Process Control Design Methodology Quiz

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Questions and Answers

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?

  • Redox/potential
  • Density
  • Flexibility (correct)
  • Conductivity

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?

<p>To ensure the process operates within safe and desired parameters (B)</p> Signup and view all the answers

What is the purpose of defining a fail-safe system in process control?

<p>To ensure the process can continue to operate safely in the event of a failure (D)</p> Signup and view all the answers

What is the main purpose of integrating and testing the process control system with other systems?

<p>To identify potential conflicts between systems (B)</p> Signup and view all the answers

Which of these is NOT considered a major cause of failures in process control?

<p>Unpredictable market fluctuations (B)</p> Signup and view all the answers

Which of these steps in the process control design methodology is directly related to ensuring the system can handle unexpected events?

<p>Create redundancy systems (A)</p> Signup and view all the answers

What is the main objective of adding control to a water tank in a heating or cooling process?

<p>To maintain water levels at operational conditions. (B)</p> Signup and view all the answers

What role do level sensors play in managing a water tank?

<p>They inform personnel about the water level. (C)</p> Signup and view all the answers

What issue could arise from failing to maintain control over the water tank levels?

<p>Water overflow from the tank. (B)</p> Signup and view all the answers

Which of the following statements accurately describes the filling process of the water tank?

<p>The tank is filled without any drainage occurring. (B)</p> Signup and view all the answers

What could potentially happen if water levels in the tank are not monitored?

<p>Potential overflows and operational disruptions. (D)</p> Signup and view all the answers

What is the primary purpose of process control in chemical engineering?

<p>To maintain process variables near desired values (C)</p> Signup and view all the answers

Which of the following best describes a Distributed Control System (DCS)?

<p>Manages interconnected processes across an entire plant (B)</p> Signup and view all the answers

What is one of the key benefits of implementing process control in a chemical plant?

<p>Improved safety measures (D)</p> Signup and view all the answers

What distinguishes a Programmable Logic Controller (PLC) from a Distributed Control System (DCS)?

<p>DCS controls an entire plant and interconnected processes (D)</p> Signup and view all the answers

Which of the following is NOT a role of process control?

<p>Increasing operator workload (C)</p> Signup and view all the answers

How does full automation in chemical plants benefit operations?

<p>It enhances the ability to communicate with field instruments (D)</p> Signup and view all the answers

Which process control advantage helps minimize environmental impact?

<p>Achieving optimal chemical ratios (B)</p> Signup and view all the answers

What is a potential risk of poor process control in a chemical plant?

<p>Decrease in safety standards (C)</p> Signup and view all the answers

What is the purpose of the input variable in a control process?

<p>It shows the effect of the surroundings on the process. (A)</p> Signup and view all the answers

Which type of control system involves a single control variable and a single manipulated variable?

<p>Single Input - Single Output (SISO) (A)</p> Signup and view all the answers

What distinguishes disturbances in a control process?

<p>They include inputs that cannot be controlled by an operator. (A)</p> Signup and view all the answers

In a cascade control system, what role does the 'Master' controller play?

<p>It sets the setpoint for the 'Slave' controller. (B)</p> Signup and view all the answers

What is referred to as dead time in control systems?

<p>The delay in the output after applying input. (A)</p> Signup and view all the answers

Which function does the 'D' part of a PID controller represent?

<p>Derivative Control (B)</p> Signup and view all the answers

What characterizes a Multiple Input - Multiple Output (MIMO) control system?

<p>Several controlled variables influenced by several inputs. (D)</p> Signup and view all the answers

Which statement about manipulated outputs is true?

<p>They can be controlled by the operator or control system. (B)</p> Signup and view all the answers

What is the formula for calculating error in process controls?

<p>Error = setpoint - process variable (A)</p> Signup and view all the answers

Which part of a PID controller is responsible for integrating past error over time?

<p>Integral Control (B)</p> Signup and view all the answers

How does the output of a proportional control change?

<p>It is proportional to the amount of error. (B)</p> Signup and view all the answers

What does the term 'setpoint' refer to in process control?

<p>The desired value for a controlled variable (D)</p> Signup and view all the answers

Which process control activity includes safety and environmental protection?

<p>Safety, Environment and Equipment Protection (D)</p> Signup and view all the answers

In what hierarchy of process control activities is real-time optimization categorized?

<p>Planning and Scheduling (A)</p> Signup and view all the answers

What is the main purpose of a PID controller?

<p>To automatically adjust system variables (C)</p> Signup and view all the answers

Which control action would respond immediately to changes in the error signal?

<p>Proportional Control (D)</p> Signup and view all the answers

Which of the following are examples of why a process would need to be transitioned from one operational condition to another?

