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
Level containers with Tanks, vessels
liquids
Gas containers or Compressors, gas
Pressure
pipelines streams
Piping near fluid Pumps,
Flow Rate
movers compressors, fans
Areas with Heat exchangers,
Temperature
temperature change furnaces, boilers
Locations with a
Reactors, unit
Composition change in chemical
operations
composition
Example
s 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
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