Process Control: Designing Process

and Control Systems for Dynamic

Performance
Chapter 2. Control Objectives and
Benefits

Copyright Thomas Marlin 2013

The copyright holder provides a royalty-free license for use of this
material at non-profit educational institutions

CHAPTER 2 : CONTROL OBJECTIVES

AND BENEFITS
When I complete this chapter, I want to be
able to do the following.

Recognize examples of the seven (7)

control objectives in chemical processes
Calculate indicators of variability in a
process variable
Be able to calculate the economic impact
of variability

CHAPTER 2 : CONTROL OBJECTIVES

AND BENEFITS
Outline of the lesson.

Seven (7) Control Objectives

1. Safety
2. Environmental protection
3. Equipment protection
4. Smooth operation
5. Product quality
6. Profit
7. Monitoring and diagnosis

Variability measures
Economic impact of variability
Workshop

EXAMPLE PROCESS: FLASH SEPARATION

Lets discuss
this process
T6

Feed
Methane
Ethane (LK)
Propane
Butane
Pentane

T1

P1

P 1000 kPa

T5

T2

Vapor
product

T 298 K
F1

T4

F2

Process
fluid

T3

L1

F3

Steam

A1
L. Key

Liquid
product

SEVEN CONTROL OBJECTIVES

Give example

1. Safety
2. Environmental
Protection

T6

3. Equipment
protection
4. Smooth operation
production rate

T1

T2

F1

T4

P1

Vapor
product

T5

Feed
T3

L1

5. Product quality
F2

F3

6. High profit
7. Monitoring &
diagnosis

Process
fluid

Steam

A1
L. Key

Liquid
product

SEVEN CONTROL OBJECTIVES

High pressure
in drum is
dangerous

1. Safety
2. Environmental
Protection
3. Equipment
protection
4. Smooth operation
production rate

T1

T2

F1

T4

T6

PC

Vapor
product

T5

Feed
T3

L1

5. Product quality
F2

F3

6. High profit
7. Monitoring &
diagnosis

Process
fluid

Steam

A1
L. Key

Liquid
product

SEVEN CONTROL OBJECTIVES

Give example

1. Safety
2. Environmental
Protection

T6

3. Equipment
protection
4. Smooth operation
production rate

T1

T2

F1

T4

P1

Vapor
product

T5

Feed
T3

L1

5. Product quality
F2

F3

6. High profit
7. Monitoring &
diagnosis

Process
fluid

Steam

A1
L. Key

Liquid
product

SEVEN CONTROL OBJECTIVES

To flare

Never release
hydrocarbons
to atmosphere

1. Safety
2. Environmental
Protection
3. Equipment
protection
4. Smooth operation
production rate

T1

T2

F1

T4

T6

P1

Vapor
product

T5

Feed
T3

L1

5. Product quality
F2

F3

6. High profit
7. Monitoring &
diagnosis

Process
fluid

Steam

A1
L. Key

Liquid
product

SEVEN CONTROL OBJECTIVES

Give example

1. Safety
2. Environmental
Protection

T6

3. Equipment
protection
4. Smooth operation
production rate

T1

T2

F1

T4

P1

Vapor
product

T5

Feed
T3

L1

5. Product quality
F2

F3

6. High profit
7. Monitoring &
diagnosis

Process
fluid

Steam

A1
L. Key

Liquid
product

SEVEN CONTROL OBJECTIVES

No flow could
damage the
pump

1. Safety
2. Environmental
Protection
3. Equipment
protection
4. Smooth operation
production rate

T1

T2

F1

T4

T6

Vapor
product

P1

T5

Feed
T3

LC

5. Product quality
F2

F3

6. High profit
7. Monitoring &
diagnosis

Process
fluid

Steam

A1
L. Key

Liquid
product

SEVEN CONTROL OBJECTIVES

Give example

1. Safety
2. Environmental
Protection

T6

3. Equipment
protection
4. Smooth operation
production rate

T1

T2

F1

T4

P1

Vapor
product

T5

Feed
T3

L1

5. Product quality
F2

F3

6. High profit
7. Monitoring &
diagnosis

Process
fluid

Steam

A1
L. Key

Liquid
product

SEVEN CONTROL OBJECTIVES

Always keep
the production
rate smooth

1. Safety
2. Environmental
