Fakulti Kejuruteraan Kimia

UiTM Pulau Pinang

CHE 314 Basic Instrumentation and Control

INTRODUCTION TO PROCESS
CONTROL

CHAPTER 1
 Topic Covered
• Definition of Process Control
• Control System
• Process Control Block Diagram
• Continuous and Discrete Process Control
• Analog and Digital Processing
• Piping & Instrumentation Diagram (P&ID)
• Feedback, Feedforward, and Cascade Controls
System
• Off-On Control, Proportion, Integral and Derivative
Control Mode
• Response of Control System
 Definition of Process Control
• What do you understand about :
1. PROCESS
2. INSTRUMENTATION
3. CONTROL
 Definition of Process Control
• Process
= material -------------------------------------> product
mechanical, electrical, physical, chemical

control
• Control
• Instrumentation = device of
 Why Control is Important
1. Safety
2. Product specification
3. Environmental regulations
4. Operation Constraints
5. Economics
 Why do you need process
control?
• Safety
– Pressure
– Temperature
• Product quality specifications and production rate
– Maintain specifications of product (no oscillation)
• Environmental Regulations
– Flow rates of effluents from plants must be within
allowable limits
Why do you need process control?
• Operational constraints
– Tanks must not overflow
– Distillation columns must not be flooded
• Economics
– Economical utilization of raw materials,
energy, capital, human labor
 Control System
Process control principle
Qin

The Process
• Self-regulation
• Qin = Q out
• Example:
h – while trouble-shooting the
H automatic control faulty
occurred at a tank by
Qout control room personnel
 Control System
Process control principle
Qin
Human Aided Control
• The equipment has the
local gauge/ side tube
• Controlled variable
• Controlling/ manipulated
H variable
h • Example:
– while trouble shooting
the faulty of automatic
control of a tank by site
Qout personnel
 Control System
Process control principle
Qin Automatic control
Sensor • Machine, electronic,
s
Controller or computer replace
human operation
u
• s = proportional signal
h Actuator of sensor
• u = output signal of
controller to actuator
Qout
 Control System
Discrete-state Control System
• Concern with
controlling a sequence
of events
• Example: chemical
packaging
– Weight of chemical
– Drying rate
– Temperature of drying
– Pouring into the bag
– Sewing the bag
 Parts of Control System
Process-Control Block Diagram

p Final Control
element

Transmitter u
e=r-b
r Controller Process

b
Measurement
Analog & Digital
Processing
 Analog ~ continuous
 Digital  computer ~ discrete
 On/Off Control – majority
 Data representation
Analog & Digital
Processing
 Smart sensor
– device with small housing contains
complete set of measurement and control
including analog – digital or digital –
analog converter.
 Programmable Logic Controller (PLC)
– Discrete-state control
– Direct digital control
Piping & Instrumentation
Diagram (P&ID)
 Essential elements
– specific symbol and tag
– ANSI and ISA
 Instrument line symbol
– Current, pneumatic, electrical, and digital data
feed
 Instrument symbol
 PLEASE REFER APP.5 Process Control
Instrumentation Technology
 To vent

CL 6
Cooling
CL 3 Utility In
Di
TIC
CL 5
CL 7
FIC Pumparound HX-2
PIC Point
Cooling Utility
P Reflux Out
LIC

FIC Point
Sd

Re
CL 4

Pump-2

CL 2 Controller
TIC: Temperature Indicator Controller
Hot Hot LIC FIC: Flow Indicator Controller
Utility HX-1 Utility LIC: Level Indicator Controller
In Out TIC PIC: Pressure Indicator Controller

Equipment
Pre-Cut Column
HX: Heat Exchanger

B CL 1
Stream
Pump-1 B: Bottom Flow Rate
Re: Reflux Flow Rate
Sd: Sidedraw Flow Rate
P: Pumparound Flow Rate
F: Feed Flow Rate
Di: Distillate Flow Rate

Symbol
CL: Control Loop
 Positive and Negative
Feedback, Feedforward
Chapter 4

and Cascade Controls

Systems
Chapter 4

Positive Feedback
Negative Feedback
Chapter 4
 Feedback control
Advantages:
• Corrective action occurs as soon as the
Chapter 4

controlled variable deviates from the set point.

• Feedback control requires minimal knowledge
about the process to be controlled; it particular,
a mathematical model of the process is not
required, although it can be very useful for
control system design.
 Feedback control
Disadvantages:
• No corrective action is taken until after a
Chapter 4

deviation in the controlled variable occurs.

