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BKF 3843

PROCESS CONTROL &


INSTRUMENTATION

By:
Junaidi Bin
Zakaria
FKKSA, UMP

JUNAIDI BIN ZAKARIA


 A3-2-9

 013-9683471/09-5492914
 junaidibz@ump.edu.my


ASSESSMENT METHOD
TEST 1 20%
TEST 2 20%
QUIZZES 10%
ASSIGNMENTS 10%
FINAL EXAM 40%

 TOTAL 100%
CHAPTER REVIEW
CHAPTER 1

Introduction to Process Control

By:
Junaidi Bin
Zakaria
FKKSA, UMP
Task
In your own words,
 - what is process control &
instrumentation
 - explain the importance of process
control
Learning Objectives
Describe the importance process control
Define and identify controlled, manipulated
variables and disturbance for a given
process
Explain the implementation of process
control in industries
Explain feedback and feedforward control
Why do I learn Process Control and Instrumentation Course

When I run a kinetics experiment, how do I


maintain the temperature and level at desired
values?
How do I manufacture products with
consistently high quality when raw material
properties change?
How much time do I have to respond to a
dangerous situation?

Why Is Control Necessary?
Control System
Process control principle
Qin
 How to keep the level
at
 desired value, H?

h
H

Qout
Control System
Process control principle
Qin Human Aided Control

The equipment has


the local gauge/
side tube
Controlled variable-
H liquid level
h
Manipulated
variable-valve
Qout
What will cause the
level high/ low?
Control System
Process control principle

Qin Automatic control


Sensor
 Machine, electronic, or
s Controller computer replace
human operation
u

h Actuator

Qout
Categories of control systems
1. Servomechanisms – change an output
variable
2. Regulators – hold an output variable

st chemical process are regulators, eg. Feedback and Feed


What is control?

Control
To maintain desired conditions in a
physical system by adjusting selected
variables in the system .

Control System
The control systems appear to have
three basic elements which is

FINAL
SENSOR CONTROLLER ELEMENT

16
SENSOR

-The first task that of acquiring information about the


process output
variables.
-Sensors are usually needed for pressure, temperature ,
liquid level , flow
and composition measurement .
-thermocouple: temperature measurement
-differential pressure cell: for liquid level measurements
-gas/liquid
Transmitter: chromatographs:
How process composition
information measurements
acquired by the sensor get back to
the controller, and the controller decision gets back to the process

CONTROLLER

-The decision maker,and hence the ‘heart’ of the control system

FINAL
ELEMENT

-Pump, variable speed fans, compressor, conveyors


17
DISTURBANCE

INPUT OUTPUT
Process
sensor
Final control element

Transmitter

Transmitter
Decision
Controller INFORMATION

The feedback control configuration


18
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.
Task 1
You are implementing control manually
Task 2
State your own objective for this chemical
reactor.
List the controlled, manipulated variables
and disturbance(s)
Answer for Task 2
Level and Temperature Control
L
C

T
C
Answer for Task 2
Composition Control
A
C
Classification of process control strategies

JIGSAW
General Form of Control System Configuration
Disturbances variable

PROCESS

Manipulated variable
Controlled variable

Structure of Open-loop System (struktur bg sistem gelung terbuka)

28
FEEDBACK
Uses direct measurements of the controlled variables to adjust the
values of the manipulated variables.

FEEDFORWARD
Uses direct measurements of the disturbances variables to adjust
the values of the manipulated variables.

29
Method 1
Method 2
Feed Back Feed Forward
Disturbances
variable
Manipulated controller Disturbances
variable Controlled variable
Process variable
Process
Manipulated Controlled
controller variable variable

Advantages
§It does not required identification and §Acts before the effects of a disturbances has
measurement of any disturbance. been felt by the system
§It is not sensitive to modeling errors. §Is good for slow systems or with significant
§It is not sensitive to parameter dead time
changes. §It does not introduce instability in the closed
-loop response

Disadvantages

§It wait until the effect of the §Required identification & measurement of
disturbances has been felt by the disturbances
system §Cannot cope with unmeasured disturbance
§It is unsatisfactory for slow processes §Sensitive to process parameter variations
§It may create instability in the close- §Requires good knowledge of the process control
loop response

35
Instrumentation Symbols
Symbols of instruments used in
process controls drawings :
A: Analyzer
F: Flow rate
L: Level of liquid or solids in a vessel
P: Pressure
T: Temperature
C: Controller
V: Valve

36
(days-months ) 5. Planning and
Scheduling

( hours-days ) 4. Real-Time
Optimization

( minutes-hours ) 3b. Multivariable


and Constraint
Control

( seconds-minutes ) 3a. Regulatory


Control

(< 1 second ) 2. Safety, Environment


and Equipment
Protection

(< 1 Second ) 1. Measurement


and Actuation

Process
Case Study
Case 1: High pressure is dangerous.
Case 2: No flow could damage the pump
Case 3: High temperature may cause
thermal loading in the column
Case 4: Quality of product at the bottom
column is the most critical
Case 5: Keep the process at smooth rate,
avoid dry column

Case 1
Case 2
Case 3
High thermal loading

T
C
Case 4
Adjusting the heating and flowrate
Case 5
THANK YOU

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