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    Process Control and Instrumentation

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    Siddhant Sinha

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    Process Control and Instrumentation

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    Siddhant Sinha
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    Lec-1&2 (1)

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    119 views14 pages

    Process Control and Instrumentation

    Uploaded by

    Siddhant Sinha

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    © All Rights Reserved
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    of 14

    Process Control And Instrumentation

    Introduction
    Course Code : CML 303
    Course Title : Process Control and Instrumentation
    Course Credit (L-T-P): 3 Credits (3-0-0)

    1
     Importance, aims and objectives of process control, introduction to system
    dynamics, concept of dynamic response, first order, second order
    interacting and non interacting systems, concepts of transfer function,
     Course Content
    time constant, process gain, overshoot, decay ratio, dead time. 
    Course Outcomes /
     Introduction to set point, disturbance, closed loop and open loop control,
    Objectives:
    feedback and feed forward configurations, dynamics of feedback control
    system.   1. Student shall be able to
    formulate the dynamic model
     Types of controllers, P, PI and PID controllers, controller gain, stability of different chemical
    analysis, Routh stability criteria. processes.
    2. Student shall be able to
     Design of controllers using open loop response, Zigeler – Nichols controller identify the different
    settings, Bode and Nyquist stability criteria. measuring instruments and
    their working principle.
     Control valve and choice of controller settings.  Basic design of pneumatic 3. Student shall be able to apply
    controllers, electric / electronic controllers, discontinuous control modes – analytical tools and design
    methodologies to tackle
    two position, classical and modern control actions. 
    process control problems.
     Process instruments used for measurement of pressure, temperature, 4. Student shall be able to apply
    liquid level, flow rate and compositions, pressure gauge, strain gauge, control schemes along with
    tuning techniques in chemical
    McLeod gauge, vacuum measurement, transducers, transmitters, digital processes.
    signal processing. 
     Introduction to set point, error, accuracy, sensitivity, Application of control
    systems to chemical process equipments such as chemical reactors, heat
    exchangers, distillation columns, boilers etc.

    2
    Lecture Lect.No. Content

    Plan 1-2
    3-4
    Introduction of Process Control, Incentives for chemical process control
    Design Aspects of Process Control System, Control configuration
    5-6 Laplace Transform , Inverse Laplace, Transfer function.
    7-8 Physical examples of 1st order system
    9-10-11 Response to first order system, Step ,Impulse And, Sinusoidal Response
    12-13 Response of Interacting and Non- Interacting systems.
    14-15 Transportation Lag and its response, practice examples.
    16-17 Examples of 2nd order system. Damped Oscillator, Mercury Manometer
    18-19-20 Response of 2nd order system, Step response (over damped, critically damped and under damped),Impulse
    response, Sinusoidal Response
    21-22 Representation of control systems in block diagrams open and closed loop transfer functions. Servo &
    regulator control, Feedback & feed forward control loop
    23-24 Pneumatic Controllers & Control Valve
    25-26 Feed Back Control System, Concept ,Types, Dynamic Behaviour
    27-28 Routh criteria of systems stability. Criteria, Routh Array, Practice Examples
    29-30 Root locus of feed back control.
    31-32-33 Control system analysis by Frequency Response ,Bode Diagram, Ziegler-Nichols optimum controller
    System
    34-35 Niquist Diagram & Stability Criteria.
    36 Various method of Tuning of controllers and self Tuning controllers .
    37-38 Principles of feed forward ratio, cascade and control schemes for the system with large transportation lag.

    39 Overall instrumentation and control of units like reactors, distillation column etc.
    40 Problem Practice

    3
    Tentative Evaluation Scheme
    Components Duration/Mode Max Marks
    Mid Semester Examination Online 30
    Class test/Quizzes and Online 30
    Assignments
    End Semester Exam Online 40

    Mid sem Exam :- 01st Oct - 9th Oct 2020


    End Sem Exam :- 08th Dec - 18th Dec 2020

    4
    Books:
     “Process system Analysis & Control”, Donald R. Coughanowr and
    Kappel, Mc Graw Hill Book Company.

     G.Stephanopoulos, "Chemical Process Control: An Introduction to


    Theory and Practice", Prentice-Hall, New Jersey, 1984.

     R.P.Vyas, “An Introduction to Process dynamics & control, Central


    publication, Nagpur, 2001

     T. Marlin, "Process Control", McGraw Hill, 1995.

     W.L.Luyben, "Process Modelling Simulation and Control for Chemical


    Engineers", McGraw Hill, 1990.
    5
    Day to Day-life……. Control Examples
     Liquid Level tank
     Cycling thermostat
    controller
    set point TC TT
    temperature heat loss
    sensor/transmitter (disturbance)

    control
    signal

    fuel flow furnace


    valve

    Copyright © 2007 by Control Station, Inc. All Rights Reserved

    6
    Driving a Car: An Everyday Example of Process Control
    Control Objective (Setpoint): Disturbance

    Maintain car in proper lane. Setpoint e c u


    Controlled variable- Location on the +- Controller Actuator Process CV

    road
    Manipulated variable- Orientation of Sensor

    the front wheels


    Actuator- Driver’s arms/steering

    wheel
    Sensor- Driver’s eyes
    Controller- Driver
     Disturbance- Curve in road

    7
    What is Chemical Plant?
     A chemical plant is an arrangement of processing units (reactors,
    heat exchangers, pumps, distillation columns, absorbers,
    evaporators, tanks, etc.), integrated with each other in a systematic
    and rational manner. The plant's overall objective is to convert
    certain raw materials (input feedstock) into desired products using
    available sources of energy, in the most economic, way.

    8
    A Chemical Plant must
    satisfy several
    requirements

    Safety

    Economics
    Chemical Plant
    Production
    Specification

    Operational Environmental
    Constraints Regulation

    9
     Why does Control Necessary?
     There are three general classes of needs that a control system
    is called on to satisfy:
    - Suppress the influence of external disturbances,
    - ensure the stability of a chemical process, and
    - optimize the performance of a chemical process.

    10
    Suppressing the influence of external disturbances
     Operational Objectives
    1. To keep the effluent temperature T at a desired value
    Ts
    2. To keep the volume of the liquid in the tank at a
    desired value Vs

    11
    Feedforward Temperature control
    Feedback liquid level control scheme scheme

    12
    Ensuring the stability of a chemical process

    13
    Optimize the performance of a chemical process.

    14

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