Page : 1 of 72

KLM Technology
Group Rev: 01 July 2013

Practical Engineering Guidelines Engineering Solutions

for Processing Plant Solutions

www.klmtechgroup.com

Co Author
KLM Technology Group Kolmetz Handbook Rev 01 Mochamad Adha Firdaus
P. O. Box 281
Bandar Johor Bahru,
Of Process Equipment Design
80000 Johor Bahru, Johor,
West Malaysia Editor / Author
Process Control Concepts
Karl Kolmetz
(Engineering Design Guidelines)

TABLE OF CONTENT

INTRODUCTION

Scope 6

Process Control Concepts 7

Control System 8

Control Objectives 10

Control Layers 11

DEFINITIONS 14

NOMENCLATURE 16

THEORY

A) Process Control Basics 17

(I) Control Loops Basis 18

(II) Transfer Signal 18

 Page 2 of 72
KLM Technology Kolmetz Handbook
Group Of Process Equipment Design Rev: 01
Practical Engineering
Guidelines for Processing PROCESS CONTROL CONCEPTS
Plant Solutions
July 2013
www.klmtechgroup.com ( ENGINEERING DESIGN GUIDELINES)

B) Control Loops 20

(I) Open Loop 20

(II) Close Loop 21

(III) Feedback Control 22

(IV) Feedforward Control 23

(V) Computer Control 24

C) Control Modes 25

(I) Offset 25

(II) On – Off Control 25

(III) The Proportional Control Mode 26

(IV) The Integral Mode 27

(V) The Derivative Mode 28

(VI) Proportional Plus Integral Mode (PI) 29

(VII) Proportional Plus Derivative Mode (PD) 29

(VIII) Proportional Plus Integral Plus Derivative Mode (PID) 30

D) Controller Tuning 31

(I) Flow Loops 32

(II) Level Loops 33

(III) Pressure Loops 34

(IV) Temerature Loops 36

These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases.
They were designed for engineers to do preliminary designs and process specification sheets. The final design must
always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the
amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for
young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 3 of 72
KLM Technology Kolmetz Handbook
Group Of Process Equipment Design Rev: 01
Practical Engineering
Guidelines for Processing PROCESS CONTROL CONCEPTS
Plant Solutions
July 2013
www.klmtechgroup.com ( ENGINEERING DESIGN GUIDELINES)

(V) On-Line Trial and Error Tuning 36

E) Advanced Control Techniques 37

(I) Ratio Control 38

(II) Cascade Control 40

(III) Selective, Override, and Split Range Control 42

(IV) Adaptive Control 47

F) Controlol Schemes for Unit Operation 48

(I) Pumps 49

(II) Heat Exchanger 50

(III) Drums / Vessels 53

G) Integrated Process Control 55

(I) Considerations of Safety Interlock Systems 56

(II) Interlock System 58

(III) Testing 60

APPLICATION

Example Case: Process Control in Distillation Tower 61

REFERENCES
69

These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases.
They were designed for engineers to do preliminary designs and process specification sheets. The final design must
always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the
amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for
young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 4 of 72
KLM Technology Kolmetz Handbook
Group Of Process Equipment Design Rev: 01
Practical Engineering
Guidelines for Processing PROCESS CONTROL CONCEPTS
Plant Solutions
July 2013
www.klmtechgroup.com ( ENGINEERING DESIGN GUIDELINES)

LIST OF TABLE

Table 1: Control Mode Comparisions 28

LIST OF FIGURE

Figure 1: General Control System 9

Figure 2: Multilayer Structure 12

Figure 3: Simple Processes Control Model 17

Figure 4: Schematic Diagram of a Control Loop Configuration 19

Figure 5: Open Loop 21

Figure 6: Closed Loop 22

Figure 7: Feedback Control Loop 23

Figure 8: Feedforward Control Loop 24

Figure 9: The response of a two-position controller 26

Figure 10: Response of step change in distrubances with tuning control 31

Figure 11: Condensate-throttle flow control 33

Figure 12: Fast Pressure Loop 35

Figure 13: Slow Pressure Loop 35

Figure 14: Ratio control computed 39

Figure 15: Ratio control flow set 39

Figure 16: Conventional single loop 41

These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases.
They were designed for engineers to do preliminary designs and process specification sheets. The final design must
always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the
amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for
young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 5 of 72
KLM Technology Kolmetz Handbook
Group Of Process Equipment Design Rev: 01
Practical Engineering
Guidelines for Processing PROCESS CONTROL CONCEPTS
Plant Solutions
July 2013
www.klmtechgroup.com ( ENGINEERING DESIGN GUIDELINES)

