Chemical Engineering

Prepared by: Mr Ali Abbas

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 Outline of Course
 Introduction
 Fundamentals of Processes Control Systems
 Control objectives and definitions of concepts; open loop, close
loop,…and etc.
 Mathematical Background
 Laplace Transformer & Inverse Laplace Transform
 Mathematical modeling
 Examples and modeling of Processes Control Systems
 Block Diagram Representation
 Dynamic response of a system [Time Response]
 Using Time Response to Design control systems (PID
controller)
 The Stability [Routh & Hurwitz, Nyquist, Root Locus plot and
Bode diagram]
 Sensors & Instrumentation
 Matlab Program
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 Course References
 Process Control Instrumentation Technology by:
Curtis D. Johson,
 Principles and Practice of Automatic Process Control by:
Carlos A. Smith & Armando B. Corripio
 Process, Modelling, Simulation and Control for Chemical
Engineers by:
William L. Luyben
 Process Industrial Instruments and Control handbook by:
Gregory K. McMillan Editor & Douglas M. Considine
 WWW ...

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 Objectives
At the end of this lecture, students should
be able to:
 Explain and identify Classification of Control Strategies
 State the control objectives for a process plant.
 Explain and identify the three elements in a feedback loop
 Be able to apply feedback manually to many chemical
process examples
 Identify common symbols and abbreviations used in piping
and instrumentation drawings (P&IDs)
 Describe the operation of a system/plant given a P&ID

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 Introduction

What is process control

system ??

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 Introduction

 The word “system” has become very popular

in recent years
 A system is defined as a combination of
components that act together to perform a
certain objective.

 Control system: An interconnection of

components forming a system configuration
that will provide a desired response.

 Process refers to the methods of changing or

refining raw materials to create end products.
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 Control system is very important for all engineers.

 Control is an important element in manufacturing and industry.

 Automatic control has become important and integral part of modern

manufacturing and industrial process.

 Most engineers and scientists must now have a good understanding

of this field.

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 Process Control
 Process control is regulation of a controlled variable
around a desired set point.

 Process plants can be operated in either continuous

or batch.

 Process control system deal with all phases of matter

- solid, liquid and vapour.

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Refining

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Petrochemical

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Pharmaceutical

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Food Processing Plants

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Career Choices
 Engineering, Design & Maintenance
– Control Systems Engineer
– Instrument Specialist

 Management
– Project Engineer / Manager
– Instrument Supervisor

 Sales Engineering

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 Why process control system?

(To improve the performance, to dispense with a lot of

manual actions...etc.)

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 Why Process Control ?
1. Safety of Equipment and Personnel
2. Productions Specification of quality & quantity
3. Operational Constraints
4. Observe Environmental and Country Laws
5. Economics
6. Monitoring & Diagnosis

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Safety of Equipment & Personnel

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Safety of Equipment

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Quality & Quantity

Liquid
product A

Liquid
product B

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Observe Environmental

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Economics

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Fundamentals & Concepts of Processes
Control Systems

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  There are three stages of control systems
• Manual control system [human control]
• Automatic control system

Mechanical Control Electronic Control

• Hydraulic Control
• Pneumatic Control

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Human Control
[Manual]

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Mechanical Control [Automatic]

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Electronic Control [Automatic]

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Classification of Control Strategies

The control system can be classified as open

loop control system, closed loop control
systems and feed forward control

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Open Loop Control System

 The open loop control system is also known as control

system without feedback.

 In open loop systems the control action is independent

of desired output .

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 Examples open Loop Control Systems

1-Heat exchanger

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 Examples open Loop Control Systems

2- Automatic washing machine:

In the machine the operating time is
set manually after completion of set
time the machine will stops.

3- Automatic control traffic.

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 Advantages:

 Open loop control systems are simple, economical,

Less maintenance is required and not difficult.

Disadvantages:
 Open loop control systems are inaccurate, not
reliable, slow and optimization is not possible.

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Closed Loop Control System
 Closed loop control systems are also know as
feedback control systems.

 In closed loop control systems the control

action is dependent on the desired output.

 In closed loop control systems the output is

compared with reference input and error signal
is produced, the error signal is fed to the
controller to reduce the error and desired
output obtained .
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 Example of closed Loop Control Systems

1- Heat exchanger

2- In room we need to regulate the temperature. Air

conditioners are provided with thermostat.

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 Advantages:

These system are more reliable, faster, a

number of variables can be handled
simultaneously and optimization is
possible.
 Disadvantages:

 Closed loop systems are expensive,

maintenance difficult and complicated
installation.
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Feed-forward
The objective of feed-forward control is to
measure disturbances and compensate for
them before the controlled variable deviates
from set point. When feed-forward control is
applied correctly, deviation of the controlled
variable is minimized.

-A feed-forward controller measures the

disturbance variable and sends this value to a
controller, which adjusts the manipulated 38
Heat exchanger feed-forward control system

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 Advantages
 If all sources of the disturbances are known and these
values can be measured accurately.
Perfect Control !

 Disadvantages
 No corrective action for unmeasured disturbances.
In industrial applications, feedforward control should
be used in combination with feedback control.

