Faculty of Chemical Engineering

UiTM Pulau Pinang

At the end of this chapter, student should be able to:

 Describe the significance of automatic control

 Sketch the standard P&ID drawing
 Develop P&ID for any given chemical processes
 Explain the various types of controllers
 Differentiate between DCS , SCADA and PLC
system
 Propose suitable control strategies for a chemical
process
 What if….

….you drive your car with

your eyes shut?
 Objective :

 To adjust the manipulated variable to maintain

the controlled variable at its set point in spite of
disturbances
1. Safety
2. Product quality
3. Environmental regulations
4. Operation Constraints
5. Economics
 Safety
◦ Pressure
◦ Temperature
 Product quality specifications and production
rate
◦ Maintain product quality (composition, purity, color,
et.c) on a continuous basis
◦ Maintain plant production rate at minimum cost
 Environmental Regulations
◦ Flow rates of effluents from plants must be within
allowable limits
◦ Protect the environment by preventing emissions and
minimizing waste
 Operational constraints
◦ Tanks must not overflow
◦ Distillation columns must not be flooded
 Economics
◦ Economical utilization of raw materials, energy,
capital, human labor
 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
 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
output
SYSTEM
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.
Control Objective (Setpoint):
Maintain the temperature in the room (27oC)

Controlled variable:
Temperature in the room

Manipulated variable:
Speed of the fan

Disturbance:
Weather
 Exercise I

Select one control objective from a simple process and

determine the controlled variable, manipulated variable and
disturbances of the process.

For example : How to control the temperature of the water from

a common shower?
 Steam in

Fluid in Fluid out

Heat Exchanger
Ti T desired

Steam out
 Steam in
(Manipulated variables)
(Controlled variables)
Fluid in Fluid out
Heat Exchanger
Ti T desired
(Load disturbances )

Steam out

(Uncontrolled variables)
 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 controller’s
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
SP Decide
Steam in
TC

TT Measure
Fluid in Fluid out
Heat Exchanger
Ti T desired

Steam out

Measured = T desired (sensor transmitter)

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

Steam in
TC
(Manipulated variables)

TT
Fluid in Fluid out
Heat Exchanger
Ti T desired

(Load disturbances ) (Controlled variables)

Steam out
(Uncontrolled variables)
 Exercise II
- How to ensure that the level in the tank remains at
or near the set point?
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.

PG

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

Unit 1: Process & Instrumentation Diagram

Symbols
Instruments / control devices:

A circle representing locally A circle with horizontal line A circle with horizontal line
mounted instrument representing control room inside a square representing
panel mounted instrument. its function in DCS.

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

P&ID: Function Devices

Function devices

√  < I
P
Square root  Integrator Low selector Current to Pneumatic 
extractor Converter

Signals

Electrical signal (low current 
or low voltage e.g. 4‐20 mA).
Straight dashed line

Pneumatic signal e.g.
// // // // 3‐15 psig or 0‐60 psig.
Straight line with //

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)
Unit 1: Process & Instrumentation Diagram

Final control elements

Control
valves =

Manual = O
valve R Not darkened 
Always open

Manual = O
valve
Darkened  Always
R closed

Solenoid =
valve

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

P&ID: Notations

Naming rule
Instruments or devices are noted by 2 to 4 letters.

1st 2nd 3rd 4th

Measurement Control device Device/ Condition Condition
Common  Common control  Common condition:  Common condition: 
measurement: devices: H = High H = High
P = Pressure I   = Indicator L = Low L = Low
T = Temperature C = Controller
L = Level R = Recorder
F = Flow T = Transmitter
A = Alarm
S = Switch
G = Gauge

Examples
See Smith & Corripio (2006) as in Appendix A, Table A‐1

LT LT LC
120 120 120

Level transmitter no. 120  Level transmitter no. 120  Level controller no. 120 

installed to vessel panel mounted, control room. in DCS, control room.

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)
Unit 1: Process & Instrumentation Diagram

Naming rule
1 2 3 4
Measurement Device Device / Condition Condition
P Pressure C Controller C Controller H High
T Temperature T Transmitter T Transmitter L Low
L Level R Recorder R Recorder
F Flow I Indicator H High
A Analysis A Alarm L Low
S Switch / V Valve
G Safety
Gauge
Complete guide on P&ID symbols & notations are available from ISA 5.1 (R1984)
Examples
 

PC Pressure Controller PCC

PIC Pressure Indicating Controller PTC
LG Level Gauge PTR
No such
FR Flow Recorder PIR
devices yet.
TAL Temperature Alarm Low TRR
TALL Temperature Alarm Low Low TRA
TAHL Temperature Alarm High Low TAV

