CDB3013 – PROCESS INSTRUMENTATION & CONTROL

INRODUCTION TO PROCESS
CONTROL

erniza.rozali@utp.edu.my
COURSE LEARNING OUTCOMES

At the end of this chapter, students shall be able to:

1. Identify the role of process dynamics and control in industry.

2. Identify control aspects of a complete plant.

3. Identify the design steps of a control system.

2
Objectives of process control

• Maintain a process at the desired

operating conditions, safely and
efficiently

• Satisfy product quality and environmental

requirements
 The need for control
Key factors for tightening product quality specifications:
• Stronger competition
• Rapidly changing economic conditions
• Tough environmental and safety regulations
• Modern plants are complex and highly integrated
• Difficulty to prevent propagation of disturbances

Process control has become increasingly

important due to the increased importance on
safe and efficient plant operation
Objectives of process control
Specific objectives of control:
• Increased product throughput
• Increased yield of higher valued products
• Decreased energy consumption
• Decreased pollution
• Decreased off-spec product
• Increased safety
• Extended life of equipment
• Improved operability
• Decreased production labor
 Economic incentives

Process control significantly reduces product

variability
 Process dynamics

• Process dynamics refer to unsteady state (or

transient) behavior

• Dynamic studies provide the behavior of the

process under unsteady state conditions

Under steady state conditions,

the flow rate out of the tank
must equal the flow rate into
the tank.
h
F = F1 + F2
 Process dynamics

What would happen if we change F1 dynamically?

F(t) and h(t) will vary with

time
 Design steps
Design of control system involves:
1. Identifying the control objectives
2. Identifying and classifying the process variables
3. Selecting appropriate control strategy/configuration
4. Selecting appropriate controller type
5. Selecting appropriate instrumentation and preparing the
P&ID
6. Tuning the controllers

A good starting document for design of control systems is the

schematic diagram of the process or process flow diagram (PFD).
 Design steps
STEP 1: Identifying the control objectives

• The control objectives should be identified and

clearly defined

• Examples:
- To maintain the outlet temperature at 65˚C
- To maintain the liquid level at h = 4  0.2m
 Design steps
STEP 2: Identifying and classifying the process variables

Process variables are classified into:

• Controlled variables (CV): Output variables that should be

maintained at a specified desired value (set-points) using a
controller

• Manipulated variables (MV): Input variables that can be

adjusted by an automatic controller or a human operator to
keep the CV at the set-points

• Disturbance variables (DV): Input variables that can cause

the CV to deviate from the respective set-points
 Design steps
STEP 3: Selecting the appropriate control strategy

Examples of control strategies:

• Feedback control: The MV is adjusted based on the

measurement of CV

• Feedforward control: The MV is adjusted based on the DV

 Design steps
STEP 3: Selecting the appropriate control strategy

Feedback control

Advantages:
• Corrective action is taken regardless of the source of the
disturbances.
• Reduces sensitivity of the controlled variable to disturbances
and changes in the process.

Disadvantages:
• No corrective action occurs until after the disturbance has
upset the process.
• Response may be oscillatory or even unstable
 Design steps
STEP 3: Selecting the appropriate control strategy

Feedforward control

Advantages:
• Correct for disturbance before it upsets the process

Disadvantages:
• Disturbance should be measureable; no corrective action
for unmeasured disturbances
 Design steps
STEP 4: Determining the type of controller

• The most commonly used controllers are Proportional

(P), Proportional Integral (PI) and Proportional Integral
Derivative (PID).
 Design steps
STEP 5: Selection of the appropriate instruments (in
addition to the controller)

Components of control loop:

• Sensor
• Transmitter
• Final control element
 Design steps
STEP 6: Tuning (setting up of the controller parameters)

Most controllers have one or more parameters to be adjusted.

The adjustment depends on the type of controller, the
dynamic behavior of the process and the desired closed-loop
(controlled) response

Example: PID controller has three parameters to be adjusted:

Controller gain (Kc ), Integral time (I) and Derivative Time (D)
Example 1: Heat exchanger

It is desired to control the temperature of oil leaving

the heat exchanger
 Example: Heat exchanger
1. Identifying the control objective
• To maintain the outlet temperature of the oil at 75˚C.

2. Identifying and classifying the process variables

• CV: T
• MV: Fs
• DV: T0, F
 Example: Heat exchanger
3. Selecting control strategy
• Feedback control
 Example: Heat exchanger
4. Selecting appropriate controller type
• PID controller

5. Selecting appropriate instrumentation and preparing the

P&ID
• Sensor: Thermocouple
• Transmitter: Temperature transmitter
• Controller: Temperature controller
• Final control element: Control valve
 Example: Heat exchanger
5. Selecting appropriate instrumentation and preparing the
P&ID
 Example: Heat exchanger
6. Tuning (setting the controller parameters)
Adjusting the values of Kc, I and D for PID controllers
based on:
• The dynamic behavior of the process
• The required control performance
Representative process control
problems

Common processes:

• Continuous
• Batch
• Semi-batch
Representative process control problems
Continuous processes

a. Heat exchanger

Control problem:
The exit temperature of the
process fluid is controlled by
manipulating the cooling
(heating) medium flow rate.

Disturbances:
Variations in the inlet
temperatures and process fluid
flow rate.
Representative process control problems
Continuous processes

b. Continuous stirred tank reactor (CSTR)

Control problem:
If the reaction is highly
exothermic, it is necessary to
control the reactor temperature
by manipulating the flow rate of
the coolant in a jacket or
cooling coil.

