Introduction to Process Control

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OBJECTIVES:
Understand the terminologies associated with process control. How the four components / elements of control system are linked. Know and classify process variables. Control objectives are identified Know Incentives of process control. Use the Control Algorithms to control the measured variables. Use of process control instrumentation to regulate the process.
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Unit 1:

Process Control Terminology

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Process control is the regulation / manipulation of variables influencing the conduct of a process in such a way as to obtain a product of desired quality and quantity in an efficient and economic manner.

Most basic process control processes consist of a control loop as shown in figure 1 below, having four main components of a control system.

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CONTROL SYSTEM
Disturbance variables

FINAL CONTROL ELEMENT

PROCESS

Controlled variable

Raw materials

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MEASUREMENT

CONTROLLER

Set point

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Process - refers to the collection of unit operations or any physical and / chemical conversion of raw materials to useful product Measurement - is a device which calculates the action based on the measured value against a preset or desired value (set point). A controller is a device used to control the process. It compares a signal from the measured value (PV) with the set point (SP) and produces an error signal which is used to adjust the final control element. Error = MV SP Final control element- An output signal resulting from the controller calculation, which is used to manipulate the process action through some form of actuator.
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 Control system can be defined as a combination of components that act together to perform a certain objectives. A system interact with its environment through signals as shown in the diagram below.

U(t)

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y(t)
System

Generally, signals are function of time as indicated in the diagram. e.g u(t) and y(t).

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Two types of signals Input signal, u(t) affect the system behaviour in some way Output signal, y(t) give information about the system behaviour

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Set Point: A reference value representing the desired value of the process variable being controlled. E.g: If the level of a liquid in a tank must be maintained within 5 ft of 50 ft, what is the liquids setpoint? = 50 ft Set-point change - implementing a change in the operating conditions. The set-point signal is changed and the manipulated variable is adjusted appropriately to achieve the new operating conditions.
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More Terminologies

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 back to its set-point. Process load is the level of material, force, torque, energy, power, or other variable applied to or externally by another instrument. Process upset is any type of disturbance that causes the control variable to depart from the set point. Process demand is the requirement made by the control system or the operator on the process. Load response is the way in which the process behaves after a change in the process load introduces an error in to the system.
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 Steady state is one that does not change with time. Every time we take snapshot, all the variables have the same values as in the first snapshot. Transient state is one that changes with time. Every time we take a snapshot, many of the variables have different values than in the first snapshot. Capacity is a measure of capacity to restore volume, mass, heat, information, or any form of energy or matter. Dead time is the time interval between the initiation of the output change or stimulus and start of resulting response. Control system lag the time for the process control loop to make necessary adjustments to the final control element. Process lag is the time delay caused by the process to eliminate errors after the manipulated variables are adjusted.
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Classification of variables in a chemical process.

The variables (Flow rates, Temperature, Pressure, Concentration, etc) are conditions which can change a process in some way. They are divided in to two groups. a) INPUT variables: which donates the effect of the surroundings on the chemical process. b) OUTPUT variables: which donates the effect of the process on the surrounding. The INPUT variables can be further classified into the following categories: Manipulated ( or adjustable ) variables, if their values can be adjusted freely by the human operator or a control mechanism. Typically flow rates of streams entering or leaving a process that we can change in order to control the plant.
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Disturbance variable, if their values are not the result of adjustment by an operator or a control system. Flow rates, temperatures, or compositions of streams entering the process. Variables in the process that affects the controlled variables but cannot be manipulated.

The OUTPUT variables can be further classified into the following categories:

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Measured (Controlled) variables, if the values are known by directly measuring them. Flow rates, compositions, temperatures, levels, and pressures in the process that we can control, either by holding them as constant or making them follow some desired values.
The desired value of a controlled variable is referred to as its set point.
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 unmeasured variable, if they are not measured or cannot be measured directly.

In the figure.1.3 below,

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the inputs x1 and w1 are the disturbances, while x2 and w2 are manipulated inputs. The output variables x and w can be measured easily and they are considered measured or the controlled outputs.

