Control and Instrumentation

of Chemical Processes

Prof. Cesar de Prada

Dpt. of Systems Engineering and Automatic
Control
UVA
[email protected]
Control and Instrumentation

 Course Information
 Basic concepts and course aims
 Programme
 Activities
 Laboratory
 Methodology
 Marking
 Course Information
Type: Compulsory, 10.5 credits (3 Instrumentation+ 7.5 Control)
Year: 4th, annual code 44316
First semester: Thursdays 9 to 11h
Timetable: Second semester: Mon., Tues. and Wednesdays 11 to 12h.
Classroom : ISA Seminar
Second semester: Tuesdays from 16 to 18 h, 18 to 20 h.
Lab. Two groups. Systems Engineering and Automatic Control
Timetable: Lab. Bottom floor, right hand wing of the Faculty, at the end
of the corridor.
Cesar de Prada Moraga, Dpt. Systems Engineering and
Course Automatic Control (ISA) / Mª Jesus de la Fuente (Spanish)
Faculty: Instrumentation topics 1.2 and 1.3 given by.M.A.Urueña
Dpt. of Chemical Eng. In the first semester

WEB page: www.isa.cie.uva.es/~prada + Moodle

 Task of a Chemical Eng.
Refrigerante
PT PC

Design
TT

LT LC
R
Alimentación F

TC FC FT
D
TC

FT FC TT

Vapor V LT

FT

FC LC

B
Build a process Operation Automatic Control
according to
some The process must
specifications function
autonomously in
Manage the process under the desired way
changing conditions
Process control
Manual operation of a process

Observe the level

Compare with desired value
Decide the valve position
Act on the valve
Manual operation of a process
Observe the temperature
Compare with desired value
Decide about the valve position
Act on the valve
Heater
Thermometer
 Process operation

Compare
Changes Process responses
Decide
Process
Act Observe
Dynamical response

Open loop or manual operation

 Automatic operation
Substitutes
the human Process
operator Changes responses

Regulator Process
Act Measure
Desired values

Closed loop or automatic operation

Feedback
Automatic operation

Measure the level

Compare with desired value
Decide the valve position
Act on the valve

LT LC
Automatic operation
Measure the temperature
Compare with desired value
Decide about the valve position
Act on the valve
Heater

TT TC
 Components of a control loop
Variables
to be controlled
Manipulated DV, v
y, CV, PV
Variables u, MV, OP
Regulator /
Actuator Process
Controller
Desired
y
Values x
(EU)
w, SP
Transmitters
Measurements
The course will deal with the
controllers and the closed loop
behaviour
 Heat exchanger

DV

MV TC TT
P/I 12 12

CV
Process Dynamics
Liquid level
time

Valve
opening time
 Coolant
PT PC

TT

LT LC
R
Feed F

TC FC FT
D
TC

TT
Process control requires:
FT FC
1 understand the process
Steam V LT (&closed loop) dynamics
FT 2 maintain some variables
FC LC close to its desires values
B in spite of disturbances
 Control and Instrumentation
PT PC

TT

R
F
TC FC
TC

FC TT

V LT
FT
FC LC

In modern process factories, the control of the

process is performed from control rooms using
distributed control systems (DCS). The course will
give also an overview of control technology
 Aims of the course
 Acquire basic concepts and a working methodology in:
 Systems Dynamics
 Automatic Control
that allow the student to:
 Understand the dynamic behaviour
 model
 analyse
 Design
 Implement and operate
automatic control systems in the process industry.
 Acquire practical experience on instrumentation, tools and
computer systems used in process control.
 Abilities the student should
acquire
Develop mathematical models for dynamic processes.
Obtain process dynamics from step response data.
Familiarity with block diagrams and process and
instrumentation diagrams.
Analyze process stability and dynamic responses
Familiarize with PID feedback controllers and tuning
methods.
Design control structures for a process (feedforward
control, cascade control, etc.)
Awareness of multivariable process interactions
Familiarize with process control technology
 PSE Process Systems
Engineering
 The course belong to the field of Process Systems
Engineering (PSE)
 PSE is the body of knowledge in chemical
engineering that deals with the systematic modelling
and development of tools and solution methods for
synthesis, analysis and evaluation of Process Design,
Process Control and Process Operation and
Optimization
 PSE is a field where multiple disciplines cooperate in
order to find useful solutions: from chemical, control,
electrical, etc. engineering, to applied mathematics,
basic sciences (biology, physics, etc.) and computer
science.
Systems Methodology
 Analyse the process
 Formulate the problem in mathematical terms
 Take into account its dynamics and
interactions
 Analyse and solve the problem with the
appropriate methods and tools
 Interpret the results in terms of the reality
 Apply the solutions
Programme
 1 Introduction
 Instrumentation
 Controllers
 Programmable logic controllers
 2 Dynamical models
 3 Linear systems analysis
 4 Design and implementation of process
control systems
 Bibliography
Control e Instrumentación de procesos químicos, Ollero, Fdez.-Camacho, Edt. Sintesis,
1997
Ingenieria de control moderna, Ogata, Edt. Prentice Hall Inter. 4ª edc, 2003
Process Dynamics, Modeling and Control, B.A. Ogunnaike, W.H. Ray, Oxford Univ. Press,
1994
Principles and practice of Automatic process control ,Smith,Corripio, Edt. John Wiley,
2006
Essentials of process control,W.L. Luyben, M.L. Luyben, Edt. Mc Graw-Hill, 1997
Process modeling, simulation and control for chemical eng., Luyben, Edt. McGraw Hill, 1990
Process Dynamics, Modelling, Analysis and simulation, B. Wayne Bequette, Edt. Prentice
Hall, 1998
Automatic Tunning of PID Regulators, Astrom, Hagglund, Edt. ISA, 1995
Tuning of industrial control systems, A. B. Corripio., Edt. ISA, 1990
Manual de instrumentación y control de Procesos, Edt. Alción, 1998
Control Avanzado de Procesos, José Acedo Sanchez, Edt. Diaz de Santos 2002
Control systems Engineering, N.S. Nise, 2ª edic. Addison Wesley, 1995
Process Dynamics and Control, D.E. Seborg, T.F. Edgar, D.A. Mellichamp, J. Willey, 1989
The Condensed Handbook of Measurement and Control, N.E. Battikh, Edt. ISA, 2nd Edition,
2003
Books
 Lecture notes
 The slides of the course in
PowerPoint can be found
in:
 www.isa.cie.uva.es/~prada
 Lab work
 Previous exams
 [email protected]
 Also in Moodle
Moodle http://campusvirtual.uva.es/