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

1.3 Construction P&ID of
Chemical Processes
Unit 1: Process & Instrumentation Diagram

Examples
Unit 1: Process & Instrumentation Diagram

Examples Instrument piping ‐ thin line

LT
120
Unit 1: Process & Instrumentation Diagram

Examples Instrument piping + field instrument – thin line + circle

LT
120
P&ID

Examples

thin process line

LT
120

thick process line

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)
 3 principle type of signals in process industries

Signal Range Symbol

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

 Signal are used by devices – transmitters,
controllers, final control element to
communicate.
• A transmitter converts the sensor output to a signal level
appropriate for input to a controller (usually a computer)
• This signal tends to be a current, in the range 4 to 20 mA
• Transmitters tend to be direct acting: the output signal
increases as the measured variable increases
• Commercial transmitters have adjustable input range (span)
and zero
 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
I/P TC
(Manipulated variables)

TT
Fluid in Fluid out
Heat Exchanger
Ti T desired

(Load disturbances ) (Controlled variables)

Steam out
(Uncontrolled variables)
 A
SP

TT TC
B

FO

 Identify the following variables.

i. Manipulated variables
ii. Disturbance variables
iii. Controlled variables
 Identify the following variables.
i. Manipulated variables
ii. Disturbance variables
iii. Controlled variables
P&ID: Process Control Loop

Process control loop

Process Transmitter Controller Transducer Control Valve

T C I/P

Flow control loop

Flow
Unit 1: Process Control Loop

Process control loop

Pressure
Flow
Level
Process Temperature
pH

dP cell
Capacitance I/P
Sensor Radar, Sonic
Magnetic
Resistance
IR/Laser

Transmitter 4‐20 mA
1‐5 Vdc

Controller PID
Fuzzy logic

4‐20 mA
Transducer 3‐15 psig

Linear
Control valve Equal percentage

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)
1.3.4 Logic Diagrams

Overview

 Most continuous process control scheme includes on‐off control.
 On‐off control can start and stop a single motor or to initiate an orderly shut down of an entire plant upon 
detection of an unsafe condition.
 P&IDs were developed to show a continuous process but on‐off control can be shown by logic diagrams.

Logic Diagrams
 A conceptual document that defines the on‐off state of a process, and depicts the scheme necessary for control.
 The basis of the information refer to ISA‐5.2‐1976‐(R1992) – Binary logic diagrams for process operations.
1.3.4 Logic Diagrams

Logic Diagrams: AND & OR
 Logic Diagrams: AND & OR. A Logic Diagram 
is set up with the inputs or actions on the 
left side of the drawing and the result, or 
results, on the right side. The AND symbol 
signifies that all inputs must exist (or all 
actions must be taken) before the result 
occurs.
 “C” occurs if and only if “A” and “B” exist or 
if action “A” and action “B” have both been 
taken. If there are more actions feeding into 
an AND, all actions must have taken place 
to get the desired result. There is no limit to 
the number of actions feeding into an AND.

 The OR symbol signifies that one or more 
inputs must exist (or one or more actions 
must be taken) if the result is to occur.
 “C” occurs if, and only if, “A” and/or “B” 
exist or if action “A” and/or “B” have been 
taken. If there are actions “A” through “Z” 
feeding into an OR, one or more of the 
actions must have taken place to get the 
desired result.
1.3.4 Logic Diagrams

Logic Diagrams: NOT & Basic Memory
 Figure shows the NOT gate and the Basic 
memory symbols. 
 The NOT symbol reverses the input. If the 
action has taken place and is fed through a 
NOT, no result will occur. If the action has 
not taken place and is fed through a NOT, 
the result will occur. 
 “B” exists if and only if “A” does not exist.

 The Basic memory symbol is more complex. 
If an action has been taken, the result will 
occur and continue to occur until another 
action takes place. The symbol has two 
outputs, and they flip‐flop. If one shows the 
action, the other will show no result.
 “C” exists as soon as “A” exists and 
continues independent of “A” until “B” 
exists. “D” exists when “C” does not.
1.3.4 Logic Diagrams

