CHEN3005

PROCESS INSTRUMENTATION AND CONTROL

Australia Malaysia

Lecture Note 1
Introduction to Process Control and Unit
Information

Prof. Moses Tadé (MOT)/Assoc. Prof. Jobrun

©Saptoro/Ingram 2019
Nandong (JN) MOT/JN Revised in 2020
MOT/JN Revised 2024
Unit Information

2
CHEN3005 Process Instrumentation
and Control
Number of credits: 25

Tuition Pattern
 2 x 2-hour lectures weekly
• Lecture 1 (Wednesday, 8 - 10 am) and Lecture 2
(Thursday, 4 – 6 pm)
 1 x 1 hour Workshop weekly (Mondays)
 4 x 2 hours Experimental Laboratory in the
Semester

3
Syllabus

 Important terminology in process control

 Process control instrumentation
 Dynamic modelling
 Mathematics in process control: Laplace Transform
 Dynamic models: 1st order, 2nd order and higher order
 Dynamics behaviours of closed-loop systems and
stability
 Design and tuning of a single-loop feedback control
system: P, PI and PID controllers
 Stability and frequency response analyses
 Advanced PID control including Artificial Intelligence
(Emergence of Industry 4.0)
 PID control applied to MIMO systems

4
Unit Learning Outcomes

5
Textbooks

6
Recommended Textbooks

7
Online resources

Please see the pdf copy of the book on

BB.

8
Unit Study Calendar

 Please refer to the unit outline

 Follow that schedule with some
degree of flexibility
 Detailed lab timetables will be
released (by next week) once
grouping is finalised this week

9
Assessments

10
Introduction to Process
Control

11
 Outline of today’s lecture

 Motivation for Process Control in

chemical/bio-chemical processing
plants
 Why do we need to learn CHEN3005
PIC?
 CHEN PIC Unit Information
 Process Control Terminology
 Feedback Control Concept

12
Today’s learning outcomes

At the end of this lecture, students will be

expected to understand and explain the
following:

1. Why is process control needed in a

plant?
2. Process control terminology
3. What is feedback process control?
4. What are the main objectives of control?
5. How control affects process safety?

13
Keywords of this unit

PROCESS (SYSTEM
DYNAMICS)

INSTRUMENTATION
&
14
Keyword 1: Process (System Dynamics)

Definition of “process” (
https://en.oxforddictionaries.com/definition/process)

 “a series of actions or steps taken in order to achieve a

particular end”
 “a systematic series of mechanised or chemical
operations that are performed in order to produce
something”

15
Resource

16
Keyword 2: Control

Definition of “control”
(https://en.oxforddictionaries.com/definition/cont
rol)

 “Maintain influence or authority over”

 “Regulate (a mechanical or scientific
process)”

17
What is Process Control?
Process control is maintaining desired
conditions in a physical system by
adjusting selected variables in the
system (Marlin, 2000)

18
 Control in everyday life
• What is the control
objective?
• What is the control
variable?
• What is
thermostat manipulated
controller variable?
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

19
 Process Control for Industrial Applications
Steam
Setpoint
Product TC • What is the
Stream control
objective?
TT • What is the
controlled
variable?
• What is the
manipulated
Feed Condensate variable?

• Heating of “cold” feed to produce “hot” product using steam.

• Here, we manipulate steam flowrate for producing water at a desired
temperature => setpoint
20
 Process Control for Industrial Applications

TC: Temperature Controller TT: Temperature Transmitter

LC: Level Controller PT: Pressure Transmitter
CC: Composition Controller
Fresh A
Feed
Fresh B
Feed

LC

TC
PT
LC
Steam
TT TC

TT LC
Steam

C Product

• How many control loops?

• How many control objectives?
21
 Process Control for Industry
Applications

What are the control objectives?

