Process Control

Lecture notes on Process Control

Welcome to Process Control

Join us as we delve into the dynamic world of process control, where theory meets practice to optimize systems across industries. From manufacturing to energy production, our course equips you with the essential skills to design, implement, and troubleshoot control systems effectively.

Learn about feedback control, system dynamics, and popular strategies like PID control. Explore the practical applications of sensors, actuators, and automation technologies in ensuring efficiency, safety, and quality in real-world processes.

Course Contents

Chapter 1: Introduction to Instrumentation & Process Control System

  • Lecture Hours: 1,2
  • Topics:
    • Basic concepts of Measurement and Instrumentation, Control Process
    • Control Terminology and Definitions: Manipulated Variables, Controlled Variables, Disturbance/Feedforward Variables
    • Process Control Dynamics and Process Open Loop Dynamics
    • Dynamic Characteristics: Transfer Function Representation of a Measurement System, Impulse and Step Responses of First and Second Order Systems, Frequency Response of First and Second Order Systems

Chapter 2: Sensors, Signal Conditioning, and Actuators

  • Lecture Hours: 3,4
  • Topics:
    • Sensors: Thermal sensors (temperature, thermistor, thermocouples), Mechanical sensor (strain sensors, motion sensor, pressure sensors, flow sensor), Optical sensors (fundamentals of EM radiation, Photodetectors, Pyrometry)
    • Final control: operation, signal conversion, industrial electronics, actuators, control element
    • Analog signal conditioning: principles, passive circuit, operational amplifier, Op Amp circuits in instrumentation
    • Digital signal conditioning: review of digital fundamentals, Converters, Data-Acquisition systems (DAS Hardware and DAS Software)

Chapter 3: Analog and Digital Controllers

  • Lecture Hours: 3,4,5
  • Topics:
    • Analog Controller: electronic controller (error detector, single mode composite controller modes), pneumatic controllers
    • Two Position Control Systems
    • Digital controller: digital electronics methods, computers in process control: PLC, PLC programming, data logging, supervisory control, controller software, characteristics of digital data Programming and Design, SCADA systems

Chapter 4: Process Control Actions

  • Lecture Hours: 6
  • Topics: Types-Discontinuous, continuous (P, I, D) and composite control actions (PI, PD, and PID), Effects of control actions, selection criteria.

Chapter 5: Process Controllers and Tuning

  • Lecture Hours: 7,8,9
  • Topics:
    • Need for controller, General features, specifications, classification & working of Pneumatic, Hydraulic, and Electronic controllers
    • Need for controller Tuning. Tuning Methods- Process reaction curve method, Ziegler-Nichols method, Cohen coon correction for quarter amplitude, Frequency response method, Relay based tuning. Concept of Auto Tuning
    • Introduction to Model-based Controller

Chapter 6: Control Schemes

  • Lecture Hours: 10,11
  • Topics: Feedback, Feed forward, cascade, Ratio, split range, selective control, adaptive control, inferential control, and selection Guidelines.

Chapter 7: Multivariable Control

  • Lecture Hours: 12,13,14,15,16
  • Topics:
    • Some transformations and matrix forms
    • Matrix polynomial descriptions
    • Introduction to SISO & MIMO systems
    • Block diagram analysis of multivariable systems, Interaction, relative gain analysis, Decoupler design

Laboratory Activities

  1. Study Features & operation of ON-OFF Controller & its Application
  2. Familiarization of various control actions (pure and composite) using PID controller with Real-time Process OR Simulator
  3. Testing Features, specifications, wiring & operation of an electronic PID controller
  4. Tuning of an Electronic PID controller
  5. Analysis of Feedback Control using Level / Pressure / Flow / Temperature Control Loop
  6. Study Feed Forward Control system using Temperature control Loop
  7. Study of split range control system using Pressure Control set up
  8. Study of Ratio control system using Flow Control Loop
  9. Study of Cascade control system
  10. Study Dynamic behavior of First Order Hydraulic system
  11. Study Dynamic behavior of Second Order Hydraulic system
  12. Development & Implementation of Relay Ladder Logic for Discrete state process control system
  13. Assignment on Relative gain analysis

Required Text and Reference

  1. Bela G. Liptak, “Instrument Engineer’s Handbook – Process Control”, Chilton Reference Books Company, 3rd Edition, 1995. ISBN-10: 0-8019-8242-1. This comprehensive guide covers the fundamentals of process control, instrumentation design, and application strategies for industrial environments.
  2. M. Chidambaram, “Computer Control of Processes”, Narosa Publishing House, 2002. ISBN-13: 978-8173194737. This book offers an in-depth look at the theory and practice of computer-based control systems, emphasizing process control applications.
  3. Deshpande P.B and Ash R.H, “Elements of Process Control Applications”, ISA Press, New York, 1995. ISBN-10: 1-55617-443-X. The book focuses on the practical aspects of designing and implementing process control applications, with examples and case studies.
  4. D. Patranabis, “Principles of Process Control”, Second edition, Tata McGraw-Hill (TMH), 2001. ISBN-13: 978-0070498419. This text delves into the basic principles underlying process control systems, including measurement, feedback mechanisms, and controller design.
  5. Dale E. Seborg, Thomas F Edgar, Duncan A Mellichamp, “Process Dynamics and Control”, John Wiley & Sons, 1989. ISBN-10: 0-471-86389-0. A foundational text on the dynamics of processes and the strategies for their control, suitable for students and professionals alike.
  6. F.G. Shinsky, “Process Control Systems”, Tata McGraw-Hill (TMH). ISBN-13: 978-0070569218. An introduction to the components and design of process control systems, including case studies from various industries.
  7. N.E. Battikha, “Condensed Handbook of Measurement and Control”, 3rd Edition, ISA Publication, 2007. ISBN-13: 978-1-934394-28-7. This handbook provides a concise overview of measurement and control technologies, along with practical guidelines for application.
  8. Donald P. Eckman, “Automatic Process Control”, Wiley Eastern Ltd., ISBN-13: 978-0471072551. This classic text covers the principles of automatic control and their application to process industries, offering both theoretical insights and practical advice.
  9. Franklyn W. Kirk, Nicholas R. Rimboi, “Instrumentation”, First edition, 1996, Delmar Cengage Learning. ISBN-10: 0827365949. This book introduces the basics of instrumentation technology, covering sensors, transducers, signal conditioning, and control elements.
  10. Multivariable Feedback Control - Analysis and design, Sigurd Skogestad & Ian Postlethwaite, Second Edition, Wiley, 2006. ISBN-13: 978-0470011683. This advanced text provides a comprehensive treatment of multivariable feedback control analysis and design, with a focus on practical applications and robust control strategies.