SISTEM KENDALI PROSES

TEK200302

I PUTU ELBA DUTA NUGRAHA, S.T., M.T.

CAPAIAN PEMBELAJARAN MATA KULIAH

• Mampu merancang dan mengembangkan komponen, sistem, atau proses yang

diperlukan untuk mendukung kegiatan rekayasa di bidang sistem kendali proses.
• Mampu mengidentifikasi, merumuskan, menganalisis, serta menyelesaikan
permasalahan di bidang sistem kendali proses.
• Mampu mengimplementasikan metode, keterampilan , dan perangkat modern yang
diperlukan dalam bidang sistem kendali proses.
• Mampu berkomunikasi yang efektif secara lisan dan tulisan terkait dengan bidang
sistem kendali proses.
• Memiliki pengetahuan tentang isu-isu terkini yang berkaitan dengan sistem kendali
proses.
KEPUSTAKAAN

• Shinskey, F. Greg. Process-Control Systems: Application, Design, and Tuning.

3rd ed, McGraw-Hill, 1988.
• Process Control Design for Industrial Applications. ISTE Ltd/John Wiley and
Sons Inc, 2017.
INTRODUCTION TO PROCESS CONTROL
CHAPTER 1
1.1 INTRODUCTION

• The technology of controlling a series of events to transform a material into a

desired end product is called process control. For instance, the making of fire could
be considered a primitive form of process control.
• Industrial process control was originally performed manually by operators. Their
sensors were their sense of sight, feel, and sound, making the process totally
operator-dependent. To maintain a process within broadly set limits, the operator
would adjust a simple control device.
• Instrumentation and control slowly evolved over the years, as industry found a need
for better, more accurate, and more consistent measurements for tighter process
control.
• Industrial process control is now highly refined with computerized controls,
automation, and accurate semiconductor sensors.
1.1 PROCESS CONTROL

• Process control can take two forms:

• sequential control, which is an event-based process in which one event follows another
until a process sequence is complete; or
• continuous control, which requires continuous monitoring and adjustment of the process
variables.
1.2.1 SEQUENTIAL PROCESS CONTROL

• Figure 1.1 shows an example of a process using a sequencer for mixing liquids in a set ratio.
The sequence of events is as follows:
• 1. Open valve A to fill tank A.
• 2. When tank A is full, a feedback signal from the level sensor tells the sequencer to turn valve A Off.
• 3. Open valve B to fill tank B.
• 4. When tank B is full, a feedback signal from the level sensor tells the sequencer to turn valve B Off.
• 5. When valves A and B are closed, valves C and D are opened to let measured quantities of liquids A
and B into mixing tank C.
• 6. When tanks A and B are empty, valves C and D are turned Off.
• 7. After C and D are closed, start mixing motor, run for set period.
• 8. Turn Off mixing motor.
• 9. Open valve F to use mixture.
• 10. The sequence can then be repeated after tank C is empty and Valve F is turned Off.
1.2.1 SEQUENTIAL PROCESS CONTROL
1.2.2 CONTINUOUS PROCESS CONTROL

• Continuous process control falls into two categories:

• elementary On/Off action, and
• continuous control action.
• On/Off action is used in applications where the system has high inertia, which prevents the
system from rapid cycling. This type of control only has only two states, On and Off; hence, its
name. This type of control has been in use for many decades, long before the introduction of
the computer. HVAC is a prime example of this type of application.
• Continuous process action is used to continuously control a physical output parameter of a
material. The parameter is measured with the instrumentation or sensor, and compared to a
set value. Any deviation between the two causes an error signal to be generated, which is
used to adjust an input parameter to the process to correct for the output change. An example
of an unsophisticated automated control process is shown in Figure 1.2.
1.2.2 CONTINUOUS PROCESS CONTROL

• A float in a swimming pool is used to continuously monitor the level of the water, and to bring
the water level up to a set reference point when the water level is low. The float senses the
level, and feedback to the control valve is via the float arm and pivot. The valve then controls
the flow of water (manipulated variable) into the swimming pool, as the float moves up and
down.
1.2.2 CONTINUOUS PROCESS CONTROL

• A more complex continuous process control system is shown in Figure 1.3, where a mixture of
two liquids is required. The flow rate of liquid A is measured with a differential pressure (DP)
sensor, and the amplitude of the signal from the DP measuring the flow rate of the liquid is
used by the controller as a reference signal (set point) to control the flow rate of liquid B. The
controller uses a DP to measure the flow rate of liquid B, and compares its amplitude to the
signal from the DP monitoring the flow of liquid A. The difference between the two signals
(error signal) is used to control the valve, so that the flow rate of liquid B (manipulated
variable) is directly proportional to that of liquid A, and then the two liquids are combined.
1.3 THE ELEMENTS IN A CONTROL LOOP

• Figure 1.4 is a block diagram of the elements in a continuous control process with a feedback
loop.
1.3 THE ELEMENTS IN A CONTROL LOOP

• The control and measuring elements in the diagram in Figure 1.4 are oversimplified, and are
broken down in Figure 1.5.
1.4 INSTRUMENTATION AND SENSORS

• The operator’s control function has been replaced by instruments and sensors
that give very accurate measurements and indications, making the control
function totally operator-independent. The processes can be fully automated.
• Instrumentationand sensors are an integral part of process control, and the
quality of process control is only as good as its measurement system.
• The subtle difference between an instrument and a sensor is that an instrument
is a device that measures and displays the magnitude of a physical variable,
whereas a sensor is a device that measures the amplitude of a physical
variable, but does not give a direct indication of the value.
1.4.1 INSTRUMENT PARAMETERS

• Accuracy of an instrument or device is the error or the difference between the indicated
value and the actual value. Accuracy is determined by comparing an indicated reading to
that of a known standard. In a system where more than one deviation is involved, the total
accuracy of the system is statistically the root mean square (rms) of the accuracy of each
element.
• Linearity is a measure of the proportionality between the actual value of a variable being
measured and the output of the instrument over its operating range.
• Sensitivity is a measure of the change in the output of an instrument for a change in the
measured variable, and is known as a transfer function.
• Reproducibility is the inability of an instrument to consistently reproduce the same reading of
a fixed value over time under identical conditions, creating an uncertainty in the reading.
• Resolution is the smallest change in a variable to which the instrument will respond. A good
example is in digital instruments, where the resolution is the value of the least significant bit.
1.4.1 INSTRUMENT PARAMETERS

• Hysteresis is the difference in readings obtained when an instrument approaches a

signal from opposite directions. For example, if an instrument reads a midscale value
beginning at zero, it can give a different reading than if it read the value after
making a full-scale reading.
• Time constant of a sensor to a sudden change in a measured parameter falls into
two categories, termed first-order and second-order responses.
• The first-order response is the time the sensor takes to reach its final output after a transient
change.
• The second-order response occurs when the effect of a transient on the monitoring unit is to
cause oscillations in the output signal before settling down. The response can be described by
a second-order equation.
• Other parameters used in instrumentation are Range, Span, Precision, Offset, Drift,
and Repeatability. The definitions of these parameters are given at the end of the
chapter.