ICE401: PROCESS INSTRUMENTATION

AND CONTROL

Class 1: Need for Process Control &

Process Terminology

Dr. S. Meenatchisundaram
Email: [email protected]

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Introduction:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Introduction:
Process controls 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:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Introduction:
Process controls 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:

Controlling the temperature of a water stream by controlling the
amount of steam added to the shell of a heat exchanger.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Introduction:
Process controls 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:

Controlling the temperature of a water stream by controlling the
amount of steam added to the shell of a heat exchanger.

Operating a jacketed reactor isothermally by controlling the
mixture of cold water and steam that flows through the jacket of a
jacketed reactor.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Introduction:
Process controls 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:

Controlling the temperature of a water stream by controlling the
amount of steam added to the shell of a heat exchanger.

Operating a jacketed reactor isothermally by controlling the
mixture of cold water and steam that flows through the jacket of a
jacketed reactor.

Maintaining a set ratio of reactants to be added to a reactor by
controlling their flow rates.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Introduction:
Process controls 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:

Controlling the temperature of a water stream by controlling the
amount of steam added to the shell of a heat exchanger.

Operating a jacketed reactor isothermally by controlling the
mixture of cold water and steam that flows through the jacket of a
jacketed reactor.

Maintaining a set ratio of reactants to be added to a reactor by
controlling their flow rates.

Controlling the height of fluid in a tank to ensure that it does not
overflow.
Process Instrumentation and Control (ICE 401)
Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Process Control Background:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Process Control Background:

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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Process Control Background:

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 involve the role of a process engineer.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Process Control Background:

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 involve the role of a process engineer.

In years past the monitoring of these processes was done at the
unit and were maintained locally by operator and engineers.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Process Control Background:

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 involve the role of a process engineer.

In years past the monitoring of these processes was done at the
unit and were maintained locally by operator and engineers.

Today many chemical / process plants have gone to full
automation, which means that engineers and operators are helped
by DCS that communicates with the instruments in the field.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Benefits of Process Control:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Benefits of Process Control:

The benefits of controlling or automating process are in a number
of distinct area in the operation of a unit or chemical plant.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Benefits of Process Control:

The benefits of controlling or automating process are in a number
of distinct area in the operation of a unit or chemical plant.

Safety of workers and the community around a plant is probably
concern number one or should be for most engineers as they
begin to design their processes.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Benefits of Process Control:

The benefits of controlling or automating process are in a number
of distinct area in the operation of a unit or chemical plant.

Safety of workers and the community around a plant is probably
concern number one or should be for most engineers as they
begin to design their processes.

Chemical plants have a great potential to do severe damage if
something goes wrong and it is inherent the setup of process
control to set boundaries on specific unit so that they don’t injure
or kill workers or individuals in the community.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Objectives of Control:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Objectives of Control:
1. Maintain the process at the operational conditions and set
points:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Objectives of Control:
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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Objectives of Control:
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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Objectives of Control:
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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Objectives of Control:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Objectives of Control:

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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Objectives of Control:

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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Objectives of Control:

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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Objectives of Control:

