CHAPTER 8.

DESIGNING THE BASIC

PROCESS CONTROL SYSTEM
 References
1. Ray Sinnott and Gavin Towler. (2019). Chapter 5 "PIPING AND
INSTRUMENTATION" in the book “Chemical Engineering Design”,
Elsevier.
2. Franklyn W. Kirk, Thomas A. Weedon, Philip Kirk, (2010).
Instrumentation, 5th Ed, American Technical Publishers, Inc.
3. Terry Bartelt, (2010). Industrial Automated Systems: Instrumentation
and Motion Control, Cengage Learning
4. D. Seborg, T. Edgar, D. Mellichamp, F. Doyle III (2017). “Process
Dynamics and Control, 4th Ed”, Wiley, chapters 13, 15, 16
5. W. Svrcek, D. Mahoney, B. Young. (2014). “A Real-time Approach to
Process Control, 3rd Ed”, Wiley, chương 3, 6
6. Seider, W. D., Seader, J. D., Lewin, D. R., & Seider, W. D. (2016).
Chapter 20 “Plantwide Controllability Assessment” in the book
Product and Process Design Principles: Synthesis, Analysis, and
Evaluation, 4th Edition. Wiley.
 Part 1

Introduction to
Process Control
Introduction
Introduction
 Introduction

Feedback Control Loop Components

Instrument line
Alarms

PV PAH PIC
Actuator PT
PAL
Controller

Process or
utility stream
Final control Sensing
element element

• The sensing instrument detects the measured variable and sends a signal to a
controller, which signals the actuator to close or open a control valve and
adjust the manipulated variable (usually a flow rate)
Introduction

7
 Introduction

Feedback Control

Error Controller
Set + signal Function
point - generator

Input Output
Sensing Final control
element element
Measured variable Manipulated variable

Process

• Controller computes error between input and set point

and adjusts output based on a control algorithm
10
 Components in a control loop

A control system is comprised of the following components:

1. Primary elements: also known as sensors, are the instruments

used to measure variables in a process such as temperature and

pressure

2. Transducer / Transmitter

3. Controllers

4. Final control elements (usually control valves)

Flow measurement by orifice plate
Flow Transmitter
and
Flow Primary
Elements
 Manipulation Devices (The Final Control Element)

In process-control systems, the final control element is the

device that directly influences the process variable. There are
several types of final control elements used in process
applications, such as electric heaters, electrical motors, and
control valves.
The most commonly used type of Final Control Element is
control valve
 Manipulation Devices (The Final Control Element)

FINAL CONTROL ELEMENT

Final Control Element is a device that directly adjusts the value of manipulated
variable of control loop.

Final control element may be control valves, Variable Speed Devices, heaters
with adjusted energy output, etc.

Variable Speed Devices Control Valve Heater

Control valves
20
Table 2.2 (Process Automation Handbook, Springer, 2007)
 Use ISA standards (table 2.2) to identify functions
of instruments in the following drawing

FY: I/P transducer T: Transmit

FT: truyền tín hiệu
đo lưu lượng (ở
V: valve dạng cường độ
FV: control dòng điện)
valve, điều
chỉnh lưu
lượng

I: Indicate, C: Control
E: Sensor or primary element FIC: điều khiển, kèm hiển thị
FE: cảm biến đo lưu lượng lưu lượng
 Part 2

