Process Control

CME 321

Chapter 1

Introductory Concepts

Dr. Hadil Abu Khalifeh

 PLANT OBJECTIVE
To maximize profits by transforming raw materials into
useful products while satisfying a number of important
criteria:
1. Safety: to protect well-being of plant personnel
and nearby communities.
2. Environmental Regulations: to comply with
environmental regulations concerning air and
water quality as well as waste disposal.
3. Product specifications: product specification,
concerning quality and production rate, must be
met.
4. Operational Constrains: process variables
must satisfy certain other operating constrains
 Introduction
In the chemical industry,

the design of a control system is essential to ensure:

Good Process Operation
Process Safety
Product Quality
Minimization of Environmental Impact
 Introduction
What is the purpose of a control system?
“To maintain important process characteristics at desired
targets despite the effects of external perturbations.”

Perturbati Processing
Plant objectives
ons

Safety
Market Make $$$
Economy Environment...
Climate Control
Upsets...
 Introduction
What constitutes a control system?
Control

Combination of process
sensors, alarms, actuators and multi-function
platform

computer systems designed and tuned

to orchestrate safe and profitable
operation.

Plant
 Introduction
• Process Dynamics:
– study of the transient behavior of processes

• Process Control
– the use of process dynamics for the improvement
of process operation and performance
or/and
– the use of process dynamics to alleviate the effect
of undesirable (unstable) process behaviors
Dynamics and Control
• Process Dynamics - time varying behaviour
of a process
• study of the transient behavior of processes

• Process Control – maintain process

conditions at their desired values by
manipulating certain process variables to
adjust the variables of interest
 Introduction
What do we mean by process?
A process, P, is an operation that takes an INPUT or a DISTURBANCE
and gives an OUTPUT
u
y
P
d

Information Flow
INPUT : (u) Something that you can manipulate
DISTURBANCE : (d) Something that comes as a result of some outside
phenomenon
OUTPUT : (y) An observable quantity that we want to regulate
 Examples: Driving an automobile
wind

Friction Engine Power

Inputs Output
(D)• Wind speed
(D)• Friction
Process Speed (SP,CV)
(MV) • Engine Power (Driving an automobile) (SP,CV)
Direction
(MV) • Steering position
(MV) • Break position
Examples of Modern Control Systems
Desired Actual
Driver Steering Car
Course of Course of
Travel Travel
Sensing

• Control Objective (Setpoint): Maintain

car in proper lane.
• Controlled variable- Location on the
road
• Manipulated variable- Orientation of
the front wheels
• Actuator- Driver’s arms/steering wheel
• Sensor- Driver’s eyes
• Controller- Driver
• Disturbance- Curve in road
the cruise control on an automobile:
The purpose of a cruise control is to maintain
the speed of the vehicle (controlled variable)
at the desired value (set point)
despite variations in terrain, hills, etc. (disturbances)
by adjusting the throttle, or the fuel flow to the engine (manipulated
variable).
 Examples:
 Controlling room temperature

TT
temperature heat loss
sensor/transmitter (disturbance)

QoutTin

fuel flow furnace

valve Fin Process T
©
 Examples: Stirred Tank
 Control variable, (CV)
 Measured Process Variable (PV)
M  Set Point (SP)
 Controller Output (CO)
Tin, w 

Manipulated Variable (MV)
Disturbances (D)

T, w
Q
Qout T RPM
Inputs Output
Tin
w Process T
Q
Examples of Manual Control Systems
 Process Flow Diagram:
Feedback Control – You are in the Shower

Main
supply
temp
Hot/Cold Main
Room
Knob supply
flow temp
text

Inputs Output
H. Valve position Temp.

C. Valve position Process Flow

Shower Pipes
(Hot and
Cold)

Cold

Hot
 Control Terminology
controlled variables - these are the variables which
quantify the performance or quality of the final
product, which are also called output variables.
Chapter 1

manipulated variables - these input variables are

adjusted dynamically to keep the controlled variables
at their set-points.
disturbance variables - these are also called "load"
variables and represent input variables that can
cause the controlled variables to deviate from their
respective set points.

16
 Control Terminology(2)

set-point change - implementing a change in the

operating conditions. The set-point signal is
changed and the manipulated variable is adjusted
Chapter 1

appropriately to achieve the new operating

conditions. Also called servomechanism (or "servo")
control.
disturbance change - the process transient
behavior when a disturbance enters, also called
regulatory control or load change. A control system
should be able to return each controlled variable
back to its set-point.

