KG32903

PROCESS CONTROL AND

INSTRUMENTATION
CHAPTER

1 Introduction to Process
Control
(Lecture week 1&2)

Prepared by Dr. Suhadat

Chapter Overview & Learning Outcomes
• 1.1 Basic concept of control system
• 1.2 Control objective and application
• 1.3 Process control problem and variables #method of teaching
• 1.4 Typical control loop and strategy flipped classroom
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tools\flipped class.mp4

At the end of this chapter, YOU should be able to:

1. Understand the role of process dynamics and control in industry
2. Understand the concept of a control system
3. Identify the important of process control objective and it’s variables
4. Identify control loop of feedback and feedforward method
5. Relate the control objective and strategy for a control loop decision
Overview of a typical chemical plant and control system

 Any chemical plant consist of various process

units which are inter connected with one
another in systematic manner
 Main objective of any plant is to convert
certain raw materials into desired product
using available sources of energy
 Other objective- safety, product specification,
environmental regulations, operation
constraints, economics
 These all parameter are control by
arrangement of various equipment like
measuring devices, valves and controller
 Career in Process Control and Instrumentation

 Control and instrumentation engineers ensure that

industrial equipment and machinery work safely and
efficiently. They may work in an office, a laboratory, on
a factory floor or all three.

 Can become a technical “Top Gun”

 Provides professional mobility. There is a shortage of

experienced process control engineers

 Is a well paid technical profession for chemical

engineers

 Jobs in control and instrumentation:

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 1.1 Basic concept of process control system
 Foundation of process control is process understanding.
 What is a process?
“The conversion of feed materials to useful products using
chemical and physical operations”
 Common processes can be continuous, batch or semi-batch.

 What is control?
“ Control is to maintain desired conditions in a system by
adjusting selected input variables of the system”

Measure Decide Correct

 What is “Process Dynamics”
refer to unsteady-state (change with time) process behavior.
 Steady state: variables do not change with time
 Unsteady state: variables change with time

 What is “Instrumentation”
- refer to a device or group of devices used for direct
reading or, when using many sensors.
- deals with the design, configuration and automation of
systems.
- part of a complex industrial control system in such as
chemical industry, oil & gas plant, manufacturing industry,
vehicles and transportation
Role of process dynamics and control in industry

How I should
do?
1.2 Control objective and application
Review on objective of a process plant;
 Purpose:
Process plants transform raw materials into
useful products

 Plant Objectives:
1. Plants must satisfy production Specification
- Good quality products
- Minimal pollution‐noise, air, water, safety standards
2. Plant must make profit
3. Safety for the equipment, workers, surrounding and hence
everybody.
How to achieve these objectives?
A process must be designed and operated in such a way that;
 It remain safe
 It constantly produces the desired amounts of high quality product
 It is profitable
A process instrument must therefore be:
 Safe to use in given process conditions
 As accurate and reliable as possible
 Selected to maximize return on investment (ROI)
An instrument should be selected according to:
 The process variable
 The process application
  Process Variables are such as temperature,
pressure, flow, level, pH and compositions
are measured and controlled.

 Process control industrial applications involve

with controlling fluids; liquids, gases, dry
solids, and slurry mixtures. Industrial
applications are designed to make a profit so
improving process control improves profits.
For example; Tubular Heat Exchanger, Continuous stirred tank reactor (CSTR),
Thermal cracking furnace, Multi-component distillation column, Stir- tank
Blending system, Liquid storage, Flash tank, Fuel oil storage and others..