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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Objectives of Control:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Objectives of Control:
2. Transition the process from one operational condition to
another:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Objectives of Control:
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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Objectives of Control:
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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Objectives of Control:
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:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Objectives of Control:
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:
1. Economics, 2. Product specifications, 3. Operational
constraints, 4. Environmental regulations, 5. Consumer /
Customer specifications, 6. Environmental regulations, 7. Safety
precautions.
Process Instrumentation and Control (ICE 401)
Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Definitions and Terminology:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Definitions and Terminology:
In controlling a process there exist two types of classes of variables.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Definitions and Terminology:
In controlling a process there exist two types of classes of variables.
1. Input Variable – This variable shows the effect of the
surroundings on the process. It normally refers to those factors
that influence the process. An example of this would be the flow
rate of the steam through a heat exchanger that would change the
amount of energy put into the process. There are effects of the
surrounding that are controllable and some that are not. These are
broken down into two types of inputs.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Definitions and Terminology:
In controlling a process there exist two types of classes of variables.
1. Input Variable – This variable shows the effect of the
surroundings on the process. It normally refers to those factors
that influence the process. An example of this would be the flow
rate of the steam through a heat exchanger that would change the
amount of energy put into the process. There are effects of the
surrounding that are controllable and some that are not. These are
broken down into two types of inputs.
a. Manipulated inputs: variable in the surroundings can be control
by an operator or the control system in place.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Definitions and Terminology:
In controlling a process there exist two types of classes of variables.
1. Input Variable – This variable shows the effect of the
surroundings on the process. It normally refers to those factors
that influence the process. An example of this would be the flow
rate of the steam through a heat exchanger that would change the
amount of energy put into the process. There are effects of the
surrounding that are controllable and some that are not. These are
broken down into two types of inputs.
a. Manipulated inputs: variable in the surroundings can be control
by an operator or the control system in place.
b. Disturbances: inputs that can not be controlled by an operator
or control system. There exist both measurable and
immeasurable disturbances.
Process Instrumentation and Control (ICE 401)
Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Definitions and Terminology:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Definitions and Terminology:
2. Output variable- Also known as the control variable. These are
the variables that are process outputs that effect the surroundings.
An example of this would be the amount of CO2 gas that comes
out of a combustion reaction. These variables may or may not be
measured.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Definitions and Terminology:
2. Output variable- Also known as the control variable. These are
the variables that are process outputs that effect the surroundings.
An example of this would be the amount of CO2 gas that comes
out of a combustion reaction. These variables may or may not be
measured.
As we consider a controls problem. We are able to look at two
major control structures.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Definitions and Terminology:
2. Output variable- Also known as the control variable. These are
the variables that are process outputs that effect the surroundings.
An example of this would be the amount of CO2 gas that comes
out of a combustion reaction. These variables may or may not be
measured.
As we consider a controls problem. We are able to look at two
major control structures.
1. Single input-Single Output (SISO) - for one control (output)
variable there exist one manipulate (input) variable that is used to
affect the process.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Definitions and Terminology:
2. Output variable- Also known as the control variable. These are
the variables that are process outputs that effect the surroundings.
An example of this would be the amount of CO2 gas that comes
out of a combustion reaction. These variables may or may not be
measured.
As we consider a controls problem. We are able to look at two
major control structures.
1. Single input-Single Output (SISO) - for one control (output)
variable there exist one manipulate (input) variable that is used to
affect the process.
2. Multiple input-multiple output (MIMO) - There are several
control (output) variable that are affected by several manipulated
(input) variables used in a given process.
Process Instrumentation and Control (ICE 401)
Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Definitions and Terminology:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Definitions and Terminology:
Cascade: A control system with 2 or more controllers, a "Master" and
"Slave" loop. The output of the "Master" controller is the setpoint
for the "Slave" controller.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Definitions and Terminology:
Cascade: A control system with 2 or more controllers, a "Master" and
"Slave" loop. The output of the "Master" controller is the setpoint
for the "Slave" controller.
Dead Time: The amount of time it takes for a process to start
changing after a disturbance in the system.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Definitions and Terminology:
Cascade: A control system with 2 or more controllers, a "Master" and
"Slave" loop. The output of the "Master" controller is the setpoint
for the "Slave" controller.
Dead Time: The amount of time it takes for a process to start
changing after a disturbance in the system.
Derivative Control: The "D" part of a PID controller. With derivative
action the controller output is proportional to the rate of change of
the process variable or error.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Definitions and Terminology:
Cascade: A control system with 2 or more controllers, a "Master" and
"Slave" loop. The output of the "Master" controller is the setpoint
for the "Slave" controller.
Dead Time: The amount of time it takes for a process to start
changing after a disturbance in the system.
Derivative Control: The "D" part of a PID controller. With derivative
action the controller output is proportional to the rate of change of
the process variable or error.
Error: In process controls, error is defined as: Error = setpoint -
process variable.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Definitions and Terminology:
Cascade: A control system with 2 or more controllers, a "Master" and
"Slave" loop. The output of the "Master" controller is the setpoint
for the "Slave" controller.
Dead Time: The amount of time it takes for a process to start
changing after a disturbance in the system.
Derivative Control: The "D" part of a PID controller. With derivative
action the controller output is proportional to the rate of change of
the process variable or error.
Error: In process controls, error is defined as: Error = setpoint -
process variable.
Integral Control: The "I" part of a PID controller. With integral action
the controller output is proportional to the amount and duration of
the error signal.
Process Instrumentation and Control (ICE 401)
Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Definitions and Terminology:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Definitions and Terminology:
PID Controller: PID controllers are designed to eliminate the need
for continuous operator attention. They are used to automatically
adjust system variables to hold a process variable at a setpoint.
Error is defined above as the difference between setpoint and
process variable.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Definitions and Terminology:
PID Controller: PID controllers are designed to eliminate the need
for continuous operator attention. They are used to automatically
adjust system variables to hold a process variable at a setpoint.
Error is defined above as the difference between setpoint and
process variable.
Proportional Control: The "P" part of a PID controller. With
proportional action the controller output is proportional to the
amount of the error signal.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Definitions and Terminology:
PID Controller: PID controllers are designed to eliminate the need
for continuous operator attention. They are used to automatically
adjust system variables to hold a process variable at a setpoint.
Error is defined above as the difference between setpoint and
process variable.
Proportional Control: The "P" part of a PID controller. With
proportional action the controller output is proportional to the
amount of the error signal.
Setpoint: The setpoint is where you would like a controlled process
variable to be.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for 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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for 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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for 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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for 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 measurables: It is important to identify the
measurables that correspond with the operating parameters in
order to control the process.
Process Instrumentation and Control (ICE 401)
Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:
Measurables for process systems include:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:
Measurables for process systems include:

