CBB 40104

Bioplant Design Project 2

(Chapter 4: Process Control)
In any industrial plant the aim is to produce standard
and high quality products and sell them at prices
which make profit. These purposes can be achieved
in a successfully designed and controlled processes.
 Environmental Equipment
Safety
Protection Protection

Smooth Plant
Profit
Operation & Product Quality
Optimization
Production Rate

Monitoring and
Diagnosis
 • to maintain the measured
First variable at its desired value when
disturbances occur.

• to respond to changes in the

Second
“desired value”.
Human Beings Manually

•Automobile driving example; feedback control by human

action

Instrumentation Automatically

• Most automatic control is implemented with electronic

equipment which uses levels of current or voltage to
represent values to be communicated.
 Desired value

Controller

Final Control Measuring

Element
Element

Process

inputs outputs
 Process Design Measurement Final Control Element
Provide necessary
Responsive control Selection & location change in
system of sensor manipulated variables

Control Structure Control Calculation

e.g. using hot/cold Calculate change in
water or direct heat manipulated
source variables
Feedback
• direct measurements of the controlled variables to adjust the
values of the manipulated variables.
• objective is to keep the control variables at desired levels.

Feed forward
• direct measurement of disturbances to adjust the values of
the manipulated variables.
• objective is to keep the controlled output variables at desired
levels.

Cascade
• different combinations of two types
 Heat exchanger

TT Sensor
Final
(Temperature
control
Controller Transmitter)
element

steam
 Creating
If inlet T  Outlet T 
disturbance

Controller send signals Signal change from

to valve to increase its transmitter to
opening controller
 ADVANTAGES

Simple techniques Works with

Most common
that compensate minimum
control strategy
for all disturbances knowledge
DISADVANTAGES

• It can compensate for a disturbance only after the

controlled variable has deviated from set point.

• That is, the disturbance must propagate through the

entire process before the feedback control scheme can
initiate action to compensate it.
 Sensor
(Temperature
Controller
HeatTT Transmitter)
exchanger
Heat exchanger
TT Sensor
Final
(Temperature
control
element ControllerFinal Transmitter)
control
steam element
steam
• The objective of feed forward control is to
measure the disturbances and compensate for
them before the controlled variable deviates from
set point. If applied correctly, the controlled
variable deviation would be minimum.
The studies on process control system should be
documented in order to be :
a. understandable
b. stable

In order to avoid misunderstanding, standard

symbols developed by Instrument Society of
America (ISA) are used.
In standard Drawing:
• All process equipment is drown in solid lines

• Sensors are designated by a circle connected to

the point in the process where they are located

• Process control loops are shown by dashed

lines.
• The first letter in the A Analyzer
instrumentation symbol F Flow rate
indicates the type of L Level of liquid or solid
variable measured
P Pressure
T Temperature
• The subsequent letter(s)
give information about
the function performed.
• In the plant there exist a large number of
possibilities for placing sensors and final control
elements.

• Every process control system is to be verified for;

i. Casual process relationship
ii. Determination of the action the controller would take
in response to a disturbance or a change in desired
value.
 FIRST SECOND THIRD

Impossible
Understand without
Simplest
the process mathematical
model
 Fi, Ti

F, T
Fst

steam

Consider the tank heating system shown in the figure.

A liquid enters the tank with a flow rate Fi and temperature of Ti where it is
heated with steam having a flow rate of Fst. Let F and T be the flow rate and
temperature of the stream leaving the tank.
 The control objective of this heater is to keep the T & V at
the desired Ts & Vs values.

 The operation of the heater is disturbed by external factors

such as changes Fi Ti.

 If nothing changed, then after attaining T=Ts and V=Vs we

could leave the system alone without any supervision and
control.
 Fi, Ti
Thermocouple

Set-point
F, T
Controller

Thermocouple Deviation is sent to

The temperature is
measures fluid control mechanism
compared with
temperature in the for temperature
desired value
tank adjustment
Notice that feed forward control does not wait
until the effects of the disturbances has been felt
by the system, but acts appropriately before the
external disturbance affects the system
anticipating what its effect will be.
 Fi, Level Measuring
Device
Ti
hs
Controller

F,
T

To keep the volume at its set point or the liquid level hs we

measure the level of the liquid in the tank and we open or
close the effluent flow rate.
 Controller

hs
Fi, Ti
Level
Measuring
Device

F, T
• For this example;
– input variables are: Fi, Ti and Fst
– output variables are: F, V and T
The input variables can be further classified into the
following categories:
1. Manipulated (or adjustable) variables, if their values can
be adjusted freely by the human operator or a control
mechanism.

2. Disturbances, if their values are not the result of

adjustment by an operator or a control system.
The output variables are also classified into the
following categories;
1. Measured output variables, if their values are known by
directly measuring them.

2. Unmeasured output variables, if they are not or cannot

be measured directly.
 For any system, definition of
manipulated and controlled variables can
only be made depending on specified
control structures.
Symbol Description
PI and PC Pressure Indicator and Pressure Controller

TI and TC Temperature Indicator and Temperature Controller

FI and FC Flow Indicator and Flow Controller

LI and LC Level Indicator and Level Controller

PAH and PAL Pressure Alarm High and Pressure Alarm Low

TAH and TAL Temperature Alarm High and Temperature Alarm Low

LAH an LAL Level Alarm High and Level Alarm Low

TIA, LIA, PIA Temperature, Flow and Pressure Indicator Alarm

 TI PI
Temperature Indicator Pressure Indicator

TC PC
Temperature Controller Pressure Controller

H
H TIA PIA
Temperature Pressure
Indicator Alarm L Indicator Alarm
L

LI FI
Level Indicator Flow Indicator

LC FC
Level Controller Flow Controller

H LIA Level Indicator

Alarm Control valve
L

Process stream Pneumatic stream

 Control Measured Manipulated Disturbances Set point
Variable Variable Variable
Liquid level in Outlet Inlet flowrate Pressure in the Specified level in
the tank Flowrate tank the tank, so as to
prevent tank
flooding (If the
level exist 90% of
set point, level
alarm will be
activated)
Focus on process

Understand behavior of individual

units

Utilize the simplest control system

Control based on design of a process