Designing the Basic Process

Control System (BPCS)
Classification of levels of process operating parameters
Classification of levels of process operating parameters
The fact that the process operating parameters (temperature,
pressure, flowrate, liquid level, chemical composition) deviate from
normal values is an unavoidable phenomena. This is due to
occurrence of “disturbances” in the process. The origins of these
“disturbances” are as follows:
- Changes in conditions (temperature, pressure, flowrate, chemical
composition) of process input streams
- Changes in ambient conditions (temperature, humidity,…),
affecting process equipment that exchange heat with the ambient
environment
- Degradation of equipment performance: for example, the overall
heat transfer coefficient of heat exchangers gradually decrease
due to fouling phenomena (solid particles, contaminants in fluid
flow deposit on the heat transfer surface)
- Change in setpoints of few operating parameters when there is a
need to change production throughput or product qualities
- Unexpected events due to flaws in process design, equipment
design
The primary objectives of the designer when specifying
instrumentation and control schemes are:
1. Safe plant operation: to keep the process variables within
known safe operating limits, eliminate safety risks using alarms,
Safety Instrumented Systems and Relief valves
2. Production rate: to achieve the design product output.
3. Product quality: to maintain the product composition within
the specified quality standards.
4. Economics: to operate at the lowest production cost,
commensurate with the other objectives.
5. Stability: to maintain steady, automatic plant operation with
minimal operator intervention.
▪ Disturbance variables: variables that are varied uncontrollably
▪ Controlled variables: process variables that need to be regulated
/ maintained steadily at predetermined values (called setpoints)
▪ Manipulated variables: variables that are varied by controllers
(within certain ranges) so as to compensate for the changes in
controlled variables caused by disturbance variables
The objective of BPCS is to “move” process variations from
disturbance variables to manipulated variables such that
controlled variables are kept steadily at setpoint values. The
following figure illustrates that “action” in a “single input-single
output” control system
 Degrees-of-Freedom Analysis

▪ The number of degrees of freedom is given by:

ND = NV - NE
where ND is the number of degrees of freedom, NV is the
number of process variables, and NE is the number of independent
equations that describe the process.
▪ The number of manipulated variables NM is given by:
NM = ND – NED = NV - NE - NED
where NED is the number of disturbances (they are externally
defined in the process model)
▪ The number of manipulated variables equals the number of
controlled variables that can be regulated.
 Selection of Controlled Variables

1. Select output variables that are either non self-regulating or

unstable: values of self-regulating variables do not "run-
away": they automatically (without a controller) transit to new
steady values in the presence of disturbances
2. Choose output variables that must be kept within equipment
and operating constraints (e.g., temperatures, pressures, and
liquid level).
3. Select output variables that are a direct measure of product
quality (e.g., composition, refractive index) or that strongly
affect it (e.g., reaction temperature)
 Selection of Controlled Variables

4. Choose output variables that exhibit significant interactions

with other output variables: the pressure in a steam header
that supplies steam to downstream units is a good example. If
this supply pressure is not well regulated, it will act as a
significant disturbance to downstream units.
5. Choose output variables that have favorable dynamic and
static characteristics. Output variables that have large
measurement time delays, or are insensitive to the
manipulated variables are poor choices.
 To be more specific, usually the controlled variables:
▪ Directly affect the operational stability and safety, and
performance of a certain process equipment
▪ Directly affect the quantity and quality of products

Controlled variables:
▪ Pressure and liquid level in
reactor (for steady operation
of the reactor)
▪ Reactor temperature (affecting
the product quality)
▪ Flowrate of all feedstock
streams entering the reactor
(affecting the product quantity
and quality)
▪ SIC (affecting the product
quality)
 Selection of Manipulated Variables
To select a manipulated variable for regulating a controlled
variable:

1. Ideally, change in the selected manipulated variable should

cause a significant change in controlled variable in a direct
and rapid manner
2. Avoid recycling disturbances: it is preferable not to
manipulate an inlet stream or a recycle stream. It is usually
better to eliminate the effect of disturbances by allowing them
to leave the process in an effluent stream rather than having
them propagate through the process by the manipulation of a
feed or recycle stream
 Selection of Manipulated Variables