• Temperature

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:
Measurables for process systems include:

• Temperature
• Pressure

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:
Measurables for process systems include:

• Temperature
• Pressure
• Flow rate

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:
Measurables for process systems include:

• Temperature
• Pressure
• Flow rate
• pH

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:
Measurables for process systems include:

• Temperature
• Pressure
• Flow rate
• pH
• Humidity

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:
Measurables for process systems include:

• Temperature
• Pressure
• Flow rate
• pH
• Humidity
• Level

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:
Measurables for process systems include:

• Temperature
• Pressure
• Flow rate
• pH
• Humidity
• Level
• Concentration

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:
Measurables for process systems include:

• Temperature • Viscosity
• Pressure
• Flow rate
• pH
• Humidity
• Level
• Concentration

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:
Measurables for process systems include:

• Temperature • Viscosity
• Pressure • Conductivity
• Flow rate
• pH
• Humidity
• Level
• Concentration

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:
Measurables for process systems include:

• Temperature • Viscosity
• Pressure • Conductivity
• Flow rate
• Turbidity
• pH
• Humidity
• Level
• Concentration

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:
Measurables for process systems include:

• Temperature • Viscosity
• Pressure • Conductivity
• Flow rate
• Turbidity
• pH
• Redox/potential
• Humidity
• Level
• Concentration

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:
Measurables for process systems include:

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

• Concentration

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:
Measurables for process systems include:

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

• Concentration • Flammability

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:
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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:
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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:
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.
These signal types include:
• Electric ● Pneumatic
• Light ● Radiowaves
• Infrared (IR) ● Nuclear

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Design Methodology for Process Control:
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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Design Methodology for Process Control:
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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Design Methodology for Process Control:
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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Design Methodology for Process Control:
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. Process Instrumentation and Control (ICE 401)
Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Design Methodology for Process Control:

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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Design Methodology for Process Control:

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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Design Methodology for Process Control:

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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
Design Methodology for Process Control:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Design Methodology for Process 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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Design Methodology for Process 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.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Design Methodology for Process 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

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Design Methodology for Process 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
1. University of Michigan Chemical Engineering Process Dynamics and
Controls Open Textbook.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015
 Design Methodology for Process 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
1. University of Michigan Chemical Engineering Process Dynamics and
Controls Open Textbook.
2. Romagnoli, Jose A. Introduction to Process Control, CRC press,
2006.
Process Instrumentation and Control (ICE 401)
Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015