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Chapter 1: Introduction To Process Control

The document provides an introduction to process control. It explains that feedback control systems have three main elements: a sensor, controller, and final control element. The feedback loop uses a sensor to measure the process variable and provide feedback to the controller. The controller then adjusts the final control element to influence the input to the process in a way that moves the process variable towards the desired setpoint. Control is necessary to maintain safe, consistent operation despite disturbances. It is possible through proper design of both control equipment and process equipment. Control is implemented through a combination of local indicators/valves and a centralized control room.

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113 views

Chapter 1: Introduction To Process Control

The document provides an introduction to process control. It explains that feedback control systems have three main elements: a sensor, controller, and final control element. The feedback loop uses a sensor to measure the process variable and provide feedback to the controller. The controller then adjusts the final control element to influence the input to the process in a way that moves the process variable towards the desired setpoint. Control is necessary to maintain safe, consistent operation despite disturbances. It is possible through proper design of both control equipment and process equipment. Control is implemented through a combination of local indicators/valves and a centralized control room.

Uploaded by

rrrtttr
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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CHAPTER 1 : INTRODUCTION TO

PROCESS CONTROL
When I complete this chapter, I want to be
able to do the following.

• Explain the feedback concept applied to


control
• Explain and identify the three elements in
a feedback loop
• Be able to apply feedback manually to
many chemical process examples
CHAPTER 1 : INTRODUCTION TO
PROCESS CONTROL
Outline of the lesson.

• Why Process Control and Why Now?


• Basic Questions about Control
- What does a feedback system do?
- Why is control necessary?
- Why is control possible?
- Where is control done?
- How is control documented?

• Workshop
• Self-Study Guides
WHY HAVE A PROCESS CONTROL COURSE?

• When I run a kinetics experiment, how do I


maintain the temperature and level at desired
values?

• How do I manufacture products with consistently


high quality when raw material properties change?

• How much time do I have to respond to a


dangerous situation?

Every engineer needs basic knowledge about control.


Many exciting career opportunities exist for a
technical specialist.
WHAT DOES A FEEDBACK SYSTEM DO?
Let’s look at a few examples first. Then, we will
develop a general concept.
WHAT DOES A FEEDBACK SYSTEM DO?
Why does the temperature cycle?

Is this good enough for all variables in a chemical


process? Hint: if “yes”, the course is over!
WHAT DOES A FEEDBACK SYSTEM DO?
The control systems appear to have three basic elements.

Desired value

CONTROLLER

FINAL
ELEMENT SENSOR
PROCESS
Inputs Outputs
WHAT DOES A FEEDBACK SYSTEM DO?

What is a typical “final element” for


chemical processes?

What is the meaning


of the arrows?

How do we select the sensor


location?
WHAT DOES A FEEDBACK SYSTEM DO?

CONTROL (verb): To maintain desired conditions in a


physical system by adjusting selected variables in the system.

FEEDBACK CONTROL makes use of an output of a system


to influence an input to the same system.

input = cause output = effect


WHAT DOES A FEEDBACK SYSTEM DO?

Caution: Common misunderstanding in terminology!

Common vernacular Engineering & Science

Negative feedback: “You are Negative feedback: Action to


an idiot! reduce the error from
desired.
Good!
Positive feedback: That was Positive feedback: Action to
a good idea. Thank you! increase the error from
desired.
WHY IS CONTROL NECESSARY?

One word: DISTURBANCES! Give some


examples in the CSTR in the figure.

We want to achieve the


v1 following:
1. Safety
T 2. Environmental Protect.
3. Equipment protect.
A 4. Smooth operation
CB 5. Product quality
6. Profit
v2 7. Monitoring and diagnosis

Chapter 2
WHY IS CONTROL NECESSARY?

xD
One word:
DISTURBANCES!
FR
Give some examples in
the distillation tower in
FV the figure.

xB
WHY IS CONTROL POSSIBLE?

Control is possible only if the engineer provides


the required equipment during process design.
Part 1: Control equipment

Communication
Final v1
element
T

Sensors A
Computing
CB and interface
for person
v2

Final element
WHY IS CONTROL POSSIBLE?

Control is possible only if the engineer provides


the required equipment during process design.
Part 2: Process equipment

v1

How do we
T
determine
the reactor A
volume?
CB

v2
How do we determine
the heat transfer area?
WHERE IS CONTROL DONE?

Sensors, local
indicators, and valves
in the process

Displays of variables,
calculations, and commands to
valves are in the centralized
control center.
Shows an older-style control
panel
WHERE IS CONTROL DONE?

Creative Commons License, see


http://en.wikipedia.org/wiki/File:Nuclear_Ship_Savannah_-_Reactor_Control_Room_-_Center_and_Left_Panels.jpg
WHERE IS CONTROL DONE?

Sensors, local
Central control room indicators, and valves
in the process

Displays of variables,
calculations, and commands to
valves are in the centralized
control center.
Shows a modern, computer-
based control panel
WHERE IS CONTROL DONE?

Photo courtesy of Worsley Alumina and Honeywell


HOW IS CONTROL DESIGN DOCUMENTED?

Piping and instrumentation (P&I) drawings provide


documentation.
• The system is too complex to describe in text.
• We must use standard symbols.

FC F = flow
L = level
TC LC P = pressure
A
T = temperature
…..
CHAPTER 1: INTRODUCTION - WORKSHOP 1

Flow Control

Controller and Final


control element?
sensor

pump valve
CHAPTER 1: INTRODUCTION - WORKSHOP 2

Level Control
Controller and final
control element ?
sensor

pump valve
FINAL CONTROL ELEMENT
Here our aim is to control level (h) of tank
So h is a controlee variable
Scenario : 1
Scenario : 2
VARIABLES

INPUT VARIABLES : That directly affects to controlled variable


Disturbance variable , Manipulated Variable
Can or Cannot be manipulated

OUTPUT VARIABLES : Cannot be manipulated


Controlled variable
measurable or can not measurable

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