Industrial Process Control

SKEE 4173
CHAPTER 1
Introduction To Process Control

The importance of process control.
Control theory basics
Components of control loops and ISA
symbology
Controller algorithms and tuning
Process control systems
Control objectives and benefits

3

Industrial Process Control 2014
Define process
Define process control
Describe the importance of process control
in terms of variability, efficiency, and safety

4

Define process

5

methods of changing or
refining raw materials to
create end products
Define process

6

methods that are used to
control process variables
when manufacturing a
product
Define process

7

Manufacturers control the production
process for three reasons:
Reduce variability
Increase efficiency
Ensure safety

8

Reduce variability (Process Variability)

9

Increase Efficiency
Some processes need to be maintained at a
specific point to maximize efficiency.
Combined Heat & Power Device.
Producing efficient output with only 10%
loss

10

Power
Heat
Ensure safety
Precise process control is required to ensure
safety
For example, maintaining proper boiler
pressure is crucial in preventing boiler
implosions that can clearly threaten the
safety of workers

11

12
Feed

Methane
Ethane (LK)
Propane
Butane
Pentane
Vapor
product
Liquid
product
Process
fluid
Steam
You built it as designed and .
You lost $100,000 per week; no one
would buy your product. .
Also, it polluted Pasir Gudang
Then, the pump was damaged $$$.
Then, an explosion killed 2 workers
13
Feed

Methane
Ethane (LK)
Propane
Butane
Pentane
Vapor
product
Liquid
product
Process
fluid
Steam
F1
F2 F3
T1
T2
T3
T5
T4
T6 P1
L1
A1
L. Key
We need to be able
to drive the
process
We need an active
element that uses
measurements to
influence the process
14
Feed

Methane
Ethane (LK)
Propane
Butane
Pentane
Vapor
product
Liquid
product
Process
fluid
Steam
F1
F2 F3
T1
T2
T3
T5
T4
T6 P1
L1
A1
L. Key
We need to be able
to drive the
process
We need an active
element that uses
measurements to
influence the process.
This can be automated
Control Theory Basics
symbology

15

The control loop
Process Control Terms

16

The control loop

17

Required Tasks
1. Measurement
2. Comparison
3. Adjustment
18

The control loop
Chapter 1 Introduction to Process Control 3
Elements of a Process Control System
Figure 1-2 illustrates the essential elements of a process control system. In
the system shown, a level transmitter (LT), a level controller (LC), and a
control valve (LV) are used to control the liquid level in a process tank.
The purpose of this control system is to maintain the liquid level at some
prescribed height (H) above the bottom of the tank. It is assumed that the
rate of flow into the tank is random. The level transmitter is a device that
measures the fluid level in the tank and converts it into a useful measure-
ment signal, which is sent to a level controller. The level controller evalu-
ates the measurement, compares it with a desired set point (SP), and
produces a series of corrective actions that are sent to the control valve.
The valve controls the flow of fluid in the outlet pipe to maintain a level in
the tank.
Thus, a process control system consists of four essential elements: process,
measurement, evaluation, and control. A block diagram of these elements is
shown in Figure 1-3. The diagram also shows the disturbances that enter
or affect the process. If there were no upsets to a process, there would be
no need for the control system. Figure 1-3 also shows the input and output
of the process and the set point used for control.
Figure 1-2. Process level control: Example
Liquid
H
LT
100
Control
Valve
Liquid
LC
100
LV
100
Level
Transmitter
Level
Controller
Hughes-Basics4ed.book Page 3 Wednesday, September 6, 2006 4:38 PM
1. What do you
want to measure?
2. What do you
compare your
measurement with?
3. What do you adjust
to obtain the required
measurement?
19

The control loop
Process control block diagram
the tank.
Liquid
H
LT
100
Control
Valve
Liquid
LC
100
LV
100
Level
Transmitter
Level
Controller
20

The control loop
the tank.
Liquid
H
LT
100
Control
Valve
Liquid
LC
100
LV
100
Level
Transmitter
Level
Controller
21

The control loop
the tank.
Liquid
H
LT
100
Control
Valve
Liquid
LC
100
LV
100
Level
Transmitter
Level
Controller
Process variable, Measured/Controlled variable
and Manipulated variable
Setpoint
Error
Offset
Load disturbance
Control algorithm
Manual and automatic control
Closed and open control loops

