Group-1 Introduction ChE-5202

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BATANGAS STATE UNIVERSITY

College of Engineering, Architecture & Fine Arts


Gov. Pablo Borbon Campus II, Alangilan, Batangas City, Philippines 4200
www.batstate-u.edu.ph Telefax: (043) 300-4404 locs. 106-118

CHEMICAL AND FOOD ENGINEERING DEPARTMENT

ChE 529
Process Dynamics and Control

Introduction To Process Dynamics


And Control

GROUP 1

Aguila, Lois Anne M.

Clerigo, Aikovin O.

De Torres, Grazielle Anne C.

Del Mundo, Zoren A.

Rivera, Feanne Aveline I.

Engr. Naneth J. Aguado

Instructor

January 28, 2020


Objectives:

 To give an overview of process dynamics and control


 To learn about process control systems
 To know the objective of Process Control
 To learn the Design Aspects of Process Control
 To learn the General Requirements of a Control System

I. WHAT IS A CONTROL SYSTEM?

Industrial processes are central to the chemical engineering discipline. Generally,


processes are controlled in order to do things such as maximize safety, minimize cost, or
limit effects on the environment.

Control engineering is an engineering science that is used in many engineering


disciplines—for example, chemical, electrical, and mechanical engineering—and it is
applied to a wide range of physical systems from electrical circuits to guided missiles to
robots.

Process dynamics determine how a process responds during transient conditions,


such as plant start-ups and shutdowns, grade changes, and unusual disturbances.
Transient operation occurs during important situations such as start-ups and shutdowns,
unusual process disturbances, and planned transitions from one product grade to another.

Process control enables the process to be maintained at the desired operating


conditions, safely and efficiently, while satisfying environmental and product quality
requirements.

It is a mixture between the statistics and engineering discipline that deals with the
mechanism, architectures, and algorithms for controlling a process. Some examples of
controlled processes are:

1. Controlling the temperature of a water stream by controlling the amount


of steam added to the shell of a heat exchanger.
2. Operating a jacketed reactor isothermally by controlling the mixture of
cold water and steam that flows through the jacket of a jacketed reactor.
3. Maintaining a set ratio of reactants to be added to a reactor by controlling
their flow rates.
4. Controlling the height of fluid in a tank to ensure that it does not
overflow.

The traditional role of process control in industrial operations was to contribute to


safety, minimized environmental impact, and optimize processes by maintaining process
variable near the desired values.

Generally, anything that requires continuous monitoring of an operation involves the


role of a process engineer. The task of engineers is to design, construct, and operate a
physical system to behave in a desired manner, and an essential element of this activity is
sustained maintenance of the system at the desired conditions—which is process control
engineering.
II. OBJECTIVE OF PROCESS CONTROL

The primary objective of process control is to maintain a process at the desired


operating conditions, safely and efficiently, while satisfying environmental and product
quality requirements.

A control system is required to perform either one or both task:

1. Maintain the process at the operational conditions and set points

Many processes should work at steady state conditions or in a state in which it


satisfies all the benefits for a company such as budget, yield, safety, and other quality
objectives. In many real-life situations, a process may not always remain static under
these conditions and therefore can cause substantial losses to the process.

One of the ways a process can wander away from these conditions is by the system
becoming unstable, meaning process variables oscillate from its physical boundaries
over a limited time span. An example of this would be a water tank in a heating and
cooling process without any drainage and is being constantly filled with water. The water
level in the tank will continue to rise and eventually overflow. This uncontrolled system
can be controlled simply by adding control valves and level sensors in the tank that can
tell the engineer or technician the level of water in the tank.

Another way a process can stray away from steady state conditions can be due to
various changes in the environmental conditions, such as composition of a feed,
temperature conditions, or flow rate.

2. Transition the process from one operational condition to another

In real-life situations, engineers may change the process operational conditions for a
variety of different reasons, such as customer specifications or environment
specifications. Although, transitioning a process from one operational condition to
another can be detrimental to a process, it also can be beneficial depending on the
company and consumer demands.

Examples of why a process may be moved from one operational set point to another:

Economics
Product specifications Consumer/Customer specifications
Operational constraints Environmental regulations
Environmental regulations Safety precautions

III. DESIGN ASPECTS OF PROCESS CONTROL

1. Understand the process.


Before attempting to control a process it is necessary to understand how the process
works and what it does.

2. Identify the operating parameters.


Once the process is well understood, operating parameters such as temperatures,
pressures, flow rates, and other variables specific to the process must be identified for
its control.
3. Identify the hazardous conditions.
In order to maintain a safe and hazard-free facility, variables that may cause safety
concerns must be identified and may require additional control.

4. Identify the measurable.


It is important to identify the measurables that correspond with the operating
parameters in order to control the process.

Measurables for process systems include:


Temperature Viscosity
Pressure Conductivity
Flow rate Turbidity
pH Redox/potential
Humidity Electrical behavior
Level Flammability
Concentration

5. Identify the points of measurement.


Once the measurables are identified, it is important locate where they will be
measured so that the system can be accurately controlled.

6. Select measurement methods.


Selecting the proper type of measurement device specific to the process will ensure
that the most accurate, stable, and cost-effective method is chosen. There are several
different signal types that can detect different things.

SIGNAL TYPES
Electric Radiowaves
Pneumatic Infrared (IR)
Light Nuclear

7. Select control method.


In order to control the operating parameters, the proper control method is vital to
control the process effectively. On/off is one control method and the other is
continuous control. Continuous control involves Proportional (P), Integral (I), and
Derivative (D) methods or some combination of those three.

8. Select control system.


Choosing between a local or distributed control system that fits well with the process
effects both the cost and efficacy of the overall control.

9. Set control limits.


Understanding the operating parameters allows the ability to define the limits of the
measurable parameters in the control system.

10. Define control logic.


Choosing between feed-forward, feed-backward, cascade, ratio, or other control logic
is a necessary decision based on the specific design and safety parameters of the
system.
11. Create a redundancy system.
Even the best control system will have failure points; therefore it is important to
design a redundancy system to avoid catastrophic failures by having back-up controls
in place.

12. Define a fail-safe.


Fail-safes allow a system to return to a safe state after a breakdown of the control.
This fail-safe allows the process to avoid hazardous conditions that may otherwise
occur.

13. Set lead/lag criteria.


Depending on the control logic used in the process, there may be lag times associated
with the measurement of the operating parameters. Setting lead/lag times
compensates for this effect and allow for accurate control.

14. Investigate effects of changes before/after.


By investigating changes made by implementing the control system, unforeseen
problems can be identified and corrected before they create hazardous conditions in
the facility.

15. Integrate and test with other systems.


The proper integration of a new control system with existing process systems avoids
conflicts between multiple systems.

References:
Seborg et al. (2004). Process Dynamics and Control. Wiley.
Woolf, P. (2009). Chemical Process Dynamics and Controls. Independent Publisher.

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