Introduction to
Process Control and
Instrumentation
M. F. Baidoo
Department of Chemical Engineering
KNUST
Learning Outcomes
Understand and define some basic terminologies related to process
control.
Explain the reasons why process control is necessary.
Categorize process control system based on the mode, time dependence
and configuration of components.
Identify and classify process variables as input and output variables.
Explain how key process variables are controlled on important unit
operation in the petrochemical industries.
Identify the hardware component of a process control systems
Explain some challenges encountered in the implementation of process
Control.
Definitions
Process: The transformation of raw materials into desired product using available
feedstock sources of energy in the most cost effective way.
Control:
1. Series of actions directed at making a system variable adhere to a reference
value of the operating conditions
2. Process of altering manually or automatically the performance of a system to
adhere to a desired one.
3. The design and algorithim for maintaining the output of a specific process
within a desired range.
Instrumentation:
The science of applying measuring device to monitor and control a process
variable.
Why Process Control?
Safety
Safety of personnel
Equipment safety
Environmental safety
Product specifications
Desired amount and quality of final products.
Environmental Regulation
Environmental Protection Agency(EPA) have regulation concerning temperature, concentration of
chemicals and flow rates of effluents from a plant. These regulations should be satisfied.
Why Process Control?
Operational Constraints:
Inherent constraints in the operation of some process equipment.
Economics:
Raw materials, energy, capital and labour should be utilized in the most cost
effective way by operating at optimum levels of minimum operating costs or
maximum profit.
Specific Role of Control System
Suppressing the influence of external disturbances.
Ensuring the stability of a chemical process.
Optimizing the performance of a chemical process.
Classification of Control Systems
Mode/ Technique for performing control action
Manual Control
A person
takes the decision and
effect the changes
Automatic Control
Devices are used for control (usually unattended)
reads output variable = measurement/Sensing
compares measured variable to set point = compares
takes a decision: how much to change = computes
Effect changes (manipulate variable) : decrease, increase = Adjusment
A combination of both manual and automatic (semi-automatic) is also
possible.
Classification of Control Systems (Cont.)
Time dependence of the reference value (steady/dynamic)
Regulator system: Ensure that system output remain close to
reference value regardless of the magnitude of disturbances and/or
noise.
Servo System: Ensure that the system output follow a changing
reference value in the absence of disturbances.
Classification of Control Systems (Cont.)
Fundamental Structure/Configuration of Control system:
Loop: sequence of instructions continually executed until a certain outcome is obtained.
Open-Loop: Controller executes action without information on the state of
the system.
Any time dependent device eg. Washing machine, microwave oven.
Feedforward is another term for open loop control systems.
Application of Feedforward Control
Pros & Cons of Feedforward/Open-Loop Control
Classification of Control Systems (Cont.)
Fundamental Structure/Configuration of Control system:
Closed-Loop: Controller acts based on the knowledge of the state of
the system. eg. Feedback control
Advantages of Feedback/Closed Control
Disadvantages of Feedback/Closed Control
Process Measurement and Control
Process Control mechanism begins with a measurement of
a process variable.
Process Variables
A process variable is a condition of the feedstock, product or utilities that can
change influence the outcome of a manufacturing process.
Temperature
Pressure
Flow rate
Level
Concentration/pH
Specific gravity/Viscosity/density
Humidity
Mass
Conductivity
Classification of Process Variables
Disturbance/Load
Two main categories
Manipulated PROCESS Output
Input variables: variables variables
the effect of surroundings on the chemical process
Output variables:
the effect of the chemical process on the surroundings
Classification of Process Variables
Input variables
Manipulated variables: variables or parameter or factor are adjusted to keep the
variables to be controlled at their set-points.
Disturbances/Load: undesired change in one of the factors that can cause the
variable to be controlled to deviate from their set-points.
Output variables:
Measured/Controlled variables: describes the condition of the process that must be
kept at the designated set-point. Their values are known by direct measurement.
Example: Continuous Stirred Tank Heater
19
Examples: Temperature and Concentration
Control
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Hardware for Control
Process: Part of control system whose output is to be controlled. It includes the equipment
together with the physical or chemical operations that occur.
Measuring instruments or sensors: Used to detect and measure the changes in the process variable.
Transducers: Converts a physical phenomenon into some other form of energy (electric voltage or
current, pneumatic signal etc) which can be easily transmitted.
Transmission lines: Carries measurement signal from measuring device to the controller.
Controller: Intelligence unit that receives information from measuring devices and decides what
action to be taken.
Final Control Element: It implements the decision taken by the controller. eg. control valves
Challenges of Process Control
Implementation
Nonlinear/non-stationary nature of a process
Unavailability of accurate measurement of controlled variable
Time delays or dead time
Multivariable interactions
Sensitivity to noise and disturbances