What are the controlled variables?
What are the manipulated variables? 22
Keyword 3: Instrumentation

Must have 4
basic elements

23
 Keyword 3: Instrumentation

Definition of “instrumentation”
(https://www.merriam-webster.com/dictionary/instrumentation)

Instrumentation: the use or application of

instruments for observation, measurement, or control

In carrying out process control, we will need

to measure, transfer the signal, compute &
analyse and take a control action

Sensors, signal filter and converter,

controller etc. will play significant roles here 24
Issues encountered in process
industries
• More stringent safety and environmental
regulations
• Increasing market competition (desiring cheaper,
higher quality products)
• Energy and resource savings (producing more
with less energy and resources)
• Lower quality of feedstocks
 Process control is an essential tool to realizing
SUSTAINABLE DEVELOPMENT goals, e.g., one of
the green engineering principles

25
 Two most important reasons for
control
1. To track setpoint changes (servomechanism/servo
control)
• Process plants, e.g., a pharmaceutical plant is facing constantly
Changing Specifications from consumers.
• Failure to meet this need – leads to rejected products and losing
money.

2. To remove the effects of disturbances (regulatory

control/load change)
• A plant is subject to changing raw material qualities, varying feed
flow rates and temperature fluctuations, etc.
• Failure to remove the effects of these disturbances will cause deviations
from a consumer’s specifications on product quality – leading to rejected
products and loss of money.
Basic Reasons for Process Control: (1) to track setpoint change, and (2) to remove the
effects of disturbances, so that a plant can be safely operated, meet the target
specifications and make a PROFIT for the shareholders.
26
 Motivation for Process Control

 Control ensures Safe & Smooth Operation to achieve

Profit.

 Safety first: people, environment, equipment

protection

 The profit motive These are our

• meeting final product specs responsibilities as
• maximising overall production rate a chemical/process
• minimising waste production engineer
• minimising energy use
• minimising environmental impact

27
 “The 7 Commandments in
Process Control”
1. Safety
2. Environmental protection
3. Equipment protection
4. Smooth plant operation (Operability)
5. Product quality and production rate
Improving
6. Profit optimization Profitability
7. Monitoring and diagnosis

Control is required for achieving Safety,

Operability and Profitability
28
 Poor Control leads to
DISASTER !!

Williams
Olefins Plant
explosion (in
Louisiana,
2013)

77 injured and
2 dead

Source
http://cdn2b.examiner.com/sites/default/files/styles/image_content_width/hash/f1/e4/f1e4d5f76319d4
c7975ea3734b456747.jpg?itok=dKdapeJe

29
 Poor Control leads to
DISASTER !!
• Mina Al-Ahmedhi Refinery, KPCL, Kuwait, June 2000
• Leak led to flammable vapor release and explosion
• 7 people killed, 50 injured
• $400 million in losses

• Petrobras, Brazil, March 2001

• Off-shore oil platform explosion
• 10 people killed, $5 billion in losses
• Platform sank into the Atlantic Ocean
30
 Poor Control leads to
DISASTER !!
Ammonium Nitrate Explosion in Toulouse - France
21st September 2001

• 31 people killed
• 2442 injured
• Losses in hundreds of
millions dollars

31
 OTHER MAJOR INDUSTRIAL
DISASTERS
 Flixborough, UK, 1974
 PEMEX, Mexico City, 1984
 UCIL, Bhopal, India, 1984
 Cairns, Australia, 1987
 Piper Alpha, UK, 1988
 Ghislenghien, Belgium, 2004
 Buncefield, UK, 2005
 Deepwater Horizon, Gulf Mexico, 2010

 Process safety must be implemented in all stages of engineering

- in project development and continuous operations
 Process control plays a significant role in system monitoring
and control to ensure process safety
Process control: an essential part of
chemical engineering

energy

PROCESS CONTROL , PLEASE HELP!

33
 Why do we need to learn CHEN3005 PIC?

• Without process control…………

…. it would not be possible to operate most
modern processing facilities safely, reliably and
profitably, while satisfying industrial quality
standards…..

• Consequently, chemical engineers need to have

a good understanding of process instrumentation
and control

34
Control Engineer – The
Mission
The control engineer is called upon:
First and foremost, to fundamentally
understand and explain the dynamic nature
of processes and,

Then, based upon this knowledge, devise

appropriate mechanisms to influence the
process behaviour over time.