22

Setpoint
Error
Offset
Load disturbance
Control algorithm

23

2 Measurement and Control Basics
cess material more efficiently. Such procedures are called automatic
because no human (manual) intervention is required to regulate them.
All process systems consist of three main factors or terms: the manipu-
lated variables, disturbances, and the controlled variables (Figure 1-1).
Typical manipulated variables are valve position, motor speed, damper
position, or blade pitch. The controlled variables are those conditions
such as temperature, level, position, pressure, pH, density, moisture con-
tent, weight, and speed that must be maintained at some desired value.
For each controlled variable there is an associated manipulated variable.
The control system must adjust the manipulated variables so the desired
value or set point of the controlled variable is maintained despite any
disturbances.
Disturbances enter or affect the process and tend to drive the controlled
variables away from their desired value or set point condition. Typical dis-
turbances include changes in ambient temperature, in demand for prod-
uct, or in the supply of feed material. The control system must adjust the
manipulated variable so the set point value of the controlled variable is
maintained despite the disturbances. If the set point is changed, the
manipulated quantity must be changed to adjust the controlled variable to
its new desired value.
For each controlled variable the control system operator selects a manipu-
lated variable that can be paired with the controlled variable. Often the
choice is obvious, such as manipulating the flow of fuel to a home furnace
to control the temperature of the house. Sometimes the choice is not so
obvious and can only be determined by someone who understands the
process under control. The pairing of manipulated and controlled vari-
ables is performed as part of the process design.
Figure 1-1. Process control variables
Process
Disturbances
Controlled
Manipulated
Variables
Variables

24

the tank.
Liquid
H
LT
100
Control
Valve
Liquid
LC
100
LV
100
Level
Transmitter
Level
Controller
Process Variable?
Measured/ Controlled
Variable?
Manipulated Variable?
Common Process Variables:
Pressure
Flow
Level
Temperature
Density
Ph (acidity or alkalinity)
Mass
Conductivity

25

Setpoint
Error
Offset
Load disturbance
Control algorithm

26

Setpoint/ reference point
Error
Offset
Load disturbance
Control algorithm

27

Open loop system
28

Closed loop system
Setpoint
Error
Offset
Load disturbance
Control algorithm

29

Offset is a sustained
deviation of the process
variable from the setpoint.
Example
In the temperature control
loop example, if the control
system held the process fluid
at 100.5 C consistently, even
though the setpoint is 100 C,
then an offset of 0.5 C exists.
Setpoint
Error
Offset
Load disturbance
Control algorithm

30

undesired change in one of
the factors that can affect the
process variable.
Setpoint
Error
Offset
Load disturbance
Control algorithm

31

a mathematical expression of
a control function.
32

Manual and Automatic Control
symbology

33

Primary element/sensor
Transducer, Converter, Transmitter
Signal

34

Primary element/sensor
Pressure sensing diaphragms, strain
gauges, capacitance cells
Resistance temperature detectors (RTDs)
Thermocouples
Orifice plates
Pitot tubes
Venturi tubes

35

Transducers/ Transmitters/
Converter
A transmitter is a device that converts a reading
from a sensor or transducer into a standard signal
and transmits that signal to a monitor or controller.
Pressure transmitters
Flow transmitters
Temperature transmitters
Level transmitters
Analytic (O2 [oxygen], CO [carbon monoxide],
and pH) transmitters

36

Signals
Pneumatic signal (3-15 psig)
Analog signal (4-20 mA)
Digital signal

37

symbology

38

39

Controllers
Local
controller
Final Control Elements
final control element is part of the control
system that acts to physically change/ adjust
the manipulated variable.
Examples; valve, pump, solenoid

40

The Instrumentation, Systems, and
Automation Society (ISA)

Developed a set of symbols for use in
engineering drawings and designs of control
loops.

Piping and Instrumentation Drawing (P&ID).
41

The Instrumentation, Systems, and
Automation Society (ISA)

Piping and Instrumentation Drawing (P&ID).
Diagram in the process industry which shows
the piping of the process flow together with the
installed equipment and instrumentation
42

43

Valves
44

Pump
Directional arrows showing the
flow direction
45

Piping and connection
46

Identification letters and tag numbers
48
Example (Heat exchanger).
Device for efficient Heat
transfer from one
medium to another
49
Appendix A
50
Appendix A
51
Appendix A
52
Appendix A
53
Appendix A
A control valve which
should go to the open
position on control signal
failure.
54
Fail open or Fail
close?
55
A Chemical Engineering Example:
A chemical reactor with recycle
a. Can T4, the reactor feed temperature be controlled by feedback?
(Hint: determine which valves have a causal effect on T4.)
b. Select the best valve to control T4 if more than one valves are possible.
Yes, strong
Valve 1 :
Influence the
flow rate
through the
heat exchanger
Valve 2 : affect
the flow of
heating oil to
the feed heat
exchanger
Valve 3 :
affect flow rate of
both fresh and
recycled feed
without changing
the ratio
Valve 5,6 :
No effect
Valve 5,6 :
No effect
56
Industrial Process Control 2014 Introduction To Process Control
57
Drum
Heat Exchangers
Pump
Liquid
Vapor
Variables to be
controlled are
input flow rate,
temperature,
compostion and
pressure.
Determine sensors & final elements important variables can be
controlled.
controlled.
Select controller pairings which measured variable should be
controlled by adjusting which manipulated variable.
58
Drum
Heat Exchangers
Pump
Liquid
Vapor
FC
TC
Variables to be
controlled are
input flow rate,
temperature,
compostion and
pressure.
controlled.
controlled.
Select controller pairings which measured variable should be
controlled by adjusting which manipulated variable.