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UNIT 1

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EXERCISE 1

Imagine yourself in the shower As observed on the insert Diagram. Identify the following:

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a) The process variable(s) b) The set point c) The comparison element d) The control unit e) The correction unit f) The process g)The measuring device h) Manipulated variables.
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EXERCISE 2
Imagine you are in a cabin in front of a small fire on a cold winter evening. You feel uncomfortably cold, so you throw another log into the fire the temperatuture to be at 5 0C of 50 0C. Identify the following:

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a) The process variable(s) b) The set point c) Controlled variable(s) d) Measured variable(s) h) Manipulated variable(s).

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Unit2: Reasons for Control (Control incentives)

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 Safety: The safe operation of a chemical process is a primary requirements for the well-being of plant personnel, the community at large, and the economic viability of the company. Thus the T, P, C (specially poisonous or explosive components) should be within allowable limits.
Product specification / quality: The final products from the plant must meet demanding quality specifications set by purchasers. Process control contributes to good plant operation by maintaining the operating conditions required for excellent product quality. Environmental Regulation: Regulation requires that T, C, and flow rate of certain chemical species be under some limits. The process must have the capacity to convert potentially toxic components to being materials. Control can contribute to the proper operation of the plant units, resulting in consistently to low effluent concentrations.
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 Operational constraint: Different types of equipments used in a chemical plant have limitations as a results of their particular design, and inherent to their operation.
E.g. a centrifugal pump can deliver only a certain flow rate as determined by its impeller size and the available pressure drop in a line. Control systems need to recognize and satisfy all such operational constrains. Economics: The operation of plant should be as economical as possible to utilize the raw material, energy, capital and human labor. Thus, the operating conditions must be controlled effectively to minimize operating costs and maximize profit.
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UNIT3. CONTROL STRATEGIES

The objective of a control system is to keep the controlled variables at their desired values (or set points). This is achieved by manipulating the manipulated variables using a control algorithm. 3.1. CONTROL ALGORITHM OPEN- LOOP SYSTEM (CONTROL) An open loop system is a system with only the input and the output but no regulation / no control action at all.
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Example of an open loop system

In an open-loop system, the control mechanism act without the current information about the status of the process. Signal path is represented by arrows, which show the direction of information flow.

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Block diagram representation

D U(t) PROCESS Y(t)

Figure: A simplified open loop control system

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3.1.1. Feedforward Control (FFC) Algorithm

Feedforward control is an example of an open-loop control system that converts one or more conditions that can disturb the controlled variable outside of any feedback loop, in to corrective action to minimize deviation of the controlled variable / mechanism which anticipate the effect of the disturbances to produce the corrective action if: The disturbance can be measured We know how the disturbances affect the output We know how the control signal affects the output
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Feedforward Control Algorithm/Strategy

FF CONTROLLER Disturbance (d) CONTROL EQUATION

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SP

U(t)
Fig:A

PROCESS

Y(t)

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Block diagram representation of fig: A

Disturbance (d)

MEASUREMENT

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SP

CONTROLLER

U(t)

PROCESS

Y(t)

Fig: B A,B : Typical Feedforward control systems control system

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Advantages and disadvantages of FF control loop

ADVANTAGES

i. Acts before the effect of a disturbance has been felt by the system.

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ii. Is good for slow systems iii. It does not introduce instability in the closed loop response

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DISADVANTAGES i. Requires identification of all possible disturbances and their measurement.

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ii. Cannot cope with unmeasured disturbance.

iii. Sensitive to process parameter variation.

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Example
Consider the example of the stirred tank heater. The objective is to control the temperature. The disturbance source is Ti.

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T C

I/ P

Feedforward control for a heated tank

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CLOSED LOOP SYSTEM

A closed loop system is a system with a total control action / regulation around the entire process. The total control action is called the feedback control. The controlled variable is measured, and the measurement is fed to the controller, thus the controller receiving information about how a control action affects the output.

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3.1.2. Feedback Control Loop (FBC)

In Feedback control, the measurement is fed to the controller. Thus the controller receives information about how a control action affects the output. Usually the measured variable is the variable we want to control

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The basic elements of a feedback controller

The process variable (PV). I.e. the variable that is to be maintained under control. The set point (SP) which is the desired value of the process variable

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The error (e), which is a measure of the difference between the PV and the SP. The controller, whose control law and turning drive the corrective action . The final control element ( typically a valve) The manipulated variable (MV), the variable in the process to which the FCE is attached. Two dividends of feedback control loop 3.1.2.1. Negative feedback, this refers to the desirable situation where the corrective action taken by the controller forces the controlled variable towards the set point.
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Error = reference feedback signal 3.1.2.2 Positive feedback occurs when the controller forces the controlled variables farther away from the set point.

