CHE3166 PROCESS DESIGN

PID LECTURE L2

DEVELOPING CONTROL AND INSTRUMENTATION

FOR P&ID
CONTENT
• Main components of control systems
• Basic methods used to control chemical processes
• Options to regulate chemical processes
• Typical regulating strategies for processes are

2
PROCESS CONTROL SYSTEM-INTRODUCTION

• Plant requires certain form of regulation in order to achieve “steady state”

• A subset of this regulation study is “process control”

• Some industry use digital processor control system and associated instrumentation for industrial
plant control.

• Examples of such system is distributed control systems (DCS) ,programmable logic controllers
(PLC) and SCADA (Supervisory Control and Data Acquisition) system

• A plant can have hundreds of complicated control system and this control systems will be centrally
monitored and controlled (if needs be) from a centralised control room.

3
 WHAT A CONTROL ROOM LOOKS LIKE

Incinerator

This is a control room for a solid waste plant. The backs of three operators are facing you. They will take a look at
the plant if the measured process variables (PV) of the plant is not looking right or if an alarm goes off

http://www.hfs.no/portfolios/duis-at-scelerisque/
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PURPOSE OF PROCESS CONTROL
• To monitor a system and to bring the process back the system back to SP if there is any deviation
in process parameters (temperature, pressure and etc)

• Think for a minute: how do you monitor things in plant? For example: pressure in a pressure
vessel? Can you see pressure?

• You need to send data to a computer so it can analyse

(which has a software that instruct an item to execute an action)

• This process involves data management

(For P&ID - shows how this data is managed by control system
and how the action is executed)

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COMPONENTS OF PROCESS CONTROL
• Regulation involves establishing strategy which can be used to control the process as well as
dynamic response of process in changing the operating variables.
• A simple control loop has the following components
1. Measuring instrument/Sensor (e.g .flowmeter)
• To measure process parameters, e.g. temperature

2. Transmitter (e.g. Flow transmitter)

• To convert the measured parameters input into something computer can understand (signals)

3. Controller (e.g. Flow controller)

• To compare measurement recorded by sensor against pre-set valve (set point, SP)
• Give instruction to regulator on what to do

4. Regulator (e.g. Flow Control Valve)

• A device that makes adjustment to process parameter (control valves, pumps etc.)

6
PID SYMBOLS FOR DATA MANAGEMENT

• Lets just focus on how to show data management of control system in the PID
(You instrument measured something with a instrument probe and transmitter change the
data to a form which your controller (computer) can understand.

• P&ID symbols for signals ->

• Signal line is thinner than process line.

(Data link)

7
EQUIPMENT TAG OF INSTRUMENT

• Instrument Tag are necessary for transmitters and controllers

• I recommend the following labelling system for instrumentation

INSTRUMENT IDENTIFICATION
XXX – UNIT NUMBER
YYY – INSTRUMENT TYPE
ZZZ – SEQUENTIAL NUMBER
Equipment Tag

• Labelling XXX and ZZZ is straight forward.

• Let’s see how YYY labelling is done in the next slide.(can be extremely confusing)

8
INSTRUMENTATION LABELLING
First Letter in YYY Subsequent Letters in YYY

We use the “Capital Letter” in the left most column to

label instrumentation, .e.g “A”, “
Measured Variable tells you “what” the First letter (in YYY)
instrument is measuring/sensing.
The meaning of subsequent letters in YYY are given in
either “READ OUT” or “DEVICE FUNCTION)

The use of modifier is less common:

Some instrumentation tag examples that contain modifier:
PSV – Pressure Safety Valve
LAL – Level Alarm Low
TAH – Temperature Alarm High

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INSTRUMENTATION LABELLING
First Letter in YYY Subsequent Letters in YYY

Example:
LI – Level indicator (Level is measured and displayed –
human can read the measurement)

LC – Level controller (Level is measured and signal is sent

to controller – human cannot read)

LIC- Level controller with indicator (Pressure is measured

and signal is sent to controller – human can read)

PDIA- Pressure difference indicator with alarm (pressure

difference between 2 points is measured and displayed –
human can read. Alarm is installed

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INSTRUMENT SYMBOLS – OPERATOR ACCESSIBILITY
• Instrumentation Bubbles have meaning too!
• First row refers to instruments that you must go to
the field (exact location in the plant) to access the
measured data
• Second row is normally used for Control System
and the measured data can be seen in the control
room (central control room as well as in the field)
• Third row is measured data for complex computer
calculation/analysis (never seen one)
• The final row is normally for safety instrument
(safety switches or ON/OFF valves). Since it has a
square enveloping the diamond symbol, the
measured data can be read by operators in the
control room (shared display).