Protection
3. Equipment
protection

T1

T2

FC

T4

T6

Vapor
product

P1

T5

Feed
4. Smooth operation
production rate

T3

L1

5. Product quality
F2

6. High profit
7. Monitoring &
diagnosis

F3

Process
fluid

Steam

A1
L. Key

Liquid
product

SEVEN CONTROL OBJECTIVES

Give example

1. Safety
2. Environmental
Protection

T6

3. Equipment
protection
4. Smooth operation
production rate

T1

T2

F1

T4

P1

Vapor
product

T5

Feed
T3

L1

5. Product quality
F2

F3

6. High profit
7. Monitoring &
diagnosis

Process
fluid

Steam

A1
L. Key

Liquid
product

SEVEN CONTROL OBJECTIVES

Achieve L.Key
by adjusting
the heating

1. Safety
2. Environmental
Protection

T6

3. Equipment
protection
4. Smooth operation
production rate

T1

T2

F1

T4

Vapor
product

P1

T5

Feed
T3

L1

5. Product quality
F2

F3

6. High profit
7. Monitoring &
diagnosis

Process
fluid

Steam

AC
L. Key

Liquid
product

SEVEN CONTROL OBJECTIVES

Give example

1. Safety
2. Environmental
Protection

T6

3. Equipment
protection
4. Smooth operation
production rate

T1

T2

F1

T4

P1

Vapor
product

T5

Feed
T3

L1

5. Product quality
F2

F3

6. High profit
7. Monitoring &
diagnosis

Process
fluid

Steam

A1
L. Key

Liquid
product

SEVEN CONTROL OBJECTIVES

Use the least
costly heating

1. Safety
2. Environmental
Protection

T6

3. Equipment
protection
4. Smooth operation
production rate

T1

T2

F1

T4

Vapor
product

P1

T5

Feed
T3

L1

5. Product quality
F2

F3

6. High profit
7. Monitoring &
diagnosis

Process
fluid

Steam

AC
L. Key

Liquid
product

SEVEN CONTROL OBJECTIVES

Give example

1. Safety
2. Environmental
Protection

T6

3. Equipment
protection
4. Smooth operation
production rate

T1

T2

F1

T4

P1

Vapor
product

T5

Feed
T3

L1

5. Product quality
F2

F3

6. High profit
7. Monitoring &
diagnosis

Process
fluid

Steam

A1
L. Key

Liquid
product

SEVEN CONTROL OBJECTIVES

Calculate & plot
key parameters,
T6
e.g., UA.

1. Safety
2. Environmental
Protection
3. Equipment
protection
4. Smooth operation
production rate

T1

T2

F1

T4

P1

Vapor
product

T5

Feed
T3

L1

5. Product quality
F2

F3

6. High profit
7. Monitoring &
diagnosis

Process
fluid

Steam

A1
L. Key

Liquid
product

UA
time

SEVEN CONTROL OBJECTIVES

All seven must be achieved. Failure to do so
will lead to operation that is

1. Safety

unprofitable or worse, unsafe.

2. Environmental
Protection
3. Equipment
protection

T6

4. Smooth operation
production rate
5. Product quality

T1

T2

F1

T4

P1

Vapor
product

T5

Feed
T3

L1

6. High profit
7. Monitoring &
diagnosis

F2

Process
fluid

F3

Steam

A1
L. Key

Liquid
product

BENEFITS FROM PROCESS CONTROL

When we control a process, we reduce the variability of
key variables to achieve the seven objectives.
Without feedback control
Composition (% H. Key)
outlet concentration

6
5
4
3

valve position (% open)

50

51

100

150

200

250
time (min)

300

350

400

450

500

300

350

400

450

500

Reflux valve

50.5
50
49.5
49
0

50

100

150

200

250
time (min)

BENEFITS FROM PROCESS CONTROL

When we control a process, we reduce the variability of
key variables to achieve the seven objectives.
With feedback control
Composition (% H. Key), note smaller scale
outlet concentration

3.5

valve position (% open)

2.5

50

100

150

200

250
time (min)

300

350

400

450

500

350

400

450

500

100

Reflux valve

80
60
40
20
0

50

100

150

200

250
time (min)

300

Variability is moved from controlled to manipulated variable!