35
What past students said about process
control

“Process control plays important roles in ensuring safety

and profitability in our company”

Mr. Haripriyan Jaganathan (Curtin Graduate, 2013)

ASU Performance Specialist at Air Liquide
(the photo was taken when he was working at Linde Malaysia)
36
What past students said about process
control

Ms Ezzah Aswany (Curtin Graduate,37 2015)

 What past students said about process
control

“Safety is the top priority and good process monitoring and control
are efforts to make it possible”

Mr. Lu See Keat (Curtin Graduate, 2012)

(the photo was taken when he worked as Process Safety Manager at BASF
Petronas Chemicals Sdn. Bhd.) 38
Optimisation and Control of a
CSTR
Optimizer
RSP
Exercise – Discuss
TC what would be the
RSP possible constraints
Feed involved in the
FV
FC Optimization
CA0
FT What are the
A B C controlled variable
Steam TT and manipulated
variable?
Product
CA,CB, CC

39
 Benefits of Improved Control

Concentration
Limit Old Controller
Impurity

Time
• Notice that the variability of the product is
large.
• The plant must be operated further away from the
limit.
• This leads to an increase in energy
consumption, more wastes, low conversion40
 Benefits of Improved Control
Old Controller New Controller

Concentration
Concentration

Limit Limit

Impurity
Impurity

Time Time

• New controller leads to lower product

variability.
• How to achieve Increased Profit from this
improved controller?
• Need to push the operation closer to the
limit while not violating the limit. 41
 Benefits of Improved
Control
Old Controller New Controller

Concentration
Concentration

Limit Limit

Impurity
Impurity

Time Time
Improved Performance
Shifting the operation Concentration
closer to the limit. Limit
Impurity

This leads to Higher

Profitability.
Time 42
 Things to ponder

Do you agree that process control plays a major role in ensuring process safety and profit
making in industry?

Can you agree now that a good understanding of process control is essential for chemical
engineers?

Are we in the same boat to learn CHEN3005 PIC together?

43
Lecture 1 - Summary
Disturbances (raw
Changing customer materials,
demands and temperature
specifications fluctuations)

Motivations

Process Control in 4 basic elements

Industry 1) Controller
2) Actuator
Need to achieve
3) Sensor
key goals 4) Process
Safety, Equipment Protection,
Feedback
Environmental Protection, Smooth
Control
Operation, Profitability
44
 Further Note

Process Control and Essential Terminologies

45
 Process Control Terminologies
• The process variable (PV)
is a measure of the process thermostat
controller
output that changes in set point TC TT
response to changes in the temperature heat loss
(disturbance)
sensor/transmitter
manipulated variable
control
signal

A variable called a fuel flow furnace

controlled variable (CV) valve

is to be kept the same as, Copyright © 2007 by Control Station, Inc. All Rights Reserved

or as closely as possible to,

the value of the set point • A final control element (FCE) is
the device that changes the value
of the manipulated variable
• The set point (SP) is the
value at which we wish to • The controller output (CO) is the
maintain the process signal from the controller to the
variable at (targeted value) final control element
46
• The manipulated variable
Input Output
Classification of Input Variables
Variables (u)
.
.
.
.
PROCESS .
.
.
.
Variables (y)

can be adjusted freely by a

human operator or a control
system
represent the effect of the
surroundings on the process Manipulated

Input Variables
Measured
Measured

Disturbances

are not the result of an

adjustment by an operator or
Unmeasured
a control system

47
 Process Control Terminologies

Controlled variables - these are the variables which

quantify the performance or quality of the final
product and are also a type of output variable
Chapter 1

Manipulated variables - these input variables are

adjusted dynamically to keep the controlled variables
at their set-points.
Disturbance variables - these are also called "load"
variables and represent input variables that can
cause the controlled variables to deviate from their
respective set points.

