Process Control Design

Process Control Design

The design of process control systems is a challenging task that usually involves multiple analysis methods as engineers develop specifications that satisfy all the performance objectives required. This applies to both new plant designs, and to existing plant or processes that need to be improved.

The very first stage of the design process involves defining rate of production, product quality, as well as various economic factors, using physics, chemistry, and a thorough knowledge of the marketplace. There are, of course, many other factors that also need to be taken into account, and hundreds if not thousands of decisions that need to be made during control design of any industrial process.

How Process Control Design Works

Engineers will often start with a preliminary process design, with a few control loops, together with specifications for the process performance required. Then they will consider what needs to be done to achieve the end result specified. Amongst other things, they will:

  • Define control strategy designs
  • Select instrumentation and measured variables
  • Specify conditions required to operate the process
  • Make minor changes to the process by:
    • Using a different variable
    • Adding a bypass
    • Changing the capacity of equipment used
  • Make major changes to the process if necessary

Good process design relies on an integrated analysis of the plant or process that is to be developed or improved. This, in turn, relies on a well-organized control structure that can be developed progressively.

A typical sequence would start with flows and inventories for process materials. Then the process environment would be addressed, allowing for all possible variables include temperature, pressure, feed ratios and so on, to ensure there is tight control of the process environment. At this stage product quality and safety would be considered because control strategies have a direct bearing on the safe operation of plant and processes.

Efficiency and profit are vital elements in the control structure, but product quality and safety should never be compromised.

The final step is monitoring and diagnosis of the process and its control performance. In situations where control performance is not up to standard, engineers will alter the process design.

Process Control Design From MESH Automation

MESH Automation offers design, programming, and commissioning of process control systems. These range from continuous to batch processes, and we have the expertise and in-house resources to provide customers with the best value in turnkey solutions.

The MESH team of engineers has experience working in many industries and the expertise to understand every company’s specific process needs. We can perform P&ID design or design a control system based on P&IDs. Whether your environment is industrial, a clean room or explosion proof, MESH has a comprehensive understanding of these environments and what is required to support your process.

Projects the MESH team has worked on include process automation in diverse areas including:

  • Tank farms
  • Water and wastewater
  • Batch processes
  • Online mixing

Customer products are also varied, ranging from liquid and powder paint, solvents, and petroleum fuels to industrial wastewater reclamation.

At MESH we work with numerous technologies to measure level and pressure, and weigh, dispense, mix, heat and cool, pump, meter, and store your products efficiently.

We use PLC-based distributed control systems to control process equipment. These control systems can use your preferred automation brand of choice, or ours. Rockwell Automation, Siemens, Omron, and Modicon are some of the most commonly utilized systems.

Ultimately, MESH can perform the design, programming, and commissioning roles to fully integrate your process control system. Contact us to see what we can do for you and your process control system.