[CHE 239 ]

PROCESS CONTROL & INSTRUMENTATION

[CHE 314]
BASIC INSTRUMENTATION & CONTROL

PR E PAR E D BY:
Nurul ‘Uyun Binti Ahmad
Faculty of Chemical Engineering, UiTM Bukit Besi, Terengganu
[email protected]
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Introduction to
Process Control
C HA PT E R
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Contents :
 1.1 Historical & modern control systems
 1.2 Parts of control systems
 1.3 Feedback, feed forward and cascade control systems
 1.4 On-off control systems, Proportional, Integral and
Derivative control modes
 1.5 Operation and response of control system
 1.6 Advanced Control System

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Aim
To describe the fundamental of various types of process
control system used in related chemical industries.

Course Learning Outcomes

After completing this course, the students should be able
to:
 Define and explain the parts that form control systems.
 Recognize/explain/differentiate various types of control
systems such as feedback feed forward and cascade.
 Explain the on-off, proportional (P), integral (I) and
derivative (D) control modes.
 Explain operational principle and response/tuning of PID
control modes.
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1.1 HISTORICAL & MODERN CONTROL SYSTEMS

 Evolution
 Definition
 Category
◦ Discrete process control, batch process control, continuous
process control
 Process control criteria
 Open loop control system
 Closed loop control system

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Definition of Process Control & Instrumentation

Process
control &
Process instrumentation
control
Process

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 Process
= material -------------------------------------> product
mechanical, electrical, physical, chemical

control

 Control
 Instrumentation = device = controller, actuator, sensor

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 Process
orefers to the methods of changing or refining raw
materials to create end products.

 Process industries
o chemical industry, oil & gas industry, food & beverage
industry, pharmaceutical industry, water treatment
industry, power industry.

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 Process Control

o Methods used to control process variables when

manufacturing a product and consists of the process
plant and the control equipment.

o Can be very simple system (domestic hot water

system), to highly complex system (automatic oil
refining plant).

o Problem of process control  matching the

characteristics of the controller with the plant to
obtain the required overall behavior of the system

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 Can be categorized into the following term:

1) Discrete Process Control

o Found in many manufacturing, motion and packaging

applications.

o Example: robotic assembly in automotive production,

metal stamping.

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2) Batch Process Control

o Applications require specific quantities of raw materials

to be combined in specific ways for a period of time to
produce an output

o Example: production of food, beverages and medicine.

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3) Continuous Process Control

o Physical system represented through variables that are

smooth and uninterrupted in time.

o Example: control of the water temperature in a heating

system, level control system.

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Process Control Criteria
 Control variables :
◦ Temperature
◦ Pressure
◦ Level
◦ Flow
◦ pH
• Slow in response with large time delay
• The system response to a set point
• Manipulator – pneumatic or heating element

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Open Loop Control System

• Also called a non-feedback controller.

• The characteristic :

o Does not use feedback to determine if its output has

achieved the desired goal of the input. This means that
the system does not observe the output of the
processes that it is controlling.
o Do not engage in machine learning.
o Do not correct any errors that it could make.
o Do not compensate for disturbances in the system.

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 CONTROLLER ACTUATOR OUTPUT
INPUT To make Gives an PROCESS The result
What you changes in the output of The procedure of your work.
need. system if some action or activitieas The impact.
Your goal needed designed to leading to The result
(if error exist) change the co the result of system

Figure 1.1: Open loop system block diagram

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Closed Loop Control System
• Also known as a feedback control system.

• The reference to “feedback”, simply means that some

portion of the output is returned “back” to the input to
form part of the systems excitation.

• Closed-loop systems are designed to automatically achieve

and maintain the desired output condition by comparing it
with the actual condition.

• It does this by generating an error signal which is the

difference between the output and the reference input

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 CONTROLLER ACTUATOR OUTPUT
INPUT To make Gives an PROCESS The result
What you changes in the output of The procedure of your work.
need. system if some action or activitieas The impact.
Your goal needed designed to leading to The result
(if error exist) change the co the result of system

SENSOR
To check
how well
the system
works

Figure 1.2: Closed loop system block diagram 21

o Also can be referred as feedback control
o Uses a measurement of the output and compare with
the set point value to create the error signal which is
amplified by the controller.

How feedback control works

o Feedback control is applied to achieve the desired

output by adjusting manipulated variable.
o Sensor is designed to communicate with controller and
final control element responds to the command from
the controller.

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• In practical applications, feedforward control is normally
used in combination with feedback control.
• Feedforward control is used to reduce the effects
of measurable disturbances, while feedback is used
to track the set point change to make the
corrective action in order to compensates for
inaccuracies in the process model, measurement
error, and unmeasured disturbances.
 REFERENCES

1. Curtis, D. Johnson, Process Control Instrumentation

Technology, Prentice Hall, 2000.
2. Thomas E. Marlin, Process Control, McGraw Hill, 2nd
Edition 2000.
3. Harriot, P.Process Control, McGraw Hill,1986
4. Dale E. Sebog, Thomas F. Edgar, Duncan A. Melichamp,
Process Dynamics Control, Wiley, 1st Edition, 1989.
5. http://blog.opticontrols.com/site-map

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