*Overview on process control and instrumentation with application:

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atrol).mp4
Active Learning-Group work discussion (Tutorial 1)
Find and discuss the meaning for the following term within your group formed using additional
information from internet/book resources;

Group A Group B Group C Group D Group E

Load variable Set point Dynamic system Actuator Feedback control
Process value Process variable Steady- state Final control element Feedforward control
Hardware Manipulated variables Instrumentation Composition Oscillatory
system
Control loop Disturbance variables Flowrate Response
Transmitter
Signal Controlled variables Concentration Compensate
Sensor/ transducer
*Heat exchanger *Thermal cracking *CSTR *Fuel oil storage
furnace *Distillation column

Answer will be discussed

- Form a group of 5
- 5 terms per group through group sharing
- get more information information
through out resources in the NEXT CLASS
1.3 Process control variables and problem
The process control problem has been characterized by identifying
three important types of process variables, which is a critical
step in developing a control system.
1. Controlled variables - CV
these are the variables which quantify the performance or quality of
the final product, which are also called output variables//Set-point.
2. Manipulated variables – MV
these input variables are adjusted dynamically to keep the controlled
variables at their set-points.
3. Disturbance variables – DV
these are also called "load" variables and represent input variables that
can cause the controlled variables to deviate from their respective
set points.
Where do Disturbances come from?

• Variation in composition of incoming raw materials (eg mineral

rock, oil/gas, waste water)
• Weather – hot, cold, dry, humid, summer vs winter, pollution
levels
• Gradual buildup of scale etc inside the process (eg heat exchanger
fouling)
• Unexpected surges due to malfunctions, wear & tear, in pumps,
animals!, valves, equipment
• Process never works “perfectly”!!
 Control Terminology
•Control: maintain desired conditions by adjusting variables in the system
• Input: Variable that causes a change (not always same as a physical input)
• Setpoint (SP): desired value or range for a controlled variable
• Process value (PV): the actual value of the variable
• Sensor: physical measurement device that senses the physical changes occurs in
the surrounding and produces an electric signal
• Transmitter: device used to change the sensing input (from sensor) converted
into a signal (pneumatic and electric signals) that can be read by the controller.
• Controller:
• Calculates difference between Process value (PV) value reported by the
sensor, and the desired set-point (SP) and decides how much to adjust the
output variable (the “brain”)
• Final control element: the physical equipment used to adjust the
controlled variable. - Usually a control valve
Process control problem

1. Tubular Heat Exchanger

 Control Variable : The exit temperature of the process fluid

 Manipulating variable: the cooling water flow rate.
 Disturbances variable: Variations in the inlet temperatures
and process fluid flow rate.
2. Continuous Stirred Tank Reactor (CSTR)

 Control Variable : The temperature of the reaction

mixture/tank/product
 Manipulating variable: rate of the coolant in a jacket or
cooling coil.
 Disturbances variable: The feed conditions (composition,
flow rate, and temperature).
3. Distillation Column

 Control Variable : Distillate composition

 Manipulating variable: the reflux flow rate or the
distillate flow rate.
• Disturbances variable: The feed conditions
1.4 Typical control loop and strategy
Control loop and hardware element
Control loop General control hardware element

• Common control loop;

Flow, level, pressure, temperature and
composition loops

Components of control loop/hardware element;

• A sensor, transmitter, controller and final control element
 •Terminology in a control loop;

• First letter:
• A= Analyzer/composition
• F = flowrate
• L = level in vessel
• P = pressure
• T= temperature

• Second letter:
• C = controller: a control calculation is performed
• T= transmitter: a variable is measured and transmitted
• I = Indicator: a variable is measured and displayed
Example:

Overview on control system for a process;

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 Overview on control system

“We want to control

the temperature of
oil leaving the heat
exchanger”….How
to control??

1. A thermocouple is inserted in a thermowell in the exit oil pipe.

2. Thermocouple wires are connected to a “temperature transmitter”
that converts the millivolt output into a 4- to 20 mA signal.
3. This signal sent to a temperature controller.
4. The temperature controller opens the steam valve if more steam is
needed or closes it a little if the temperature is too high.

Home appliance control loop system……...\..\..\VIDEO& OTHERs\PC\home appliance.mp4

Illustrative Example: Blending system
•Control Objective:
•Keep x at a desired value (or “set point”) xsp, despite variations in
x1(t). Flow rate w2 can be adjusted for this purpose.

