To allow students to explore more difficult problems than would otherwise bepossible in the time available for the course materialACKNOWLEDGMENTSWe would like to thank the following reviewers of the third edition for their helpful comments and suggestions: Thomas F. Edgar, University of Texas–Austin; JohnErjavec, University of North Dakota; Duane Johnson, University of Alabama; CostasMaranas, Penn State University; Michael Nikolaou, University of Houston; F. JosephSchork, Georgia Institute of Technology; Delmar Timm, University of Nebraska; andWilliam A. Weigand, University of Maryland. We especially acknowledge the helpfulsuggestions from Susan Montgomery of the University of Michigan and thank her forher thoroughness and useful comments to help make the text more student-friendly.I would like to thank McGraw-Hill for having confidence in this project andproviding the opportunity to revise and update the text. Special thanks go to LorraineBuczek, Developmental Editor, and Melissa Leick, Project Manager, for their help inthe final stages of this revision.I would also like to thank my students and my University of Toledo colleagueSasidhar Varanasi for his help in using manuscript drafts when he taught the ProcessControl course to “field-test” the revisions. I am also grateful to my friend and colleagueDean Nagi Naganathan, of the College of Engineering at the University of Toledo, forhis general support and his willingness to allow me the time required to complete thiswork. I especially want to thank my wife, Molly, for her love and continuing encouragement and support over the course of the writing and revising.Dr. Steven E. LeBlancUniversity of ToledoRESOURCES FOR INSTRUCTORS AND STUDENTS:For instructors, the solutions to the end-of-chapter problems are available at the text’swebsite: www.mhhe.com/coughanowr-leblancELECTRONIC TEXTBOOK OPTIONSThis text is offered through CourseSmart for both instructors and students. CourseSmartis an online browser where students can purchase access to this and other McGrawHill textbooks in a digital format. Through their browser, students can access the complete text online for one year at almost half the cost of a traditional text. Purchasingthe eTextbook also allows students to take advantage of CourseSmart’s Web tools forlearning, which include full text search, notes and highlighting, and e-mail tools forsharing notes between classmates. To learn more about CourseSmart options, contactyour sales representative or visit www.CourseSmart.com.cou9789x fm i-xx.indd xvi8/25/08 2:48:43 PM
Confirming PagesHISTORY OF PROCESS SYSTEMSANALYSIS AND CONTROL (FROMTHE SECOND EDITION PREFACE)Since the first edition of this book was published in 1965, many changes have takenplace in process control. Nearly all undergraduate students in chemical engineering arenow required to take a course in process dynamics and control. The purpose of thisbook is to take the student from the basic mathematics to a variety of design applications in a clear, concise manner.The most significant change since the first edition is the use of the digital computer in complex problem solving and in process control instrumentation. However, thefundamentals of process control, which remain the same, must be acquired before onecan appreciate the advanced topics of control.In its present form, this book represents a major revision of the first edition. Thematerial for this book evolved from courses taught at Purdue University and DrexelUniversity. The first 17 chapters on fundamentals are quite close to the first 20 chaptersof the first edition. The remaining 18 chapters contain many new topics, which wereconsidered very advanced when the first edition was published.Knowledge of calculus, unit operations, and complex numbers is presumed on thepart of the student. In certain later chapters, more advanced mathematical preparation isuseful. Some examples would include partial differential equations in Chap. 21, linearalgebra in Chaps. 28 through 30, and Fourier series in Chap. 33.Analog computation and pneumatic controllers in the first edition have beenreplaced by digital computation and microprocessor-based controllers in C
Confirming Pages ix CONTENTS Preface to the Third Edition xv Chapter 1 Introductory Concepts 1 1.1 Why Process Control? 1 1.2 Control Systems 1 PART I MODELING FOR PROCESS DYNAMICS 9 Chapter 2 Modeling Tools for Process Dynamics 11 2.1 Process Dynamics—A Chemical Mixing Scenario 11 2.2 Mathematical Tools for Modeling 18 2.3 Solution of Ordinary Differential Equations (ODEs) 26
This section discusses the basic concepts of statistical process control, quality control and process capability. 1. How did Statistical Quality Control Begin? 2. What are Process Control Techniques? 3. What is Process Control? 4. What to do if the process is "Out of Control"? 5. What to do if "In Control" but Unacceptable? 6. What is Process .
1. CONTROL SYSTEMS: BASICS 1 1.1 What is Control Systems 1 1.2 Classification of Systems 1 1.3 Classification Based on the Parameters 2 1.4 Analysis of Control Systems 3 1.5 General Classification: Open and Closed-Loop Systems 3 1.6 Elements of Automatic or Feedback Control Systems 5 1.7 Requirements of Automatic Control Systems 6 2.
3.0 PROCESS INSTRUMENTATION AND CONTROL SYSTEMS The systems discussed in this chapter are those that have to do with process instrumentation or process control. The control systems used to alter reactor core reactivity are discussed in Chapter 7. The process instrumentation and control
Process Modeling For control applications: Modeling objectives is to describe process dynamics based on the laws of conservation of mass, energy and momentum The balance equation 1.Mass Balance 2.Energy Balance 3.Momentum Balance (Newton’s Law) Rate of Accumulation of fundamental quantity Flow In Flow Out Rate of Production - File Size: 1MBPage Count: 32Explore furtherPDF Download Process Dynamics Modeling And Control Freewww.nwcbooks.comProcess Dynamics and Control - PDF Free Downloadepdf.pubUnderstanding Process Dynamics And Control PDF Download .www.fuadherbal.netA Short Introduction to Process Dynamics and Controlwww.users.abo.fiProcess Dynamics And Control Lecture Notesrims.ruforum.orgRecommended to you b
the processes. The terms "feedback control systems," as used in system analysis and industrial technology, and "control of processes," for measurements of variations, are interrelated. Process control is a part of the feedback control system. Feedback control systems influence ev ery facet of modem life, from chemical process plants, 317
report, includes Supervisory Control and Data Acquisition (SCADA) systems, Process Control Systems, Distributed Control Systems, and other control systems specific to any of the critical infrastructure industry sectors. Although differences in these systems exist, their similarities enable a common framework for discussing and
Statistical Process Control (SPC) applies statistical methods to monitor and control a process to operate at full potential. Statistical process control is a collection of tools that when used together can result in process stability and variance reduction. Control charts are used in SPC for measuring the variation in the process and that can be
Closed Loop Optimization Equipment Sentinel FDC Discover Analysis Dicing tool NSX320 Inspection Rudolph KERF Solutions 6 KERF Metrology & SAW Process Control SAW PROCESS Process Monitoring Faster Process improvement Predictive Yields FDC PROCESS CONTROL High speed data collection 100 signals recorded Fleet Process Control INSPECTION / METROLOGY
