Podcast
Questions and Answers
What is the first step in the process control design methodology?
What is the first step in the process control design methodology?
- Identify the hazardous conditions
- Identify the operating parameters
- Identify the measurables
- Understand the process (correct)
Which of these are NOT considered a measurable parameter in process control?
Which of these are NOT considered a measurable parameter in process control?
- Redox/potential
- Density
- Flexibility (correct)
- Conductivity
Which of these are NOT a commonly used measurement method for process control?
Which of these are NOT a commonly used measurement method for process control?
- Infrared
- Magnetic (correct)
- Ultrasonic
- Radiowaves
What is the purpose of setting control limits in the process control design methodology?
What is the purpose of setting control limits in the process control design methodology?
What is the purpose of defining a fail-safe system in process control?
What is the purpose of defining a fail-safe system in process control?
What is the main purpose of integrating and testing the process control system with other systems?
What is the main purpose of integrating and testing the process control system with other systems?
Which of these is NOT considered a major cause of failures in process control?
Which of these is NOT considered a major cause of failures in process control?
Which of these steps in the process control design methodology is directly related to ensuring the system can handle unexpected events?
Which of these steps in the process control design methodology is directly related to ensuring the system can handle unexpected events?
What is the main objective of adding control to a water tank in a heating or cooling process?
What is the main objective of adding control to a water tank in a heating or cooling process?
What role do level sensors play in managing a water tank?
What role do level sensors play in managing a water tank?
What issue could arise from failing to maintain control over the water tank levels?
What issue could arise from failing to maintain control over the water tank levels?
Which of the following statements accurately describes the filling process of the water tank?
Which of the following statements accurately describes the filling process of the water tank?
What could potentially happen if water levels in the tank are not monitored?
What could potentially happen if water levels in the tank are not monitored?
What is the primary purpose of process control in chemical engineering?
What is the primary purpose of process control in chemical engineering?
Which of the following best describes a Distributed Control System (DCS)?
Which of the following best describes a Distributed Control System (DCS)?
What is one of the key benefits of implementing process control in a chemical plant?
What is one of the key benefits of implementing process control in a chemical plant?
What distinguishes a Programmable Logic Controller (PLC) from a Distributed Control System (DCS)?
What distinguishes a Programmable Logic Controller (PLC) from a Distributed Control System (DCS)?
Which of the following is NOT a role of process control?
Which of the following is NOT a role of process control?
How does full automation in chemical plants benefit operations?
How does full automation in chemical plants benefit operations?
Which process control advantage helps minimize environmental impact?
Which process control advantage helps minimize environmental impact?
What is a potential risk of poor process control in a chemical plant?
What is a potential risk of poor process control in a chemical plant?
What is the purpose of the input variable in a control process?
What is the purpose of the input variable in a control process?
Which type of control system involves a single control variable and a single manipulated variable?
Which type of control system involves a single control variable and a single manipulated variable?
What distinguishes disturbances in a control process?
What distinguishes disturbances in a control process?
In a cascade control system, what role does the 'Master' controller play?
In a cascade control system, what role does the 'Master' controller play?
What is referred to as dead time in control systems?
What is referred to as dead time in control systems?
Which function does the 'D' part of a PID controller represent?
Which function does the 'D' part of a PID controller represent?
What characterizes a Multiple Input - Multiple Output (MIMO) control system?
What characterizes a Multiple Input - Multiple Output (MIMO) control system?
Which statement about manipulated outputs is true?
Which statement about manipulated outputs is true?
What is the formula for calculating error in process controls?
What is the formula for calculating error in process controls?
Which part of a PID controller is responsible for integrating past error over time?
Which part of a PID controller is responsible for integrating past error over time?
How does the output of a proportional control change?
How does the output of a proportional control change?
What does the term 'setpoint' refer to in process control?
What does the term 'setpoint' refer to in process control?
Which process control activity includes safety and environmental protection?
Which process control activity includes safety and environmental protection?
In what hierarchy of process control activities is real-time optimization categorized?
In what hierarchy of process control activities is real-time optimization categorized?
What is the main purpose of a PID controller?
What is the main purpose of a PID controller?
Which control action would respond immediately to changes in the error signal?
Which control action would respond immediately to changes in the error signal?
Which of the following are examples of why a process would need to be transitioned from one operational condition to another?
Which of the following are examples of why a process would need to be transitioned from one operational condition to another?
What is the primary objective of control in a process?
What is the primary objective of control in a process?
What is the primary factor that causes a water tank to overflow when there is no drainage and it is being constantly filled?
What is the primary factor that causes a water tank to overflow when there is no drainage and it is being constantly filled?
What is the purpose of setting operational conditions and set points in a process?
What is the purpose of setting operational conditions and set points in a process?
Which of the following is NOT a factor influencing the transition of a process from one operational condition to another?
Which of the following is NOT a factor influencing the transition of a process from one operational condition to another?
What is the purpose of adding control valves and level sensors to a water tank in a heating or cooling process?
What is the purpose of adding control valves and level sensors to a water tank in a heating or cooling process?
Which of the following is an example of an operational constraint that may necessitate a change in process conditions?
Which of the following is an example of an operational constraint that may necessitate a change in process conditions?
