Fakulti Kejuruteraan Kimia

UiTM Cawangan Johor ,

Kampus Pasir Gudang
CHE 314 Basic Instrumentation and Control

INTRODUCTION TO PROCESS CONTROL

CHAPTER 1
Compiled by : Mohammad Bin Abdullah

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.
2.
3.
4.
5.

Safety
Product specification
Environmental regulations
Operation Constraints
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
H
Qout

while trouble-shooting the

automatic control faulty
occurred at a tank by
control room personnel

Control System

Process control principle

Qin

Human Aided Control

The equipment has the
local gauge/ side tube
Controlled variable
Controlling/ manipulated
variable
Example:

H
h

Qout

while trouble shooting

the faulty of automatic
control of a tank by site
personnel

Control System

Process control principle

Qin
Sensor

Controller
u

Actuator

Qout

Automatic control
Machine, electronic,
or computer replace
human operation
s = proportional signal
of sensor
u = output signal of
controller to actuator

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

Transmitter

Final Control
element
u

e=r-b
r

Controller

Process
c

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
CL 3

Cooling
Utility In

Di
TIC
CL 5

Pumparound
Point

FIC
PIC

LIC
FIC

Sd

HX-2

Reflux
Point

Re
CL 4

F
Pump-2

CL 2

Hot
Utility
In

HX-1

Hot
Utility
Out TIC

LIC

Pre-Cut Column
B

CL 1

Pump-1

Controller
TIC: Temperature Indicator Controller
FIC: Flow Indicator Controller
LIC: Level Indicator Controller
PIC: Pressure Indicator Controller
Equipment
HX: Heat Exchanger
Stream
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

CL 7

Cooling Utility
Out

Chapter 4

Positive and Negative

Feedback, Feedforward
and Cascade Controls
Systems

Chapter 4

Positive Feedback
Negative Feedback

Chapter 4

Chapter 4

Feedback control
Advantages:
Corrective action occurs as soon as the
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.

Chapter 4

Feedback control
Disadvantages:
No corrective action is taken until after a
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.

Chapter 4

Feedforward Control
Advantage:
Measure important disturbance variables and
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

Chapter 4

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
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.

Chapter 4

Cascade control

Chapter 4

Cascade Control
Measuring Tc and taking the control action
before its effect has been felt by the
reacting mixture.
If Tc increase, increase the coolant
flowrate to remove the same amount of
heat.

Chapter 4

Feedback control configuration

~ one measurement and one manipulated
variable in a single loop.
Cascade control
~ 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.

Chapter 4

Cascade control
The output signal of the primary controller
serves as the set point for the secondary
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.

Chapter 4

Simple Feedback Control

DI
Set point
+

GcI(s)

Process II

Measuring
device

DII
+

Process I

Cascade Control
Chapter 4

Primary Loop

DI

Secondary Loop
Set point
GcI(s)
+

GcII(s)

Process II

Measuring device

Measuring device

DII

Process I

Cascade Control (multi-loop)

Chapter 4

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 setpoint 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

GP Gd 2
Y1

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-IntegralDerivative 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.