DIPLOMA IN PALM OIL MILLING

TECHNOLOGY & MANAGEMEMT 

Basic Control Principles and System Integration

Andrew Yap Kian Chung

 Lecture Outline
 Control loop types
 Control algorithms – Proportional, Integral, Derivative
 Control approach – PLC, Fuzzy logic, Neural network
 Control protocol – HART, Profibus
 Control system architecture
 System integration
 Definition
Process control is an engineering discipline that deals with
architectures, mechanisms, and algorithms to maintain the
process output within a desired range.

The control variable is the value or parameter of the

current process status under control.

The state variable is the variable set that is used to

describe the mathematical system’s dynamic condition.
The disturbance is an external force that is unable to be
manipulated acts on the system and causes a significant
change.
Deadtime is a delay between a process variable changes
until a mitigation response can be observed.
Open-loop controllers apply a single control effort and
assume that the desired results will be achieved without
referring to any feedback information.
Closed-loop controllers repeat the measure-decide-
actuate sequence until the desired process condition is
achieved.
Feed forward Control Loop

Feedback Control Loop

Cascade Control Loop
 Control Algorithms

The main tasks in a control loop are Measurement,

Comparison, and Adjustment

A sensor is used to measure the process variable and

provide feedback to the control system.

The difference between the process variable and the set

point is used by the control system algorithm to
determine the desired actuator output.
The proportional response depends only on the
difference between the set point and the process
variable known as error, e(t). Thus u(t) = Kpe(t)
PID Controller Tuning
• Set the Integral and Derivative terms (KI and KD) to
zero and increase the Proportional gain, KP until the
loop output oscillates.

• Then increase the Integral term, KI to stop the

oscillations.

• Finally increase the Derivative term, KD until the

loop reaches the set point acceptably fast.
 Control Approach
Programmable Logic Control (PLC) involves programming
simulation to monitor the input devices’ state and make
decisions to control the output devices’ state continuously.
Human-machine interface (HMI) is needed for the control
configuration and can communicate over a network via
Supervisory Control And Data Acquisition (SCADA).
Fuzzy logic design is based on empirical methods
consisting of a fuzzification interface, fuzzy inference
engine, fuzzy rule matrix, and defuzzification interface.
Fuzzification converts input variables to fuzzy values
mapped by fuzzy sets.
Defuzzification converts fuzzy rules to control output
based on certain defined methods such as the centroid
method.
A neural network consists of many interconnected inputs
and outputs neurons with many simple and similar
processing elements each having internal parameters
known as weights. Changing the weights of an element
will alter the behavior of the element and the whole
network. Choosing the weights of the network to achieve
desired input/output relationship is known as training the
network.
 Control Protocol
 Data exchange is needed in order controller and
connected field devices to perform as required.
 Simple analog 4 – 20 mA signal is sufficient and usually
used in the simple process control loop.
 A self-governing intelligent protocol is required for
robust communication between controllers to support
complex system integration in advance control.
 Human Machine Interface (HMI) in Supervisory Control
and Data Acquisition System (SCADA) demands
protocol for controller-computer interaction
Highway Addressable Remote Transducer (HART)
Communication protocol was developed by Rosemount
Inc., in the mid-1980s.

Process Field Bus (PROFIBUS) is a standard for Fieldbus

communication in automation technology promoted by the
German department of education and research (BMBF) in
1989 and then used by Siemens.

FOUNDATION Fieldbus is an all-digital, serial, two-way

communications system that serves as the base-level
network in a plant or factory automation environment
developed and administered by the Fieldbus Foundation.
 Annunciator

I/P

Exhaust Pressure
Valve Transmitter
PT
Steam
Inlet Valve

Control Panel

Door Limit Switch

Local Control Panel

Sterilizer

Condensate
Valve

Sterilizer Control System

 PT

Steam

Steam
Make-Up
PC I/P Valve
Turbine

PT

Back Pressure Receiver / Vessel

Sterilizers

Back Pressure Control System

 Fibre

Pneumatic Actuator

FIC I/P Damper

FT

Mass Air
Flowmeter

Press #1 Press #2 Press #3

Steam Jacketed Cake Breaker

Conveyor (CBC)

Depericarper

Nuts

Depericarper Control System

 Shell

Pneumatic Actuator

FIC I/P
Damper

Nuts

Nutcrackers or
Mass Air Flowmeter
Ripple Mills

#1 #2 #3

Cracked Mixture Conveyor

Winnower

Kernel

Winnower Control System

Alarm Annunciator
Boiler No. 1

Steam Flow
Boiler No. 2
FE
102
FT
102
Drum Level

Boiler Drum
FY FY Control Panel
LT
101 102 201

LIC FY FIC
101 103 201
FT
Level Feedwater Flow 201
Controller Flow Computer Controller FE
201