In the context of process control, what does the term 'set point' refer to?
In the context of process control, what does the term 'set point' refer to?
Flashcards
Operational Conditions
Operational Conditions
Parameters under which a process operates effectively.
ADD Control
ADD Control
Control mechanism for managing the input and output of liquid in a system.
Water Level Sensors
Water Level Sensors
Devices that measure the water level in a tank and send feedback.
Overflow Management
Overflow Management
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Level Indicators
Level Indicators
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Process Control
Process Control
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Purpose of Process Control
Purpose of Process Control
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Controlled Variables
Controlled Variables
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Distributed Control System (DCS)
Distributed Control System (DCS)
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Programmable Logic Controller (PLC)
Programmable Logic Controller (PLC)
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DCS vs PLC
DCS vs PLC
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Safety in Process Control
Safety in Process Control
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Environmental Impact
Environmental Impact
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Control Objectives
Control Objectives
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Overflow
Overflow
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Transition of Process
Transition of Process
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External Factors
External Factors
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Operational Set Points
Operational Set Points
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Safety Precautions
Safety Precautions
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Error in Process Control
Error in Process Control
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Integral Control
Integral Control
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PID Controller
PID Controller
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Proportional Control
Proportional Control
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Setpoint
Setpoint
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Hierarchy of Process Control Activities
Hierarchy of Process Control Activities
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Regulatory Control
Regulatory Control
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Measurement and Actuation
Measurement and Actuation
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Operating Parameters
Operating Parameters
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Hazardous Conditions
Hazardous Conditions
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Measurables
Measurables
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Control Limits
Control Limits
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Control Logic
Control Logic
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Redundancy System
Redundancy System
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Fail-Safe
Fail-Safe
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Lead/Lag Criteria
Lead/Lag Criteria
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Input Variable
Input Variable
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Manipulated Output
Manipulated Output
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Disturbances
Disturbances
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Output Variable
Output Variable
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Single Input – Single Output (SISO)
Single Input – Single Output (SISO)
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Multiple Input – Multiple Output (MIMO)
Multiple Input – Multiple Output (MIMO)
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Cascade Control System
Cascade Control System
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Dead Time
Dead Time
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Derivative Control
Derivative Control
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Study Notes
Introduction to Process Dynamics and Control
- Course name: Process Dynamics and Control
- Course code: CH158-2P
- Instructor: Engr. Louise Grace Avena-Ardeta
Process Control
- Process control combines statistics and engineering principles to manage processes.
- It involves mechanisms, architectures, and algorithms for process control.
- Examples of tasks include: controlling water stream temperature, operating a jacketed reactor isothermally, maintaining reactant ratios in a reactor, and preventing tank overflow.
Further Objectives of Process Control
- Safety is a crucial aspect, aiming to minimize environmental impact.
- Optimizing processes involves maintaining process variables near desired values.
Distributed Control System (DCS)
- Modern chemical plants often utilize full automation, facilitated by DCS.
- DCS systems communicate with instruments in the field, aiding engineers and operators.
DCS vs PLC
- Programmable Logic Controllers (PLC) manage individual machines.
- Distributed Control Systems (DCS) manage entire interconnected plants.
Objectives of Control
- Maintain processes at their operational conditions and setpoints.
- For example, maintaining a water tank level in a heating/cooling process without drainage.
Design Methodology for Process Control
- Understand the process.
- Identify operating parameters.
- Identify hazardous conditions.
- Identify measurable elements (temperature, pressure, flow rate, pH, humidity, level, concentration, viscosity, etc.).
- Select measurement points.
- Select measurement methods (electric, pneumatic, light, radiowaves, infrared, nuclear).
- Select a control method.
- Design the control system.
- Set control limits.
- Define the control logic.
- Create a redundant system (for fail-safe).
- Establish lead/lag criteria.
- Integrate and test the system with other systems.
Hierarchy of Process Control Activities
- Activities involved in controlling a process span different time scales (days, hours, minutes, seconds).
Failures in Process Control
- Real-world incidents like the Bhopal gas tragedy highlight the importance of safety controls.
- Operational failures can be attributed to factors like equipment malfunctions and safety control failures.
- Examples of relevant incidents are the Bhopal Gas Tragedy (1984) and the BP Texas City Refinery explosion (2005).
- These case studies illustrate the risks associated with neglecting safety precautions in process control.
Definitions and Terminologies
- Input Variable: The impact of surroundings on the processes.
- Manipulated Output: A variable in the surroundings controllable by the system or operator.
- Disturbances: Uncontrollable inputs influencing the process.
- Output Variable: The variables that are the effect of a process on its surroundings.
- Single Input Single Output (SISO): One input variable influences one output variable.
- Multiple Input Multiple Output (MIMO): Multiple input variables influence multiple output variables.
- Cascade Control: Two or more controllers working together (Master-Slave loops).
- Dead Time: The time delay between a disturbance and its effect.
- Derivative Control: Proportional response to the change rate of an error in the system.
- Error: The difference between the setpoint and the process variable.
- Setpoint: The desired value for process variable to attain.
- Proportional Control: Proportional output in response to the system error.
- Integral Control: Proportional output in response to the duration and amount of system error.
- PID Controller: A controller consisting of proportional, integral, and derivative control actions.
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