Chemical Process Control

What if.

.you drive your car with

your eyes shut?

IMPORTANCE

OF PROCESS CONTROL

SAFETY
PRODUCT QUALITY
PRODUCTION RATES
REDUCE ENERGY

Why

we need to control a process?

Because processes are dynamic changes

always occurred
What

does a control system do?

Maintain certain variables within some limit

e.g temperature in a room

*dynamic
time-dependent behavior of a process.

There

are many applications where part or

all of a process has to be controlled. e.g.
temperature
pressure
flow
level
composition
others

Automatic

Control

Maintaining the process variables (temperature,

pressures, flows, compositions) at some
desired operating value.
Systems that control the variables without
requiring intervention from the operator.

System

input
SYSTEM

output

VARIABLES

Controlled variables the variable that must be maintained at

the desired value (set point)

Manipulated variables the variable that need to be regulated

in order to maintain the controlled variable at the set point

Disturbances variables that tend to drive the controlled

variable away from the set point

c. Uncontrolled variables. Variables in the process that are

not controlled.

An Everyday Example of
Process Control
Control Objective (Setpoint):
Maintain the temperature in the room (27oC)
Controlled variable:
Temperature in the room
Manipulated variable:
Speed of the fan
Disturbance:
Weather

An Everyday Example of Process

Control
Driving a Car
Control Objective (Setpoint):
Maintain car in proper lane.
Controlled variable-

Location of car on the road

Manipulated variableOrientation of the front wheels
DisturbanceCurve in road

Exercise
Select one control objective from a simple process and
determine the controlled variable, manipulated variable and
disturbances of the process.

HEAT EXCHANGER
Steam in

Fluid in

Fluid out
Heat Exchanger

Ti

T desired
Steam out

HEAT EXCHANGER
Steam in
(Manipulated variables)
(Controlled variables)
Fluid out

Fluid in
Heat Exchanger
Ti
(Load disturbances )

T desired
Steam out
(Uncontrolled variables)

THREE BASIC COMPONENT OF

CONTROL SYSTEM
Measurement (M)
measure the variable to be controlled.
sensor-transmitter
combination
Decision (D)
Controller decides what to do to maintain the variables
at its desired value
feedback controller
Action (A)
System must take an action based on controllers
decision
control valve (final control element)

Another

important term

Set point (SP)-desired value of the control variable.

Open loop system - The behavior with no
controllers in the system
Closed loop system the controller is connected to
the process, comparing the set point to the
controlled variable and determining and taking
corrective action

Action
Steam in

SP

Decide

TC
TT

Fluid in

Fluid out
Heat Exchanger

Ti

T desired
Steam out

Measured = T desired (sensor transmitter)

Control = Steam in
Action = valve (final control element)

Measure

Steam in
(Manipulated variables)

TC
TT

Fluid in

Fluid out
Heat Exchanger

Ti
(Load disturbances )

T desired
(Controlled variables)

Steam out
(Uncontrolled variables)

Question

- How to ensure that T remains at or near the

set point?
w ,T
1

w, T

Unit 1: Process & Instrumentation Diagram

Process & Instrumentation Diagram (P&ID)
Purpose
1. To indicate the instruments or control devices attached to the process.
2. To indicate the control system architecture associated with the process.

How it is done?
Standard symbols and notations representing instruments or control devices
are placed to the pipings and vessels.Standard symbols and notations are
available from ISA-5.1(1984) standard.

Methodology?
Process piping and sub-piping

A thick straight line represent main process piping

A thin straight line represent process sub-piping either
to instruments or by-pass process line.

Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

PG

Unit 1: Process & Instrumentation Diagram

Symbols
Instruments / control devices:

A circle representing locally

mounted instrument

A circle with horizontal line A circle with horizontal line

representing control room inside a square representin
panel mounted instrument.
its function in DCS.

Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

Unit 1: Process & Instrumentation Diagram

Final control elements

Control
valves

Manual
valve

O
R

Manual

O
R

valve

Solenoid
valve

Not darkened
Always open

Darkened Always
closed

Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

Unit 1: Process & Instrumentation Diagram

Naming rule

P
T
L
F
A

Measurement

Device

Device / Condition

Condition

Controller
Transmitter
Recorder
Indicator
Alarm
Switch /
Safety
Gauge

C
T
R
H
L
V

Pressure
Temperature
Level
Flow
Analysis

C
T
R
I
A
S
G

Controller
Transmitter
Recorder
High
Low
Valve

H
L

High
Low

Complete guide on P&ID symbols & notations are available from ISA 5.1 (R1984)
Examples

PC
PIC
LG
FR
TAL
TALL
TAHL

Pressure Controller
Pressure Indicating Controller
Level Gauge
Flow Recorder
Temperature Alarm Low
Temperature Alarm Low Low
Temperature Alarm High Low

PCC
PTC
PTR
PIR
TRR
TRA
TAV

No such
devices
yet.

Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

Transmission signal
3

principle type of signals in in in process

industries
Signal

Range

Pneumatic

3 15 psig

Electrical

4 20 mA
1 to 5 V

Digital/discrete

Usually

signal is in percent

Example

0-100% = 3-15 psig

Symbol

Signal

are used by devices transmitters,

controllers, final control element to
communicate.

Change

type of signal using transducer /

converter

Example of transducer
Current to pneumatic (I/P)
Digital-to-analog (D to A)
Pneumatic to current (P/I)

Steam in
(Manipulated variables)

TC
TT

Fluid in

Fluid out
Heat Exchanger

Ti
(Load disturbances )

T desired
(Controlled variables)

Steam out
(Uncontrolled variables)

Unit 1: Process Control Loop

Process control loop

Process

Sensor

Transmitter

Controller

Transducer

Control valve

Pressure
Flow
Level
Temperature
pH
dP cell
Capacitance
Radar, Sonic
Magnetic
Resistance
IR/Laser
4-20 mA
1-5 Vdc

PID
Fuzzy logic

4-20 mA
3-15 psig

Linear
Equal percentage

Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

I/P

Unit 1: Tutorial 1

02:01

Can you read the following P&ID.

Main process line
Process instrument piping
Temperature transmitter
Temperature controller

product
Feed

Flow controller

TT

Current to pnuematic transducer

Control valve

Fuel

Electrical signal

Pneumatic signal
Temperature controller DCS function

I/P

12

11 Automatic shut down PLC unit

12 Solenoid valve

Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

FC

TC SP

FT
ASD

11

TC

Regulatory and servo control

For

process that the controlled variable

deviates from set point because of
disturbance regulatory control

For

process that the most important

disturbance is the set point itself servo
control