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Error = reference + feedback signal

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Advantages and disadvantages of FB control loop

ADVANTAGES I. Does not require identification of disturbances and their measurements. II. It is insensitive to modelling error. III. It is insensitive to parameter changes. all possible

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DISADVANTAGES
I. It waits until the effect of disturbance is felt by the system. II. It is unsatisfactory for slow system. III. It may create instability in the closed loop response.
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Example 1: Man in the shower.

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Process variables The disturbances = Water from toilet flushing Manipulated variables = Temperature and the flow rate of the water Measured / controlled variables = Temperature of the water
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Block diagram representation

Disturbance = flushing
PROCESS Water temperature

FINAL CONTROL ELEMENT

Fw , T

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MEASUREMENT

CONTROLLER

Set point

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EXAMPLE 2

Consider the example of the stirred tank heater. The objective is to control the temperature. The disturbance source is Ti.

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SOLUTION

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T T TC Q

SP

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REVISIT THE BLENDING PROCESS: A CONBINATION OF

FEEDBACK FEEDFORWARD CONTROL LOOPS
AT AC I/P

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Mixture (A,B) W1 X1

Pure A W2 X2=1

I/P

AC AT W X xsp

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Class exercise 1. Riding a bicycle is an inherently unstable system.

a) Identify all process variables. b) Could the process be considered as an open loop or closed loop? Explain. c) Construct the control mechanism of this process.

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CLASS EXERCISE

2. Your bathtub at home is a control system that keeps the water level constant. A constant flow from the tap yields a constant water level, because the flow rate through the drain increases as the water level increases, and decreases as the water level decreases. After equilibrium has been reached, the level can be controlled by controlling the input flow rate. A low input flow rate yields a lower level, while a higher input flow rate yields a higher level. a) Which control strategy is used in this process? b) Sketch a control system that uses this principle to precisely control the fluid level in a tank. Show the intake and the drainage valves, the tank, any sensors and transmitters, and the interconnection of all components. c) Draw a block diagram of the system, identifying the input and output signals of each block.

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Unit 4: Design element of a control system

In the design of a process control system, one should be able to have answers to the WHAT,WHY and the HOW methods of achieving the process needs.

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Series of steps to follow during the design of a control system to follow the decision making process. 4.1. Define the control objectives Question: what are the operational objectives that a control system is called upon to achieve?
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The answer to this question will be determining the control objective . Answer: For the blending process in the example, the control objective is to Keep x at a desired value (or set point) xsp despite variations in x1(t). 4.2. Select measured variables. Question : What variables should be measured to monitor the operational performance of the process. Answer: the first attempt will be to install the measuring devise that will monitor the values of x and w directly.
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4.3. Select manipulated variables.

Question : What variables are to be manipulated to achieve the control objective ? Answer: the first attempt will be to install the measuring devise that will monitor the values of x and w directly.

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4.4. Design the controller.

In every control configuration, the controller is the active element that receives the information from the measurements and takes appropriate control action to adjust the values of the manipulated variables. E.g FF,FB.
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Question:
How is the information, taken from the measurement used to adjust values of the manipulated variables?

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DESIGN QUESTION

Suppose that the inlet concentration x1 changes with time. How can we ensure that x remains at or near the set point ?
As a specific example, ifx1 x1 and w2 w2 than x > xSP.
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4.4.1. Some Possible Control Strategies:

Method 1. Measure x and adjust w2.
if x is too high, we should reduce w2;

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Method 2. Measure x1 and adjust w2. Thus, if x1 is greater than , we would decrease w2 so that w2 w2 ;

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Method 3. Measure x1 and x, adjust w2.

This approach is a combination of Methods 1 and 2.

AT

AC

I/P

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Mixture (A,B) W1 X1 W X

Pure A W2 X2=1

I/P

AC

AT
xsp
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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.

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However, a larger tank means an increased capital cost.

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EXERCISE 2
On the process, construct the possible control strategies that will help to achieve the desired products.

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