1.

Introduction to Process Control

Outline
 Definition of process control.
 Incentives for using process control.
 Example on process control systems.
‘Definition of Process Control’:
 process control can be defined as: maintaining
process variables, temperatures, pressures, flows,
compositions, and the like at some desired
operating
value

Figure 1.1 Process control (a) shows the manual control of a simple heat exchanger process
loop and (b) automatic control of a heat exchanger process loop
Incentives for using process control
 ‘Process Control’ makes processes satisfy
following requirements.
◦ Safety
◦ Production specifications
◦ Environmental regulations
◦ Operational constraints
◦ Economics
1.1 Illustrative Examples
EX 1. Continuous stirred-tank heater 
Question ; Assume that inlet temperature changes with 
time. How can we ensure that T remains at or near the
set point TR?

Figure 1.1. Continuous stirred-tank heater.

 Possible Strategies
1. Measure T and adjust Q .
2. Measure Ti and adjust Q.
3. Measure T and adjust w.
4. Measure Ti and adjust w.
5. Measure T and Ti and adjust Q.
6. Measure T and Ti and adjust w.
7. Place a heat exchanger on the inlet stream.
8. Use a large tank.
 Classification
1 & 3; Feedback control
2 & 4; Feedfoward control
5 & 6; Feedfoward-Feedback control
7 & 8; Design change
• EX 2. Furnace using electrical power
 Question ; Can you find any problem in controlling the
following furnace process?
well insulated

y(t)
thermocouple
temperature
heating coil

thermocouple

SCR unit + u(t)

-
SCR unit input
thermocouple

+ -
power

Figure 1.2. Furnace using electrical power

• EX 2. Furnace using electrical power
 Question Can you find any problem in controlling the
following furnace process?
well insulated

y(t)
thermocouple
temperature
heating coil

thermocouple

SCR unit + u(t)

-
SCR unit input
thermocouple

+ -
power

Figure 1.2. Furnace using electrical power

 There is no way to decrease the temperature!

• The power cannot be negative.
• The heat loss is nearly zero.