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Introduction to
Process Dynamics and Control,
y
and Instrumentation Laboratory

WhatshouldIcontrol?Whereonthe
processdoIputmycontrolloops?
d I t
t ll
? AsI
A I
proceedwiththedesignofaprocess,
whataspectsofcontrolshouldIconsider
atwhichstages?

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Process Control
and Instrumentation
Instrumentation
Controllers
Sensors
Transmitters
Final Control Elements
P
Process
Analysis
A l i
Process Model
Development/Solution
Process Dynamics
1st, 2nd, higher order

Analysis
A
l i and
dD
Design
i
of Control Systems
Time/Laplace Domain
Frequency Domain
Advanced Control Methods

Definitions
What is Control?
methods to force parameters in the environment
to have specific values
e.g. controlling of room temp
Control System
elements necessary to accomplish the control
objective

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Definitions
Process Control
study of automatic control principles
applied to chemical processes
applies principles of mathematics and
engineering science to the regulation of the
dynamic operation of process systems

Definitions
Process Control
study of elements and methods of control
system operation used in industry to
control industrial processes
any condition, natural or artificial, by
which a physical quantity is regulated

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Main Functions
Set point tracking
the ability to shift from one desired
operating point to another
Disturbance rejection
the ability to maintain an operating point
despite fluctuating conditions and external
forces

Hierarchy of Control Objectives

1. Safety
2. Environmental
Protection
3. Equipment Protection
4. Smooth Plant Operation
5. Product Quality
6 Profit Optimization
6.
7. Monitoring and
Diagnosis

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Advantages of Process Control

allows basic operation by product tracking and
inventory
ensures safety
y byy preventing
p
g dangerous
g
situations
guides startup, shutdown, and setpoint tracking
saves energy, material, and time
reduces waste and maintains product quality

Applications of Control Systems

industrial processes, manufacturing, robotics
consumer g
goods,, home appliances
pp

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Applications of Control Systems

computers, networks, communications systems
transportation
p
systems,
y
, cars,, planes,
p
, aircraft

Simple Process Control

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Ancestor of Automatic Control

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Process Control Principles

The main objective of process control is to
regulate the value of a certain quantity
To regulate means to maintain a certain
quantity at some desired value
The desired value is called the setpoint or the
reference value
The actual value of the variable is called the
control point

Self-Regulation

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Human-Aided (Manual) Control

Controlled Variable
Setpoint

Manipulated Variable

Inthecontrolsystem,weadjustthe
manipulatedvariable
i l t d
i bl tomaintainthe
t
i t i th
controlledvariable atitssetpoint.

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Automatic Control System

Automatic Control
Sensor
measures the value of the level and
converts it to a signal
Controller
a machine, electronic circuit, or a
computer that accepts the signal
Actuator
receives the output signal to change the
valve settings

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Identification of Elements
The Process
flow of liquid in and out of the tank
the tank and the liquid
all the are under control with respect to fluid
level
could be single or multivariable

Identification of Elements
1. Measurement
used to get some information about the variable
being controlled
refers to conversion of a variable into some
corresponding analog of the variable (pneumatic
pressure, electrical voltage or current)
a sensor is used to perform the initial
measurement
a transducer converts one signal to another
further transformation of the signal to an
information that can be used by other elements in
the system is called signal conditioning

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Identification of Elements
2. Controller
examines the error presented by the detector
determines the appropriate action that should
be undertaken by an operator
computers are widely used in process controls
because of the capability of decision-making and
handling multi-variables
requires input of controlled variable and set
point
Error Detector
part of the controller device that determines the
kind of error in the system

Identification of Elements
3. Control Element
the final element in the process control that
exerts direct influence on the process
provides the required changes to bring the
controlled variable to the set point
the valve adjust the liquid outflow from the tank

Final Control Element

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What is a loop?

the loop is the complete circuit formed when a signal

flows through measurement, error detection, controller,
and final controlling

Open Loop (Command)

there is no feedback mechanism

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Open Loop
non-feedback controller
computes inputs by comparing the current
state and its model
does not observe the output of the
process that it controls
cannot correct errors and may be affected
by disturbances in the system

Open Loop
used in well-defined systems where the
relationship between the input and the
resultant state can be modeled by a
mathematical formula
e.g. irrigation sprinkler, washing machines

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Disturbance

Input

Process

Output

Closed Loop (Regulation)

there is a repeating series of actions

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Feedback Control
a controller reacts to the error between the
setpoint and the process value
Low Cost Operation
its structure and algorithm are independent of
the process since it only reacts to the error
Poor Performance
an error is always present
Easy and Simple
tuning methods are always the same

Disturbance
Output
Input

Process
Adjustment

Measurement
Controller
Setpoint

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Two-knob Faucet Shower

Disadvantages of Feedback
Large magnitude disturbance
Large time delay

http://www.see.ed.ac.uk

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Feedforward Control
designed to compute the output of the
controller to ensure the process variable is
unaffected by any predictable disturbances
in the process
process conditions are monitored and
compared with a model system
if conditions deviate from the model they
are altered
e.g. regulation of heartbeat, heater
systems

Feedforward Control
Expensive Solution
the solution is unique and each controller
is different
algorithms are expensive and it cannot be
tuned easily
Good Performance
since the error is predicted, almost no
error is present

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Disturbance
Feedforward

Input

Process

Output

Block Diagrams
the block diagram of a control loop defines
all the basic elements and signals involved in the
process

Setpoint, r

Controlled Variable, c

Measured Representation, b

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Process Flow Diagrams (PFD)

simple illustration that describes the
primary flow path to a unit
includes primary equipment and flows of
chemicals through the unit

Sections: Feed, preheating, the process, and final products. Left-toright approach.

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A process flow diagram of an amine treating system for the removal

of gaseous hydrogen sulfide from gas streams. It is widely used in oil
refineries and chemical plants.

Piping and Instrumentation

Diagrams (P&ID)
analogous to circuits schematics
graphic representation of equipment,
piping, and instrumentation
uses symbols to represent elements in a
process-control system
developed
p by
y Instrument Society
y of
America (ISA)

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Purpose of using P&ID

to have a common language for
instrument technicians, process engineers,
and suppliers
to properly document plant designs for
installation in a graphical format
to help in equipment maintenance, failure
analysis,
a
a ys s, a
and
d troubleshooting
oub es oo g

systematic illustration of functional relationships of piping,

instrumentation, and system equipment components

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P&ID Symbols and Guidelines

identify process lines from instrument
lines
identify the location of the instrument
identify the function of the instrument
provide other relevant information

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P&ID Signal and Process Lines

uses lines that denotes the particular nature of the signal

P&ID Symbols
for Sensors
and Elements

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Balloon Symbols
/ Instrument Tags
denotes the actual instruments used in processcontrol
uses circles called balloon
FC means Flow Controller (nature,function)
117 denotes the loop it represents

Balloon Symbols
/ Instrument Tags
e.g. PRC 143
1. Process variable

2. Function

3. Function Modifier/
Instrument

PRC
143
PRC: pressure recording controller on loop #143

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P&ID Symbols for Transducers

and other Elements

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Constructing an
Instrument Flow Sheet
1.
2
2.
3.
4.

Identify your process

Define your control objective/s
Create a process flow diagram
Identify the needed equipment and process
lines
5. Determine the instrument and connecting lines
needed
6. Extract information with ISA symbology
convention
7. Apply the ISA codes to identify instrument and
functions

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