Aditya Engineering College (A) : Process Dynamics and Control

ADITYA ENGINEERING COLLEGE (A)
PROCESS DYNAMICS AND

CONTROL
By
Dr. Anil Kumar T

Sr. Assistant Professor
Department of Petroleum Technology
Aditya Engineering College (A)
Surampalem.
Course Objectives
Ensure Quality
Enhanced process safety
Satisfying environment constraints
Energy conservation and more efficient use of raw materials
Increase profitability
Obtain a realistic understanding of industrial process control practice.
Process Dynamics and Control Dr. Anil Kumar T 12/16/21

Introduction to Process Control

Why do we need process control?
- Required to maintain safe operations, quality products and

business viability.


SAFETY
- the primary purpose of process control system.
- personnel safety, environmental safety and equipment safety.


QUALITY
- process control systems are central to maintaining product quality.


PROFIT
- when safety and quality concerns are met, process control objectives
can be focused on profit.


What is a process?
- when safety and quality concerns are met, process control objectives
can be focused on profit.


What is process control?
A process control is the act of controlling a final control element

to change the manipulated variable to maintain the process variable at
a desired set point.

The Manipulated Variable (MV) – is the measure of resource

being fed into the process, for instance how much thermal energy.
A Final Control Element (FCE) – is the device that changes the

value of the manipulated variable.


The Controller Output (CO) – is the signal from the controller to the
final control element.
The Process Variable (PV) – is a measure of the process output that

changes in response to changes in the manipulated variable.
The Set Point (SP) – is the value we wish to maintain the process
variable at.




What are the basic elements of process control?
The process itself, the sensor that measures the process value, the final
control element that changes the manipulated variable and the controller.

The process
Processes have a dynamic behavior that is determined by physical properties

which cannot be altered without making a physical change to the process.
Sensors
Measure the value of the process output called Process Variable (PV) such as
temperature, pressure, mass, flow and level.

Final control element
The physical device that receives commands from the controller that manipulate
the resource.
The controller
Provides the signal to the final element.

Design methodology for process control

1.) Understand the process. 9.) Set control limits.
2.) Identify the operating parameters. 10.) Define control logic.
3.) Identify the hazardous conditions. 11.) Create a redundancy system.
4.) Identify the measurable. 12.) Define a fail-safe.
13.) Set lead/lag criteria.
5.) Identify the points of measurement. 14.) Investigate effects of changes
6.) Select measurement methods. before/after.
7.) Select control method. 15.) Integrate and test with other systems.
8.) Select control system.

Design methodology for process control
1.) Understand the process. 8.) Select control system.
2.) Identify the operating parameters. 9.) Set control limits.
3.) Identify the hazardous conditions. 10.) Define control logic.
4.) Identify the measurable. 11.) Create a redundancy system.
12.) Define a fail-safe.
5.) Identify the points of measurement. 13.) Set lead/lag criteria.
6.) Select measurement methods. 14.) Investigate effects of changes
7.) Select control method. before/after.
15.) Integrate and test with other
systems.
• The continuous change of measurements in a chemical or biological

process leads to the conclusion that processes are dynamic.
• Process dynamics refer to an unsteady-state or transient behavior.
• Steady-state vs. unsteady-state behavior
i. Steady state: variables do not change with time
 So far, your curriculum has emphasized steady-state or equilibrium
situations.

Process Dynamics
• Only with an understanding of transient behavior of physical

systems can an engineer design good processes.
• This is exactly what process control does: it provides the expertise
needed to design plants that function well in a dynamic environment.
• Bottom Line: process control has a major impact on profitability

Examples
Continuous processes with examples of transient behavior:

i. Start up & shutdown
ii. Major disturbance: e.g., refinery during stormy or hurricane
conditions
iii. Equipment or instrument failure (e.g., pump failure)
iv. Batch Processes- Batch reactor
i. Composition changes with time

Multidisciplinary Field
Process control is used in many engineering fields:

 Chemical
 Electrical
 Mechanical

Control
The following definition of control will be used in this course:
To maintain desired conditions in a physical system by adjusting selected

variables in the system.

What does a control system do?

