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PROCESS
DYNAMIC
AND
CONTROL

How to design a
control system Source: http://www.sdnito.com/en

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 2 Students should be able to
• ask necessary questions
CLASS for developing a control
system.
OBJECTIVES • determine possible
control objectives, input
and output variables, and
constraints.
• assess the importance of
process control from
safety, environmental
and economics point of
view
Although the
specific control
objectives vary
SAFETY STABLE PLANT PRODUCT
OPERATION SPECIFICATIONS AND

from plant to
PRODUCTION RATE

plant, there are a

number of
general
requirements: ENVIRONMENTAL
REGULATIONS
ECONOMIC PLANT
OPERATION
 • The most widely used process control
Steps of strategy is multi-loop control.

Control • A multi-loop control system consists of a set

System of PI, PID controllers, one for each
controlled variable.
Design
 • The key design decision for multi-
Steps of loop control is to determine an
Control appropriate control structure, that
System is, to find a suitable pairing of
controlled and manipulated
Design variables.
 Formulate control objective (s)
• What are the control objectives ?
The first step • …………………..
of developing • …………………..
a control • ………………….
strategy is to
Typically they are dependent on the
process boundary.
 After the control objectives have been
formulated, the control system can be
Steps of designed. The second step is to identify:
Control System • Select input variables: manipulated and
disturbance variables
Design
• Select output variables: measured and
unmeasured variables
 • Input Variables :- effect of the
Classification of the surroundings on the chemical process
Variables in Chemical
Process Control
System • Output Variables:- effect of the process
on the surroundings
 Input
• Manipulated (or adjustable) variables
variables • they can be adjusted freely by the human
operator or a control mechanism.

Effect of the
• Disturbances
surroundings on • their values are not the result of adjustment
the chemical by an operator or a control system.
process
 F(t), Ti(t) Mt

What are the F(t), T(t)

input variables? Q(t)

(8)

Which one is manipulated variable?

Which one can be disturbance variable?
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Pressure vessel Process variables are:
P, V, R, T, F, L,W,MW

PT PC

 
P, V,
F
T

L
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Pressure vessel Process variables are:
P, V, R, T, F, L,W,MW

PT PC

 
P, V,
F
T

Constants are: MW, R, V, T

Assume: Isothermal system
L
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Pressure vessel Process variables are:
P, V, R, T, F, L,W,MW

PT PC

 
P, V,
F
T

What are the inputs and outputs?

L
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Pressure vessel Process variables are:
P, V, R, T, F, L,W,MW

PT PC

 
P, V,
F
T
Inputs are W, F
Output is P, L

L
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 After selecting the control structure, control
algorithm or controller type has to choose for
Steps of taking action during the controller correction.

Control The most widely used process control strategy is

System multi-loop control.

Design A multi-loop control system consists of a set of PI,

PID controllers, one for each controlled variable.

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 Typical types of control algorithm or controller
are
Steps of • On/Off controller
• PID controller
Control • Model based controller
System • Fuzzy logic controller
• etc.
Design

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 The most popular control algorithm or controller
in industries are:
Steps of • On/Off controller
Control • PID controller
System • Proportional controller
• Proportional integral controller
Design • Proportional integral derivative controller

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Controller algorithm / PID controller

CO = Controller output

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Controller algorithm / PID controller

Proportional Controller

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Proportional action
Controlled Variable

Setpoint
{ysp(t)-y(t)}

0 t Time

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PID controller

Integral Controller

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Integral action
Controlled Variable

Setpoint

= shade area

0 t Time
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PID controller

Derivative Controller

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Controlled Variable
Magnify

Setpoint

{ysp(t)-ym(t)}

0 t Time

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Derivative action

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 • Proportional controller uses current data for
decision making
Data for each • Integral controller uses past till present data for
mode decision making
• Derivative controller uses future data for
decision making

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 Which variable will be kept constant?
1. Level
Design 2. Temperature
control 3. Pressure

objectives 4. Concentration
5. Flow

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Selection of Guideline 1
Controlled • All variables that are not self regulating must be
controlled.
Variables

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Which one is self-regulating system?

Fi
If Fi changes,
how h will be changed.

h
F

• F is the function of the liquid height.

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Which one is self-regulating system?

Fi
If Fi changes,
how h will be changed.

F
h

• F has constant flow rate.

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 Guideline 1
Selection of • Choose output variables that must be kept
Controlled within equipment and operating constraints.
• Select output variables that represent a direct
Variables measure of product quality (composition), or
conditions strongly affecting it (T, P).

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Selection of Guideline 2
• Choose output variables that seriously interact
Controlled with other controlled variables such as steam
header pressure is affected the pressure of
Variables downstream units

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Selection of Guideline 2
• Choose output variables that have favorable
Controlled dynamic and static characteristics.
• Variable that has large time delay or insensitive
Variables to manipulated variables are poor choices.

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 Selection of Guideline 3
• Choose input variables that have the large
Manipulated impact on controlled variables.
• Choose input variables that rapidly affect the
Variables controlled variables.

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 Guideline 3
Selection of • The manipulated variables should affect the
Manipulated controlled variables directly rather than
indirectly.
Variables • Avoid recycling of disturbances (prefer not to
manipulate an inlet stream or recycle stream.)

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 Guideline 4

Selection of • Reliable, accurate measurements are essential

for good control
Measured • Select measurement points that have an
adequate degree of sensitivity
Variables • Select measurement points that minimize time
delays and time constants.

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 Besides the guideline 4, the following issue has to
Selection of be considered as well:
• The availability of the sensor
Measured • Its operating range
Variables • Its response time
• Its cost

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 After that: we have to realize
Steps of • operating constraints such as:
Control • hard constraints: max or min flow
System rate
• soft constraints: product
Design composition

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Steps of What are the operating characteristics of the
considered process?
Control • Continuous
System • Batch
Design • Semibatch

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Steps of Safety, environmental, and economic
considerations are all important.
Control • Economics is the driving force
System • Unsafe and environmentally
hazardous process will cost more to
Design operate

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 • Define control objective
Steps of
• Select controlled variable
Control • Select manipulated variable
System • Identify measured variable
Design • Choose control configuration

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