Basics of computer aided process control

Introduction

Figure: Computer in a Plant Control

In 1950, Brown & campbell proposed use of computer in process control. In 1954, computer was used for real time in air borne application Digitrac digital computer was used

First Industrial computer control system called RW-300 (RamoWoolridge Company) was installed at Port Arthur refinery of Texaco Company in Texas which achieved closed loop in march 1959. The first direct digital control (DDC) computer system was Ferranti Argus 200 system installed in November 1962 at ICI ammonia soda plant at Fleetwood, Lancashire. 1959 1962 : The early period 1963 1974 : Centralized computer control ( Mainframe and mini computer architecture) 1975 onwards : Advent of the microprocessor and distributed computer control system.

Role of Computer in Process Control

Two major applications
Passive applications
Acquiring Monitoring Alarming Data reduction systems

Active applications
Above all and manipulation of process as well Optimization of process

Figure : Digital data acquisition

Elements of computer aided process control

Basics functions of computer aided process control
1. Measurements and data acquisition 2. Data conversion with scaling and checking 3. Data accumulation and formatting 4. Visual display 5. Comparing with limits and alarm rising 6. Recording and monitoring of events, sequences and trends 7. Data logging and computation 8. Control actions

Computer Aided Process Control

Figure: Typical computer aided process control system

Computer Aided control of hot air blower

Computer Aided control of hot air blower

Computer Aided control of hot air blower

Classification of computer aided process control 1. Batch or Sequential Process 2. Continuous control 3. Supervisory control 4. Direct Digital control .

Batch process

Figure : Chemical reactor ( batch reactor)

Classification of batch process

Based on the number of products
1. Single product batch process 2. Multi grade batch process 3. Multi product batch process

Based on the structure of the process facility

1. Serial (Single Stream) Structure batch process 2. Parallel (Multi stream) Structure batch process 3. Serial/parallel structure batch process

Structure based batch process

Complexity of batch processes

Continuous Control Processes

The production is maintained for long durations without interruptions, typically over a few months or years.

Differences between batch and continuous process

Discrete loads are fed in batch process whereas continuous loads in continuous process Each batch of material being processed can be identified easily in batch process where as it is difficult in case of continuous processes. Each batch of raw material can be processed differently in various parts of the process. Same equipment can be used for different products or different grade of products. Movement of batch from one equipment to another can occur only when the operation in that equipment is complete and the next equipment is ready to receive the material. Whereas continuous process materials flow is steadily from one equipment to the next.

Supervisory Computer control process

Three general types of optimization problems are encountered in industrial process operations
1. Operating conditions ( such as reactor temperature, reflux ratio, etc., in refinery operations) 2. Allocation, i.e., optimal distribution of a limited resource among several parallel (alternative) process units ( such as fuel use, feedstock selection, etc.) 3. Scheduling i.e., batch processing , cleaning, maintenance , relining.

Supervisory Computer control system

Direct digital control(DDC) processes

In 1962 Imperial Chemical Industries (ICI) in England replaced complete analog instrumentation for process control by Ferranti Argus computer. The computer considered 224 variables and controlled 129 valves directly. DDC is also called loop control, the functions of comparator , controller , limiting and other safe guarding operations are provided by the digital computer itself.

DDC for chemical reactor system

DDC software

DDC drawbacks
If only one processor was used , a single failure could affect a large number of controlled variables and possibly disable an entire process.

Computer aided process control architecture Centralized computer control Distributed computer control Hierarchical computer control

Centralized computer control systems

Early computer control had many limitations such as
slow magnetic drum memory, very small memory size, programming to be done in machine language which was very difficult to program, Little or no experience of the supplier and the use in computer applications Unreliable computer hardware and software, etc.

Centralized computer control systems

Use of centralized computer also suffered from problems such as Expensive requirement of large communication systems to bring the plant (field) signals to the centralized computer location and output control signals to the field devices, electrical noise problems for large distance communication of signals, Complete stoppage of plant/process in case of failure of the centralized computer system, communication system, etc,.

Distributed computer control systems

DCCS became popular as opposed to a centralized computer control system and the limitations of centralized computer control system were removed. In 1969, Honeywell company, USA, designed TDC 2000 system, a distributed computer control system as an alternative to the unwieldy and unreliable centralized computer control system.

Distributed digital control architecture

Features of Distributed computer control systems

Hierarchical computer control systems

Hierarchical computer control architecture

Tasks of computer control systems

Tasks of computer control systems

Man Machine Interface

Benefits of using computer in process control