BASIC

PROCESS
CONTROL
SYSTEM

Pham Hoang Huy Phuoc Loi

Distributed control system

Distributed control system (DCS)—a computer-based system that controls

and monitors process variables. The main role of the DCS is to handle BPCS
(basic process control system) actions, to “adjust” the process to make it run
smoothly. However, the action of the BPCS is not only regulating or throttling
a valve (control valve); it could also be opening or closing a valve!
Programmable logic
controller

Programmable logic controller (PLC)—a simple, stand-alone,

programmable computer. The role of the PLC is to handle SIS (Safety
Instrumented System) actions. The SIS is not an adjusting, regulatory action
like BPCS but rather a direct action, which may involve opening a valve,
shutting down, or starting up a pump. It is a drastic action, intended to protect
equipment from damage and to keep operators safe. These may be called
“safety interlocks.”
Fundamen
tal
terminolo
gy
 Main
operati
on
bands
Process
guard
layers
Action levels or bands for process guards
 The level
of
parameter
versus the
level of
hazard
and
control
Operators’ actions
Disturbances

The deviation of
operational parameters in
the process (temperature,
pressure, flow rate, liquid
level, chemical
composition) from the
desired or “normal” values
is a common (and
inevitable) phenomenon.
This is due to the presence
of disturbances
The origins of disturbances
Changes in the conditions (temperature, pressure, flow rate, chemical
composition) of input streams.

Changes in surrounding environmental conditions (temperature,

humidity, etc.) primarily affecting heat transfer.

Changes in equipment performance (e.g., a gradual decrease in the

heat transfer coefficient of heat exchange equipment due to fouling on
the heat transfer surfaces).

Changes in the setpoint (desired value) of certain operational

parameters; reason: adjustments are made to alter product flow rate or
product quality.

Equipment-related incidents or design errors.

The purpose of the plant's
automated control and safety
protection systems

• BPCS, alarm, SIS, and Relief systems are to eliminate the

above disturbances:
• Ensuring safe operation: keeping the operational
parameters of the process within safe limits.
• Achieving production and product quality targets.
• Maximizing economic benefits: minimizing the time
the process operates under unstable conditions and
reducing the production of off-spec products.
• Stability: enabling smooth, stable plant operation with
minimal operator intervention.
Classification of Variables

• Disturbance variable: a
variable that causes
disturbances.
• Controlled variable: a
variable that needs to be
controlled to maintain its
value at a setpoint.
• Manipulated variable: a
variable that can be
adjusted (within a certain
range) to counteract the
effect of disturbances on
the controlled variable.
The objective of the BPCS
control system

To "shift" the fluctuations or

changes caused by
disturbances onto the
manipulated variables so
that the controlled variables
can maintain their stable
values (i.e., the setpoints).
The diagram below illustrates
a single control loop: 1
manipulated variable – 1
controlled variable.
Example
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.
Selecting the controlled variable

Unstable (non-self-regulating) output variables must

be controlled. Self-regulating variables do not "run
away": they will shift to a new stable state when a
disturbance occurs.

Control output variables that need to be kept within

limits during equipment operation (e.g., temperature,
pressure, liquid level).

Control output variables that directly indicate product

quality (e.g., composition, refractive index) or have a
strong impact on product quality (e.g., reaction
temperature).
Selecting the controlled
variable

• Variables that have a strong impact on the

operation of related equipment in the process, for
example: steam pressure in the steam generation
and distribution system must be controlled
because it affects equipment that uses steam in
the process.
• Variables that can be measured with quick
response times and are “sensitive” to one (or a
few) manipulated variables.
Summary of Controlled
variables
• Controlled variables:
• Have a direct impact on operational stability,
safety, or the performance of certain process
equipment.
• Directly affect product yield and quality.
Example of
Controlled
variables:

• Reaction temperature and

pressure
• Liquid level in the reaction
vessel
• Flow rates of all reactant
feed streams into the
reaction vessel
• Stirring speed (SIC
controller)
 • To select the manipulated variable for a
Selecting given controlled variable
•
the Ideally, a change in the
manipulated variable should cause
manipulat a significant change in the
controlled variable in a quick and
ed •
direct manner.
Should have minimal impact on
variable other operating parameters.
• Avoid using the recycle stream as
a manipulated variable, as it tends
to "recycle" disturbances rather
than eliminate them.
Selecting the The hot shot / cold shot (option A) as
manipulated variable has more rapid /
manipulated direct effect on the controlled variable
(reactor temperature) than the cooling /
variable heating fluid (option B)
Example of
Manipulated
variables:
• Flow rates of hot and cold utility streams in
the process (e.g., steam, hot oil, furnace
fuel, cooling water, etc.), which are among
the most commonly used.
• Process streams that do not need further
downstream processing; for example, gas
streams sent to the flare or gas collection
system, and product streams directed to
storage tanks.
• Other types of variables: liquid level in
heat exchange equipment (which
determines heat transfer surface area and
capacity), bypass stream ratio through a
heat exchanger, and reflux ratio in
distillation columns.
Example of Manipulated variable: liquid level
in heat exchange equipment (determines the heat
transfer surface area and heat transfer capacity).
 Example
Controlled variables:
• Liquid level: necessary
for stable and safe
operation of the CSTR
(Continuous Stirred Tank
Reactor).
• Reaction
temperature:
necessary for stable and
safe operation of the
CSTR and affects the
composition of the
product stream
(influences reaction
rate).
• Composition (quality)
of the product
stream: controlled by
adjusting the feed flow
Example
Controlled
variables:
• Liquid level:
necessary for
stable and safe
operation of the
flash separator.
• Temperature
and pressure:
necessary for
stable and safe
operation of the
equipment and
determine the
composition of
product streams.
• Feed flow rate
(optional):
determines the
flow rates of the
 Example

Control diagram for

a binary distillation
column
• Configuration (a) has
better dynamic
characteristics than
configuration (b): it
allows for easier
control of the top
product composition
compared to
configuration (b).
• Configuration (b) is
used when the reflux
ratio is high, and the
top product flow rate
is small (compared to
the reflux stream).