CHE 239

PROCESS CONTROL &

INSTRUMENTATION

NURUL HAZWANI SABRI

CHEMICAL ENGINEERING FACULTY, UITM PASIR GUDANG
CHAPTER 1
INTRODUCTION TO PROCESS CONTROL

– Introduction to Process Control

– Historical & modern control systems
– Parts of control systems
– Feedback, feed forward and cascade control systems
– On-off control systems, Proportional, Integral and Derivative control modes
– Operation and response of control system
– Advanced Control System
Aim
To describe the fundamental of various types of process
control system used in related chemical industries.

Course Learning Outcomes

After completing this course, the students should be able
to:
 Define and explain the parts that form control systems.
 Recognize/explain/differentiate various types of control
systems such as feedback feed forward and cascade.
 Explain the on-off, proportional (P),integral (I) and
derivative (D) control modes.
 Explain operational principle and response/tuning of PID
control modes.
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 WHAT

WHEN WHY
CHEMICAL
PROCESS
CONTROL

HOW WHERE
Definition of Process Control & Instrumentation

Process
control &
Process instrumentation
control
Process

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 Process
orefers to the methods of changing or refining raw
materials to create end products.

 Process industries
o chemical industry,oil & gas industry,food & beverage
industry, pharmaceutical industry, water treatment industry,
power industry.

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 Process Control

o Methods used to control process variables when

manufacturing a product and consists of the process plant
and the control equipment.

o Can be very simple system (domestic hot water

system), to highly complex system (automatic oil refining
plant).

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 Process
= material -------------------------------------> product
mechanical,electrical,physical,chemical

control

 Control
 Instrumentation = device = controller, actuator,sensor

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 PRODUCT PRODUCTION
QUALITY RATE

REDUCE
SAFETY
ENERGY
Process
control
– What does a control system do?
– Maintain certain variables within some limit
e.g temperature in a room

– Why we need to control a process?

– Because processes are dynamic – changes always occurred,
and processes are not in steady state.
 There are many applications where part or all of a
process has to be controlled. e.g.
 temperature
 pressure
 flow
 level
 composition
 others
HISTORICAL OF PROCESS CONTROL
Manual process
Automatic process
– Manual Control
– Before process automation, people rather than machines,
will performed many of the process control tasks. Control
operations that involve human action to make an
adjustment are called manual control systems.

– Automatic Control
– Control operations in which no human intervention is
required, are called automatic control systems
BASICS OF
CONTROL
THEORIES
HEAT EXCHANGER

Steam in

Fluid in Fluid out

Heat Exchanger
Ti T desired

Steam out
THREE BASIC COMPONENT OF
CONTROL SYSTEM
 Measurement (M)
◦ measure the variable to be controlled.
 sensor-transmitter combination

 Decision (D)
◦ Controller decides what to do to maintain the variables at its desired value
 Single control loop (feedback control loop)
 Multi-variable control loop/ advanced control loop

 Action (A)
◦ System must take an action based on controller’s decision
 final control element ( control valve or pump or actuator)
 PROCESS CONTROL TERMS
◦ Process Variables (PV) – condition of the process fluid (a liquid or gas) that can
change the manufacturing process.
◦ Measured Variables - condition of the process fluid that must be kept at the
designated set point
◦ Set point (SP)- desired value of the control variable.
◦ Manipulated Variables (MV) - The factor that is changed to keep the measured
variable at set point
◦ Disturbance Variables (DV) – undesire/unsteady process condition that effect the
process output
◦ Error - difference between the measured variable and the set point and can be
either positive or negative
◦ Offset – sustained deviation of the process variable from the set point
◦ Open loop system - The behavior with no controllers in the system
◦ Closed loop system– A closed control loop exists where a process variable is
measured, compared to a set point, and action is taken to correct any deviation
from set point.
 Action
SP Decide
Steam in
TC

TT Measure
Fluid in Fluid out
Heat Exchanger
Ti T desired

Steam out

Measured = T desired (sensor transmitter)

Control = Steam in
Action = valve (final control element)
 SP

Steam in
TC
(Manipulated variables)

TT
Fluid in Fluid out
Heat Exchanger
Ti T desired

(Load disturbances ) (Controlled variables)

Steam out
(Uncontrolled variables)
 Open Loop Control System
• Also called a non-feedback controller,.(No control system)

• The characteristic :

o Does not use feedback to determine if its output has achieved

the desired goal of the input. This means that the system does
not observe the output of the processes that it is controlling.
o Do not engage in machine learning.
o Do not correct any errors that it could make.
o Do not compensate for disturbances in the system.

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 CONTROLLER ACTUATOR OUTPUT
INPUT To make Gives an PROCESS The result
What you changes in the output of The procedure of your work.
need. system if some action or activitieas The impact.
Your goal needed designed to leading to The result
(if error exist) change the co the result of system

Figure 1.1: Open loop system block diagram

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Closed Loop Control System

• Also known as a feedback control system. Control mode is on.

• The reference to “feedback”, simply means that some portion

of the output is returned “back” to the input to form part of
the systems excitation.

• Closed-loop systems are designed to automatically achieve and

maintain the desired output condition by comparing it with
the actual condition.

• It does this by generating an error signal which is the

difference between the output and the reference input

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 CONTROLLER ACTUATOR OUTPUT
INPUT To make Gives an PROCESS The result
What you changes in the output of The procedure of your work.
need. system if some action or activitieas The impact.
Your goal needed designed to leading to The result
(if error exist) change the co the result of system

SENSOR
To check
how well
the system
works

Figure 1.2: Closed loop system blockdiagram 26

o Uses a measurement of the output and compare with the set
point value to create the error signal which is amplified by the
controller.

How feedback control works

o Feedback control is applied to achieve the desired output

by adjusting manipulated variable.
o Sensor is designed to communicate with controller and final
control element responds to the command from the controller.

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• In practical applications, feedforward control is normally used
in combination with feedback control.
• Feedforward control is used to reduce the effects of
measurable disturbances, while feedback is used to track
the set point change to make the corrective action in
order to compensates for inaccuracies in the process
model, measurement error and unmeasured
disturbances.