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Table of Contents

Practical Process Control

Proven Methods and Best Practices for Automatic PID Control

I. Modern Control is Based on Process Dynamic Behavior (by Doug
Cooper)

1) Fundamental Principles of Process Control

  * Motivation and Terminology of Automatic Process Control
  * The Components of a Control Loop
  * Process Data, Dynamic Modeling and a Recipe for Profitable
    Control
  * Sample Time Impacts Controller Performance

2) Graphical Modeling of Process Dynamics: Heat Exchanger Case Study

  * Step Test Data From the Heat Exchanger Process
  * Process Gain is the "How Far" Variable
  * Process Time Constant is the "How Fast" Variable
  * Dead Time is the "How Much Delay" Variable
  * Validating Our Heat Exchanger Process FOPDT Model

3) Modeling Process Dynamics: Gravity Drained Tanks Case Study

  * The Gravity Drained Tanks Process
  * Dynamic "Bump" Testing of the Gravity Drained Tanks Process
  * Graphical Modeling of Gravity Drained Tanks Step Test
  * Modeling Gravity Drained Tanks Data Using Software

4) Software Modeling of Process Dynamics: Jacketed Stirred Reactor
Case Study

  * Design Level of Operation for the Jacketed Stirred Reactor
    Process
  * Modeling the Dynamics of the Jacketed Stirred Reactor with
    Software
  * Exploring the FOPDT Model With a Parameter Sensitivity Study

II. PID Controller Design and Tuning (by Doug Cooper)

5) Process Control Preliminarie

  * Design and Tuning Recipe Must Consider Nonlinear Process Behavior
  * A Controller's "Process" Goes From Wire Out to Wire In
  * The Normal or Standard PID Algorithm

 6) Proportional Control - The Simplest PID Controller

  * The P-Only Control Algorithm
  * P-Only Control of the Heat Exchanger Shows Offset
  * P-Only Disturbance Rejection of the Gravity Drained Tanks

 7) Caution: Pay Attention to Units and Scaling

  * Controller Gain is Dimensionless in Commercial Systems

 8) Integral Action and PI Control

  * Integral Action and PI Control
  * PI Control of the Heat Exchanger
  * PI Disturbance Rejection of the Gravity Drained Tanks
  * The Challenge of Interacting Tuning Parameters
  * PI Disturbance Rejection in the Jacketed Stirred Reactor
  * Integral (Reset) Windup, Jacketing Logic and the Velocity PI Form

 9) Derivative Action and PID Control

  * PID Control and Derivative on Measurement
  * The Chaos of Commercial PID Control
  * PID Control of the Heat Exchanger
  * Measurement Noise Degrades Derivative Action
  * PID Disturbance Rejection of the Gravity Drained Tanks

10) Signal Filters and the PID with Controller Output
Filter Algorithm

  * Using Signal Filters In Our PID Loop
  * PID with Controller Output (CO) Filter
  * PID with CO Filter Control of the Heat Exchanger
  * PID with CO Filter Disturbance Rejection in the Jacketed Stirred
    Reactor

 

III. Additional PID Design and Tuning Concepts (by Doug Cooper)

11) Exploring Deeper: Sample Time, Parameter Scheduling, Plant-Wide
Control

  * Sample Time is a Fundamental Design and Tuning Specification
  * Parameter Scheduling and Adaptive Control of Nonlinear Processes
  * Plant-Wide Control Requires a Strong PID Foundation

12) Controller Tuning Using Closed-Loop (Automatic Mode) Data

  * Ziegler-Nichols Closed-Loop Method a Poor Choice for Production
    Processes
  * Controller Tuning Using Set Point Driven Data
  * Do Not Use Disturbance Driven Data for Controller Tuning 

13) Evaluating Controller Performance

  * Comparing Controller Performance Using Response Plot Data

IV. Control of Integrating Processes (by Doug Cooper & Bob Rice)

14) Integrating (Non-Self Regulating) Processes

  * Recognizing Integrating (Non-Self Regulating) Process Behavior
  * A Design and Tuning Recipe for Integrating Processes
  * Analyzing Pumped Tank Dynamics with a FOPDT Integrating Model
  * PI Control of the Integrating Pumped Tank Process

V. Advanced Classical Control Architectures (by Doug Cooper & Allen
Houtz)

15) Cascade Control For Improved Disturbance Rejection

  * The Cascade Control Architecture
  * An Implementation Recipe for Cascade Control
  * A Cascade Control Architecture for the Jacketed Stirred Reactor
  * Cascade Disturbance Rejection in the Jacketed Stirred Reactor

16) Feed Forward with Feedback Trim For Improved Disturbance
Rejection

  * The Feed Forward Controller
  * Feed Forward Uses Models Within the Controller Architecture  
  * Static Feed Forward and Disturbance Rejection in the Jacketed
    Reactor

17) Ratio, Override and Cross-Limiting Control

  * The Ratio Control Architecture
  * Ratio Control and Metered-Air Combustion Processes
  * Override (Select) Elements and Their Use in Ratio Control
  * Ratio with Cross-Limiting Override Control of a Combustion
    Process

18) Cascade, Feed Forward and Three-Element Control

  * Cascade, Feed Forward and Steam Boiler Level Control
  * Dynamic Shrink/Swell and Steam Boiler Level Control

VI. Process Applications in Control

19) Distillation Column Control (by Jim Riggs)

  * Introduction to Distillation Column Control
  * Major Disturbances & First-Level Distillation Column Control
  * Inferential Temperature & Single-Ended Column Control
  * Dual Composition Control & Constraint Distillation Column Control

20) Discrete Time Modeling of Dynamic Systems (by Peter Nachtwey)

  * A Discrete Time Linear Model of the Heat Exchanger

21) Fuzzy Logic and Process Control (by Fred Thomassom)

  * Envelope Optimization and Control Using Fuzzy Logic

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