Subject: Process Control / 4th year

First Semester-Week 1

Kurdistan Region – Iraq

Ministry of Higher Education and

Scientific Research

Koya University

MODULE DESCRIPTOR FORM

Module Information

Module Title Chemical Engineering Process Control Module Type C

Module Code KOU20462 Credits 04

Module Level Bachelor Semester of Delivery 07

Administering Department DCHE Faculty FENG

Module Leader Dr. Goran Abdulrahman Mohammed e-mail [email protected]

Module Leader’s Acad. Title Lecturer Module Leader’s Qualification Ph.D.

Module Tutor None e-mail None

Peer Reviewer Name Ribwar Abdulrahman e-mail [email protected]

Review Committee Approval DD/MM/2021 Version Number 1.0

Relation With Other Modules

Pre-requisites Type module codes

Co-requisites Type module code

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 Subject: Process Control / 4th year
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Module Aims, Learning Outcomes and Indicative Contents

The aim of this module is to provide the students with the skills, knowledge, and
Module Aims
competencies in Process Control.

Indicative Contents

Learning and Teaching Strategies

The normal type of university teaching frequently comprises lectures being given
to the students, tutorials, and assignments, with self-study.

Nevertheless, there are numerous other modes of delivery that can also be very
effective, for example:

Active learning

Explore teaching and learning methods that put the student in charge of their own
learning through meaningful activities.

Problem based learning

Strategies
A student-centred approach, where students learn about a subject through
understanding and solving problems.

Blended learning

Traditional classroom teaching combined with online learning and independent study.

Student-led learning

Students work together to support each other's learning.

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Module Delivery

Lecture (hr/w) 2 Lab. (hr/w) Practical (hr/w) Tutorial (hr/w) 3

SSWL (hr/sem)

USSWL (hr/sem)

Total workload (hr/sem)

Module Evaluation

Number/Time Weight (Marks) Week Due Relevant Learning Outcome

5
Quizzes 2/30 min 5%
10

3
Assignments 2 5%
12

Project/Lab. 10 X% Continuous All

Midterm Exam 2 hr 40% 8

Final Exam 3 hr 50% 16

Total 100% (100 Marks)

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Learning and Teaching Resources

Text Available in the Library?

Donald R. Coughanower , Process Systems Analysis and

Required Texts Control, 2nd Edition, McGraw Hill,

Chemical Engineering Series.

Recommended Texts Modern Control Engineering, by Ogata, 5th edition

Websites

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Delivery Plan (Weekly Syllabus)

Material Covered

Week 1 Introduction to Control Loops: Simple Loop Theory

Week 2 Revision of Laplace transformation.

Transfer functions and the input-output models.

Week 3
Linear open-loop systems

Week 4 Block Diagram Reduction

Week 5 Response of first order systems (dynamic behavior for first-order systems).

Week 6 Continuous Stirred Tank Heater, Continuous Stirred Tank Reactor, Transfer function.

Week 7 Mid-Term Exam

Week 8 Theory Proportional, Integral and Derivative modes, PI, PD, PID Controller, Dynamic Behaviour of
closed loop systems with P, I, D , PI , PID modes

Week 9 Physical examples of first order systems.

Higher-order systems: second order and transportation lag (dynamic behavior for
Week 10
second-order systems).

Week 11 Stability analysis

Week 12 Sensors and Transducers

Signal Transmission
Week 13
Types of signals, Analog to digital and digital to analog conversion, The digital signal transmission,
Industrial communications

Week 14 Actuators

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On-off actuators, Continuous actuators

Week 15 Preparatory Week

Week 16 Final Exam

APPENDIX:

KOYA UNIVERSITY

GRADING SCHEME

Group IRQ GPA

ECTS Grade % of Marks Definition
System

A - Excellent Best 10% Outstanding Performance 90-100 5

B - Very Good Next 25% Above average with some errors 80-89 4
Success
Group C - Good Next 30% Sound work with notable errors 70- 79 3
(50-100)
D - Satisfactory Next 25% Fair but with major shortcomings 60-69 2

E - Sufficient Next 10% Work meets minimum criteria 50-59 1

Fail Group FX – Fail (45-49) More work required but credit awarded 40-49

(0–49) F – Fail (0-44) Considerable amount of work required 0-44

NB Decimal places above or below 0.5 will be rounded to the higher or lower full mark (for example a mark of 54.5
will be rounded to 55, whereas a mark of 54.4 will be rounded to 54. KOU has a policy NOT to condone "near-pass
fails" so the only adjustment to marks awarded by the original marker(s) will be the automatic rounding outlined
above.