As an example, consider the heating system of a house.
 We need to maintain the house temperature at a certain point.

 This is done by circulating hot water through a heat exchanger.
 The temperature is determined by a thermostat that compares the value of the
room temperature to a desired range.
 If the temperature is in the desired range, the pump halts water circulation.
 The temperature can exceed the limits, because the furnace and heat exchanger
cannot respond immediately.

Common features in process control cases

• There is always a specific value (or range) as a desired value (referred to as
set point) for the controlled variable.
• The conditions of the system are measured; that is, all control systems use
sensors to measure the physical variables that are to be maintained near the
desired values.
• There is always a control calculation, or algorithm , which uses the measured
and desired values to determine the correction to the process operation.
• The results of this calculation are implemented by adjusting some item of
equipment in the system, which is termed the final control element.

Some more definitions

• Input: input does not necessarily refer to material moving into the
system. In Process Control, input denotes the effect of the
surroundings on the chemical or biochemical process.
• Output:denotes the effect of the process on the surroundings.
• Input variables cause the output variables.

Example
In the heated room example, what are:
The Input variable
The Output variable

Important terms
• Controlled variable: it is the variable that needs to be maintained or controlled at
some desired value or range. Sometimes also referred to as process variable.
• Set Point: it is the desired value of the controlled variable. Thus the job of a
control system is to maintain the controlled variable at its set point.
• Manipulated variable: is the variable used to maintain the controlled variable at

its set point.
• Disturbance: any variable that causes the controlled variable to deviate from its
set point. Also referred to as upset.

Example
• In the room heating example, what are the:
Controlled variable
Manipulated variable
Possible Disturbance variable(s)

Why is Control necessary?
Control is necessary because during its operation, a chemical

plant must satisfy several requirements imposed by its designers
and the general technical, economic, and social conditions in the
presence of ever changing external influences (disturbances). Such
requirements are the following:

Safety
• The safe operation of a chemical process is a primary requirement
for the well-being of the people in the plant and for its continued
contribution to the economic development.
• Thus the operating pressures, temperatures, concentration of

chemicals and so on should always be within allowable limits.

Production specifications
• A plant should produce the desired amounts and quality of the
final products.
• For example, we may require the production of 2 million pounds

of ethylene per day, of 99.5% purity. Therefore, a control system is
needed to ensure that the production level and the purity
specifications are satisfied.

Production specifications
Product certification procedures (e.g., ISO9000) are used to
guarantee product quality and place a large emphasis on process
control.
http://www.iso.ch/iso/en/ISOOnline.openerpage

Environmental regulations
• Various federal and state laws may specify that the temperatures,
concentrations of chemicals and flow rates of the effluents from a
plant be within certain limits.
• Such regulations exist for example on the amounts of SO2 that a

plant can eject to the atmosphere, and on the quality of the
water returned to a river or lake.

Operational constraints
• The various types of equipments used in a chemical plant have constraints inherent
to their operation. Such constraints should be satisfied throughout the operation of
a plant.
• For example, pumps must maintain a certain net positive suction head; tanks
should not overflow or go dry; distillation columns should not be flooded; the
temperature in a catalytic reactor should not exceed an upper limit since the
catalyst will be destroyed. Control systems are needed to satisfy these operational
constraints.

Economics
The operation of a plant must conform with the market
conditions, that is, the availability of raw materials and the demand
of the final products. Furthermore it should be as economical as
possible in its utilization of raw materials, energy, capital and
human labor. Thus, it is required that the operating conditions are
controlled at given optimum levels of minimum operating cost,
maximum profit and so on.

Why is control necessary?

All the previous requirements dictate the need for continuous
monitoring of the operation of a chemical plant and external
intervention (control) to guarantee the satisfaction of the operational
objectives.

How is control done
Control is accomplished through a rational arrangement of

equipment (measuring devices, valves, controllers, computers) and
human intervention (plant designers, plant operators), which
together constitute a control system.

Where is control implemented?
The short answer to this question is:

• Sensors, local indicators and valves are in the process.
• Displays of all plant variables and control calculations are in a centralized facility.

What does control engineering “engineer”?

