EI3551 Process Control Syllabus:

EI3551 Process Control Syllabus – Anna University Regulation 2021

COURSE OBJECTIVES:

1. To introduce technical terms and nomenclature associated with Process control domain.
2. To introduce the fundamentals of mathematical modeling of processes.
3. To familiarize the students with characteristics, selection and sizing of control valves.
4. To provide an overview of the features associated with Industrial type PID controller.
5. To make the students understand the various PID tuning methods.
6. To elaborate different types of control schemes such as cascade control, feed-forward control and Model Based control schemes.

UNIT – I PROCESS DYNAMICS

Need for process control – Hierarchical decomposition of control functions – Servo and regulatory operations – Continuous and Batch processes – Mathematical Modeling of Processes: Level, Flow and Thermal processes – Lumped and Distributed parameter models – Degrees of Freedom – Interacting and non-interacting systems – Self regulation – Linearization of non-linear systems.

UNIT -II CONTROL VALVE

Actuators: Pneumatic and electric actuators – I/P converter – Control Valve Terminology – Characteristic of Control Valves: Inherent and Installed characteristics – Valve Positioner – Modeling of a Pneumatically Actuated Control Valve – Valve body: Commercial valve bodies – Control Valve Sizing: ISA S 75.01 standard flow equations for sizing Control Valves – Cavitation and flashing– Control Valve selection.

UNIT – III CONTROL ACTIONS

Characteristic of ON-OFF, Proportional, Single speed floating, Integral and Derivative controllers – P+I, P+D and P+I+D control modes – Practical forms of PID Controller –PID Implementation Issues: Bumpless Auto/manual Mode transfer, Anti-reset windup Techniques and Direct/reverse action.

UNIT – IV PID CONTROLLER TUNING AND ADVANCED CONTROL SYSTEMS

PID Controller Design Specifications: Criteria based on Time Response and Frequency Response – PID Controller Tuning: Z-N and Cohen-Coon methods, Continuous cycling method and Damped oscillation method, Auto tuning – Cascade control –selective control – Feedforward control – Ratio control – Inferential control – Split-range– Adaptive Control.

UNIT – V MODEL BASED CONTROL SCHEMES & INTRODUCTION TO MULTI-LOOP REGULATORY CONTROL & CASE –STUDIES

Smith Predictor Control Scheme – Internal Model Controller – IMC PID controller –Model Predictive Control- Introduction to Multi-loop Control Schemes – Control Schemes for Distillation Column, pH-Three-element Boiler drum level control.

TOTAL: 45 PERIODS

SKILL DEVELOPMENT ACTIVITIES (Group Seminar/Mini Project/Assignment/Content Preparation / Quiz/ Surprise Test / Solving GATE questions/ etc)

1. List the hardware involved in a control system.
2. Find the importance of digital computers for the present and future implementation of advanced control techniques.
3. Outline the steps that should be considered during the development of a mathematical model for chemical processes.
4. Analyse the strength and weaknesses of a feedback control system using MATLAB software.
5. Elaborate your answer how the stability characteristics of the closed loop response of a cascade control system is better than a simple feedback?
6. Examine the similarities and differences between MRAC and STRs using MATLAB software.
7. Explore various types of controllers presently used in industries.

COURSE OUTCOMES:

Students able to
CO1 Develop models using first principles approach for processes such as level, flow, temperature and pressure as well as analyze models.
CO2 Recommend the right type of control valve along with its characteristics for a given application.
CO3 Design Size a control valve following the procedure outlined in the ISA S 75.01 standard.
CO4 Design & implement a suitable control scheme for a given process and validate through simulations.
CO5 Analyze various control schemes and recommend the right control strategy for a given application.
CO6 Use appropriate software tools (Example: MATLAB/SCILAB) for analysis, design and implementation of Process Control System.

TEXT BOOKS:

1. Raghunathan Rengaswamy, Babji Srinivasan, Nirav Pravinbhai Bhatt“Process Control Fundamentals: Analysis, Design, Assessment, and Diagnosis”,1st Edition,2020.
2. Seborg ,D.E., Mellichamp, D.P., Edgar, T.F., and Doyle,F.J., III, “Process Dynamics and Control”, John Wiley and Sons, 4th Edition,2017.
3. George Stephanopoulos, “Chemical Process Control – An Introduction to Theory and Practice”, Prentice Hall of India, 2005.

REFERENCES:

1. Bequette, “Process Control: Modeling, Design, and Simulation”, Prentice Hall of India, 1st edition, 2013
2. Michael King, “Process Control: A Practical Approach”, Wiley, 2016.
3. Hans D. Baumann, Control Valve Primer: A User’s Guide, 4th edition, ISA, 2009.
4. Aidan O’Dwyer, “Handbook of PI and PID Controller Tuning Rules”, Imperial College Press; 3rd edition, 2009.