17
 Example - Shower
• controlled variables - variables to be regulated
– total flow, temperature

• manipulated variables - variables that are

adjusted
– Position of hot water tap
– Position of cold water tap
 Control Loop Block Flow Diagram:
Feedback Control - You are in the Shower
Hot/Cold Water
Temperature
Brain Disturbance
(D)

Your Personal Your Hand

Temperature Turning Hot/Cold Shower Water
Preference the Knob Actuator Water Flow Temperature
 Brain Process
Set Point+ Error Controller (valve) Manipulated Controlled
Output Variable Variable
(SP) - (e)
(CO) (MV) (CV)
Hot/Cold Knob Shower Pipes
(Hot and Cold)

Signal from Receptors to Brain Sensor /

Measured Controlled Variable Transmitter

Hot/Cold Receptors in your Skin /

Nerves

Error = SP-CV
Hot water tank control system • The desired hot water
temperature is selected by you (120
to 140 F).
• Assume that the set point is
130F.
• The thermocouple measures the
temperature of the water in the
tank /sends a signal to the
thermostat
• The thermostat (controller)
determines the error as
Error= Tset point- Tmeasured
Error is >0 , thermostat opens the fuel valve to the burner which adds
heat to the tank.
Error is < 0, thermostat closes the fuel valve and no heat is added
to the tank.
• The ability to maintain the process variable at its desired
value in spite of disturbances that might be experienced (this
is termed disturbance rejection )

• Disturbance rejection is sometimes called the

“load problem”
• The ability to move the process variable from one setting to a
new desired setting (this is termed set point tracking )
– move to new target values
• change to warmer temperature
– frequently for economic reasons
• grade changes to satisfy different customers
• summer vs. winter gasoline

• Also known as the “servo problem”

Industrial Example: Heat Exchanger
STEAM

FY TC

TT

PROCESS FLUID

HEAT EXCHANGER

(Process Instrumentation Diagram)

 Control Loop Block Flow Diagram:
Feedback Control - Heat Exchanger Steam Temp.
Disturbances
D

Air to Process Fluid

Process Fluid Actuator Steam Flow Temp.
Controller Manipulated Controlled
Temp. Desired Output Variable Variable
Set Point Error Actuator
 Controller Process
SP + e CO (valve) MV CV
-
TC Valve Heat Exchanger

Temp. Signal from TT to TC

Controlled Variable
(Measured Value) Sensor /
CV Transmitter

TT
Controller ‘sees’ the effect of its action.
 Definition of Control
Use of manipulated variable to
maintain the controlled variable at the
set point in spite of the disturbances
The three main components of all control systems:
•Sensor/transmitter
•Controller: the brain of the control system
•Final control element: often a control valve, variable speed pumps,
electric motors.

The three basic operations in every control system:

•Measurement: measuring the variable to be controlled by
sensor/transmitter
•Decision: on the basis of the measurement, the controller
decides what to do to maintain the variable at its desired value.
•Action: based on the controller decision, the system take an
action by the final control element.
 Control Objectives
• Safety - paramount
– maintain proper operation to avoid dangerous situations
– emergency systems
• pressure relief valves
• automatic reactor shutdown systems

• Environmental Protection
– proper operation and containment
• prevent tanks from overflowing
• maintain low concentrations of undesirable compounds in
effluent
 Control Objectives
• Equipment Protection
– proper operation and shutdown at limiting
conditions
• prevent pumps from running dry
• prevent furnace tubes from getting too hot

• Smooth Operation
– for both inputs and outputs
• be a good neighbour
• minimize disturbances to integrated units
 Control Objectives
• Product Quality
– Maintain composition, physical properties and
performance properties of products within
customer specifications

After these objectives have been

satisfied, we can focus on profit.
 (a) Closed loop Control System and
(b) Open-Loop Control System

(a)

(b)
 Closed-loop Artificial Pancreas
glucose u
setpoint
y
r

controller pump patient sensor

measured glucose
 Transmission signals:
pneumatic signal, or air pressure
(3 and 15 psig).

electrical signal normally ranges (4

and 20 mA)

Transducer, or converter.: change from an electrical signal in

milliamperes (mA) to a pneumatic signal in (psig): (I/P)
An analog to-digital converter (A to D) changes from a mA, or a
volt signal to a digital signal.
Other types of transducers: digital-to-analog (D to A), pneumatic-
to current (P/I), voltage-to-pneumatic (E/P), pneumatic-to-voltage
(P/E), and so on. The term analog (either pneumatic or electrical).
Controllers: microprocessor-based.
 Process Instrumentation Diagram:
CONTROLLER
Feedback Control – Basic Format
TE Temperature
Temp. 101 Element
TC
Set 101
Point
TT Temperature
Current to pneumatic TT
101 Transmitter
(I/P) converter 101
TRANSMITTER

TC Temperature (line in middle indicates

101 Controller remote control)
FY
ACTUATOR 101
TE
SENSOR
101 FE Flow
Cooling
101 Element
Manual
Water
Valve
Pneumatic Valve (automatic valve)

Electrical Signal (4-20 mA)

Pneumatic Signal (3-5 psig)

(arrow indicates flow/signal direction)
Material Flow Line

Often the sensor is integrated into the transmitter and the I/P converter is integrated into a
position controller or “valve positioner” on the actuator that is also not shown on the P&ID.
 Control Strategies
• EX 1. Continuous stirred-tank heater
Assume that inlet temperature changes with time. How can
we ensure that T remains at or near the set point TR?

Figure 1.1. Continuous stirred-tank heater.

