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Control System
Design Aspect of Process
Variables

Output Variables
Input Variables

Measured Unmeasured
Disturbance
Manipulated
Known by directly Known by in
Values can be Perturbation by directly means
External Environment measuring
adjusted freely
Externa Disturbances
Measured Unmeasured

Measured outputs
Manipulated Variables Process

Unmeasured outputs
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Design Aspect of Process Control System

Input Variables
Disturbances CA, F, T, Secondary Measurement

Thermocouple Melt Index

T
Measured Output Variables
Ts -
C . F, T
Model

Fo Tco Unmeasured CA
CAS
Controller Fo Ta

Input Varlables:CAi T, F, Ta, Fe. (F) Output Variables:C . T, F, Teo V

Disturbances: CA T, F, Ta Manipulated Variables: F F Measured: T, Toos F,V
Unmeasured: CA
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Design Aspect of Process ControlSystem

To design the control system, following are the basic questions that need to be
answered.
1) What are the operational objectives that a control system is called upon to achieve?
2) What variables should we measure in order to monitor the operational performance
of a plant?
3) What are the manipulated variables to be used to control a chemical process?
4)) What is the best control configuration for a given chemical process control
situation?
5) How is the information taken from the measurements used to adjust the values of
the manipulated variables?

1) Question (1) often lead to: (a) Ensuring stability, (b) suppressing the effect of
external disturbances or (c) optimizing the economic performances or combinations
of these
2) Forstirred tank healer the objective is to maintainT and V. For stirred tank reactor
tive is to maintain the stable operation. For a distillation column the
objective is to maintain the quality of distillate and bottom.
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Design Aspect of Process Control System

one need to decide the variables to be
1) Once the question (1) is fixed, system,
measured. Forastirred tank heater the objectives are to keep T= Ts and
V= Vs.
that will monitor T and V directly.
2) Thus, one need to install a measuring device differential pressure cell is used to
Thermocouple is used for measuring T whereas
measure the volume.
quantities. For such
3) Sometimes the control objectives are not measurable
to measure are monitored.
are easy
unmeasured outputs, other variables whichconverted
Such secondary measurements are then to desired output variables
models.
using appropriate (i.e., empirical or theoretical)

mixture of
Example: Consider a simple distillation column separating a binaryand hexane
pentane and hexane into two product streams of pentane (distillate) stream with
(bottoms). Our control objective is to maintain the production of distillate
Draw the feedback
composition.
95 mole % pentane in presence of changes in feed is
and feedforward control action with composition analyzer. What control action
required for a practical difficulty of lousy composition analyzer
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Design Aspect of Process Control System

Cooling Water Condenser

Reflux
Distillate

Feed
Controller
Composition
Analyzer

soam Reboiler
- Set Point

Bottoms

Feedback
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Design Aspect of Process Control System

Cooling Water Condenser

Reflux
Distillate

Feed
Composition
Controller
Analyzer

Steam Set Point

Reboiler
Bottoms

Feedfoward
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Design Aspect of Process Control System

Cooling Water Condenser

Measure T1, TT Reflux
and T, at three Distillate
Trays
Feed

Controller
Estimate
Distillate
Composition steam ----Set Point
Reboiler
Bottomns

Inferential
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Design Aspect of Process Control System

The third question is to select the manipulated variables:
1) These are the variables which are adjusted freely. For stirred tank heater, Fs (steam
flowrate) and F (outlet flowrate) are the manipulated variables. For CSTR With
exothermic reaction, the coolant flowrate is the manipulated variable. For Distillation
column, reflux ratio is the manipulated variable.
The fourth question is to select the control configuration:
1) Distillation column has three choices: feedback, feedforward, or inferential.
2) Stirred tank heater has two choices: feedback or feedfoward. Also, to maintain V
either from Fi and F can be manipulated.

Depending on how many controlled outputs and manipulated inputs are

present, we can have

Control Systen

SISO MIMO
(Single input single output) (Multiple input multiple output)