TẬP ĐOÀN DẦU KHÍ VIỆT NAM

TRƯỜNG ĐẠI HỌC DẦU KHÍ VIỆT NAM

Process Control

Chapter 1: Introduction to
Process Control
CBGD : TS. Trương Thanh Tuấn
Email : tuantt@pvu.edu.vn
Website : www.pvu.edu.vn/tuantt
1
 What is process control ?

Watch the video and answer the question:

1. Industrial Automation and Control - A Galco TV Tech Tip

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 Objectives

End of this chapter, you should be able to identify:

1.1 The need for control system
1.2 The role of process dynamics, instrumentation and control in
industry
1.3 Design steps of a control system
1.4 Control aspects of a complete plant
1.5 Representative control problems
1.6 Hierarchy of process control activity

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 1.1 Need for control system

Performance requirements for process plants have become

increasingly difficult to satisfy.

Key factors for tightening product quality specifications:

▪ Stronger competition
▪ Rapidly changing economic conditions
▪ Tough environmental and safety regulations
▪ Modern plants are complex and highly integrated
▪ It is difficult to prevent disturbances from propagating from one unit
to other interconnected units.

Process control has become increasingly important due to increased

importance on safe and efficient plant operation.

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 Justification of Process Control

Specific Objectives of Control

▪ Increased product throughput
▪ Increased yield of higher valued products
▪ Decreased energy consumption
▪ Decreased pollution
▪ Decreased off-spec product
▪ Increased Safety
▪ Extended life of equipment
▪ Improved Operability
▪ Decreased production labor

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 Economic Incentives - Advanced Control

Advanced process control significantly reduces product

variability

Figure 1.1

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 1.2 The Roles of PIC in Industry
Some of the roles of PIC
❑ Understanding dynamic behavior of processes and trouble
shoot relevant problems
❑ Designing control system that address specific control
problems
❑Tuning of controllers
❑ Stability analysis of controlled processes
❑Drawing and interpretation of piping and instrumentation
diagrams (P & ID)
❑Selection of appropriate control instruments

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 Process Dynamics

❖ The term process dynamics refer to unsteady state (or

transient) behavior.

❖ Dynamic studies provide us the behavior of the process

under unsteady-state conditions
Under steady state conditions, the
flow rate out of the tank must
equal the flow rate into the tank.

F = F1 + F2

Figure 1.2 Gravity flow tank

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 Example 1: Gravity Flow Tank

What would happen if we change F1 dynamically?

How will h(t) and F(t) vary with

time?

Figure 1.3 Responses of the gravity flow tank

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 1.3 Design Steps of Process Control Systems

Design of control system involves:

1.3.1 Identifying the control objective
1.3.2 Identifying and classifying the process variables and developing model
1.3.3 Selecting the appropriate control configuration
1.3.4 Selecting the appropriate controller type
1.3.5 Selecting the appropriate instrumentation and preparing the P & ID
1.3.6 Tuning the controllers

A good starting document for design of control systems is the

schematic diagram of the process or process flow diagram (PFD).

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 1.3.1 Identifying control objective

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 1.3.1 Identifying control objective

1.3.1 Identifying control objective

The control objectives should be identified and
clearly defined.
-Control objectives can be defined as follows:
▪ To maintain the outlet temperature T at 65oC
▪ To maintain the liquid level at h = 4  0.2m

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 1.3.2. Identifying and classifying the process variables

1.3.2. Identifying and classifying the process variables

(variables related to the control objective)
❖ Process variables are classified into
❑ Output variables :- Variables that reflect the effect of mass, energy, component or
momentum variation in the system.
▪ Controlled Variables(CV):- Output variables that should be maintained at a specified desired value
using a controller.

❑ Input variables :- Variables that affect the process (output variables) but which are not
affected by the process.
▪ Manipulated variable (MV):- Input variable that can be adjusted by an automatic controller or a
human operator to bring the CV to a desired value.
▪ Disturbance Variable (DV):- Input variable that affects the process (the output variable) but we do
not have control over.

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 1.3.3 Selecting the appropriate control configuration/ strategy

1.3.3 Selecting the appropriate control configuration/

strategy
Examples of control strategies
▪ Feedback control strategy :- The manipulated variable is
adjusted based on the measurement of the controlled
variable (CV).
▪ Feeforward control strategy :- The manipulated variable is
adjusted based on the measurement of the disturbance
variable (DV).

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 Feedback Control

Distinguishing feature of feedback control strategy

• Take corrective action based on measurement of the controlled
variable(CV)
Advantages:
• Corrective action is taken regardless of the source of the
disturbances.
• Reduces sensitivity of the controlled variable to disturbances and
changes in the process.

Disadvantages:
• No corrective action occurs until after the disturbance has upset the
process.
• Response may be oscillatory or even unstable

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 Feedforward Control

Distinguishing feature of feedforward control

strategy
• Take corrective action based on measurement of a
disturbance variable
Advantage:
• Correct for disturbance before it upsets the process.
Disadvantage:
• Disturbance should be measureable
No corrective action for unmeasured disturbances

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 1.3.4 Type of Controller

Determining the type of controller /Design of

controller
The appropriate type of controllers should either be
selected from a set controllers or designed from the
desired control performance and the model of the plant.
▪ For feedback control strategy the most commonly used
controllers are , Proportional(P), Proportional Integral (PI) or
Proportional Integral Derivative (PID)
▪ For feedforward control system the controller is generally
designed from the model of the process and the desired
response.