Disturbances:
The feed conditions
(composition, flow rate, and
temperature)
Representative process control problems
Continuous processes

c. Thermal cracking furnace

Control problem:
The furnace temperature and
amount of excess air in the flue
gas to be controlled by
manipulating the fuel flow rate
and the fuel/air ratio.

Disturbances:
The crude oil composition and
the heating quality of the fuel.
Representative process control problems
Continuous processes

d. Multi-component distillation column

Control problem:
Distillate composition can be
controlled by adjusting the reflux
flow rate or the distillate flow
rate.

Disturbances:
The feed conditions
Representative process control problems
Batch or semi-batch processes
Batch or semi-batch reactor Batch digester

The reactor temperature is The lignin content can be controlled to a

controlled by manipulating a desired value by adjusting the digester
coolant flow rate. temperature, pressure, and/or cycle time.
 Example 2: Blending process

Mixture of A and B Pure A

𝑥1 𝑥2 = 1
𝑤1 𝑤2
Assumptions:

• 𝑤1 is constant

• 𝑥2 = constant = 1

𝑥 • Perfect mixing in
𝑤 the tank

𝑤1 , 𝑤2 and 𝑤 are mass flow rates

𝑥1 , 𝑥2 and 𝑥 are mass fractions of

component A
Example 2: Blending process

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.

Process variables:
CV: 𝑥
MV: 𝑤2
DV: 𝑥1

Design question:
What nominal flow rate 𝑤ഥ2 is required to produce the desired
outlet concentration, 𝑥𝑠𝑝 ?
Example 2: Blending process

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.

Process variables:
CV: 𝑥
MV: 𝑤2
DV: 𝑥1

Design question:
What nominal flow rate 𝑤ഥ2 is required to produce the desired
outlet concentration, 𝑥𝑠𝑝 ?
Example 2: Blending process

Consider steady-state material balance

Overall balance:
0=𝑤
ഥ1 + 𝑤
ഥ2 − 𝑤
ഥ ----------(1.1)

Component A balance:
0=𝑤ഥ1 𝑥ҧ1 + 𝑤
ഥ2 𝑥ҧ2 − 𝑤
ഥ 𝑥ҧ ----------(1.2)

According to the process description, 𝑥ҧ2 = 1 And 𝑥ҧ = 𝑥𝑠𝑝 .

Substituting these values in Equation 1.2 and solve for 𝑤
ഥ2 to give
the design equation for the blending process:

𝑥𝑠𝑝 − 𝑥ҧ1
𝑤
ഥ2 = 𝑤
ഥ1 ----------(1.3)
1 − 𝑥𝑠𝑝

This value of 𝑤
ഥ2 will keep 𝑥ҧ at 𝑥𝑠𝑝 , if 𝑥1 = 𝑥ҧ1
Example 2: Blending process

Control question:
Suppose that the inlet concentration 𝑥1 changes with
time. How can we ensure that 𝑥 remains at or near its
desired value, 𝑥𝑠𝑝 ?

As a specific example, assume that 𝑥1 > 𝑥ҧ1 , then 𝑥 > 𝑥𝑠𝑝

Several control strategies for reducing the effects of 𝑥1

disturbances on 𝑥 can be considered.
Example 2: Blending process
Possible control strategies

Method 1: Measure 𝒙 and adjust 𝒘𝟐 .

• If 𝑥 is too high, 𝑤2 should be reduced

• Simple control algorithm for this strategy:

𝑤2 𝑡 = 𝑤ഥ2 + 𝐾𝑐 [𝑥𝑠𝑝 − 𝑥 𝑡 ]
𝐾𝑐 is a constant called the controller gain

• 𝑤2 𝑡 and 𝑥(𝑡) indicates that 𝑤2 and 𝑥 change with

time.

• The change in the flow rate, 𝑤2 𝑡 − 𝑤 ഥ2 is proportional

to the deviation from the set point, 𝑥𝑠𝑝 − 𝑥 𝑡 .
Example 2: Blending process
Possible control strategies

Method 1: Measure 𝒙 and adjust 𝒘𝟐 .

Example 2: Blending process
Possible control strategies

Method 2: Measure 𝒙𝟏 and adjust 𝒘𝟐 .

• If 𝑥1 > 𝑥ҧ1 , 𝑤2 should be reduced

• Control algorithm for this strategy can be derived form

Equation 1.3:
𝑥𝑠𝑝 − 𝑥1 (𝑡)
𝑤2 (𝑡) = 𝑤
ഥ1
1 − 𝑥𝑠𝑝

• This control law might not be accurate for transient

condition because Equation 1.3 applies only for
steady-state condition.
Example 2: Blending process
Possible control strategies

Method 2: Measure 𝒙𝟏 and adjust 𝒘𝟐 .

Example 2: Blending process
Possible control strategies

Method 3: Measure 𝒙𝟏 and 𝒙, adjust 𝒘𝟐 .

• Combination of Methods 1 and 2.

Method 4: Use a larger tank.

• If a larger tank is used, fluctuations in 𝑥1 will tend to be
damped out due to the larger capacitance of the
tank contents.
• However, a larger tank means an increased capital
cost.
Example 2: Blending process
Possible control strategies

Measured Manipulated
Method Category
variable variable
1 𝑥 𝑤2 FB
2 𝑥1 𝑤2 FF
3 𝑥1 and 𝑥 𝑤2 FF and FB
4 - - Design change
Example 3: Complete plant
Example 3: Complete plant