Controlling reactor Controlling reactor

temperature: option A temperature: option B

The hot shot / cold shot (option A) as manipulated variable has

more rapid / direct effect on the controlled variable (reactor
temperature) than the cooling / heating fluid (option B)
To be more specific, usually manipulated variables are:
• Flowrates of utilities in the process (steam, hot oil, fuel oil,
fuel gas, cooling water,…): the most popular choice
• Flowrate of a process stream that is not further processed in a
downstream unit; examples: gas stream goes to flare or gas
gathering unit, product stream goes to storage tank
• Other types of manipulated variables: liquid level in heat
exchanger with mixed-phase stream (affecting the heat
transfer area and the amount of heat transferred), flowrate of
bypass stream in a heat exchanger, reflux ratio in distillation
column,..
Manipulated variables: liquid level in heat exchanger that uses
steam as hot utility (affecting the heat transfer area and the
amount of heat transferred)
Controlled variables:
▪ Liquid level: for stable operation and safety of CSTR
▪ Reactor temperature: for stable operation and safety of CSTR,
affecting the product composition (affecting reaction rate)
▪ Product composition / product quality is controlled by adjusting
feed flowrate (this variable determines the reactor residence
time)
Controlled variables:
▪ Liquid level: for stable operation and safety of the flash drum
▪ Temperature and pressure: for stable operation and safety of the
flash drum, affecting the product composition
▪ Feed flowrate (optional): determine the product flowrates
Control scheme for binary distillation tower:
Configuration (a) has better dynamic performance than the config.
(b): easier to control the composition of the overhead product
Configuration (b) is used when reflux ratio is large, the flowrate of
the overhead product is small when compared to the reflux flowrate
▪ The design of the BPCS requires technical expertise of the

designers, usually performed by engineers specializing in

instrumentation and control (the I & C department)

▪ The approach to design BPCS based on mathematical models

of process control systems becomes more and more popular

▪ A step-by-step procedure, not involving mathematical models,

described in references 4, 5, 6 is used in this course

 BPCS design procedure

A step-by-step procedure to design the Basic Process Control

Systems is described as follows:
1. Establish the Control Objectives. Common control objectives
are:
• Maintain product flowrate at required value
• Achieve maximum feedstock-to-product conversion
• Satisfy specifications on product quality

2. Determine the Control Degrees of Freedom: the number of

control valves in the flowsheet equals the degrees of freedom
 BPCS design procedure

3. Establish the Energy-management System

In this step, control loops are positioned to regulate
exothermic and endothermic reactors at desired temperatures.
In addition, temperature controllers are positioned to ensure
that disturbances are removed from the process through utility
streams rather than recycled by heat-integrated process units.”
4. Set the Production Rate. This is accomplished by placing a
flow control loop on the principal feed stream (referred to as
fxed feed or fresh feed) or on the principal product stream
(referred to as on-demand product)
 BPCS design procedure

5. Control the Product Quality and Handle Safety,

Environmental, and Operational Constraints: set the control
loops for composition of the product streams or the process
variables that strongly affect the product composition (e.g.
reaction temperature)
6. Fix a Flow Rate in Every Recycle Loop and Control
Vapor and Liquid Inventories (i.e. pressures and liquid
levels in vessels)
7. Check Component Balances. In this step, control loops are
installed to prevent the accumulation of individual chemical
species in the process
 BPCS design procedure

8. Control the Individual Process Units. At this point, the

remaining degrees of freedom are assigned to ensure that
adequate local control is provided in each process unit.
Usually, the BPCS has been fully configured in steps 1-7, this
steps often requires no additions to the control system.
9. Optimize Economics and Improve Dynamic Controllability.
Usually, this step involves the use of advanced control
techniques such as cascade control, combined feedforward /
feedback control to improve the dynamic and economic
performance of the process.
Use the following guidelines to design the BPCS:
▪ There can only be a single control valve on any given stream
between unit operations.
▪ A level controller is needed anywhere where a vapour-liquid or
liquid-liquid interface is maintained.
▪ Always control the pressure for unit operations and process
units whose function depends on pressure. Examples are flash
drums, hydrocyclones…
▪ Pressure control is more responsive when the pressure
controller actuates a control valve on a vapour
stream
Use the following guidelines to design the BPCS (tt):
▪ Two operations cannot be controlled at different pressures
unless there is a valve or other restriction (or a compressor or
pump) between them.
▪ Temperature control is usually achieved by controlling the
flow of a utility stream (such as steam or cooling water) or a
bypass around an exchanger.
▪ The overall plant material balance is usually set by flow
controllers or flow ratio controllers on the process feeds
 Feedback control loop