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Heat exchanger feed-forward control
system with feedback compensation

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 Feedback Control
 There are several important elements in a feedback
control system.
• Sensor / Measurement
• Controller
• Final Element (Actuator)

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Feedback Control

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 Sensor / Measurement
 To effect control of a variable, we need to have information

on the variable itself.

 Measurement also includes transducers, devices that

converts signal from one form to another.

What are the common variables

measured in a process plant ?

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 Controller
 Part of the system that examine the error and determine
the amount of action needs to be taken.

 In modern control systems, control operations are

performed by computers or PLCs.

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 Final Element (Actuator)
 Device that exert direct influence on the process and bring
the controlled variable to its desired value.

 Accepts input from the controller which is then converted

into proportional operation on the process.
 Examples:
- control valves.
- pumps, motors.

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Classification of the variables

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 Classification of the variables
 Input variables
The effect of the surroundings on the chemical process.
1. Manipulated variable (MV or Control variable)
Its value can be adjusted freely by the human operator or a
control mechanism.
Ex.) In heated tank, the amount of heat added (Q) or mass flow
rate (w).
2. Disturbance variable (DV)
Its value is not the result of the adjustment by an operator
or a control system.
Ex) In heated tank, inlet temperature, because we can’t
usually control the temperature of inlet water.
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 Output variables

The effect of the process on the surroundings

1. Measured output variable or Controlled variable (CV)
Its value is known by directly measuring it.
Ex) In heated tank, outlet temperature.

2. Unmeasured output variables

It is not or cannot be measured directly.

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 Classification of the variables

 Input variables  Output variables

• denote the effect of the surroundings • denote the effect of the process on
on the chemical process. the surroundings

Measured output or Unmeasured

Manipulated Controlled variable variable
variable (MV) Disturbance (CV)
Control variable variable (DV)

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 Example: level control
Flow in f
desired value
(set-point)
transmitter
disturbance

SP

LT LC

controller
controlled
variable
(measurement)

process
Flow

manipulated
variable 51
 Example : Surge Tank
Open loop system

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Feedback control strategy 1

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Feedback control strategy 2

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Feed-forward control strategy

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 Example : Heat Exchanger
Control
 Control Objective (Setpoint): Maintain
temperature.
 Controlled variable- Outlet temperature of
product stream
 Manipulated variable- Steam flow

 Actuator- Control valve on steam line

 Sensor- Thermocouple on product stream

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 Driving a Car: Example of
Process Control
 Control Objective (Setpoint): Maintain car
in proper lane.
 Controlled variable- Location on the road
 Manipulated variable- Orientation of the
front wheels
 Actuator- Driver’s arms
 Sensor- Driver’s eyes
 Controller- Driver
 Disturbance- Curve in road 57
 How is Control Possible ?
 Control is possible only if the required and suitable
equipments (sensor, final element, communication, etc.)
are provided during the process design.

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 How is Control Possible ?

 Control is also possible only when the equipments have a

large enough maximum capacity to respond to all possible
disturbances.

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 Process Control Engineering
 In designing a process control system, control engineers
should ask themselves questions such as:

How do we select
a suitable sensor ?60
Where is Control Done ?

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Where is Control Done ?

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 Process Diagrams/Schematics

 Process Flow Diagram (PFD)

 Piping & Instrumentation Drawing
(P&ID)
 Instrument Loop Diagram
 Instrument Manual

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 What is a P&ID ?

 A drawing that represent a plant and its associated

control systems.
 Employs a standard set of symbols and abbreviations
to represent operating units, product flow lines,
measurement and control signal lines, sensors, final
control elements, computers and programmable logic
controllers (PLCs).
 Uses letter and number designations to identify each
control and process element.

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 Why Do We Use P&IDs ?

 Standard practice around the world

 Visual
 Simplified

INTERESTING FACT :
This standard is developed by the American National
Standards Institute (ANSI) and the Instrumentation, Systems
and Automation (ISA) Society, designated as ANSI/ISA S5.1-
1984 (R1992) .Instrumentation Symbols and Identification
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(A) Connecting Lines

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(B) General Instruments Label

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(C) Identification Letters

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(D) Process Elements

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(E) Process Elements

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(F) Final Elements (ISA)

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 Example
Describe the operation of this
plant.

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 Example
Describe the operation of this
plant.

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 Example
Describe the operation of this
plant.

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 Example
Describe the operation of this
plant.

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Assingments

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a) For figure below: Identify the controller, the actuator, the
process, the sensor and the controlled variable. Also,
indicate the set point and potential disturbances. Remember
that the process is affected by the actuator to change the value
of the controlled variable.

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b) A process furnace heats a process stream from near
ambient temperature to a desired temperature of
300°C. The process stream outlet temperature is
regulated by manipulating the flow rate of fuel gas to
the furnace, as shown below:

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a. Discuss the objectives of this control strategy.
b. What is the measured output?
c. What is the manipulated input?
d. What are possible disturbances?
e. Is this a continuous or batch process?
f. Is this a feed-forward or feedback controller?
g. Discuss safety, environmental, and economic issues.

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