Figure 17: Cascade control loop 42

Figure 18: Selective Control 43

Figure 19: Override control concept 44

Figure 20: Split Range control 46

Figure 21: Controller’s output vs Stem Travel on SR control 46

Figure 22: Control schemes for pump (1) 49

Figure 23: Control schemes for pump (2) 49

Figure 24: Control schemes for pump (3) 50

Figure 25: Control schemes for Heat Exchanger (1) 51

Figure 26: Control schemes for Heat Exchanger (2) 51

Figure 27: Control schemes for Heat Exchanger (3) 52

Figure 28: Control schemes for Heat Exchanger (4) 52

Figure 29: Control schemes for Drum (1) 53

Figure 30: Control schemes for Drum (2) 53

Figure 31: Control schemes for Drum (3) 54

Figure 32: Control schemes for Drum (4) 54

Figure 33: Total control system with parallel task 57

Figure 34: Control pressure for distillation towers 62

Figure 35: Control pressure for distillation towers (2) 62

These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases.
They were designed for engineers to do preliminary designs and process specification sheets. The final design must
always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the
amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for
young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 6 of 72
KLM Technology Kolmetz Handbook
Group Of Process Equipment Design Rev: 01
Practical Engineering
Guidelines for Processing PROCESS CONTROL CONCEPTS
Plant Solutions
July 2013
www.klmtechgroup.com ( ENGINEERING DESIGN GUIDELINES)

Figure 36: Control pressure for distillation towers (3) 63

Figure 37: Control pressure for distillation towers (4) 64

Figure 38: Control pressure for distillation towers (5) 64

Figure 39: Control temperature for distillation towers 65

Figure 40: Control temperature for distillation towers (2) 66

Figure 41: Control level for distillation towers 67

Figure 42: Control level for distillation towers (2) 67

Figure 43: Control level for boilup for distillation towers 68

These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases.
They were designed for engineers to do preliminary designs and process specification sheets. The final design must
always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the
amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for
young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 7 of 72
KLM Technology Kolmetz Handbook
Group Of Process Equipment Design Rev: 01
Practical Engineering
Guidelines for Processing PROCESS CONTROL CONCEPTS
Plant Solutions
July 2013
www.klmtechgroup.com ( ENGINEERING DESIGN GUIDELINES)

INTRODUCTION

Scope

Safety regulations, stronger competition between each plant, tougher environmental

regulations, and cost effectiveness have been key factors in the tightening of plant
product quality specifications. The complexity of modern process plants had been
increasing rapidly. As a result of this modern processes have become more difficult to
operate because of the trend toward larger, more highly integrated plants with smaller
surge capacities between the various processing units.

Many process plants are continuous or batch systems requiring stable operating
conditions which should be maintained at each step of processing under various
disturbances. Advances in the theory and practice of process control; automatic
process control has taken an important place to maintained the process control issues.

Automatic process control has played a vital role in the advancment of engineering and
science. For example, automatic process control is essential in such process industrial
operations as controlling pressure, temperature, humidity, viscosity, and flow. Process
control has to maintain the dynamic stability of an operation in process plant. It is only
natural that the subject of process control has become increasingly important in recent
years. In fact, without process control it would not be possible to operate most modern
processes safely and profitably while satisfying plant quality standards.

This guideline covers many things which are related to the process control such as;
general control concepts, control modes, control tuning, control systems, control schemes
of general cases in plant field, and also the integrity control with safety. This guideline
also explains about advanced control techniques that classified in four type like
Multivariable Control, Model Predictive Control, and Real – Time Process Optimization in
details.

The decision of a suitable method for process control is different for each plant. It’s
generally based on kind of process, environmental around the plant, and economical
analysis. This decision shall not sacrifice the essential value of process control such as
the stability and safety of an operation in process plant.

