Safety-centered process control design based on dynamic safe set

The objective of this research is to develop an approach for the process control design problem with safety as the primary target. The work proposes the concept of dynamic safe set (DSS) to characterize and evaluate the safeness of a closed-loop system.The DSS is defined as a set of initial states of the process that guarantees safe operation, which is represented by a set of safety-critical constraints that is to be satisfied at all times. The DSS calculation accounts for potential safety threatening disturbances that may significantly affect the dynamics of the system. An addon control scheme based on the DSS concept is proposed to guide the system when it is under sudden and large set point changes that may be needed during abnormal situations. Existing system theoretic concepts of maximal output admissible sets is used to mathematically formulate and determine the DSS. The concept of dynamic safety margin (DSM) is proposed as a quantitative measure of the size of DSS. An approach based on the DSS and DSM concepts for process control design with the objective to maximize safety, subject to other performance constraints, is proposed.The approach is tested on an exothermic CSTR case study. The results showed the strong effect of steady state operating conditions, control parameters and actuator design parameters on DSM. A grid of design parameters that includes the reactor set point, the controller parameters, and the heat exchanger design parameter was analyzed. The analysis led to identifying a maximally safe control system design. The proposed approach allowed to formulate the process control design problem by bringing safety upfront, without compromising performance metrics.