<p>Economic considerations (A), Changes in product specifications (B)</p> Signup and view all the answers

What is the primary objective of control in a process?

<p>To ensure consistent and predictable results (D)</p> Signup and view all the answers

What is the primary factor that causes a water tank to overflow when there is no drainage and it is being constantly filled?

<p>Lack of sufficient tank capacity (D)</p> Signup and view all the answers

What is the purpose of setting operational conditions and set points in a process?

<p>To achieve optimal product quality and consistency (D)</p> Signup and view all the answers

Which of the following is NOT a factor influencing the transition of a process from one operational condition to another?

<p>Employee productivity (C)</p> Signup and view all the answers

What is the purpose of adding control valves and level sensors to a water tank in a heating or cooling process?

<p>To prevent the tank from overflowing or running dry (B)</p> Signup and view all the answers

Which of the following is an example of an operational constraint that may necessitate a change in process conditions?

<p>A new regulation prohibiting the use of certain chemicals (D)</p> Signup and view all the answers

In the context of process control, what does the term 'set point' refer to?

<p>The specific value at which a process variable should be maintained (C)</p> Signup and view all the answers

Flashcards

Operational Conditions

Parameters under which a process operates effectively.

ADD Control

Control mechanism for managing the input and output of liquid in a system.

Water Level Sensors

Devices that measure the water level in a tank and send feedback.

Overflow Management

Systems in place to prevent tank overflow by controlling water input.

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Level Indicators

Tools or devices that display the current water level in a tank.

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Process Control

The engineering discipline combining statistics for controlling processes.

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Purpose of Process Control

To ensure safety, minimize environmental impact, and optimize processes.

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Controlled Variables

Elements like temperature and ratios that must be maintained in a process.

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Distributed Control System (DCS)

A system that automates entire plants by communicating with field instruments.

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Programmable Logic Controller (PLC)

A machine that automates specific tasks within a process.

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DCS vs PLC

DCS oversees the entire plant, while PLC manages individual machines.

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Safety in Process Control

The aspect of process control that focuses on avoiding accidents and ensuring safe operations.

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Environmental Impact

The effect processes have on the environment, which control aims to minimize.

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Control Objectives

Goals aimed at maintaining or adjusting a process's operational state.

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Overflow

A situation where the water level exceeds the tank's capacity.

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Transition of Process

Moving a process from one operational condition to another.

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External Factors

Elements outside the process that can affect its operation.

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Operational Set Points

Target values that processes aim to maintain during operation.

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Safety Precautions

Measures taken to ensure the safety of processes and personnel.

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Error in Process Control

Error is the difference between the setpoint and the process variable: Error = setpoint - process variable.

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Integral Control

The 'I' part of a PID controller; it adjusts output based on the total error over time.

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PID Controller

A control system designed to adjust variables automatically to maintain a process at a setpoint.

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Proportional Control

The 'P' part of a PID controller, where output is proportional to the current error value.

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Setpoint

The desired value for a process variable that the control system aims to maintain.

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Hierarchy of Process Control Activities

A structured approach to process control, categorized by time response and purpose.

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Regulatory Control

A type of process control that maintains variables at a setpoint within defined limits.

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Measurement and Actuation

The foundational processes for controlling systems, involving measuring variables and taking action.

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Operating Parameters

The key conditions for effective process function, such as temperature and pressure.

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Hazardous Conditions

Dangerous scenarios that could disrupt process operation or safety.

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Measurables

Factors that can be quantified in a process like pH, flow rate, and conductivity.

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Control Limits

The defined boundaries within which a process variable must remain to ensure safety and performance.

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Control Logic

The set of rules or algorithms used to govern the operation of a control system.

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Redundancy System

A backup mechanism designed to enhance reliability in process control systems.

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Fail-Safe

Design features that ensure a system defaults to a safe state in case of failure.

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Lead/Lag Criteria

Parameters used to manage time delays in process control to ensure smooth operation.

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Input Variable

Shows the effect of the surroundings on the process.

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Manipulated Output

Variable in the surroundings controlled by an operator or system.

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Disturbances

Inputs that cannot be controlled by an operator or control system.

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Output Variable

Variables that are process outputs affecting the surroundings.

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Single Input – Single Output (SISO)

A control system with one input variable affecting one output variable.

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Multiple Input – Multiple Output (MIMO)

Control system with several inputs affecting multiple outputs.

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Cascade Control System

A control system with two or more controllers, master and slave loops.

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Dead Time

The time it takes for a process to change after a disturbance.

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Derivative Control

The 'D' part of a PID controller, based on the rate of change of the process variable.

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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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