Single-input/single-output feedback control loop

Corrective actions: Taking corrective action after upset
propagated, to eliminate the error after occurrence
 Feedback control loop
Advantages:
▪ Simple: easy to design, install, and operate
▪ The most popular choice, the first candidate to be considered
when designing the process control system
▪ Adequately satisfy the job requirement for “not-too-
complicated” applications: pressure control, level control,…
Disadvantages:
▪ Not a good choice for “demanding” applications, for example:
when disturbances frequently occur; or the time lapse since
the appearance of disturbances to the appearance of induced
change in controlled variable is long (a few minutes)
Cascade control loops
 Cascade control loops

Single-input/single-output
feedback control loop

Flowrate / pressure of steam

input to the heat exchanger
frequently changes

Cascade control loops

 Cascade control loops
Single-input/single-output
feedback control loop

Flowrate of hot oil input to

the heat exchanger frequently
changes

Cascade control loops

Cascade control loops
 Cascade control loops
When to use cascade control architecture?
- When the conventional feedback control loop has a poor
performance that makes it not suitably used for the intended
application
- When flowrate / pressure of the manipulated stream (usually
an utility stream) frequently changes
- When it is possible / advisable to control a process variable
(for example, composition) via controlling another process
variable (for example, reaction temperature)
 Cascade control loops

Remote setpoint
Cascade control loops
 Feedforward control

"Proactive mode": Taking corrective action before upset

propagated. It “predicts” the disturbance and proactively takes
action to prevent it. It prevents error before occurrence
Feedback vs. Feedforward control
Feedback

Feedforward
Combined Feedback / Feedforward control
Combined Feedback / Feedforward control
Combined Feedback / Feedforward control
 Ratio control
Ratio control can be
used where it is
desired to maintain
two flows at a
constant ratio; for
example, it is usually
required to maintain a
constant ratio
between two feed
stream flowrates of a
reactor or a mixing
tank
 Ratio control

Method 1 Method 2
Common configurations for level control

Level control
Common configurations for pressure control
Common configurations for flowrate control
Common configurations for temperature control
Some examples of process control systems
Some examples of process control systems
Some examples of process control systems
Some examples of process control systems

Distillation column – Preheat train

Some examples of process control systems

Comment: outlet
temperature of the
overhead stream is
usually controlled
via the temperature-
to-flow cascade
control loop

Distillation column
– Overhead system
Some examples of process control systems

Distillation column
– Bottom section

Kettle reboiler,
Ex-705, utilizes a
natural circulation
feed system
Designing the BPCS – Illustrated example 1
 Designing the BPCS – Illustrated example 1

1. Establish the Control Objectives: the primary goal is to meet

the required production rate. There are two approaches:
• Control / regulate the flowrate of the product stream (set
up a flow control that uses the control valve V-7): the
“on-demand product” option
• Control / regulate the flowrate of the principal feed
stream (set up a flow control that uses the control valve
V-1): the “fixed feed” option

2. Determine the Control Degrees of Freedom: the number of

controlled variables = the number of control valves = 7
 Designing the BPCS – Illustrated example 1
3. Establish the Energy-management System:
▪ Temperature in the reactor R-100 is controlled by adjusting
the flowrate of cooling water (use valve V-2)
▪ Temperature of the feed stream entering the reactor R-100 is
controlled by adjusting the flowrate of heating steam (use
valve V-3)