These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases.
They were designed for engineers to do preliminary designs and process specification sheets. The final design must
always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the
amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for
young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 8 of 72
KLM Technology Kolmetz Handbook
Group Of Process Equipment Design Rev: 01
Practical Engineering
Guidelines for Processing PROCESS CONTROL CONCEPTS
Plant Solutions
July 2013
www.klmtechgroup.com ( ENGINEERING DESIGN GUIDELINES)

Process Control Concepts

The Meriam – Webester Dictioanry defines a process as a natural, progressively

continuing operation or development marked by a series of gradual changes that succeed
one another in a relatively fixed way and lead toward a particular result or end; or an
artificial or voluntary, progressively continuing operation that consists of a series of
controlled actions or movements systematically directed toward a particular result or end.
Any operation to be control called a process. For examples are chemical, economic, and
biological processes.

Control theory is an interdisciplinary branch of engineering that deals with the behaviour
of dynamical systems with inputs. The external input of a system is called the reference.
When one or more ouput variables of a system need to follow a certain reference
overtime, a controller manipulates the inputs to a system to obtain the desired affect on
the output of the system. The objective of a control is to calculate solutions for the proper
corrective action from the controller that result in system stability, that is the system will
hold the set point and not oscillate around it.

Control System

Control problems exist and can arise in numerous fields of process plant activity. Process
Control can be defined as influencing it in such a way as to force it to operate in
accordance with certain assumed requirements. This definition applies to all processes
which undergo control.

A controlled process is always surrounded by the environment in which it exists,

undergoing controlled or uncontrolled influences of this environtment. The controlled
influences are generated by a control unit for example in a form of algorithms executed by
an automatic control computer or in a form or decisions made by human beings. Such as
a control computer or a human operator tries to achieve the deisre parameters of
technological processes in a chemical reactor or in a distillation column by enforcing
appropriate values of selected process variables which influence its behaviour (flows,
levels, temperatures, etc.), counteracting changes in supply (raw materials, utilities) and
in ambient conditions, which distrub a desired course of the process.

These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases.
They were designed for engineers to do preliminary designs and process specification sheets. The final design must
always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the
amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for
young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 9 of 72
KLM Technology Kolmetz Handbook
Group Of Process Equipment Design Rev: 01
Practical Engineering
Guidelines for Processing PROCESS CONTROL CONCEPTS
Plant Solutions
July 2013
www.klmtechgroup.com ( ENGINEERING DESIGN GUIDELINES)

The process input variables may be at the disposal of a control unit or may be not,
thereby distrubing the behavior of the process from the point of view of the control unit.
Therefore, the uncontrolled input variables are usually called disturbances. The process
input variables, whose values can be changed by the control unit are usually called the
process manipulated variables or the process control inputs.

Evaluation of the state of a controlled process, whether or not it fulfills the assumed
requirements, whether or not the influence of manipulated inputs is correct, is done on the
basis of measurements. More generally, it is done characterizing the process behavior.
These variables are called process output variables. In a vase of the control of a chemical
reactor or a distillation column, examples of process outputs are parameters of a reacting
or distilled mixture, such as temperature or composition, as well as parameters
characterizing the state of technological apparatus (temperatures, pressures, liquid levels,
etc.).

Knowing objecitves of control and analyzing values of the process outputs and those
distrubances which are measured, the control unit makes decisions whether to maintain
or appropriately changes values of the control inputs. The general sturcture of a control
system is presented in Fig. 1.

Fig. 1 General Control System

These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases.
They were designed for engineers to do preliminary designs and process specification sheets. The final design must
always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the
amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for
young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 10 of 72
KLM Technology Kolmetz Handbook
Group Of Process Equipment Design Rev: 01
Practical Engineering
Guidelines for Processing PROCESS CONTROL CONCEPTS
Plant Solutions
July 2013
www.klmtechgroup.com ( ENGINEERING DESIGN GUIDELINES)

Control Objectives

The control objectives can be of variable nature. A complex process can be a single
reactor or a distillation column. Production line consisting of several technological
processes, mutually influencing each other, are typical examples of very complex
processes. Centralized automatic control of such complex processes, although in many
cases now theoretically possible, is extremely difficult and is characterized by drawbacks
practically eliminating such an option.

