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Process Control Lecture 1

The document provides an introduction to process control and instrumentation, highlighting key concepts, definitions, and the importance of process control in ensuring safety, product quality, and compliance with environmental regulations. It categorizes control systems into manual, automatic, and semi-automatic types, while also discussing the classification of process variables and the hardware components involved in control systems. Additionally, it addresses challenges faced in the implementation of process control, such as nonlinear processes and measurement inaccuracies.

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Richeal Owusu
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2 views

Process Control Lecture 1

The document provides an introduction to process control and instrumentation, highlighting key concepts, definitions, and the importance of process control in ensuring safety, product quality, and compliance with environmental regulations. It categorizes control systems into manual, automatic, and semi-automatic types, while also discussing the classification of process variables and the hardware components involved in control systems. Additionally, it addresses challenges faced in the implementation of process control, such as nonlinear processes and measurement inaccuracies.

Uploaded by

Richeal Owusu
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Introduction to

Process Control and


Instrumentation
M. F. Baidoo
Department of Chemical Engineering
KNUST
Learning Outcomes
 Understand and define some basic terminologies related to process
control.
 Explain the reasons why process control is necessary.
 Categorize process control system based on the mode, time dependence
and configuration of components.
 Identify and classify process variables as input and output variables.
 Explain how key process variables are controlled on important unit
operation in the petrochemical industries.
 Identify the hardware component of a process control systems
 Explain some challenges encountered in the implementation of process
Control.
Definitions
Process: The transformation of raw materials into desired product using available
feedstock sources of energy in the most cost effective way.

Control:
1. Series of actions directed at making a system variable adhere to a reference
value of the operating conditions
2. Process of altering manually or automatically the performance of a system to
adhere to a desired one.
3. The design and algorithim for maintaining the output of a specific process
within a desired range.

Instrumentation:
The science of applying measuring device to monitor and control a process
variable.
Why Process Control?
Safety
 Safety of personnel
 Equipment safety
 Environmental safety

Product specifications
 Desired amount and quality of final products.

Environmental Regulation
 Environmental Protection Agency(EPA) have regulation concerning temperature, concentration of
chemicals and flow rates of effluents from a plant. These regulations should be satisfied.
Why Process Control?
Operational Constraints:
 Inherent constraints in the operation of some process equipment.

Economics:
 Raw materials, energy, capital and labour should be utilized in the most cost
effective way by operating at optimum levels of minimum operating costs or
maximum profit.
Specific Role of Control System
 Suppressing the influence of external disturbances.

Ensuring the stability of a chemical process.

Optimizing the performance of a chemical process.


Classification of Control Systems
Mode/ Technique for performing control action
 Manual Control
 A person
 takes the decision and
 effect the changes

 Automatic Control
 Devices are used for control (usually unattended)
 reads output variable = measurement/Sensing
 compares measured variable to set point = compares
 takes a decision: how much to change = computes
 Effect changes (manipulate variable) : decrease, increase = Adjusment

 A combination of both manual and automatic (semi-automatic) is also


possible.
Classification of Control Systems (Cont.)
Time dependence of the reference value (steady/dynamic)

Regulator system: Ensure that system output remain close to


reference value regardless of the magnitude of disturbances and/or
noise.

Servo System: Ensure that the system output follow a changing


reference value in the absence of disturbances.
Classification of Control Systems (Cont.)
Fundamental Structure/Configuration of Control system:
Loop: sequence of instructions continually executed until a certain outcome is obtained.
Open-Loop: Controller executes action without information on the state of
the system.

 Any time dependent device eg. Washing machine, microwave oven.


Feedforward is another term for open loop control systems.
Application of Feedforward Control
Pros & Cons of Feedforward/Open-Loop Control
Classification of Control Systems (Cont.)
Fundamental Structure/Configuration of Control system:
Closed-Loop: Controller acts based on the knowledge of the state of
the system. eg. Feedback control
Advantages of Feedback/Closed Control
Disadvantages of Feedback/Closed Control
Process Measurement and Control

Process Control mechanism begins with a measurement of


a process variable.
Process Variables
A process variable is a condition of the feedstock, product or utilities that can
change influence the outcome of a manufacturing process.
 Temperature
 Pressure
 Flow rate
 Level
 Concentration/pH
 Specific gravity/Viscosity/density
 Humidity
 Mass
 Conductivity
Classification of Process Variables
Disturbance/Load

Two main categories


Manipulated PROCESS Output
Input variables: variables variables

the effect of surroundings on the chemical process

Output variables:

the effect of the chemical process on the surroundings


Classification of Process Variables
Input variables
 Manipulated variables: variables or parameter or factor are adjusted to keep the
variables to be controlled at their set-points.

 Disturbances/Load: undesired change in one of the factors that can cause the
variable to be controlled to deviate from their set-points.

Output variables:
 Measured/Controlled variables: describes the condition of the process that must be
kept at the designated set-point. Their values are known by direct measurement.
Example: Continuous Stirred Tank Heater

19
Examples: Temperature and Concentration
Control

20
Hardware for Control
Process: Part of control system whose output is to be controlled. It includes the equipment
together with the physical or chemical operations that occur.

Measuring instruments or sensors: Used to detect and measure the changes in the process variable.

Transducers: Converts a physical phenomenon into some other form of energy (electric voltage or
current, pneumatic signal etc) which can be easily transmitted.

Transmission lines: Carries measurement signal from measuring device to the controller.

Controller: Intelligence unit that receives information from measuring devices and decides what
action to be taken.

Final Control Element: It implements the decision taken by the controller. eg. control valves
Challenges of Process Control
Implementation
 Nonlinear/non-stationary nature of a process

 Unavailability of accurate measurement of controlled variable

 Time delays or dead time

 Multivariable interactions

 Sensitivity to noise and disturbances

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