Introduction to Process

Control
hancl@unikl.edu.my
 Introduction to Process
Control
Chapter 1

a) Classification of Process Control

Strategies
b) The hierarchy of Process Control
Activities
c) An Overview of Control System Design

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 Control Terminology
Controlled Variables (CVs) – The process variables
that are controlled. The desired value of a controlled
variable is referred to as its set point.
Chapter 1

Manipulated Variables (MVs) – The process

variables that can be adjusted in order to keep the
controlled variables at or near their set points.
Typically, the manipulated variables are flow rates.
Disturbance Variables (DVs) – Process variables
that affect the controlled variables but cannot be
manipulated. Disturbances generally are related to
changes in the operating environment of the process:
for example, its feed conditions/ambient temperature.
Some disturbance variables can be measured on-
online but many cannot. 3
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 Control Terminology(2)

Set-point change - implementing a change in the

operating conditions. The set-point signal is
changed and the manipulated variable (MVs) is
Chapter 1

adjusted appropriately to achieve the new operating

conditions.
Disturbance change - the process transient
behavior when a disturbance enters, also called
regulatory control or load change. A control system
should be able to return each controlled variable
(CVs) back to its set-point.

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Chapter 1 Illustrative Example: Blending system

Notation:
• w1, w2 and w are mass flow rates
• x1, x2 and x are mass fractions of component A
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 Assumptions:
1. w1 is constant
2. x2 = constant = 1 (stream 2 is pure A)
3. Perfect mixing in the tank
Chapter 1

Control Objective:
Keep x at a desired value (or “set point”) xsp, despite variations in
x1(t). Flow rate w2 can be adjusted for this purpose.

Terminology:
• Controlled variable (or “output variable”): x
• Manipulated variable (or “input variable”): w2
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• Disturbance variable (or “load variable”): x1
 Design Question. What value of w2 is required to have
x = xSP ?

Overall balance:
0 = w1 + w2 − w (1-1)
Chapter 1

Component A balance:

w1 x1 + w2 x2 − wx =
0 (1-2)

(The overbars denote nominal steady-state design values.)

• At the design conditions, x = xSP. Substitute Eq. 1-2, x = xSP

and x2 = 1 , then solve Eq. 1-2 for w2 :
xSP − x1
w2 = w1 (1-3)
1 − xSP
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 • Equation 1-3 is the design equation for the blending
system.
• If our assumptions are correct, then this value of w2 will keep x
at xSP . But what if conditions change?
Chapter 1

Control Question. Suppose that the inlet concentration x1

changes with time. How can we ensure that x remains at or near
the set point xSP ?
As a specific example, if x1 > x1 and w2 = w2, then x > xSP.

Some Possible Control Strategies:

Method 1. Measure x and adjust w2.
• Intuitively, if x is too high, we should reduce w2; 10
 • Manual control vs. automatic control
• Proportional feedback control law,
w2 ( t ) =
w2 + K c  xSP − x ( t )  (1-4)

1. where Kc is called the controller gain.

Chapter 1

2. w2(t) and x(t) denote variables that change with time t.

3. The change in the flow rate, w2 ( t ) − w2 , is proportional to
the deviation from the set point, xSP – x(t).

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 Method 2. Measure x1 and adjust w2.

• Thus, if x1 is greater than x1, we would decrease w2 so that

w2 < w2 ;

• One approach: Consider Eq. (1-3) and replace x1 and w2 with

x1(t) and w2(t) to get a control law:
Chapter 1

xSP − x1 ( t )
w2 ( t ) = w1 (1-5)
1 − xSP

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 • Because Eq. (1-3) applies only at steady state, it is not clear
how effective the control law in (1-5) will be for transient
conditions.

Method 3. Measure x1 and x, adjust w2.

• This approach is a combination of Methods 1 and 2.
Chapter 1

Method 4. Use a larger tank.

• If a larger tank is used, fluctuations in x1 will tend to be damped
out due to the larger capacitance of the tank contents.
• However, a larger tank means an increased capital cost.

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 Classification of Control Strategies

Table. 1.1 Control Strategies for the Blending System

Method Measured Manipulated Category
Variable Variable
Chapter 1

1 x w2 FB
2 x1 w2 FF
3 x1 and x w2 FF/FB
4 - - Design change

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 Justification of Process Control

Specific Objectives of Control

• Increased product throughput
Chapter 1

• Increased yield of higher valued products

• Decreased energy consumption
• Decreased pollution
• Decreased off-spec product
• Increased Safety
• Extended life of equipment
• Improved Operability
• Decreased production labor

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 Economic Incentives - Advanced
Control
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