Example of Logic Diagram: Motor Start Circuit and Logic
Logic Diagram:
 For the pump to start, all three inputs to
the AND are necessary.
 The first action is to actuate the start
button.
 The next action (as “action” is used in
connection with binary logic) is not to
actuate the stop button. This action is
reversed by the NOT, and so the top two
inputs are satisfied.
 Including the “not stopped” allows you to
have a separate action to stop the motor.
The motor is not overloaded; there is no
input, and therefore, no output.
 However, there is a NOT in the line which
Explanation on electrical drawing. reverses the “no output” and the pump
To start the motor, someone depresses the start button starts.
located next to the motor or on the starter housing itself. If  In the MEMORY, a small o is placed around
the overload relay contacts are closed—that is, if the motor is or next to the S. This means that the starter
not overloaded—this action completes the circuit to the coil overload relay overrides the starter reset. In
in the motor contactor. As the coil is energized, coil contact real terms, this means that if the starter
“C” closes, or “seals” the start, and the motor starts. To stop overload relay shows an overload, the reset
the motor, the stop button is depressed. This interrupts the button will not start or jog the motor.
circuit to the contactor coil, which opens the contacts and
removes power to the motor.
 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
Unit 1: Terminology

Terminology I/P TC


Manipulated variable Heat exchanger TT

(saturated steam)
100°C 80°C

30°C
100 L/min controlled variable
(temperature of
Load variable  sterilised saline)
95°C
(Flow, temperature Uncontrolled variable
of saline solution)
(Saturated steam)

   
Controlled Manipulated variable Load variable Set point
variable
Sym: m, CO, MV Sym: Sym: r, SP, SV
Sym: c, PV
A process being “All other The desired
“The parameters adjusted (controlled) affecting operating
that indicate by a final control variable, other condition.
product quality or element (such as than the one
the operating control valve, being
condition of the damper, motor manipulated.”
process.” (L.M. speed). (L.M. Gordon)
Gordon)
Chapter 4
Chapter 4

Positive Feedback
Negative Feedback
 For example Heat Exchanger :
 If the inlet temperature decreases, thus
creating a disturbance, its effect must
propagate through the heat exchanger before
the outlet temperature decreases.
 Deviation from set point has occurred and it
must compensate for the disturbance by
manipulating the steam valve.
 Controller signals the valve to increase its
opening and thus increase the steam flow.
 It is a trial-and-error operation until the
temperature reaches and remains at set
point.
Chapter 4
Unit 1: Control strategies

Feedback control I/P TC

Heat exchanger TT
Manipulated variable
(saturated steam) 100°C 80°C
30°C controlled variable
Load variable
100 L/min (temperature of
(Flow of saline solution)
sterilised saline)

What is feedback control? 95°C

Manipulated variable
A method of control that the action taken is (Saturated steam)
based on past result.

Merit?
Simple design. Easy to tune (for linear, fast & The Process
short deadtime processes: flow, level & Saline solution at 30°C is sterilized by
pressure). heating the solution in a heat-exchanger
system to 80°C. The temperature of the
Demerits? sterilized saline solution is maintained by
Slow recovery for slow process such as regulating the control valve of steam input
temperature control upon load disturbance or to the heat-exchanger.
change in setpoint. A process with long deadtime
may exhibit oscillatory process response with
long settling time.
 Advantages:
 Corrective action occurs as soon as the
controlled variable deviates from the set
Chapter 4

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.
 Disadvantages:
 No corrective action is taken until after a
deviation in the controlled variable occurs.
Chapter 4

 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
Unit 1: Control strategies

Feedforward control I/P FFC

Cp
Ws  Wp T2  T1 
Hs

Manipulated variable
(saturated steam) Heat exchanger 80°C
FT TT
30°C controlled variable
Load variable
100 L/min (temperature of
(Flow of saline solution)
sterilised saline)

What is feedforward control? 95°C

Manipulated variable
A method of control based on process model: (Saturated steam)
mass and energy balances.

Merit? Characteristic of feedforward control:

Faster recovery than cascade or (SISO). Measurements of load variables online and
Compensate for disturbances before they effect Utilization of computational blocks.
the controlled variable.

Demerits?
 Cannot work if any of the sensors fail esp. load
variable.
 Requires process model in order to design
feedforward system.
 Advantage:
 Measure important disturbance variables
and take corrective action before they
Chapter 4

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.
Chapter 4
Unit 1: Control strategies
TSP
FSP
Cascade control I/P FC TC

FT Heat exchanger TT
Manipulated variable
(saturated steam) 100°C 80°C
30°C controlled variable
Load variable
100 L/min (temperature of
(Flow of saline solution)
sterilised saline)

What is cascade control? 95°C

Manipulated variable
A method of control of which the inner loop (Saturated steam)
controller obtains its set point from an outer loop
controller.
Characteristic of cacade control:
Merit? Two transmitters, two controllers and one
Faster recovery time as compared to single- control valve (2-level cascade).
input-single-output (SISO) feedback control.

