Process Control

&
Automation
If you have a smart project, you can say "I'm an engineer“

Staff boarder
Dr. Mostafa Elsayed Abdelmonem
 Process Control & Automation
 Course aims:
 Understand the basic process modeling, Understand of feedback,
feedforward control strategies
 Develop dynamic models for processes and solve them
 Obtain a realistic understanding of industrial process control practice
 Create and innovate the real model to simulate the some cases

 References

• William L Luyben (1996). Process modeling, simulation and control for chemical engineers. McGraw-Hill . (Ref-01)
• Dale E. Seborg, Thomas F. Edgar, and Duncan A. Mellichamp (2006). Process dynamics & control. Wiley. (Ref-02)
• Curtis D. Johnson. (2014). Process control and instrumentation technology. Pearson. (Ref-03)
• George Stephanopoulos (2014). Chemical process control. Prentice-Hall (Ref-04)
week Date Contents Requirements Laboratory References Marks
1 3-10 Syllable/Course specs
Introduction of process Control system
2 10-10 System Modeling, process description
control specifications and connections.

3 17-10 System Modeling, process description

Course plan
control specifications and connections. Ref-01

4 24-10 Process dynamic Response Electrical- 5/3

Ref-02
mechanical analogy quizes
5 31-10 Process Flow Diagram (PFD)
Piping and instrumentation Diagrams
6 7-11 Industrial Sensors and Actuators Sensor and
instrumentation
7 14-11 Industrial Sensors and Actuators 5/3
quizes
8 21-11 Midterm 15
week Date Contents Requirements Laboratory References Marks

9 28-11 Frequency Response and Filters

Bode Plot
10 5-12 Design Controller and
system compensation
11 12-12 PID and controller Filling process _Kit
Design

12
Course plan
19-12 PID and controller
Design
Reports
(instrumentation
Ref-03
5

in Labview )
13 26-12 SCADA system or HMI Quiz Filling process _Kit 5/3 quizes
14 26-12 SCADA system or HMI Ref-03
DCS system
Receive project 10 for exam
20 for
project
 Evaluation rules

Report Contents
• Research plane Marks distribution
• Aim
• Tools/facilities Marks \ Assessments Final Total
• Methodology/control strategy assessments Exam
• Experimental works • Midterm 20
• Result/ conclusions
• Practical & Projects 25
40
• Report and assignment 10
• quizzes 5
TOTAL 60 40 100
Control concept
 The Process

The Closed Coldwater

Control Loop In

Computation Comparison

Steam
Valve
Correction

Steam
Input Measurement

Hot Water
Output

The Controller
 Definition (1)
 Process

 A series of interrelated actions which transform material

It covers all resources that are involved in the process and talks about process “inputs” (e.g.

resources, raw material) and “outputs” (e.g. finished product)

Energies Out
Raw Materials Products
Process

Energies Out
 Control

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 To maintain desired conditions in a physical system by adjusting selected variables in the system
 Definition (2)
 Process Control
 To maintain desired conditions in a physical system by adjusting selected variables in
the system in spite of disturbances affecting the system and observation noise

Corrective Action Process

Data
Knowledge
9
Information
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

 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.
 Consider a house in a
cold climate which is to
be maintained near a
desired temperature by
circulating hot water
through a heat exchanger

•Temperature of the room is determined by a thermostat

•This temperature is compared with the desired temperature or range of
temperature
•If the temperature is below than the desired, the furnace and the pump are
turned on; if the temperature is above the furnace and pump are turned off.
 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.
 Desired value

Controller

Final Control Measuring

Element
Element

Process

inputs outputs
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.

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.
Elements of Process Control Loop
 Sensor
 Measure process variable
 Transmitter
 Convert the measured process variable into standard signal
 Controller
 Drive actuator by giving an appropriate controller output signal
 Actuator
 Adjust manipulated variable based on the value of the controller output signal
 Process
 Physical system to be controlled

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 Daylife Example: Driving a Car
 Control Objective (Setpoint):
 Maintain car in proper lane
Brain: Eyes:
 Controlled variable: Control Sensor
 Location on the road calculation
 Manipulated variable:
 Orientation of the front wheels

 Actuator:
 Steering wheel

 Sensor:
 Driver’s eyes

 Controller:
 Driver Steering wheel:
 Disturbance: Actuator
 Curve in road

19 Noise:
 Rain, fog
Industrial Example #1: Heat Exchanger
 Control Objective (Setpoint):
 Maintain temperature
 Controlled variable:
 Outlet temperature of product stream
Product
 Manipulated variable: Stream TC Steam
 Steam flow
TT
 Actuator:
 Control valve on steam line
 Sensor:
 Thermocouple on product stream
 Controller: Feed Condensate

 Temperature controller
 Disturbance:
 Changes in the inlet feed temperature

20 Noise:
 Measurement noise
Industrial Example #2: Liquid Level Control
 Control Objective (Setpoint):
 Maintain level
 Controlled variable:
 Fluid level in the tank Fluid
 Manipulated variable:
 Fluid flow
 Actuator:
 Control valve on fluid line
LC
 Sensor:
 Level transmitter on the tank
 Controller:
LT
 Level controller
 Disturbance:
 Changes in the inlet feed flow

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Noise:
 Measurement noise
 In standard Drawing:
• all process equipment is drown in solid lines

• sensors are designated by a circle connected to the point

in the process where they are located

• process control loops are shown by dashed lines.

 The first letter in the A analyzer
instrumentation symbol indicates
F Flow rate
the type of variable measured
L Level of liquid or solid
 The subsequent letter(s) give
P Pressure
information about the function
T temperature
performed.
Goal of Process Operation
24 hours process operation?
Hmm… I think, to achieve those,
we need to continuously monitor
 Safety & Reliability & control the process
24 hours a day,
7 days a week!!!
 Product Specification
 Environmental Regulation
 Operating Constraint
 Efficiency
 Maximum profit

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Safety and Reliability
 The control system must provide safe operation

 Alarms, safety constraint control, start-up and shutdown

 A control system must be able to “absorb” a variety of disturbances

and keep the process in a good operating region

 Feed composition upsets, temporary loss of utilities (e.g., steam

supply), day to night variation in the process

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 Product Specification
 Quality

 Products with reduced variability

 For many cases, reduced variability products are in high demand and have high value added (e.g.
feedstocks for polymers)
Old Controller New Controller

Concentration
Concentration
Limit Limit

Impurity
Impurity

Time Time

 Product certification procedures (e.g., ISO 9000) are used to guarantee product
quality
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and place a large emphasis on process control
 Environmental Regulation

 Various government laws may specify that the temperatures, concentrations

of chemicals, and flow rates of the effluents from a process be within
certain limit

Examples:

 Regulations on the amounts of SO2 that a process can eject to the atmosphere, and on the
quality of water returned to a river or a lake

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 Operational Constraint

 All real process have constrained inherent to their operation which

should be satisfied throughout the operation
Examples:
 Tank should not overflow or go dry

 Distillation column should not be flooded

 Catalytic reactor temperature should not exceed an upper limit since the catalyst will be
destroyed

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 Efficiency
 The operation of a process should be as economical
as possible in utilization of raw material, energy
and capital

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Tutorial
# Course material
•http://52.174.38.133/login/index.php

•http://www.bu.edu.eg/staff/mustafaabdelmonem3-courses/13958

# contacts
•[email protected]