48
Home Heating Feedback Control

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

49
 thermostat

Home Heating Feedback Control Block Diagram set point

controller

TC TT
temperature heat loss
sensor/transmitter (disturbance)

control
signal

fuel flow furnace

valve

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

50
Four main categories of control
configurations
1. Open-loop Control
The control mechanism acts without any information about
the current status of the process

2. Feedback Control
• The control mechanism acts using the information fed
back from the measurements
• Based on measurement of a output (controlled
variable).
• Use measurement error to generate control action.
• A Proportional-Integral-Derivative (PID) controller is
often used in industry

3. Feedforward Control
• The control mechanism anticipates the effect of the
disturbance.
• Based on measurement of a disturbance.
51
• Uses a model to make predictions
 Open-loop Control

d(t)

u(t) y(t)
? Process
Process

Open-Loop Control
52
Feedback Control Configuration

d(t)

Feedback Control

u(t) y(t)
? Process

53
 D
Feedback Control Configuration
R E C Final U Y
Controller Process
+ Control
- Element

Ym
Sensor

Block Diagram of a Feedback Control System

Manipulated Variables, e.g.,

Terminology fuel flow rate in furnace
Controlled Variables, e.g.,
furnace temperature
Sensors, e.g., thermocouple
Processes, e.g., heating in
furnace
D = Disturbance Controllers, e.g., Proportional-
Integral (PI) controller 54
Feedforward Control Configuration

d(t)

u(t) y(t)
?? Process

Feedforward Control

55
Combined feedforward and feedback Control

d(t)

u(t) y(t)
? Process
Process

Feedforward-Feedback Control

56
Examples of process control terminologies
and configurations

57
Example 1: Driving a Car: An
Everyday Example of Process Control

 Control Objective (Setpoint) - Maintain a car in the proper

lane
 Controlled variable - Location on the road
 Manipulated variable - Orientation of the front wheels
 Final Control Element - Driver’s arms/steering wheel
 Sensor - Driver’s eyes
 Controller - Driver
 Disturbance – A curve or bump on the road or an unexpected
crossing buffalo, etc.
 Control configuration - combined feed-forward and feedback
control
58
More industrial examples of process
instrumentation and control
Single-loop

Cascade control

59
SUMMARY
Motivation for Process Control
• Setpoint Tracking and Disturbance Rejection
Basic reasons for why Process Control is
essential in chemical/bio-chemical
processing plants
• Five major constraints leading to 5 explicit control
objectives
Why do we need to learn CHEN3005 PIC?
• To be able to run a given plant in a safe, reliable
and profitable manner
Process Control Terminologies
• Control objective, controlled variable,
manipulated variable, disturbance 60
 Supplementary Material
***
Note:
Due to the time limitation, the subsequent materials
cannot be covered during the normal lecture time.
Students are urged to go through the supplementary
materials by themselves to enhance their knowledge of the
topics in this lecture. A good understanding this material
would be useful for your ETests.

61
Example 2 – Temperature Control in Heat Exchanger

• Controlled variable- Outlet

temperature of product
stream
• Manipulated variable- Steam
flow
• Final Control element-
Control valve on steam line
• Sensor- Thermocouple in
product stream
• Disturbance- Changes in the
inlet feed temperature
• Control configuration-
Feedback control

62
Comparison of Driving a Car and Control of
a Heat Exchanger

• Final Control Element (Actuator): Driver’s arm and steering wheel

vs. control valve
• Controller: the driver vs. an electronic controller
• Sensor: the driver’s eyes vs. thermocouple
• Controlled variable: the car’s position on the road vs. temperature
of the outlet stream

63
Example 3 – DO Control in a Bio-
Reactor
 Controlled variable- the
Setpoint measured dissolved O2
concentration
AC AT
 Manipulated variable- air flow
rate to the bio-reactor
Air
 Actuator- variable speed air
compressor
Variable Speed
Air Compressor
 Sensor- ion-specific electrode in
contact with the broth in the bio-
reactor

 Disturbance- Changes in the

metabolism of the
microorganisms in the bio-reactor

 Control configuration- Feedback

control 64
Example 4 - Schematic diagram of a stirred-
tank heating process (Control Configuration:
Feedback Control)
F • Controlled variable –
T
Fin outlet temperature T
Tin • Manipulated variable
– heating medium
TC
flow Fh
Tdesired
• Disturbances – Feed
temperature Tin
Heating
medium • Setpoint – or desired
Fh value for outlet
temperature, i.e. T =
Tdesired
• Final Control Element
– control valve
• Control
configuration: 65

Feedback control
Example 5 - Tank Heater System with a
(Control Configuration: Feedforward Control)

66
Example 6 - Blending
Two liquid streams each with a different composition are mixed in a vessel.

Aim is to produce a product with a desired concentration while maintaining

a constant level in the tank.