• Most of the engineering decisions are introduced in the
following five topics:
1. Process Design
2. Measurements
3. Final elements
4. Control structure
5. Control calculations

Process Control Design

• We want to design a process that we can then control well and
easily.
• For example, we would like a chemical plant to be more
responsive.
• By responsive we mean that the controlled variable responds
quickly to adjustments in the manipulated variable.

Measurements
• A key decision is the selection and location of sensors, because one
can control only what is measured.
• The engineer should select sensors that measure important variables

rapidly and with sufficient accuracy.

Final elements
We will typically consider control valves as the final elements, with

the percentage opening of these valves determined by a signal sent to
the valve from a controller.

Control structure
• The engineer must decide some very basic issues in designing a

control system.
• For example, which valve should be manipulated to control which

measurement?

Control calculations
• After the variables and control structure have been selected,
equations are chosen that use the measurement and desired values in
calculating the manipulated variable.
• As we will see, we only need to develop a few equations that we will

then use to control many different types of plants.

Duties of a Control Engineer

• Tuning controllers for performance and reliability
• Selecting the proper PID mode and/or advanced PID options
• Control loop troubleshooting
• Multi-unit controller design
• Documentation of process control changes

Characteristics of Effective Process Control

Engineers
• Use their knowledge of the process to guide process control
applications
• Have a fundamentally sound picture of process dynamics and feedback
control
• Work effectively with the operators

Operator Acceptance
• A good relationship with the operators is a NECESSARY condition for the

success of a control engineer
• Build a relationship with the operators based on mutual respect
• Operators are a valuable source of plant experience
• A successful control project should make the operators job easier, not
harder
Process Control and Optimization

• Control and optimization are terms that are many times erroneously
interchanged
• Control has to do with adjusting flow rates to maintain the controlled

variables of the process at specified set-points
• Optimization chooses the values for key set-points such that the
process operates at the “best” economic conditions

Background needed for Process Control

• To be successful in the practice of automatic process control, the engineer must
first be familiar with the basic principles of thermodynamics, fluid flow, heat
transfer, separation process, reaction processes etc.
• Another important tool for the study and practice of process control is computer
simulation. Many of the equations developed to describe processes are nonlinear
in nature and consequently, the most exact way to solve them is by numerical
methods. The computer simulation of process models is called simulation.













Short-Tube Vertical Evaporators



THANK YOU

Aditya Engineering College (A) : Process Dynamics and Control

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Aditya Engineering College (A) : Process Dynamics and Control

Uploaded by

Copyright:

Available Formats

ADITYA ENGINEERING COLLEGE (A)

PROCESS DYNAMICS AND

Dr. Anil Kumar T

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

Introduction to Process Control

- Required to maintain safe operations, quality products and

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

Introduction to Process Control

- the primary purpose of process control system.

- personnel safety, environmental safety and equipment safety.

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

Introduction to Process Control

- process control systems are central to maintaining product quality.

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

Introduction to Process Control

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

Introduction to Process Control

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

Introduction to Process Control

A process control is the act of controlling a final control element

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

Introduction to Process Control

The Manipulated Variable (MV) – is the measure of resource

A Final Control Element (FCE) – is the device that changes the

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

Introduction to Process Control

The Process Variable (PV) – is a measure of the process output that

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

Introduction to Process Control

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

Introduction to Process Control

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

Introduction to Process Control

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

Introduction to Process Control

Processes have a dynamic behavior that is determined by physical properties

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

Introduction to Process Control

Final control element

Provides the signal to the final element.

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

Design methodology for process control

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

Introduction to Process Control

• The continuous change of measurements in a chemical or biological

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

• Only with an understanding of transient behavior of physical

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

Continuous processes with examples of transient behavior:

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

Process control is used in many engineering fields:

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

To maintain desired conditions in a physical system by adjusting selected

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

What does a control system do?

 We need to maintain the house temperature at a certain point.

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

Common features in process control cases

Process Dynamics and Control Dr. Anil Kumar T 12/16/21

Some more definitions

• Output:denotes the effect of the process on the surroundings.

• Input variables cause the output variables.

Process Dynamics and Control Dr. Anil Kumar T 12/16/21