The most serious of these is the difficulty in ensuring proper safety of the controlled
process, difficulty in the necessary participation of people in the process of supervision
and reaction to unpredictable phenomena, connected with the necessity of fast and
simultaneous processing of large amounts of data. Therefore, in control (and
management) of complex processes, there has formed over the years the practice
supported by theory. The essence of hierarchical approach is a decomposition of the
primary, basic task (objecitve) of the control into a set of a partial, less complex and
connected tasks, from which every task processes a smaller amount of information and is
usually responsible for one partial objective.

There are two basic methods of decomposition of the overall control objective : (1)
Functional decomposition and (2) Spatial decomposition. The functional decomposition
applies to a process treated as a whole and is based on assigning a set of functionally
different partial control objectives – in a structure of vertical, hierarchical dependence,
called the multilayer control structure. A decision unit connected with each layer makes
decisions concerning the controlled process, but each of them makes decisions of a
different king.

On the other hand, the spatial decomposition is connected with a spatial structure of a
complex (large-scale) complex controlled process. It is based on a division of the control
task or a functionally partial task, for example within one layer of the described multilayer
structure, intor local subtasks of the same functional kind but related to individual spatially
isolated parts of the entire complex control process – subtasks of smaller dimensionally,
smaller amount of the processed information. This lead to multilevel structures.

The multilayer control structure is a result of a functional decomposition of the general

basic control objective. The realization of the basic, economic objective of the on-line

These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases.
They were designed for engineers to do preliminary designs and process specification sheets. The final design must
always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the
amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for
young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 11 of 72
KLM Technology Kolmetz Handbook
Group Of Process Equipment Design Rev: 01
Practical Engineering
Guidelines for Processing PROCESS CONTROL CONCEPTS
Plant Solutions
July 2013
www.klmtechgroup.com ( ENGINEERING DESIGN GUIDELINES)

control a industrial (technological) plant can be expressed as the realization of a number

of partial objectives. The three most important are : (1) Ensuring a safe running the
processes in the controlled palnt, in exmaple limiting the possiblitity of emergency
situations to an acceptable level. (2) Ensuring required features of the process outputs
(quality of products, etc.) in example, maintaining the output variables within ranges of
acceptable values. (3) Optimization of effectiveness of the process operation, usually
maximization of the product value (under restrictions on usage of raw materials or utilites)
or minimization of production costs at an assumed level of production, over a long time
horizon.

It is not difficult to notice that the first two partial control objectives are also of an
economic nature and they are connected with the basic objective : to maximize the
economic effectiveness of the process.

The occurence of failures or other emergency conditions usually leads to serious losses
of direct and indirect nature, connected with necessities to remove consequences of
delays or production breaks. These losses are usually more severe than the ones
resulting from a non-optimal, yet safe production running. Failing to keep to the quality
parameters leads, in the best cases, to a partial loss of the product, if the one not fulfilling
the quality requirements cannot find a buyer or is useless for further production process.

Here, financial losses are usually larger thatn in the case of an economically non-optimal
operation of the process, but one which ensures the quality requirements. Therefore, it is
usually worth to operate closer to the limits of quality constrains to lower the costs, but
this requires more precise control systems because it is more risky due to an ever-
present uncertainty connected with the influence distrubances.

Control Layers

The most important issue is the safety of the control system, next in the sequence is to
care about the quality of the products. Only after ensuring the realization of these two
aims, can there be room for on-line economic optimization of variables determining the
plant economic objective. Exactly in this order the layers of the basic multilayer control
structure are located, on top of the controlled process situated at the very bottom as
shown in Fig. 2.

These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases.
They were designed for engineers to do preliminary designs and process specification sheets. The final design must
always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the
amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for
young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 12 of 72
KLM Technology Kolmetz Handbook
Group Of Process Equipment Design Rev: 01
Practical Engineering
Guidelines for Processing PROCESS CONTROL CONCEPTS
Plant Solutions
July 2013
www.klmtechgroup.com ( ENGINEERING DESIGN GUIDELINES)

Plant Management

Optimization

Set Point Control

Direct Control (Basic Control)

Measurements
Control Inputs

Process (Plant)
Disturbances

Fig. 2. Multilayer structure

These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases.
They were designed for engineers to do preliminary designs and process specification sheets. The final design must
always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the
amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for
young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 13 of 72
KLM Technology Kolmetz Handbook
Group Of Process Equipment Design Rev: 01
Practical Engineering
Guidelines for Processing PROCESS CONTROL CONCEPTS
Plant Solutions
July 2013
www.klmtechgroup.com ( ENGINEERING DESIGN GUIDELINES)