F 1, x 1 F 2, x 2

Inputs: F1, x1, F2, x2

Outputs: F, x, V

F, x

67
 Example 6 - Blending

Feedforward Controller
Monitor composition variations Controller
in a feed stream and adjust the
flow rate of the other. CI
Distinguishing feature: measure
a disturbance variable

Advantage:
 Corrects for the disturbance before it
upsets the process.
Disadvantage:
 Must be able to measure the
disturbance.
 No corrective action for unmeasured
disturbances. 68
 Example 6 - Blending
Feedback Controller Monitor product composition
and adjust the flow rate of one
of the feed streams.
•Advantages:
 Corrective action is taken regardless
of the source of the disturbance.
 Reduces sensitivity of the controlled
variable to disturbances and
changes in the process.
•Disadvantages: Controller

 No corrective action occurs until

after the disturbance has upset the
CI
process, that is, until there is offset
between the set point and CV.
 Very oscillatory responses, or even
instability, may occur.

69
 Control Configurations:
No. of inputs and outputs
• Depending on how many controlled outputs and
manipulated inputs we have in a given process, we
can classify the control configuration as one of:
- Single Input-Single Output (SISO) control.
or,
- Multiple Input-Multiple Output (MIMO) control.

70
Example 6 - Blending
Two Input-Two Output System

LC QC

LI QI

Level Control Loop

Composition Control Loop

71
Typical symbols and notation used in Piping and
Instrumentation Diagrams (P&IDs)

72
More industrial examples of process
instrumentation and control

73
Control System Design

The control design task is a much more involved

question than a simple adjustment of the
controller parameters.
It involves a whole strategy of design !!!

74
Control System Design - Steps

Define Control Objectives

Select Measured Variables

“Maintain process output
variables close to their
targets.”
Select Manipulated Variables
By ensuring stability,
eliminating disturbances, and
optimizing the economic
performance of the process, Select Control Configuration
the control system strives to
achieve this objective.

Controller Tuning

75
Define the Control Objectives
 Control Objectives can be implicit or
explicit.
• Implicit control objectives cannot be
measured directly, e.g., smooth
operation, optimum profit, minimum
energy consumption, maximum product
yield, etc.
• Explicit control objectives involve directly
measured variables, e.g., to control
reactor temperature at 500oC, or to
control tank level at 2 m high, etc. Both
temperature and liquid level are directly
measured.
76
Control System Design - Steps

Define Control Objectives

Select Measured Variables

“We need a means to
monitor the performance of
the process.” Select Manipulated Variables
We would like to directly
monitor the variables that
represent the control Select Control Configuration
objectives.

Controller Tuning

77
Selection of Measured Variables

 For large chemical plants, there could be

several hundreds or thousands of
measurements, e.g., flow rates, temperatures,
pressures, concentrations, etc.
 The Question is, “do we need to control all of
them?”
 The Answer is of course NO. It is not practical
to control all of the outputs.
 Hence, we just need to select a small subset of
variables from the set of outputs.
 This is a very challenging task.

78
Control System Design - Steps

Define Control Objectives

“How can we cause a

change in the process?” Select Measured Variables

In other words, what are

the variables to be
manipulated to achieve the Select Manipulated Variables
control objectives?

Select Control Configuration

Controller Tuning

79
Selection of Manipulated Variables

 In large chemical plants, there could be

several dozens or hundreds of input variables.
 BUT not all of them are suitable to be
Manipulated Variables (MVs).
 Essentially, engineers must properly select a
subset of input variables as the MVs.
 Important characteristics of good MVs:
• Strong and fast effects on the controlled variables
• Exhibit small time delays (which can cause instability)
• Preferably do not exhibit strong inverse-responses
 Again, selection of MVs is a challenging task!