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 Subject: Process Control / 4th year
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Introduction to Control Systems

What is a system

A collection of components that interact with one another and with their
environment. Some examples of systems, Human beings, mechanical devices,
plants, animals, the atmosphere, the stock market, the political system.

Control System Definition

A control system consists of subsystems and processes (or plants) assembled for
the purpose of obtaining a desired output with desired performance, given a
specified input. The basis for analysis of a system is the foundation provided by
linear system, which assumes a cause-effect relationship for the components of a
system. A component or process to be controlled can be represented by a block as
shown in Figure 1.

Figure 1 Process under control

An open-loop control system utilizes a controller or control actuator to obtain the

desired response, as shown in Figure 2. The open-loop control system utilizes an
actuating device to control the process directly without using device. An example
of an open-loop control system is an electric toaster.

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Figure 2 Open-loop control systems (no feedback)

In a closed-loop control system a signal indicating the state of the output of the
system is feedback to the input where it is compared with what was required and
the difference used to modify the output of the system so that it maintains the
output at the required value (Figure 3). The term closed loop refers to the loop
created by the feedback path. Closed-loop systems have the advantage of being
relatively accurate in matching the actual to the required values. They are,
however, more complex, and so more costly with a greater chance of breakdown as
a consequence of the greater number of components.

Figure 3: Closed-loop system with feedback of output to modify the input and so adjust for any
extraneous disturbances

An example of closed-loop control system is a person steering an automobile

by looking at the auto’s location on the road and making the appropriate
adjustments.

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Closed loop systems have different characteristics when compared to open-loop

systems.

 They are more accurate.

 They are less sensitive to disturbances.
 They are less sensitive to system characteristics/parameter variations.
 They have a tendency to oscillate.

What are the objectives of controller design?

The main objective is to meet system specifications in the presence of large input
disturbances and plant variations. Generally, controller design goals are
characterized by,

• Speed
• Accuracy
• Stability

Example:

A basic, manually controlled closed-loop system for regulating the level of fluid in
a tank is shown in Figure 4. The input is a reference level of fluid that the operator
is instructed to maintain. (This reference is memorized by the operator). The
power amplifier is the operator, and the sensor is visual. The operator compares
the actual level with the desired level and opens or closes the valve (actuator),
adjusting the fluid flow out, to maintain the desired level.

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Figure 4 A manual control system for regulating the level of fluid in a tank by adjusting the output

valve. The operator views the level of fluid through a port in the side of the tank.

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Computer-Controlled Systems

In many modern systems, the controller (or compensator) is a digital computer.

The advantage of using a computer is that many loops can be controlled or
compensated by the same computer through time sharing. Furthermore, any
adjustments of the compensator parameters required to yield a desired response can
be made by changes in software rather than hardware. The computer can also
perform supervisory functions, such as scheduling many required applications.

Example:

The modern, large-capacity plants, which exceed several hundred megawatts,

require automatic control systems that account for the interrelationship of the
process variables and optimum power production. It is common to have as many as
90 or more manipulated variables under coordinated control. A simplified model
showing several of the important control variables of a large boiler generator
system is shown in Figure below. This is an example of the importance of
measuring many variables, such as pressure and oxygen, to provide information to
the computer for control calculations

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The diagram of a computer control system is shown in Figure below; note that the
computer is the control device.

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History of automatic control

The first automatic feedback controller used in an industrial process is generally

agreed to be James Watt’s flyball governor, developed in 1769 for controlling the
speed of a steam engine. The all-mechanical device, shown in Figure below,
measured the speed of the output shaft and utilized the movement of the flyball
with speed to control the valve and therefore the amount of steam entering the
engine. As the speed increases, the ball weights rise and move away from the shaft
axis, thus closing the valve. The fly weights require power from the engine to turn,
and therefore cause the speed measurement to be less accurate.

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The first historical feedback system, claimed by Russia, is the water-level float
regulator said to have been invented by I. Polzunov in 1765. The level regulator
system is shown in Figure below. The float detects the water level and controls the
valve that covers the water inlet in the boiler.

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Modelling

A model is a mathematical relationship between the input and the output of a

system. It approximates the physical system.

A model may be described by differential equations (continuous-time systems) or

difference equations (discrete-time systems), or a combination of both (hybrid
systems).

Modelling depends on your goal

 A single system may have many models

 Always understand what the purpose of the model

Main goals of modelling in control engineering

• Conceptual analysis of the system

• Detailed simulation

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