Introduction to Process
Control and Instrumentation
M. F. Baidoo
17.01.2024
Definitions
Process: The transformation of raw materials into desired product using
available feedstock and sources of energy in the most cost effective way.
Control:
1. Series of actions directed at making a system variable adhere to a reference
value.
2. Process of altering manually or automatically the performance of a system
to adhere to a desired one.
3. The design and algorithim for maintaining the output of a specific process
within a desired range.
Instrumentation:
The science of applying measuring device to monitor and control a process
variable.
Learning Outcomes
• Define some basic terminologies related to process control.
• Explain the reasons why process control is necessary.
• Categorize process control system based on the mode, time
dependence and configuration of components.
• Identify and classify process variables as input and output
variables.
• Explain how key process variables are controlled on important
unit operation in the petrochemical industries.
• Identify the hardware component of a process control systems
• Explain some challenges encountered in the implementation of
process Control.
Why Process Control?
Safety
• Safety of personnel
• Equipment safety
• Environmental safety
Product specifications
• Desired amount and quality of final products.
Environmental Regulation
• Environmental Protection Agency(EPA) have regulation concerning temperature,
concentration of chemicals and flow rates of effluents from a plant. These
regulations should be satisfied.
Why Process Control?
Operational Constraints:
• Inherent constraints in the operation of some process equipment.
Economics:
• Raw materials, energy, capital and labour should be utilized in the most cost effective
way by operating at optimum levels of minimum operating costs or maximum profit.
Preventive Maintenance:
• Variables such as the operating hours on a pump are essential for plant operators to
carry out routine maintenance operations to ensure a processing system or
component runs continuously without error.
Classification of Control Systems
Mode/ Technique for performing control action
Manual Control
A person
• takes the decision and
• effect the changes
Automatic Control
Devices are used for control (usually unattended)
• reads output variable = measurement/Sensing
• compares measured variable to set point = compares
• takes a decision: how much to change = computes
• Effect changes (manipulate variable) : decrease, increase = Adjusment
A combination of both manual and automatic (semi-automatic) is also
possible.
Classification of Control Systems (Cont.)
Time dependence of the reference value (steady/dynamic)
Regulator system: Ensure that system output remain close to
reference value regardless of the magnitude of disturbances and/or
noise.
Servo System: Ensure that the system output follow a changing
reference value in the absence of disturbances.
Classification of Control Systems (Cont.)
Fundamental Structure/Configuration of Control system:
Loop: sequence of instructions continually executed until a certain outcome is
obtained.
Open-Loop: Controller executes action without information on the
state of the system.
Any time dependent device eg. Washing machine, microwave oven.
Feedforward is another term for open loop control systems.
Feedforward Control in Chemical Engineering
Classification of Control Systems (Cont.)
Fundamental Structure/Configuration of Control system:
Closed-Loop: Controller acts based on the knowledge of the state of
the system. eg. Feedback control
Example 1: Temperature Control
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Example 2: Concentration Control
Pros & Cons of Feedforward/Open-Loop Control
Advantages of Feedback/Closed Control
Disadvantages of Feedback/Closed Control
Process Measurement and Control
Process Control mechanism begins with a measurement of
a process variable.
Process Variables
A process variable is a condition of the feedstock, product or utilities
that can change influence the outcome of a manufacturing process.
• Temperature
• Pressure
• Flow rate
• Level
• Concentration/pH
• Specific gravity/Viscosity/density
• Humidity
• Mass
• Conductivity
Classification of Process Variables
Disturbance/Load
Two main categories: Manipulated Output
PROCESS
variables variables
Input variables:
the effect of surroundings on the chemical process
Output variables:
the effect of the chemical process on the surroundings
Classification of Process Variables
Input variables
• Manipulated variables: variables or parameter or factor are adjusted to keep the
variables to be controlled at their set-points.
• Disturbances/Load: undesired change in one of the factors that can cause the
variable to be controlled to deviate from their set-points.
Output variables:
• Measured/Controlled variables: describes the condition of the process that must be
kept at the designated set-point. Their values are known by direct measurement.
Example: Continuous Stirred Tank Heater
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Hardware for Control
Process: Part of control system whose output is to be controlled. It includes the equipment
together with the physical or chemical operations that occur.
Sensors: Used to detect and measure the changes in the process variable.
Transducers: Converts a physical phenomenon into some other form of energy (electric
voltage or current, pneumatic signal etc) which can be easily transmitted.
Transmitters: It is a device that standardizes signals.
Transmission lines: connects and carries signal from one device to the other in the control
loop.
Controller: Intelligence unit that receives information from measuring devices and decides
what action to be taken.
Final Control Element: It implements the decision taken by the controller. eg. control valves
Hardware for control
Challenges of Process Control Implementation
• Nonlinear/non-stationary nature of a process
• Unavailability of accurate measurement of controlled variable
• Time delays or dead time
• Multivariable interactions
• Sensitivity to noise and disturbances