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INSTRUMENTATION BUBBLES
The line(s) in the center of the bubble tells you about the accessibility of the instrument by operator
and where it can be accessed. The only difference is operator can only access left on its field
location. Data on the right can be accessed both at the field and local panel.

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INSTRUMENTATION BUBBLES
What’s the difference? Both can be seen in the control room (shared display) and at field. Both the
operator can see the data or access the instrument on a local panel. The left symbol does not have
a local panel designed for it.

If there are two lines in the middle, it means that the data is located/accessible at the secondary
panel.

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INSTRUMENTATION BUBBLES – SECRETS?
What about dash line?
Data not normally accessible to operators. It is locked behind a covered panel or the
data display is not available at the common display.
You need to use a key to open the locked panel or use password to access the
information in the control room (similar to your phone’s lock screen)

The bottom row is similar to the top row…except that the data is not normally
accessible in the secondary panel (data is locked and normally you required a key to
access it) or behind the secondary panel. You also need key (data display is not
normally accessible to people without keys, example in a locked room) or password
to access this data in control room

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SUMMARY – RARE INSTRUMENTS

• I do not foresee you to use these instrument.

• Hexagon – used for advanced process control, such as dynamic

matrix control

• Requires a “special purpose computer”/ supercomputer

16
SISO CONTROL SYSTEM - TRANSMITTER

• SISO – single input single output, the controller receive a signal and send a signal to control valve
• A transmitter is needed to convert the physically measured variable (say liquid level) to a form the
computer software can understand.
• Common algorithm of SISO control: Feedback Control or Feedforward Regulation

010 010
FIC TIC
001 002

010 010
FT 010 010 TT
001 FCV TCV 002
001 002

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FEEDBACK CONTROL LOOP

Feedback control loop:

Advantages: Directly monitored the controlled variable – straight forward. Do not need to identify the cause of
change in the controlled variable
Disadvantages: Corrective measurement is only taken when an error has propagated through the process
Not suitable for process with large process lag time.

12 12
LT LIC
001 001

12
LCV
001

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FEEDFORWARD CONTROL LOOP
Feedforward control loop:

Advantages: Predict changes in controlled variable and adjustments are made in advanced of any deviation
from desired output.

Disadvantages: Need to identify all possible variables that is likely to cause changes in controlled variables and
to describe the process by a model. Controller perform calculations needed to predict
controlled variable. Controlled variable is not used in control algorithm

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FEEDFORWARD CONTROL LOOP
Feedforward control loop:
Process parameter that needs to
be controlled: Liquid Level in tank
12
FIC
001

12 12
FT FCV
001 001

12 12
LT LI
001 001

To constant flow rate pump

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PID – DEVELOP CONTROL LAYER
• Let’s say we wish to modify the design of this water basin – I am sick of adjusting water temperature every
time and want to design a control system that will do the water temperature regulation for me
• The temperature range you find comfortable : say 40 °C

Restrictions:
Hot water tab has an average temperature of 70 °C;
cold water tab has an average temperature of 25 °C

Your target:
Modify your PID to include a control system that
regulate the water temperature for you
(set point of temperature controller = 40 °C).
Use only SISO feedback controller(s).

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 Equipment Tag V-1801
Equipment name Water Basin
Design Pressure Atmospheric + 0.1 bar
Original Design: Design Temperature 60 °C
Operating Pressure Atmospheric
25 – W – 18001 – 150SS – N
L3-11-001 Operating Temperature 20-45 °C
Material Ceramic

Hot Water

25 – W – 18001 – 150SS – N
25 – W – 18002 – 150SS – N
L3-11-002
Cold Water

Flanged Tee

Idea: We need to include control

valves and controllers so that
the mixed liquids stream has the
right temperature.

22
Modified Design:

18
TCV
25 – W – 18001 – 150SS – H 001

L3-11-001

Hot Water
18
FCV
001
25 – W – 18002 – 150SS – N
L3-11-002
18
Cold Water 18 FIC
FT 001
001
Equipment Tag V-1801 18
18
Equipment name Water Basin TIC
TT
001
Design Pressure Atmospheric + 0.1 bar 001
Design Temperature 60 °C
Operating Pressure Atmospheric
Operating Temperature 20-45 °C Spray Nozzle
Material Ceramic

23
Modified Design:

18
TCV
25 – W – 18001 – 150SS – H 001

L3-11-001

Hot Water
18
FCV
001
25 – W – 18002 – 150SS – N
L3-11-002
18
Cold Water 18 FIC
FT 001
001

Question: Do you need such advanced system in your 18

18
TIC
bathroom? TT
001
001
Do you realise the water is continuously flowing and
there is no way to stop the water flow in this design ?
Spray Nozzle

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PID – BEWARE OF OVER CONTROLLING THINGS
• A mistake in P&ID may cause bad control of a process, leading to operational problems.

