Module overview
The primary objective of process control is to maintain a process at the desired operating conditions, safely and efficiently, while satisfying environmental and product quality requirements.
Aims and Objectives
Learning Outcomes
Knowledge and Understanding
Having successfully completed this module, you will be able to demonstrate knowledge and understanding of:
- Explain how control systems operate and the inputs required for their design and operation.
- Employ mathematical techniques and models to design control systems relevant to chemical engineering.
- Understand the principles of risk assessment, safety management, identification of process hazards (HAZOP) and environmental impact.
- Understand the nature of safety and loss prevention processes, and identify principal hazard sources such as flammability, explosivity and toxicity.
Disciplinary Specific Learning Outcomes
Having successfully completed this module you will be able to:
- Understand system dynamics and be able to predict responses to changes in a dynamic system, by designing and analysing the performance of control functions.
- Describe the industrial automation of batch processes with specific attention to the S88 standard to attain flexibility of batch process operations;
- Describe and implement the basic elements of process control including analysis, tuning and design of the control system using tools of differential equations and transfer functions, with the specific focus on PID control strategy;
- Identify the major issues in the control applications in chemical engineering processes with specific attention to reactor and distillation units.
Subject Specific Practical Skills
Having successfully completed this module you will be able to:
- Identify chemical reaction hazards based on physical and chemical properties.
- Understand how elements in a complex process are interdependent and how techniques can used to integrate and synthesise these into process steps.
- prepare a “basis for safety” case document for reaction hazards found in the Chemical Industry, using appropriate codes of conduct and industry standards.
Subject Specific Intellectual and Research Skills
Having successfully completed this module you will be able to:
- Assess the potential for hazardous reactions by conducting an analysis of heat generation and heat transfer and use of calorimetric techniques.
Syllabus
Process Control and Automation: elements of feedback control, process modelling and mathematical modelling (review of ODEs and mathematical tools); discrete (Sequence) event Control
Stability and Performance Analysis: Open loop, closed loop, on-off, PID Control, and PID Tuning
Introduction to Transfer Functions (TF): definition of TFs; application of TFs to rudimentary feedback Control Analysis and Design: application of TFs to Other Control Configuration
Applications of Control: to distillation,reactors and blending with an introduction to ISA 88 for batch process control
Assessment of risks and design of safety controls: safety, hazards and control in reactions and reactors; control and safety documentation; legal frameworks and standards.
Practicals: Laboratory and computer based exercises using a PID control unit or simulation.
Learning and Teaching
Teaching and learning methods
Teaching will be done with a combination of formal lectures, paper-based problem-solving sessions and laboratory sessions. There will be a emphasis on active learning techniques, including workshops and tutorial sessions that focus on exercises and problems.
| Type | Hours |
|---|---|
| Guided independent study | 52 |
| Workshops | 10 |
| Preparation for scheduled sessions | 42 |
| Practical | 10 |
| Revision | 12 |
| Lecture | 24 |
| Total study time | 150 |
Assessment
Summative
This is how we’ll formally assess what you have learned in this module.
| Method | Percentage contribution |
|---|---|
| Final Exam | 50% |
| Computer practicals | 20% |
| A lab report | 30% |
Repeat Information
Repeat type: Internal & External