Demerits? Application: Transform from SISO to

Controllability will be worst than SISO if both
cascade strategy if faster recovery time is
controllers were not properly tuned.
desired.
Chapter 4
Chapter 4
  Measure T and manipulate coolant flowrate.
 T will response faster when changes in inlet
temperature, Ti than to changes in coolant
Chapter 4

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

 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.
  The output signal of the primary controller
serves as the set point for the secondary
controller
Chapter 4

 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

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

Measuring
device
 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
Unit 1: Control strategies

Feedforward/ +
I/P TC
Feedback control +

Ws 
Cp
Wp T2  T1 
FFC
Hs TT
Manipulated variable
(saturated steam) Heat exchanger 80°C
FT TT
Load variable 30°C controlled variable
100 L/min (temperature of 
(Flow of saline solution)
sterilised saline)

What is feedforward/feedback control? 95°C

Manipulated variable
Feedback compensation added to feedforward (Saturated steam)
control

Merit?
Feedforward control compensates for major
disturbances, while feedback control compensates
for all other disturbances.
Chapter 4
Unit 1: Control strategies

Ratio control I/P FC

X
FT
Manipulated variable
(saturated steam) Heat exchanger 80°C
FT
Wild flow 30°C controlled variable
100 L/min (temperature of
(Flow of saline solution)
sterilised saline)

What is ratio control? 95°C

Manipulated variable
Keeps a flowrate in proportion to another (Saturated steam)
flowrate.

Merit?
Keep two flow in proportion.

Demerits?
Inherits PID characteristics
Ratio Control

 Type of feedforward control

 The objective is to maintain the ratio of two
variables at a specified value
 One variable is manipulated to keep it as ratio
of another.
 Implemented in two basic schemes.
multiplier

divider
 Keep a constant ratio between the feed flow
rate and the steam in the reboiler of a
distillation column
 Hold constant the reflux ratio in a distillation
column
 Control the ratio of 2 reactants entering
reactor at desired value
 Keep ratio of fuel/air in a burner at its
optimum value
 Hold the ratio of a purge stream to the
recycle stream constant
 Required to blend 2 liquid streams, A and
B in some ratio
R=FB/FA
The flow of stream B must vary, as the flow rate of stream A is varies

Multiplier : set the ratio

(Wild flow)
•Measuring the flow in steam A
•Multiplying it with the desired ratio to obtain
the required flow rate in stream B (set point to
the flow controller of stream B)
•FBset = R x FA
•If the flow of stream A varies, the set point of
the controller of stream B will vary.

*wild flow : manipulated to control something

else, such as level or temperature, upstream
 Divider

•Measuring both stream

•Divide them in FY16 to obtain the actual ratio
flowing through the system
•R=FB/FA
•The calculated ratio is the sent to the controller
which manipulated the flow B to maintain set
point.
•The set point to this controller is the required
ratio.
 BLOCK DIAGRAM

 Feedback control D
Y(s)
Y
Feedback Process
controller

•Feedforward control
D
Y(s) Y
Feedforward Process
controller
•Cascade control

Y(s)
Primary Secondary Y
Process II Process I
controller controller
 Question
- How to ensure that the level in the tank remains at
or near the set point? Propose the following control
strategy:
- Feedback
- Feedforward
Chapter 4
Purposes :

 To maintain process variables within limits

that must be enforced to ensure the safety of
personnel and equipment.
 Also permits smooth transition between
control schemes to obtain maximum benefits.
 Higher and Lower Selectors: HS, LS
◦ Measure one variable
◦ To select the higher (lower) of several measurement
signals
◦ To pass on as the process variable to a feedback
controller
 Consider the plug flow reactor where an
exothermic catalytic reaction take place.
 The figure shows the reactor temperature control
 The sensor providing the temperature
measurement should be located at the hot spot.
 As the catalyst in the reactor ages, or as conditions
change, the hot spot moves.
 It is desired to design a control scheme so that its
measured variable moves as the hot spot moves.
 A control strategy that accomplishes the
desired specification
 The high selector in this scheme selects the
transmitter with the highest output, and
thus the controlled variable is always the
highest or closest to the highest
temperature.
 All temperatures transmitters must have the
same range so that their output signals can
be compared on the same basis
 Installation an indication as to which
transmitter is giving the highest signal. If the
hot spot moves past the last transmitter, this
maybe an indication that it is time to either
regenerate or change the catalyst.
• ➢ Basic Idea:
• Selector selects between the higher or lower of several controller
• outputs for implementation

• ➢Normal operation:
• One process variable is the controlling variable

• ➢Abnormal operation:
• Some other process variable becomes the controlling variable to
• prevent it from exceeding a process or equipment limit