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 1.3.5 Process Instrumentation

Selection of the appropriate instruments (in addition

to the controller)
− Sensors
− Transmitters
− Final control element
• Selection of instruments depends on:
− The type of variable measured (Temperature, pressure,…)
− The range of the variable measured
− The dynamic behavior of the process
− The control performance requirement

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 Process control loop diagram

Figure 1.4 Process control closed-loop diagram

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 Analog Transmitters

Figure 1.5 Analog Transmitter

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 Pneumatic Transmitters

Figure 1.6 Pneumatic Transmitter

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 1.3.6 Tuning the controllers

Tuning:- Setting up of the controller parameters

Most controllers have one or more parameters to be
adjusted. The adjustment depends on the type of
controller, the dynamic behaviour of the process and
the desired closed-loop (controlled) response.
▪ PID controller has three parameters to be adjusted:
Controller gain (Kc), Integral time (I) and Derivative Time (D)
What the video and answer What are PID Tuning Parameters?
What are PID Tuning Parameters

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 Example 2 – Heat Exchanger

We want to design a control system to maintain the

temperature of oil leaving the heat exchanger at 75oC.

Figure 1.7 Heat exchanger flow diagram

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 Example 2 – Heat Exchanger, Cont.

Design of a control system

1. Defining the Control Objective
− To maintain the outlet temperature of the oil at T=75oC

2. Identifying and Classifying the Process variables:

Process variables : T, Fs, T0, F
Classification:
− Controlled variable (CV): T
− Manipulated variable (MV): Fs
− Disturbance variable (DV) : T0, F

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 Example 2 – Heat Exchanger, Cont.

3. Selecting Control strategy : Feedback

Selection depends on:
▪ The dynamic behavior of the process
▪ The available measured process variables
▪ The required control performance

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 Example 2 – Heat Exchanger, Cont.

Feedback controlled heat exchanger

Figure 1.8 Schematic diagram for feedback controlled heat exchanger

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 Process control-Cont.

4. Selecting Type of controller: PID

Selection depends on:
− The dynamic behavior of the process
− The required control performance
5. Process instrumentation
▪ Identification of the hardware elements for the control system
− A sensor :-Thermocouple
− A transmitter :- Temperature transmitter
− A controller :- Temperature controller
− A final control element :- Control valve
▪ Preparing specification of the above hardware elements
▪ Drawing and interpretation of the piping and instrumentation diagram (P&ID).

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 P&ID (Piping and Instrumentation Diagram)

❖ P&ID for a feedback controlled heat exchanger

Figure 1.8 Schematic diagram for feedback controlled heat exchanger

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 Tuning of controllers

6. Tuning (Setting the controller parameters) : For PID

controllers, tuning means adjusting the values of Kc, I
and D
Selection of , Kc, I and D for PID controller depends on :
− The dynamic behavior of the process
− The required control performance

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 Example 3-Control of a complete plant

Figure 1.9 Typical chemical plant process flow diagram

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 Example 3-Control of a complete plant

Figure 1.10 Typical chemical plant and control system

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 Example 3-Control of a complete plant
Control objective CV MV DV Control
strategy
To maintain the
flow rate of
reaction stream 1
at 200kg/hr

To maintain the Temperature of Cooling Temperature Cascade

reaction the reaction water in the s and Flow controller
temperature of R- medium in R-100 jacket of R- rates of
100 at 200oC 100 feeds to R-
100
Temperature
of cooling
water

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 Example 3-Control of a complete plant

❖ Large-scale integrated processing plants such as oil refineries or

ethylene plants require thousands of process variables such as
temperature, pressure, flow, level and compositions are
measured and controlled.

❖ Large number of process variables, mainly flow rates, can be

manipulated.

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 Representative process control problems

❖ Common processes can be continuous, batch or semi-batch.

Shell and tube Heat Exchanger (Continuous)

Control problem: The exit temperature of the process fluid is

controlled by manipulating the cooling (heating) medium flow rate.
Disturbances: Variations in the inlet temperatures and process
fluid flow rate.
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 Continuous Processes, cont.
Continuous Stirred Tank Reactors (CSTR)

Control problem: If the reaction is highly exothermic, it is

necessary to control the reactor temperature by manipulating the
flow rate of the coolant in a jacket or cooling coil.
Disturbances: The feed conditions (composition, flow rate, and
temperature).

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 Continuous Processes, cont.
Thermal Cracking Furnace

Control Problem: The furnace temperature and amount of

excess air in the flue gas to be controlled by manipulating the
fuel flow rate and the fuel/air ratio.
Disturbances: The crude oil composition and the heating
quality of the fuel.
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 Continuous Processes, cont.

Multi-component distillation column

Control Problem: Distillate composition can be controlled by

adjusting the reflux flow rate or the distillate flow rate.
Disturbances: The feed conditions

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 Batch and semi-batch processes, cont.

❖ Batch or semi-batch reactor: The reactor temperature is

controlled by manipulating a coolant flow rate.

❖ Batch digester: The end point of the chemical reaction is

indicated by Kappa number, a measure of lignin content. It is
controlled to a desired value by adjusting the digester
temperature, pressure, and/or cycle time.

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 1.6 Hierarchy of process control activities
(days-months ) 5. Planning and
Schedul ing

(hour s- days) 4. Real -Time

Optimi zati on

3b. M ul tivari able

(minutes- hour s ) and Constr aint
C ontr ol

(seconds-mi nutes ) 3a. R eg ulatory

C ontr ol

(< 1 second)
2. Safety, Envir onment
and Eq uipment
-Alarm management for abnormal situations
Protection
- Safety instrumented systems for emergency
shutdown
(< 1 second) 1. Measurement
and Actuation

Process

Figure 1.11 Hierarchy of process control

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 Conclusion

❖ The role of process dynamics, instrumentation and

control in industry
❖ Design steps of a control system
❖ Control aspects of a complete plant
❖ Representative control problems
❖ Hierarchy of process control activity

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