• It may not be satisfactory for processes
with large time constants and/or long time
delays.
• In some situations, the controlled variable
cannot be measured on-line.
 Feedforward Control
Advantage:
• Measure important disturbance variables and
Chapter 4

take corrective action before they upset the

process.
Disadvantages:
• The disturbance variables must be measured
on-line.
• The quality of feedforward control depends on
the accuracy of the process model.
Cascade Control
 An exothermic chemical
reactor
Chapter 4
 Simple feedback control
Chapter 4
 Simple feedback control
• Measure T and manipulate coolant flowrate.
• T will response faster when changes in inlet
Chapter 4

temperature, Ti than to changes in coolant

temperature, Tc.
• Therefore, the feedback controller effective
in compensating for changes in Ti and less
effective in compensating for changes in Tc.
 Cascade control
Chapter 4
 Cascade Control
• Measuring Tc and taking the control action
before its effect has been felt by the
Chapter 4

reacting mixture.
• If Tc increase, increase the coolant
flowrate to remove the same amount of
heat.
 • Feedback control configuration
~ one measurement and one manipulated
variable in a single loop.

• Cascade control
Chapter 4

~ More than one measurement and one

manipulated variable.
~ Useful when the disturbances are
associated with the manipulated variable.
~ Two control loops using two different
measurement but sharing the same
manipulated variable.
 Cascade control
• The output signal of the primary controller
serves as the set point for the secondary
Chapter 4

controller
• The two feedback control loops are
nested, with the secondary loop inside the
primary loop.
• There are two controlled variable, two
sensor and one manipulated variable.
 Simple Feedback Control
Chapter 4

DI DII
Set point + +
Process II + Process I +
GcI(s)
+
-

Measuring
device
 Cascade Control
Primary Loop
Chapter 4

DI DII
Secondary Loop

Set point + +
GcI(s) GcII(s) Process II + Process I +
+
- -

Measuring device

Measuring device
 Cascade Control (multi-loop)
• Distinguishing features:
1. Two FB controllers but only a single control valve (or
other -final control element).
2. Output signal of the "master" controller is the set-
Chapter 4

point for “slave" controller.

3. Two FB control loops are "nested" with the "slave"
(or "secondary") control loop inside the "master" (or
"primary") control loop.

• Terminology

slave vs. master

secondary vs. primary
inner vs. outer
Chapter 4

Y1 GP Gd 2

D2 1  GC 2GV GM 2  GC 2GV GM 1GC1GP
 On – off, Proportional,
Integral, Derivative Control
modes
 Topic Covered
• On – off control
• Proportional control
• Proportional-Derivative control
• Proportional-Integral control
• Proportional-Integral-Derivative control
• General tips for designing a PID controller
 Topic Outcome
• Able to understand the characteristics of
the each of proportional (P), the integral
(I), and the derivative (D) controls.
• Able to use them to obtain a desired
response.
 Introduction
• Consider the following unity feedback system:
• Plant: A system to be controlled
Controller: Provides the excitation for the plant; Designed
to control the overall system behavior
 On – off control

• a thermostat is a simple negative-feedback control: when the

temperature (the "measured variable" or MV) goes below a set point
(SP), the heater is switched on.
• Another example could be a pressure-switch on an air compressor:
when the pressure (MV) drops below the threshold (SP), the pump is
powered.
 The three-term controller
• Kp = Proportional gain
• Ki = Integral gain
• Kd = Derivative gain
 The characteristics of P, I, and
D controllers
CL RESPONSE RISE TIME OVERSHOOT SETTLING TIME S-S ERROR
Kp Decrease Increase Small Change Decrease
Ki Decrease Increase Increase Eliminate
Kd Small Change Decrease Decrease Small Change

The goal of this problem is to show you how each of Kp, Ki and Kd
contributes to obtain:

• Fast rise time

• Minimum overshoot
• No steady-state error
Open-loop step response

Self-regulated
• The rise time is about one
second, and the settling time is
about 1.5 seconds.
• Let's design a controller that
will reduce the rise time,
reduce the settling time, and
eliminates the steady-state
error.
Proportional control

The proportional controller

reduced both the rise time
and the steady-state error,
increased the overshoot, and
decreased the settling time
by small amount.
Proportional-Derivative
control

This plot shows that the

derivative controller reduced
both the overshoot and the
settling time, and had small
effect on the rise time and the
steady-state error.
Proportional-Integral control

• We have reduced the proportional

gain (Kp) because the integral
controller also reduces the rise
time and increases the overshoot
as the proportional controller does
(double effect).
• The above response shows that
the integral controller eliminated
the steady-state error.
Proportional-Integral-
Derivative control

Now, with PID gain, we have

obtained the system with no
overshoot, fast rise time, and
no steady-state error.
 General tips for tuning a PID
controller
• Obtain an open-loop response and determine what needs to be
improved
• Add a proportional control to improve the rise time
• Add a derivative control to improve the overshoot
• Add an integral control to eliminate the steady-state error
• Adjust each of Kp, Ki, and Kd until you obtain a desired overall
response.

You can always refer to the table shown in this "PID Tutorial" page
to find out which controller controls what characteristics.
 Summary
• Lastly, please keep in mind that you do not
need to implement all three controllers
(proportional, derivative, and integral) into a
single system, if not necessary. For example, if a
PI controller gives a good enough response (like
the above example), then you don't need to
implement derivative controller to the system.
Keep the controller as simple as possible.