The registered e-mails will be used in

all communications with the students
 Laboratory
Aim: Learn by doing

Practice the theory

Familiarize the student
with the tools and control
technologies
Two types of processes:

• Simulated processes
• Lab plants with
industrial instrumentation
and computer control
Forum, discussion groups,
systems
Internet
Laboratory
Topics:
1. Lab plants, Instrumentation, Simulation environment
(CStation), PLCs, Real time control software (JavaRegula)
2. Process Modelling and Identification (EcosimPro, Cstation)
3. Analysis of dynamical systems (Matlab, Simulink)
4. PID controllers and control structures (JavaRegula, Cstation,
EcosimPro)

Four compulsory reports (one per group (3 student max.)):

1. Logic control PLC. Report due on February
2. Process modelling. Report due on March
3. System Analysis. Report due on April
4. Control design. Report due on May

Oral presentations of selected groups

Groups can be organized by the students’ representatives
 Control room Simulator
 Control room of a
sugar factory
 Developed in the
CTA by ISA
 Two groups per
day
 Starting April the
16th
 Visits to industries

ACOR Olmedo factory (Valladolid)

Control rooms and process instrumentation
December 2012

Petronor, Muskiz petrol refinery (Vizcaya)

Process and control rooms / Advanced control systems
9th May 2013(Registration until 26th April)

In cooperation with the ISA (International Society of

Automation) student section, UVA
http://www.isa.org/ http://www.isa-spain.org
 Conferences

"Control Predictivo Multivariable"

Rafael Gonzalez, Petronor, 9nd May 2013

“Hacia la excelencia en Automatización”

Raquel Mateos, Honeywell, Presidenta de ISA-España, 8 Marzo

In cooperation with ISA (International Society of Automation)

student section, UVA
 CEA-ISA contest
Organized jointly by ISA and CEA with the aim of providing challenging
problems to students interested in control

http://www.ceautomatica.es/og/control-inteligente/concurso-en-
ingenieria-de-control-2013-0

http://youtu.be/-7yW2yhJ3LQ
 ISA papers

ISA european student competition to the best student paper.

(ESPC'12). The papers can deal with any topic related to
instrumentation, control, systems, automation, etc.
They will be publish in the EuroXchange Journal. 4-6 pages.
Closing date: 25th March
 Marking
 The Instrumentation topics (1.2 y 1.3) given by Dr.
Urueña Dpt. Of Chemical Eng. in the first semester
have an independent exam and will weight 25 % of
the final mark.
 The control topics will weight 75% of the final mark.
 In order to pass the course, it is necessary to pass
both parts, or compensate the marks, assuming that
at least 4 points have been obtained on each one.
 The marks are valid during the whole academic year.
Marking 2nd semester
(Control)
 Lab reports (30%) Assuming that at
least 4 points have been obtained in
the exam.
 Lab contest to the best presentation.
Prize: 2 points in the exam.
 Exam (70%)
 EuroXchange Journal (ISA)


 Prize CEA- ISA estudiantes

 Prize Empresarios Agrupados
 Prize Omron
 ….
 Marking 2nd semester
(Control)

Exam: 5th June 2013 / 16th July 2013

Exam:
 2 problems (3 h., open book)

 a set of questions (theory + exercises) (1 h. closed

book)

Marking: 60 % problems and 40 % questions. Minimum

mark for compensation: 4

Examples of typical exams can be found in the web page .

Doubts / Questions, etc.
 I shall be available in my room at the Dpt.
of Systems Engineering and Automatic
Control. Ground floor, right wing of the
Faculty
 E-mail:
 [email protected]
 [email protected]

 Dissertation projects
 Several projects are available for those students wishing to
develop his final degree project with the ISA department. They
cover applications in the petrochemical and sugar industry, pilot
plant development, CERN, energy, etc.
 Topics in: http://www.isa.cie.uva.es/~prada/
 The doors are open for those students wishing to collaborate in
current research projects develop with ISA partners: Repsol-
Petronor, CERN, HYCON2, SYSGAS, EA, CTA etc. Topics cover
modelling, simulation, advanced control, process optimization, etc.
 Other projects can be developed with pilot plants in the lab.
 Research work: Also, a set of projects is offered to those students
that wish to develop a research project (1 -15 credits).
 Complementary courses
 They will give you an specialization in the Process
Systems Engineering field
 Control por computador
 Informática aplicada a la Ingeniería Química
 Sistemas de supervisión de procesos