Feedwater Flow
Feedwater
Control Valve

Three-Element Drum Level Control System

 Blowdown Line

Conductivity Sensor
Conductivity Controller
and
Sample Programmer

Blowdown Valve

Orifice

To Drain

Boiler Automatic Blowdown Control System

 Received FFB (By Weighbridge)

Processed FFB (By FFBWeigher )

( By MassFlowmeter ) Oil Production Kernel Production ( By Dumping Scale )

Level Sensor Level Sensor Level Sensor Level Sensor

Kernel Kernel
Oil Storage Oil Storage Bulk Bulk
Silo # 1 Silo # 2
Tank # 1 Tank # 2

Despatch Oil Despatched

Despatch Kernel
Kernel
( By MassFlowmeter )
( By Weighbridge )

Typical Mill Production Mass Balance Measurement System For Raw Materials &
Processed Products
 FFB From
Loading Ramp

M
Load Cell

Control
FFB Cage FFB Cage
Panel

Processed FFB Weighing System For Mill Using FFB Feed Conveying System For Filling
Cage
 Nut

M Weigher

Speed

Nut Silo Nut Silo

#1 #2
Control Weight
From Nut
Polishing Drum Panel

Nut Nut
Cracker Cracker

Nut Weighing System

 To Kernel
Bunker
Kernel Kernel
Silo # 1 Silo # 2

M Weigher

Weight
Control
Panel
Spped
Speed

Kernel Weighing System

 Fibre Fibre
Cyclone Cyclone
No. 1 No. 2

Bucket
Elevator

M
Fuel To Next Boiler
Weigher

Fibre To
Excess Boiler
Shell Fibre
Flowrate

Fibre Storage
Conveyor
Control Boiler Steam
Panel Pressure

M Inv

Fibre Feeding Control System

 Dry Shell

Boiler Steam
Fuel Flowrate Pressure

Low Level
Shell Hopper Switch
Conveyor
Ls Control
Panel

Inv M

Shell To Boiler

Shell Hopper Feeding Control System

 Excess Fruits Recycle
Auto-feeder

Variable
Level Level Sensor Level Sensor Drive
Flow Sensor
Detector VD
Max Max Max

Load M Thresher
Excess Digester Digester Digester
Fruitlets No. 3 No. 2 No. 1
Recycle Fruitlets

M M M

Load Load Load

Fruitlets Elevator
Control
Panel

Thresher Feed Control System

Automation objectives are

- improve efficiency, reduce the production cost

- improve product quality, reduce variability

- improve safety standards, avoid the accident

The degree of automation required for a particular plant is
governed by
 

- the process throughput for cost-efficient

- the process complexity

- the process conditions (dirty, dangerous, difficult)

- plant utilization requirements

 System Integration

The present automation approach is mostly on a stand-

alone basis without any integration with others.  

The primary objective of the Plant-wide Automatic Control

System (PACS) is to achieve the concept of a central
control room operation for the entire palm oil mill.

Automation Technology and Information Communication

Technology (ICT) are combined to provide a total solution
for comprehensive palm oil mills requirements.
Distributed Control System (DCS) is an ideal solution for
system integration where multiple controllers could be
operated as one across multiple operation units, plants,
and facilities in geographically distributed locations
across the enterprise.
Hierarchy control approaches such as Integrated System
Optimization and Parameter Estimation (ISOPE) has
been used in the system design and evaluation.
 Automation Approaches

Enterprise Resource
5
Planning (ERP) Level
Corporate

4 Management
Control Level
Plant
Visualization

3 Production
Control Level
Area/Host

2 Supervisory
Control Level
Cell

Plant Floor /
1
Operational Level
Machinery / Process Control

Automation Hierarchy
 Central Control Room
Headquarters

- Production Information
- Production Information System System
Main Control
- Monitoring and Control System Panel c/w - Monitoring System
- Maintenance / Asset Management System Master PLC CC
P M
UM

Remote Control
Telephone Line
RCP No. 1 RCP No. 2 RCP No. 3 RCP No. 4 RCP No. 5 Panel (RCP) No. 6
c/w PLC

Mill Office

Reception Sterilization Threshing & Depericarper & Clarification Boiler Station &
Station Station Pressing Stations Kernel Station Power Room
(Loading Ramp) Recovery Stations (Oil Room)
- Production Information System
- Monitoring and Control System
- Inventory Control System
- Maintenance / Asset Management System
Ethernet LAN

Workshop Store Weighbridge Station Laboratory Station

- Inventory Control System Weighbridge System Laboratory System

- Maintenance / Asset Management System

Architecture / System Configuration Layout for Plant-wide Automatic Control System

Schematic diagram for Hierarchical Distributed Control System
Production Information System Monitoring And Control System

Plant Maintenance System

Inventory System

Basic Components of Plantwide Automatic Control System (PACS)