59
60

Example of P&ID
In-class
Assignment.
Identify the process
by explaining the
symbols
symbology

61

Types of controllers:
Discrete controllers
Multistep controllers
Continuous controllers

62

Discrete controllers

63

Multistep controllers

64

Continuous controllers

65

Continuous Controller Modes
Proportional Control Mode (P)
Integral Control Mode (I)
Derivative Control Mode (D)

Composite Controller Modes
Proportional-Integral (PI)
Proportional-Derivative (PD)
Proportional-Integral-Derivative (PID)

66

Controllers are tuned in an effort to:

The system responds quickly to errors.

The system remains stable (PV does not
oscillate around the SP).

67

Gain
Gain is defined simply as the change in output
divided by the change in input.

Example:
Change in Input to Controller - 10%
Change in Controller Output - 20%
Gain = 20% / 10% = 2

68

Proportional Mode
Integral Mode
Derivative Mode

69

symbology

70

Single Control Loops
Multivariable/Advanced Control
Loops
71

Feedback Control
72


73
74
Feedback Control
Feedback loop measures a process variable and sends the
measurement to a controller for comparison to set point
Control action is taken to return process variable to set point
Figure shows a transmitter that measure fluid temperature,
opens and closes hot steam valve when necessary to adjust the
fluids temperature

Pressure Control
75

Vary in speed hence able to respond to load changes and control
action quickly
Speed required in pressure control dictated by volume of process fluid
High volume systems (natural gas storage) tend to change more slowly
than low-volume system
Flow Control
76

Fast loops:response quickly to changes: fast sampling & response time
Flow transmitter produce rapid noise sensitive devices
Temperature of process fluid affects its density temperature
measurements are often taken with flow measurement and
compensation for temperature is accounted for in the flow calculation
Typically flow sensor, transmitter, controller, valve/ pump are used in
flow control loop
Level Control
77

Speed of changes depend on size and shape of process (Large
vessel takes longer time to fill), flow rate of input & outflow pipes
Final control element valve on the input and/or outflow
connections to tank
To avoid overflow, redundant level control systems are employed

Temperature Control
78

Temperature loop is relatively slow time required to change the
temperature of a process fluid
To increase speed of temperature loop response feedforward
control strategies are used
RTDs and thermocouple are typical temperature sensors used
Final control element fuel valve to a burner or a valve to some
kind of heat exchanger
Find a Piping & Instrumentation
Drawing (P&ID) Diagram of a single
control loops process (of your choice)
and explain the process of the system
briefly using the P&ID Diagram.
79
Single Control Loops
Multivariable/Advanced Control
Loops
80


Control loops in which a primary controller controls one
process variable by sending signals to a controller of a
different loop that impacts the process variable of the
primary (main) loop
Primary controller will manipulate the setpoint of the
secondary controller to maintain the setpoint temperature of
the primary process variable
Normally, the secondary loop will be tuned first before the
primary loop adjustment to secondary loop will impact the
primary loop
Feedforward Control

81

Control system that anticipates load disturbances and
controls them before giving any impact to the process
variable
Mathematical understanding of how the manipulated
variables will impact the process variable
Example : Flow transmitter opens or closes a hot steam
valve based on how much cold fluid passes through the flow
sensor
Error is prevented before
occurring, rather than
corrected
Generally used where
controlled variable has the
potential of being a major
load disturbance on the
process variable ultimately
being controlled
Feedforward Plus Feedback

82

83
Feedforward Plus Feedback
To overcome the difficulty of anticipating every possible load
disturbances in a feedforward systems, combination with
feedback system is used
Total input from feedforward and feedback loop is combined
unified signal to the final control element
Flow transmitter and temperature transmitter provide
information for controlling a hot steam valve

Methods of control currently being used in process industries.
Cascade Control

84

Control system in which a secondary (slave) control loop is
set up to control variable that is a major source of load
disturbance for another primary (master) control loop
The controller of the primary loop determines the setpoint of
the summing controller in the second loop