• Possible Strategies
1. Measure T and adjust Q .
2. Measure Ti and adjust Q.
3. Measure T and adjust w.
4. Measure Ti and adjust w.
5. Measure T and Ti and adjust Q.
6. Measure T and Ti and adjust w.
7. Place a heat exchanger on the inlet stream.
8. Use a large tank.
• Classification
1 & 3; Feedback control
2 & 4; Feedfoward control
5 & 6; Feedfoward-Feedback control
7 & 8; Design change
 CONTROL STRATEGIES
SP
1)Feedback control
TC
Controller
Final control
element
Steam

Transmitter
Process TT
fluid
Ti(t) T(t)
Sensor
T
Condensate
return

The feedback controller works with minimum knowledge of the

process provides corrective action for unmeasured disturbances
The disadvantage of feedback control:Can compensate for a
disturbance only AFTER the controlled variable has deviated
from the set point because of the disturbance.
 (2) Feedforward control

 measure the inlet

temperature/process flow

 Feedforward controller
makes the decision about how
to manipulate the steam valve
to maintain the controlled
variable at set point.
The feedforward control

The feedforward control is a very common control

strategy in the process industries. It is the simplicity
that accounts for its popularity.
The objective of feedforward control is to measure
the disturbances and compensate for them before
the controlled variable deviates from the set point.
Eliminate measured disturbances before the
controlled variable is upset
 Feedback Control:
• Distinguishing feature: measure the controlled variable
• Advantages:
 Corrective action is taken regardless of the source of
the disturbance.
 Reduces sensitivity of the controlled variable to
disturbances and changes in the process (shown later).
• Disadvantages:
 No corrective action occurs until after the disturbance
has upset the process,
 Very oscillatory responses, or even instability…

41
Feedforward Control:
 Distinguishing feature: measure a disturbance
variable
• Advantage:
 Correct for disturbance before it upsets the process.
• Disadvantage:
 Must be able to measure the disturbance.
 No corrective action for unmeasured disturbances.

42
 The disadvantage of feedforward control

In this example,
1. disturbance variable
must be measured
2. no corrective action for
unmeasured disturbances
 Feedforward control with feedback control

Feedforward control now compensates for the “major” disturbances,

while feedback control compensates for all other disturbances.
Justification 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

45
 3.2 Economic Incentives - Advanced
Control
Chapter 1

46
 Chapter 1

47
Feedback Control
o One of the simplest process control schemes.
o A feedback loop measures a process variable and sends the
measurement to a controller for comparison to set point. If the process
variable is not at set point, control action is taken to return the process
variable to set point.
o The advantage of this control scheme is that it is simple using single
transmitter.

LC
Fluid in
LCV-100
V-100
LT

Fluid out
V-100
Feedback Control (cont…)
o Feedback loop are commonly used in the process control industry.
o The advantage of a feedback loop is that directly controls the desired
process variable.
o The disadvantage of feedback loops is that the process variable must
leave set point for action to be taken.

LC
Fluid in
LCV-100
V-100
LT

Fluid out
V-100
Example
Figure below shows the liquid vessel for boiler system. This
system has to maximum desire temperature of 120 oC (L2)
where the heater will be cut off when the temperature reached
desired temperature. Draw feedback control loop for the
system.
TC

Fluid in

V-100 TT

Fluid out
V 100
 Feedforward Control
 Feedforward loop is a control system that anticipates load disturbances
and controls them before they can impact the process variable.
 For feedforward control to work, the user must have a mathematical
understanding of how the manipulated variables will impact the process
variable.

FC

FT Process variable need to be

Fluid in controlled = Temperature
TI
Y

Steam Fluid out

LCV-100
Feedforward Control (cont…)
o An advantage of feedforward control is that error is prevented, rather than
corrected.
o However, it is difficult to account for all possible load disturbances in a
system through feedforward control.
o In general, feedforward system should be used in case where the
controlled variable has the potential of being a major load disturbance on
the process variable ultimately being controlled.

FC

FT Process variable need to be

Fluid in controlled = Temperature
TI
Y

Steam Fluid out

LCV-100
Example
Figure below shows compressed gas vessel. Process variable
that need to be controlled is pressure where the vessel should
maintain pressure at 60 psi. This pressure controlled through the
gas flow measurement into the vessel. By using feedforward
control system, draw the loop.

FC

FT Process variable need to be

PI controlled = Pressure
V-100
Feedforward-plus-Feedback Control
o Because of the difficulty of accounting for every possible load
disturbance in a feedforward system, this system are often
combined with feedback systems.
o Controller with summing functions are used in these combined
systems to total the input from both the feedforward loop and the
feedback loop, and send a unified signal to the final control element.


FC TC

FT Process variable need to be

Fluid in controlled = Temperature
TT

Steam Fluid out

LCV-100
Example
Figure below shows compressed gas vessel. Process variable that need to be
controlled is pressure where the vessel should maintain pressure at 60 psi. By
using pressure controlled through both the gas flow measurement into the
vessel and vessel pressure itself, draw a feedforward-plus-feedback control
loop system.

PIC

PT
FC

FT Process variable need to be

controlled = Pressure
V-100