The direct control layer (also called basic control layer) is responsible for the safety of
dynamic processes. It is usually also equipped with certain control logic responsible for
overriding the control designated for normal operating conditions, if violating certain
constraints leading to an emergency state is encountered. Only this layer has direct
access to the plant, and can directly change the values of the control inputs. Technical
realization of the task of this layer is nowadays ensured, for industrial processes, by
distributed control systems (DCS). These are complex computer systems measurement
acquisition, usually equipped with SCADA (supervisory control and data acquisition) type
software used for visualization, operator and engineer supervision and archivization of
data.

DEFINITION

Adaptive Control - Method of control whereby tuning (response) of the control system is
varied with the process condition, unlike other control where tuning is manual and
remains constant.

Basic Control Layer – Control system that responsible for the safety of dynamic
processes.

Cascade Control – Controllers arranged such that the output of one controller
manipulates the set point input of a second controller instead of manipulating a process
variable directly.

Control Action, Derivatives (Rate) - Control action with the controller output proportional
to the rate of change of the input.

Control Action Integral (Reset) – Control action with the controller output proportional to
the time integral of the error signal.

Control Action, Proportional – Control action with the controller output has a linear
relationship to the error signal.

Controller - A device which receives a measurement of the process variable, compares

that measurement with a set point representing the desired control point, and adjusts its
output based on the selected control algorithm to minimize the error between the

These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases.
They were designed for engineers to do preliminary designs and process specification sheets. The final design must
always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the
amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for
young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 14 of 72
KLM Technology Kolmetz Handbook
Group Of Process Equipment Design Rev: 01
Practical Engineering
Guidelines for Processing PROCESS CONTROL CONCEPTS
Plant Solutions
July 2013
www.klmtechgroup.com ( ENGINEERING DESIGN GUIDELINES)

measurement and the set point. If an increase in the measured process variable above
the set point causes an increase in the magnitude of the controller output, the controller is
said to be “direct acting”. If a process variable increase above the set point causes a
decrease in the magnitude of the controller output, the controller is “reverse acting”.

Control Theory – An Interdisciplinary branch of engineering that deals with behaviour of

dynamical systems with inputs.

Distribution Control System (DCS) – Is a system consists of some number of

microprocessor-based nodes that are interconnected by a digital communications
network, often called a data highway. It is type of computer process control system.

Disturbances – uncontrolled input variables.

Maninpulated Variables – The process input variables, whose values can be changed
by the control unit.

PD Controller- A controller with proportional plus derivatives (rate) control action.

PI Controller – A controller with proportional plus integral (reset) control action.

PID Controller – A controller with proportional plus integral plus derivative control action.

Process – A natural, progressively continuing operation marked by a series of gradual

changes that succeed one another in relatively fixed way and lead toward a particular
result.

Reference – The external input of a system.

Set Point – The desired value at which a process variable is to be controlled.

SCADA – Supervisory control and data acquisition.

Transmitter – A device that converts a process measurement variable into an electrical

or pneumatic signal suitable for use by an indicating or control system.

These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases.
They were designed for engineers to do preliminary designs and process specification sheets. The final design must
always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the
amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for
young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
 Page 15 of 72
KLM Technology Kolmetz Handbook
Group Of Process Equipment Design Rev: 01
Practical Engineering
Guidelines for Processing PROCESS CONTROL CONCEPTS
Plant Solutions
July 2013
www.klmtechgroup.com ( ENGINEERING DESIGN GUIDELINES)

NOMENCLATURE

C Controlled Variable
c Output bias or Manual reset
E Error = PV –SP
Ki Integral mode gain constant
Kp Proportional gain, (pure number)
PB Proportional band in percent, %
SP Set – Point
Ti Integral mode time constant
T Temperature change, o C
Kd Derivative mode gain constant
Td Derivative mode time constant
R Set Point
M Manipulated variable
L Load

These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases.
They were designed for engineers to do preliminary designs and process specification sheets. The final design must
always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the
amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for
young engineers or a resource for engineers with experience.

This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.