Methods of control currently being used in process
industries.
Batch Control

85


Those processes that are taken from start to finish in batches
Example, mixing ingredients for a juice drink
Limited amount of one flavour is mixed at one time
Not practical to have a continuous process running
Getting correct proportion of ingredients into batch
At various stages of batch processes Level, flow, pressure,
temperature, mass measurement
Disadvantage :
Process must be frequently restarted
Start-up problem all measurements are below set point
As recipe changes, control instruments need recalibration
Methods of control currently being used in process industries.
Ratio Control

86

A process which requires a ratio of certain amount to be mixed.
Example diluting acid in water
A control system can be developed to control the ratio of acid to
water though the water supply may not be controlled
Used in many applications and involves a controller that
receives input from a flow measurement device on the
unregulated (wild) flow
Controller performs a ratio calculation and signals the
appropriate setpoint to another controller that sets the flow of
the second fluid proper proportion of the second fluid can be
added
Used continuous process is going on and an additive is
being put into the flow
Methods of control currently being used in
process industries.
Selective Control
More important of two variables will be maintained
Selective control is most often used when equipment
must be protected or safety maintained.
For example, in a boiler control system, if fuel flow
outpaces air flow, then uncombusted fuel can build up
in the boiler and cause an explosion. Selective control
is used to allow for an air-rich mixture, but never a
fuel-rich mixture.

87

Methods of control currently being used in process
industries.
Fuzzy Control
The controller uses fuzzy logic to make decisions about adjusting
the process
A form of computer logic whether something is included/not based
on grading scale
Kind of artificial intelligence that will account for numerous variable,
formulate a theory of how to make improvement, adjust the process
and learn from the results
Fuzzy control is a relatively new technology removes operators
the ability but none of the responsibility to control a process

88

symbology

89

90
1. Safety
2. Environment protection
3. Equipment protection
4. Smooth operation production rate
5. Product quality
6. High profit
7. Monitoring & diagnosis
91
A process which is generally used to separate a mixture of two or more
liquids and vapor based on their boiling points by passing it to a flash drums
at a fixed temperature and pressure.
The mixture is allowed to reach equilibrium, and vapor exits at the top and
liquid exits the bottom of the drum
9
2

A
B

The process separates 2
components (A & B) based on
their different vapor pressures.
Liquid feed stream, consisting of
components A and B, is heated
using two heat exchangers.
Stream flows through a
valve to a vessel at a
lower pressure.
Due to higher T and
lower P, stream forms
two phases, vapor and
liquid.
93
1. Safety
5. Product quality
6. High profit
High pressure drum
is dangerous
Control Pressure
94
1. Safety
5. Product quality
6. High profit
High pressure drum
is dangerous
Control Pressure
95
Never release
harmful gasses to
atmosphere
To flare for
combustion
96
Flow of liquid is
controlled
LC
97
The production
rate need to be
kept smooth
98
5. Product quality
Level Key is achieved
by adjusting the
heating
99
6. High profit
Use the least
costly
heating
10
0
Calculate & plot key
parameters
10
1
1. Safety
5. Product quality
6. High profit
All seven must be
achieved
Otherwise the process
can be unprofitable, or
worse unsafe

10
2
Manufacturers control the production
process for three reasons:
Reduce variability
Increase efficiency
Ensure safety

103

Remember this?
1
0
4

When we control a process, variability of the process key variables are
reduced seven objectives achieved
1
0
5

When we control a process, variability of the process key variables are
reduced seven objectives achieved
What statistics can
we calculate from
this data?
How do we relate
variability to process
peformance?
Reduced key variables
variation economically
beneficial
Variations of key plant
variable frequency
distribution
Increase variation broader
distribution of frequency
1
0
6

1
0
7

Hence, the
effectiveness of
control in max profit
depends on
reducingthe
temperature
variations
Small variations
temperature can be
operated very close
to maximum
constraint
Fired heater
(furnace) with a
chemical reaction
occurring as fluid
flows through the
pipe
Temperature of the
reactor must be held
minimum (no reaction)
and maximum (metal
damage)
When economic
favors increased
conversion feed
profit increases as
temperature
increases
From data
temperature varies
about the desired
value due to
disturbance fuel
composition and
pressure
1
0
8

Base case reactor
temperature plant
performance with
poor control
Uses tighter
distribution
improved control
1
0
9

Calculating average performance of the process
yield the following equation:
M
j
j j ave
P F P
1
P
ave
=average process performance
F
j
=fraction of data in interval j=N
j
/N
T
N
j
=Number of data points in interval j
N
T
=total number of data points
P
j
=performance measured at the midpoint of interval j
M=number of intervals in the frequency distribution
1
1
0

T;
Temperature
Pj;Performance
measured at the
midpoint of interval
Fj; Fraction of
data in interval
Improved performance
reduce variance &
increase average
temperature
Comparing Operation A and B

11
1

QUESTION??
11
2

Industrial Process Control

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