•Terminology:

• Controlled variable (or “output variable”): x

• Manipulated variable (or “input variable”): w2
• Disturbance variable (or “load variable”): x1

•Design Question. What value of w2 is required to have x  xSP ?

Mass Balance Equation
•Overall balance:
0  w1  w2  w (1-1)
•Component A balance:
w1 x1  w2 x2  wx  0 (1-2)
•(The overbars denote nominal steady-state design values.)

• At the design conditions, x  xSP. Substitute Eq. 1-2, x  xSP

and x2  1 , then solve Eq. 1-2 for w2 :
xSP  x1
w2  w1 (1-3)
1  xSP
• Equation 1-3 is the design equation for the blending system.
• If our assumptions are correct, then this value of w2 will keep x
at
xSP . But what if conditions change?

•Control Question. Suppose that the inlet concentration x1

changes with time. How can we ensure that x remains at or near
the set point xSP ?
•As a specific example, if x1  x1 and w2  w2 , then x > xSP.
Some Possible Control Strategies:
Method 1 Measure x and adjust w2.(Feedback)
• Intuitively, if x is too high, we should reduce w2;
• Manual control vs. automatic control
• Proportional feedback control law,

w2  t   w2  K c  xSP  x  t   (1-4)

1. where Kc is called the controller gain.

2. w2(t) and x(t) denote variables that change with time t.

w2  t   w2 ,
3. The change in the flow rate, is proportional to
the deviation from the set point, xSP – x(t).
Control Method 1
Method 2 Measure x1 and adjust w2.(Feedforward)
 Control Method 2

Method 3 Measure x1 and x, adjust w2.

• This approach is a combination of Methods 1 and 2.
Classification of Control Strategies: Feedback & Feedforward

1. Feedback Control: 2. Feedforward Control:

measure the controlled measure a disturbance
variable to influence an input variable in the input and
variable, which compensate compensate (corrective)
(corrective) After controlled Before the controlled
variables are affected variables are affected

Table. 1.1 Control Strategies for the Blending System

Method Measured Variable Manipulated Variable Category
1 x w2 FBa
2 x1 (disturbance) w2 FF
3 x1 (disturbance) and x w2 FF/FB
 Feedback Feedforward
Advantages • Corrective action is taken • Correct for disturbance
regardless of the source of before it upsets the process
the disturbance.

Dis- • Adjustment takes place • No corrective action for

advantages only after the controlled unmeasured disturbances.
variable is affected
significantly

Response Very oscillatory responses, or Faster response to

even instability disturbances in the feed.
Example on Heat Exchanger control system:
Feedback, Feedforward & FB/FF Strategy

Feedback control Feedforward control

Feedback & Feedforward control
Overview on Block Diagram
 Block diagram shows process variables and control signals
 Each block contains dynamic response model (process, controller)
 Negative feedback – output linked to input (like a recycle loop)
 Sensors and valves also have dynamics, and may need to account for
these.
Summary of Control objectives & Strategy on
control loop decision

Flash Separation
Hierarchy of process
control activities
Major steps in control system development
(days-months) 5. Planning and
Scheduling

(hours-days) 4. Real-Time
Optimization

3b. Multivariable
(minutes-hours) and Constraint
Control

(seconds-minutes) 3a. Regulatory

Control

2. Safety, Environment
(< 1 second) and Equipment
Protection

(< 1 second) 1. Measurement

and Actuation

Process
Task 1 (in class exercise)
In a continuous stirred-tank blending system (mixture of i and j species), the control objective is
to blend the two inlet streams to produce an outlet stream that has the desired composition (i
species). It is assumed that for stream 1, its mass flow rate w1 is constant, but the mass fraction of
A, xi1, varies with time. Stream 2 consists of pure A and thus xi2 = 1. The mass flow rate of
Stream 2, w2, can be manipulated using a control valve. The mass fraction of i in the exit stream is
denoted by xi
 
From the information given, Draw a complete diagram and identify the controlled variable,
manipulate variable and disturbance variable for this control problem.

* Review lesson for Chapter 1: Kahoot!