BENEFITS FROM PROCESS CONTROL

When we control a process, we reduce the variability of
key variables to achieve the seven objectives.
What statistics
can we calculate
from this data?

How do we relate
variability to
process performance?

BENEFITS FROM PROCESS CONTROL

Process performance =
efficiency, yield, production
rate, etc. It measures
performance for a control
objective.
Calculate the process
performance using the
distribution, not the average
value of the key variable!

Example of Benefits of reduced

variability for chemical reactor
Goal: Maximize conversion of
feed ethane but do not exceed
864C
Which operation, A or B, is better
and explain why.

Example of Benefits of reduced

variability for chemical reactor
Goal: Maximize efficiency and
prevent fuel-rich flue gas
Which operation, A or B, is better
and explain why.

CHAPTER 2: GOALS AND BENEFITS WORKSHOP 1

Determine one example for each of the seven control objective categories.
Flue
gas

PIC
1

AT
1
FT
1

PI
4

TI
1

feed

The feed flows

through a pipe and
is heated by the
combustion of fuel

PI
5
TI
5

TI
2

TI
6

PT
1
TI
3

TI
7

TI
4

air

TI
8

FT
2

PI
2

PI
3

product
TI
9

TI
10

FI
3

TI
11

PI
6

fuel

CHAPTER 2: GOALS AND BENEFITS WORKSHOP 2

Two process examples show the benefit of reduced variability,
the fired heater reactor and the boiler. Discuss the difference
between the two examples. Can you think of another example
that shows the principle of each?
Squeeze down the variability

0.4

frequency of occurrence

0.3

0.2

0.1

0
-3

-2

-1

deviation from mean

CHAPTER 2: GOALS AND BENEFITS WORKSHOP 3

In both the flash drum and the fired heater examples,
temperature measurement is very important. Describe
several methods for measuring temperature and recommend
the most appropriate for the flash drum example.
How hot is it?

T6

T1

T2

F1

T4

P1

Vapor
product

T5

Feed

F2

Process
fluid

T3

L1

F3

Steam

A1
L. Key

Liquid
product

CHAPTER 2: GOALS AND BENEFITS WORKSHOP 4

Here is your chance to investigate a
problem!
Research the design of a vapor-liquid
separator vessel. Determine
the equipment included,
how to determine the diameter and
height,
how to select the materials of
construction, and
how to change the operating
variables to achieve the desired
product purity as feed composition
changes
Figure source: Mbeychok, public domain, http://en.wikipedia.org/wiki/File:Vap-Liq_Separator.png

CHAPTER 2 : CONTROL OBJECTIVES & BENEFITS

When I complete this chapter, I want to be
able to do the following.

Recognize examples of the seven (7)

control objectives in chemical processes
Calculate indicators of variability in a
process variable
Be able to calculate the economic impact
of variability
Lots of improvement, but we need some more study!
Read the textbook
Review the notes, especially learning goals and workshop
Try out the self-study suggestions
Naturally, well have an assignment!

CHAPTER 2: LEARNING RESOURCES

SITE PC-EDUCATION WEB

- Instrumentation Notes
- Interactive Learning Module (Chapter 2)
www.pc-education.mcmaster.ca/
- Tutorials (Chapter 1/2)

CHAPTER 2:
SUGGESTIONS FOR SELF-STUDY
1. Discuss the importance of consistent quality in your
decisions to purchase food, clothing, etc.
2. A P&I drawing of a distillation process is given in
Woods*. Determine at least one example of each of the
seven control objectives for this process. Evaluate the
control designs given; do they achieve your objectives?
3. Find process examples in your previous textbooks and
determine the advantage for reduced variability in each.
Can you provide quantitative values for the economic
benefit?
* Woods, D. Process Design and Engineering Practice, Prentice-Hall, 1995 (page 2-65).