1.1.

1 CE 560 – INSTRUMENTATION & PROCESS CONTROL (FULL CREDIT)

Assessment: Written examination (60%); Continuous Assessment (40%).

1.1.2 Objective

To equip students with in-depth knowledge on instruments and control principles relevant for
effective design and operation of control systems for process and allied industries such as the
mineral processing industries.

1.1.3 Course Outline

1.0 Instrumentation; Instrument characteristics: 1.1 Accuracy 1.2 Precision 1.3

Reproducibility 1.4 Sensitivity 1.6 Offset 1.7 Hysteresis 1.8 Resolution 1.8 Repeatability 1.9
Linearity 1.10 Pressure measurement 1.10.1 Brief review of manometers 1.10.2 Gauges:
Capsules and bellows, Bourdon tubes, Piezoelectric, Capacitive, 1.10.3 Vacuum pressure
instruments: Pirani gauge, Ionisation gauges, 1.10.4 Selection, calibration and installation of
pressure gauges. 1.11 Level measurement: Direct level sensing, Conductive probes,
capacitive probes, indirect level sensing, Resistive tapes, load cells, Radiation methods 1.11.1
Application considerations 1.12 Flow measurement: brief review of venturi, orifice and nozzle
flow meters, pilot static tube and rotameters 1.12.1 moving vane, vortex, magnetic and strain
gain flow meters, dry particulate and slurry flow measurement 1.12.2 Brief review of open
channel flow measurement 1.12.3 application considerations 1.13 Temperature and heat
measurement: Brief review of liquid-in-glass and bimetallic thermometers, Resistance
temperature devices (RTD), thermistors, Thermocouples, semiconductors temperature
sensors, application considerations 1.14 Humidity measurement, density, viscosity and pH
1.15 composition measurement.
*May or may be covered

2.0 Introduction to process control; 1.1 Process variables 1.2 Input variable 1.4 Output
variables 1.5 Manipulated -Adjustable variables 1.6 Disturbances 1.7 Measured variables 1.8
Unmeasured variables 1.9 Measurement of process variables 1.10 Elements of a Control
system 2.0 The process; 2.1 Measuring instruments/sensors 2.2 Transducers 2.3
Transmission lines 2.4 The controller 2.5 The final control element 2.6 Recording elements
3.0 Types of control configurations; 3.1 Feed forward control systems 3.2 Feed Back
control systems 3.3 Inferential Control Configuration 3.4 SISO and MIMO control systems 4.0
Control modes and controllers; 4.1 on-off control 4.2 Proportional control 4.3 Proportional-
integral control 4.4 Cascade control 4.5 Direct digital control 4.6 Controller tuning 4.7
Decentralized and centralized control 5.0 Block diagram representation of a control
system; 5.1 Standard Block diagram of a control system 5.2 Transfer functions 5.3 Block
diagram algebra 6.0 Modeling for process control; 6.1 Introduction to process modelling
6.2 Experimental and theoretical approaches to modelling 6.3 Some process models; 6.3.1
Measuring Element –Thermometer/Thermocouple 6.3.2 Stirred tank heater 6.3.3 Mixing
process 6.3.4 Tubular heat exchanger 7.0 Tools for analysing the dynamic behavior of a
Chemical process; 7.1 Computer simulations 7.2 Numerical solutions of algebraic equations
7.3 Numerical integration of differential equations 7.4 Linearization; 7.4.1 Systems with one
variable 7.4.2 Systems with many variables 7.5 Laplace transforms; 7.5.1 Laplace transforms
of some basic functions 7.5.2 Ramp function 7.5.3 Translated function 7.5.4 Unit
pulse/impulse 7.5.5 Transforms of derivatives and Integrals 7.5.6 Final value theorem/ initial
value theorem 7.5.7 Solution of some process models by Laplace transform 7.5.8 Transfer
function development 8.0 Dynamic behavior of first order systems; 8.1 Open loop response
of first order systems to some common disturbances 8.2 Physical examples of first order
systems 8.3 Application of linearization to first order systems 8.3 First order systems in series;
8.3.1 Open loop Interacting responses 8.3.2 Open loop non-interacting responses 9.0
Dynamic behavior of higher order systems; 9.1 Open loop response of second order
systems to some common disturbances 9.1.1 Step response 9.1.2 Terms used to describe
the response of an under dumped open loop system 10.0 Stability Analysis; 10.1 Stability
criterion 10.2 Ruth test for process stability 10.3 Root locus 10.4 Nyquist stability criteria of
process systems 11.0 Frequency Response; 11.1 Bode plots 11.2 Polar plots

1.1.4 Recommended Textbooks

1. Coughanowr D.R., (1991). Process Systems Analysis and Control. McGraw-Hill, Inc: New
York.

2. Stephanopoulos G. (1984). Chemical Process Control: An Introduction to the Theory &

Practice. Prentice Hall: New Jersey.

3. Smith C. A. & Corripio, A. B. (1985). Principles and Practice of Automatic Process Control,
John Wiley, 1985.

4. Curtis D. J. (2003). Process Control Instrumentation Technology, Pearson Education.

5. William C. D. (2006), Introduction to Instrumentation, Sensors, and Process Control,

Artech House, Inc.