4. Set the Production Rate: already established in step 1: use

valve V-7 (the “on-demand product” option) or valve V-1
(the “fixed feed” option)
 Designing the BPCS – Illustrated example 1
5. Control the Product Quality:
▪ Composition of the effluent stream of R-100 (stream that has
valve V-4) is to be controlled. The process variable that strongly
affects the composition of the effluent stream is the temperature
of R-100 => it is needed to control temperature of R-100
(already established in step 3)
▪ Composition of the product stream B is determined by the
composition of the effluent stream of R-100, as well as the
pressure and temperature in V-100: use valve V-6 to control
temperature and valve V-5 to control pressure in flash drum V-
100
 Designing the BPCS – Illustrated example 1
6. Fix a Flow Rate in Every Recycle Loop and Control Vapor and
Liquid Inventories: there is no recycle stream
▪ Pressure control: applicable for V-100 (use valve V-5). R-100
has liquid phase only
▪ Level control: liquid level in a vessel is controlled by
manipulating either the liquid feed stream or the liquid effluent
stream of the vessel:
✓ The “on-demand product” option: liquid level in V-100 is
controlled via valve V-4 => liquid level in R-100 is
controlled via valve V-4
✓ The “fixed feed” option: liquid level in R-100 is controlled
via valve V-4 => liquid level in V-100 is controlled via
valve V-7
 Designing the BPCS – Illustrated example 1

7. Check Component Balances: N/A

8. Control the Individual Process Units: N/A
9. Optimize Economics and Improve Dynamic Controllability:
assuming that it is possible to measure stream composition
(with fast response time), we will establish a “composition-to-
temperature” cascade controllers with primary controller
being the composition controller, secondary controller being
the temperature controller of R-100
Designing the BPCS – Illustrated example 1
Designing the BPCS – Illustrated example 1
Designing the BPCS – Illustrated example 2
 Designing the BPCS – Illustrated example 2

1. Establish the Control Objectives: the primary goal is to meet

the required production rate. Use only the “fixed feed” option
because it is technically not recommended to control flowrate
of a vapor / gas stream coming out of a vessel:
• Control / regulate the flowrate of the principal feed
stream (set up a flow control that uses the control valve
V-1): the “fixed feed” option

2. Determine the Control Degrees of Freedom: the number of

controlled variables = the number of control valves = 6
 Designing the BPCS – Illustrated example 2
3. Establish the Energy-management System:
▪ Temperature in the reactor R-100 is controlled by adjusting
the flowrate of cooling water (use valve V-2)

4. Set the Production Rate: already established in step 1: use

valve V-1 (the “fixed feed” option)
 Designing the BPCS – Illustrated example 2
5. Control the Product Quality:
▪ Composition of the effluent stream of R-100 (stream that has
valve V-3) is to be controlled. The process variable that strongly
affects the composition of the effluent stream is the temperature
of R-100 => it is needed to control temperature of R-100
(already established in step 3)
▪ Composition of the product stream B is determined by the
composition of the effluent stream of R-100, as well as the
pressure and temperature in V-100: use valve V-5 to control
temperature and valve V-4 to control pressure in flash drum V-
100
 Designing the BPCS – Illustrated example 2
6. Fix a Flow Rate in Every Recycle Loop…:
▪ Fix / control the flowrate of the recycle stream (use valve V-6)
▪ Pressure control: applicable for V-100 (use valve V-4). R-100
has liquid phase only
▪ Level control:
✓ Liquid level in V-100 is controlled via valve V-3 because the
flow of liquid effluent stream is already regulated
✓ For R-100: manipulation of the effluent stream via V-3 (used
by the LC in V-100) and regulation of recycle stream via
valve V-6 is needed for stable process operation. Whereas
regulation of input stream via valve V-1 has been established
to meet the required production rate => flowrate of input
stream can be adjusted to control the liquid level in R-100
 Designing the BPCS – Illustrated example 2

