Sudan University of Sciences and Technology

College of Engineering and Technology of

Process measurement
& Control II
Lecture 1
Lecturer: Arafa Ali 1
 Course content
Total credit hours: 3 hr
Lectures
Exam: 100 mark
Course work:50 mark
 Attendance
 Lab
 Tutorial
 Test
 Home work 2
 Course content
Feedback control system
Classification of control system
Types of controllers and their dynamics
Two position controller
Proportional, integral and derivative
control action
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Three term controller together with
suggested applications
The optimum controller setting using
Cohen-Coon method and Ziegler Nichol's
method.
System stability using direct method,
Algebric method and graphical method
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General example in automatic control
application in distillation towers,
reactors, mixers and heat exchangers.
Control using computer.

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 References
Chemical Process Control An
Introduction to Theory and Practice,
GEORGE STEPHANOPOULOS
A TEXT BOOK OF CHEMICAL ENGINEERING
PROCESS CONTROL,Prof.Gurashi A.
Gasmelseed, Fourth Edition
PROCESS MODELING,SIMULATION, AND
CONTROL FOR CHEMICAL ENGINEERS,
WILIAM L LUYBEN
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INTRODUCTION
PROCESS CONTROL
Process as used in the terms process
control and process industry, refers
to the methods of changing or refining
raw materials to create end products.

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The raw materials, which either pass
through or remain in a liquid, gaseous,
or slurry (a mix of solids and liquids)
state during the process, are
transferred, measured, mixed, heated
or cooled, filtered, stored, or handled in
some other way to produce the end
product.
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Process industries include the
chemical industry, the oil and gas
industry, the food industry, the
pharmaceutical industry, the water
treatment industry, and the power
industry.

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Process control refers to the methods
that are used to control process
variables when manufacturing a
product.
For example:
factors such as the proportion of one
ingredient to another
the temperature of the materials,
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how well the ingredients are mixed
and the pressure under which the
materials are held can significantly
impact the quality of an end product.

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Manufacturers control the production
process for three reasons:
Reduce variability
Increase efficiency
Ensure safety

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Reduce Variability
 Process control can reduce variability
in the end product, which ensures a
consistently high-quality product.
 Manufacturers can also save money by
reducing variability.

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Increase Efficiency
some processes need to be maintained at a
specific efficiency.
For eample, a control point might be the
temperature which a chemical reaction takes
place.
Accurate control ensures process efficiency.
Manufacturers save money by the resources
required to produce the end product. 14
Ensure Safety
Precise process control required to
ensure safety
for example, maintaining proper boiler
pressure by control of air used in
combustion and the outflow of exhaust
gases in preventing boiler implosions that
can clearly threaten the safety of workers.
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 Control Theory Basics
Control loops:
Control loops in the process control
industry work in the same way, requiring
three tasks to occur:
Measurement
Comparison
Adjustment 16
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In Figure above, a level transmitter (LT)
measures the level in the tank and
transmits a signal associated with the level
reading to a controller (LIC).
The controller compares the reading to a
predetermined value, in this case, the
maximum tank level established by the plant
operator, and finds that the values are
equal. 18
The controller then sends a signal to
the device that can bring the tank level
back to a lower level—a valve at the
bottom of the tank. The valve opens to
let some liquid out of the tank.

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Simple Control Loop & Process Control
Terms
PROCESS VARIABLE
A process variable is a condition of the
process fluid (a liquid or gas) that can
change the manufacturing process in
some way.
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Common process variables include:
❑ Pressure
❑ Flow
❑ Level
❑ Temperature
❑ Density
❑ PH (acidity or alkalinity)
❑ Liquid interface (the relative amounts of different liquids
that are combined in a vessel)
❑ Mass
❑ Conductivity 21
SETPOINT
The setpoint is a value for a process
variable that is desired to be maintained.
For example, if a process temperature
needs to keep within 5 °C of 100 °C, then
the setpoint is 100 °C.

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A temperature sensor can be used to
help maintain the temperature at
setpoint.
The sensor is inserted into the process,
and a contoller compares the
temperature reading from the sensor to
the setpoint.
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If the temperature reading is 110 °C, then the
controller determines that the process is above
setpoint and signals the fuel valve of the burner
to close slightly until the process cools to 100
°C.
Set points can also be maximum or minimum
values.
For example, level in tank cannot exceed 20
feet.
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MEASURED VARIABLES, AND MANIPULATED
VARIABLES
In the temperature control loop example, the
measured variable is temperature, which must be
held close to 100 °C.
In this example and in most instances, the
measured variable is also the process variable.
The measured variable is the condition of the
process fluid that must be kept at the designated
set point. 25
Sometimes the measured variable is not the
same as the process variable.
For example, a manufacturer may measure
flow into and out of a storage tank to
determine tank level.
In this scenario, flow is the measured
variable, and the process fluid level is the
process variable.
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The factor that is changed to keep the
measured variable at setpoint is called
the manipulated variable.
In the example described, the
manipulated variable would also be flow.

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ERROR
Error is the difference between the
measured variable and the setpoint and
can be either positive or negative.
The objective of any control scheme is
to minimize or eliminate error.

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OFFSET
Offset is a sustained deviation of the
process variable from the setpoint.
LOAD DISTURBANCE
A load disturbance is an undesired change
in one of the factors that can affect the
process variable.
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 MANUAL AND AUTOMATIC CONTROL
Control operations that involve human
action to make an adjustment are called
manual control systems.
Conversely, control operations in which
no human intervention is required, such
as an automatic valve actuator that
responds to a level controller, are called
automatic control systems. 31
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