80
Control System Design - Steps

Define Control Objectives

The control configuration is

the information structure Select Measured Variables
used to match the available
measurements with the
available manipulated
variables. Select Manipulated Variables

Feedback, feedforward,
SISO, MIMO, etc…
Select Control Configuration

Controller Tuning

81
Control System Design - Steps

Define Control Objectives

“How is the information

taken from the
measurements used to Select Measured Variables
adjust the values of the
manipulated variables?”

The answer to this question Select Manipulated Variables

constitutes the control law,
which is implemented
automatically by the
controller. Select Control Configuration

Controller Tuning

82
Controller Tuning
 About 90% of industrial controllers are of the
Proportional-Integral-Derivative (PID) type:

 This is an ideal PID form with 3 tuning

parameters:
 A chemical plant could consist of hundreds
of PID controllers
• This means that there are a lot of parameters to be
tuned correctly.
• A very challenging task, fortunately there several
procedures that have been developed to address this
problem.

83
Control and Optimisation
 Control and Optimization are two
different things but are always used in
the process industry.
 Control is about maintaining a certain
variable at its desired value or setpoint.
• E.g., a desired furnace temperature is
700oC.
 Optimisation chooses the values for
key setpoints such that the process
operates at the “best” economic
conditions.
• Will the chosen temperature at 700oC 84
Optimisation and Control of a
CSTR
Optimizer Exercise –
RSP
Discuss what
would be the
TC
RSP possible
Feed constraints
FV involved in the
FC
CA0 Optimization.
FT
What are the
Steam
A B C controlled
TT
variable and
manipulated
Product variable?
CA,CB, CC

85
Optimisation Example - CSTR

A B C
Mole balance on A :
Q C A0  Q C A  k1 exp[  E1 / RT ] C A Vr 0
Solving for C A
C A0
CA 
k1 exp[  E1 / RT ] Vr
1
Q
Likewise, C B and CC are calculated from mole
balances.
86
Optimisation Algorithm
Example - CSTR

1. Select initial guess for reactor

temperature
2. Evaluate CA, CB, and CC
3. Evaluate F (see next slide)
4. Choose new reactor temperature
and return to step 2 until the
optimum T* identified.

87
Economic Objective Function
Example - CSTR

  Q C A V A  Q C B VB  Q CC VC  Q C A0 VAF

• VB > VC, VA, or VAF

• At low T, little formation of B
• At high T, too much of B reacts to form C
• Thus, there exists an optimum reactor
temperature, T*

88
Graphical Solution of
Optimum Reactor
Temperature, T *
2
Economic Objective

1.5

1
Function,

0.5 T*

0
250 275 300 325 350
-0.5
Reactor Temperature (K)

89
Generalized Optimisation Procedure

Initial Estimate Numerical Optimum

of Optimization Optimization Operating
Variables Algorithm Conditions

Optimization Economic
Variables Function
Value
Model
Results Economic
Process Economic
Function
Model Parameters
Evaluation

90
Optimisation and Control
of a CSTR
Optimizer
RSP

TC
RSP
Feed
FV
FC
CA0
FT

A B C
Steam TT

Product
CA,CB, CC

91
Maximising Plant Profit

 Often involves controlling against several

constraints.
 The trick is to operate closer to these constraints
 The closer to the constraints, the more the profit
 Constraint Optimisation is an important tool to
determine Setpoints lying close to the constraints.
 Several constraints, e.g., maximum Pressure and
Temperature, minimum concentration and flow rate,
etc., often form a Feasible Operating Window.
 Values lying outside the Operating Window are
not feasible or practical due to being unsafe,
uneconomic or both.
92
 Chemical Plant:
Where is control implemented?
 Sensors, local Local display

indicators, and valves Local manipulation

are located next to
the process.
 Displays of all plant
variables and control
calculations occur in Sensor
the centralized
facility.
 Control room – Control
monitoring and control Room
software.

93
Operator console

94
A modern Control system

95
 Controller

 Motorola PPC
 100 Mbit Ethernet ports
 … :-)

96
References

97
So ...

Any questions?

Have Fun and Good luck

with the unit!

98