7. Check Component Balances: N/A

8. Control the Individual Process Units: N/A
9. Optimize Economics and Improve Dynamic Controllability:
“To maximize conversion, a cascade controller is installed as
in the previous example in which the setpoint of the reactor
temperature controller (TC on V-2) is adjusted to control the
concentration of B in the reactor effluent. Again, for an
irreversible reaction, it is enough to operate the reactor at the
highest possible temperature”
Designing the BPCS – Illustrated example 2
 Thiết kế hệ thống điều khiển – ví dụ minh họa 3
Một thiết bị bay hơi (evaporator) được dùng để cô đặc một dung dịch
(của chất tan + dung môi D) đến nồng độ mong muốn của chất tan xB.
Nhiệt cho quá trình hóa hơi được cung cấp bởi hơi nước. Các biến có
thể được điều chỉnh là lưu lượng dòng hơi, lưu lượng hơi nước, lưu
lượng dòng sản phẩm. Các yếu tố gây nhiễu (yếu tố thay đổi) là lưu
lượng và thành phần dòng nhập liệu. Giả sử thành phần dòng sản phẩm
có thể được đo lường với thời gian có kết quả nhanh. Thiết kế hệ thống
điều khiển cho thiết bị này.
 Thiết kế hệ thống điều khiển – ví dụ minh họa 3

1. Thiết lập mục tiêu điều khiển: sản phẩm đạt tiêu chuẩn chất
lượng về thành phần sản phẩm:

2. Xác định bậc tự do điều khiển = 3

3. Kết quả của các bước 3, 4, 5 ở slide sau

 Thiết kế hệ thống điều khiển – ví dụ minh họa 3
▪ Vì dung môi D bay hơi ở nhiệt độ xem như không đổi (khi áp
suất được giữ cố định), vòng điều khiển nhiệt độ không cần
thiết
▪ Vì thành phần dòng sản phẩm có thể được đo lường với thời
gian có kết quả nhanh, chúng ta có thể thiết lập một vòng điều
khiển thành phần dòng sản phẩm.
▪ Để đạt được tiêu chuẩn về thành phần sản phẩm (xB theo yêu
cầu), 1 lượng dung môi tương ứng với thành phần và lưu
lượng dòng nhập liệu phải được hóa hơi
▪ Ở điều kiện áp suất (và nhiệt độ) được giữ cố định, lượng dung
môi bay hơi (trong khoảng thời gian bằng thời gian lưu của lưu
chất) phụ thuộc vào lượng nhiệt cấp vào thiết bị
▪ Phương án được áp dụng là sử dụng lưu lượng hơi nước như
biến điều chỉnh của vòng điều khiển thành phần sản phẩm
 Thiết kế hệ thống điều khiển – ví dụ minh họa 3
6. Điều khiển lưu lượng các dòng hồi lưu, điều khiển áp suất và
mực chất lỏng:
▪ Điều khiển áp suất: gắn và sử dụng van điều khiển trên dòng
hơi ra khỏi thiết bị
▪ Điều khiển mực chất lỏng: mực chất lỏng được điều khiển
bằng cách điều chỉnh lưu lượng dòng sản phẩm lỏng ra khỏi
thiết bị
7. Kiểm tra cân bằng vật chất của các cấu tử: N/A
8. Điều khiển từng thiết bị cụ thể trong quy trình: N/A

Kết quả đến bước 8 được trình này ở slide sau

Thiết kế hệ thống điều khiển – ví dụ minh họa 3
 Thiết kế hệ thống điều khiển – ví dụ minh họa 3

9. Tối ưu hóa tính kinh tế, cải thiện đặc tính điều khiển động học
của quy trình (nếu có thể): phương án thiết kế vừa trình bày
có thể được cải thiện thêm bằng cách thêm feedforward
control, trong đó thông tin về lưu lượng (hoặc thành phần)
dòng nhập liệu sẽ được dùng để điều chỉnh lưu lượng hơi
nước, ví dụ: khi lưu lượng dòng nhập liệu tăng lên thì lưu
lượng hơi nước được điều chỉnh tăng lên. Như vậy ta sử dụng
combined feed forward/feedback control để điều khiển thành
phần dòng sản phẩm với biến được điều chỉnh là lưu lượng
dòng hơi nước.
 Thiết kế hệ thống điều khiển – ví dụ minh họa 3

Signal selector

Feedforward controller FFC

FT