• Example … making steam

• We have a controller to control the steam pressure to the pressure we want, and another controller to
control the temperature to the temperature we want.
• THIS WILL NOT WORK.
• If we control the steam pressure, the fact that we have pure water boiling will determine the pressure
temperature combination, so no need to control both.
• And … because they are not 100.000000000% accurate, they will try to control to different conditions,
therefore they will “fight”

Lesson: Do not try to control everything, know how many degree of freedoms you have

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PID – BEWARE OF OVER CONTROLLING THINGS
• Be careful when there are 2 control systems in a series (located on the same pipe)
• Will this control system works? FIC
35

FIT
35
LIT LIC
34 34
Separator

LCV FCV
34 35
FE
Centrifugal Pump 35
26
PID – DEGREE OF FREEDOM IN CONTROL?
• For control to work, there needs to be a “degree of freedom” between control devices. Is there a
degree of freedom in this system?
• Your control valve need a variable (a degree of freedom) to adjust its output variable.
• Will this control works?
PIT
35

PIC
LIT LIC 35
34 34
Separator

LCV PCV
34 35

Centrifugal Pump 27
SUMMARY
• Drawing symbols for process control system
• SISO control system
• How to draw and label the control layer of P&ID
• Ensure not too many control valves in a system.

• Next: Safety System

28
APPENDIX: COMPLEX CONTROL SYSTEM

• There are times when a SISO feedback control system is not good enough and feedforward
controller cannot control the output variables effectively.
• In these scenarios, a more complex control system is required:
1. Combination Feedback and Feedforward Control
2. Cascade Controlling

• You will not (most likely) use these control systems (not in final exam too) in this unit but
this is included in case you need it for fourth year design project.

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APPENDIX: FEEDBACK + FEED-FORWARD CONTROL

• Combination Feedback and Feed-forward control

Advantages : The control system has the advantages of both feedback and feed-forward control
system. The feed-forward regulators made some adjustment to the controlled variables before any
deviation in process output takes place. These feedback regulator will supplement the feed-forward
regulators and make sure that final set point is achieved.

Disadvantages : The control algorithm and hardware of this form are more complicated and more
expensive.

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FEEDBACK + FEED-FORWARD CONTROL EXAMPLE

• Consider a compressed gas vessel. We wish to control pressure and maintain at 5 bar. Use a
pressure controller and gas controller to achieve this:

Feedback Control
∑ Part
12
PIC
001

12
Feedforward Control FIC
001 12

Part PT
001
12
PCV
001
12
FT
001

V-1201
Process parameter that needs to
be controlled: pressure in tank

31
APPENDIX: CASCADE CONTROL

• Cascade System - Uses controllers connected in series. The first control element in the system
measures a process variable and changes the set point of the next control loop.

Advantages : This system reduces lags and allows finer control. It limits the disturbance of
entering the secondary variable on the primary output. Useful in process with
relatively slow process dynamics
Disadvantages : It is more complicated than single-loop designs. Second loop must be faster than
the first loop and have influence over the primary loop.

32
APPENDIX: CASCADE CONTROL
Steam • Since you have not learn the type of
heat exchanger, we use a simple
16
symbol (PFD version) to represent a
FT
Temperature
001
heat exchanger here. We will discuss
Controller (primary)
16
FCV
more about types of heat exchangers
001
16 16 in later lectures.
FIC TIC
Steam Valve
• Primary loop measuring temperature
001 001

Flow Controller is slow (TT needs to wait for thermal

(secondary) 16
TT
equilibrium)
001

• Flow measurement is a lot faster (<

1s) hence is made the secondary loop
Process fluid • Temperature of Process fluid will affect
Shell and Tube the set point of secondary flow
Heat Exchanger controller.

33
APPENDIX: RATIO CONTROL
• The need to maintain the ratio between 2 concentrations or between 2 flowrates entering a system to
satisfy certain design objectives.
• Ratio controller can be used to fixed the ratio of certain parameters in 2 different streams

Advantages : A special type of feed-forward control system which a ratio is maintained.

Do not require process model for control to work
Disadvantages : The controller does not take other process variable into account other than the
the process variables it is measuring. For a flow ratio controller
a change in concentration in one of the flow streams will cause the control system
to miss the design objective.

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APPENDIX: RATIO CONTROL
Example: a flow ratio controller

16 16
FT FF
001 001

16
FIC
001
Mixed fluid
16 12
FT FCV
002 001

35