• ➢The limiting controller is said to override the normal process

• controller
• Normal Control: level in the tank is at height
h1

• If the liquid level drop below h2, will cause

cavitations at the pump.
• It is necessary to design a control scheme
that avoids this condition.
• Under normal condition, the low selector selects the output
signal of the flow controller to manipulate the pump speed.
• The level controller is not connected to the pump because the
level is not at an undesired state.
• As soon as the level drops below the set point on the level
controller, this controller will slow down the pump by
reducing the output.
• When the level controller output drops below the output of
the flow controller, the low selector selects the output of the
level controller to manipulate the pump. Level controller
‘overrides’ the flow controller.
 Explain the basic principle of
◦ Feedback control
◦ Feedforward control
◦ Cascade control
◦ Ratio control
◦ Selective control
◦ Override control
Chapter 4
Chapter 4
Unit 1: Control System Configuration
Field control is a control system configuration whereby instruments (transmitters, recorders and indicators) are
placed at the process site. They can be grouped together at a control panel. Suitable for small scale industries.
Advantage: Fast control. Disadvantage: cumbersome monitoring.

FC
101

I/P
101
PROCESS 
CONTROL FT
LOOP 102 101
TY
PROCESS 
LT
101 102 CONTROL
LOOP 101

TT
102

LC TC TR
102 102 102

PUMP SWITCH
PANEL 
BOX
Can be at plant site or 
control room © Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)
Unit 1: Control System Configuration
DCS (Distributed control system). Unlike SCADA, DCS system monitors and controls processes. Field controllers
are replaced with a single computer. Server can run processes when computer breakdown, but change on SP, A to
M to A or P, I, & D cannot be made.

I/P
101
PROCESS 
CONTROL FT
LOOP 102 101
TY
PROCESS 
LT
101 102 CONTROL
LOOP 101

TT
102

Server
Fieldbus or mA

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)
Unit 1: Control System Configuration
Computer control. Very much like DCS system: monitors and controls processes. Field controllers are replaced
with a single computer. A “fundamental and crude” version of DCS.

I/P
101
PROCESS 
CONTROL FT
LOOP 102 101
TY
PROCESS 
LT
101 102 CONTROL
LOOP 101

TT
102

Signals based on card I/O

DAQ PCI card

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)
Unit 1: Control System Configuration
SCADA (supervisory control and data acqusiition) is a control configuration system whereby a computer is used
to monitor the process variables (PV). It is also possible to change the controller set point (SP) and control the
process manually by opening /closing the control valve (MV). However, the computer has no capability of
controlling the process. Suitable for medium scale industries. Can switch to ‘LOCAL’ control when computer /
software break down. FC
101
R/L
I/P
101
PROCESS 
CONTROL FT
LOOP 102 101
TY
PROCESS 
LT
101 102 CONTROL
LOOP 101

TT
102

DAQ card
LC TC TR
102 102 102

DAQ card

PUMP SWITCH
PANEL 
BOX
Can be at plant site or 
control room © Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)
 Data acquisition (DAQ) is the process of measuring an
electrical or physical phenomenon such as voltage, current,
temperature, pressure, or sound with a computer. A DAQ
system consists of sensors, DAQ measurement hardware, and
a computer with programmable software.
 A PROGRAMMABLE LOGIC CONTROLLER (PLC) is an industrial
computer control system that continuously monitors the
state of input devices and makes decisions based upon a
custom program to control the state of output devices.

 Almost any production line, machine function, or process

can be greatly enhanced using this type of control system.

 Advantages :
 Able to change and replicate the operation or process while
collecting and communicating vital information
 It is modular ; can mix and match the types of Input and
Output devices to best suit your application.
 The Central Processing Unit, the CPU, contains an
internal program that tells the PLC how to perform
the following functions:
 Execute the Control Instructions contained in the
User's Programs. This program is stored in
"nonvolatile" memory, meaning that the program
will not be lost if power is removed
 Communicate with other devices, which can include
I/O Devices, Programming Devices, Networks, and
even other PLCs.
 Perform Housekeeping activities such as
Communications, Internal Diagnostics, etc.
 Figure 1 shows a stirred chemical reactor where cooling water flows
through the reactor jacket to regulate the reactor temperature. An
increase in the cooling water temperature can cause unsatisfactory
performance in this reaction. The resulting increase in the reactor
temperature, due to a reduction in heat removal rate, may occur
slowly. The corrective action taken will be delayed if the dynamic
lags occur in the jacket as well as in the reactor. In order to
overcome this problem, design a suitable control configuration for
this process and justify your answer.