Design of a basic
process control
system
Pham Hoang Huy Phuoc Loi
Methods for Control System
Design
• Design by Analysis:
• Mathematical approach for complex unit operations.
• Design by Intuition:
• Combines practical experience and observation.
→ Design by intuition for this chapter.
Steps in Control System Design
1. Select the parameter to control and the sensor's location.
2. Identify the manipulated stream or actuator.
3. Determine the set point.
4. Build the control loop.
Selecting the Parameter to Control
• Inventory control: Pressure for gas vessels; level for liquids.
• Temperature control: For heat transfer operations.
• Composition control:
• Rare due to unreliable sensors.
• Used for equipment affecting composition changes.
• Flow rate control:
• Common in piping systems.
• Locates control loops near fluid movers.
• Note:
• Controlling a container as part of/inside the unit operation and unit process involves inventory
control
• Always control the pressure for unit operations and process units whose function depends on
pressure (e.g., flash drums, two-phase flow separators, hydrocyclones).
Sensor Location Guidelines
Parameter Sensor on Examples
Non-flooded containers
Level Tanks, vessels
with liquids
Gas containers or Compressors, gas
Pressure
pipelines streams
Pumps, compressors,
Flow Rate Piping near fluid movers
fans
Areas with temperature Heat exchangers,
Temperature
change furnaces, boilers
Locations with a change Reactors, unit
Composition
in chemical composition operations
Examples
of sensor
location
Feedback control loop
Single-input/single-output feedback control loop
Corrective actions: Taking corrective action after upset
propagated, to eliminate the error after occurrence
Feedback control loop
• Advantages:
• Simplicity: Easy to design, install, and operate.
• Most Popular Choice: Typically the first option considered.
• Suitable for Simple Control Applications:
• Examples: Pressure control, liquid level control, etc.
• Disadvantages:
• Not Ideal for Complex Control Applications:
• Unsuitable for scenarios with frequent disturbances.
• Ineffective when there is a long delay between the appearance of
disturbances and their impact on the controlled variable (e.g., several
minutes).
Cascade control loops
Cascade control loops
Single-input/single-output
feedback control loop
The steam flow rate/pressure to
this device frequently fluctuates
Cascade control loops
Cascade control loops
When to Use Cascade Control Architecture?
•When simpler methods (e.g., conventional feedback
control loop) fail to meet performance requirements.
•When the flow rate or input pressure of the controlled
variable (typically a utility stream) fluctuates frequently.
•When it is possible to control one variable (e.g.,
composition) by regulating another variable (e.g., reaction
temperature).
Cascade control loops
Single-input/single-output
feedback control loop
The hot oil flow to this
equipment frequently varies
Cascade control loops
Cascade control loops
Remote setpoint
Cascade control loops
Feedforward control
"Proactive mode": Taking corrective action before upset
propagated. It “predicts” the disturbance and proactively takes
action to prevent it. It prevents error before occurrence
Feedback vs. Feedforward control
Feedback
Feedforward
Combined Feedback / Feedforward control
Combined Feedback / Feedforward control
Combined Feedback / Feedforward control
Ratio control
Ratio Control
•Purpose: Used to
maintain a constant
ratio between the
flow rates of input
streams entering a
device (e.g., reactor,
mixer, etc.).
•Setpoint: The
setpoint in ratio
control represents
the desired ratio
between the flow
rates of the input
streams.
Ratio control
Method 1 Method 2
Example 1
Example 2
Example 3
Example 4
Distillation column – Preheat train
Example 5
Comment:
temperature-to-flow
cascade control loop
Distillation column
– Overhead system
Example 6
Distillation column
– Bottom section
Kettle reboiler,
Ex-705, utilizes a
natural circulation
feed system