2nd Edition

Designing Controls for the Process Industries

By Wayne Seames Copyright 2023
    600 Pages 322 B/W Illustrations
    by CRC Press

    616 Pages 322 B/W Illustrations
    by CRC Press

    Also available as eBook on:

    Offering a modern, process-oriented approach emphasizing process control scheme development instead of extended coverage of LaPlace space descriptions of process dynamics, Designing Controls for the Process Industries focuses on aspects that are most important for contemporary practical process engineering and reflects the industry’s use of digital distributed control-based systems. The second edition now features 60 tutorial videos demonstrating solutions to most of the example problems.

    Instead of starting with the controller, the book starts with the process and moves on to how basic regulatory control schemes can be designed to achieve the process objectives while maintaining stable operations. In addition to continuous control concepts, process and control system dynamics are embedded into the text with each new concept presented. The book alsoincludes sections on batch and semi-batch processes and safety automation within each concept area. It discusses the four most common control techniques: control loop feedback, feedforward, ratio, and cascade, and discusses application of these techniques for process control schemes for the most common types of unit operations. It also discusses more advanced andless commonly used regulatory control options such as override, allocation, and split range controllers; includes an introduction to higher-level automation functions; and provides guidance for ways to increase the overall safety, stability, and efficiency for many process applications. It introduces the theory behind the most common types of controllers used in the process industries and provides various additional plant automation-related subjects. The new edition also includes new homework problems and examples, including multiple choice questions for flipped classes, information about statistical process control, and a new case study that documents the development of regulatory control schemes for an entire process area.

    Aimed at chemical engineering students in process control courses, as well as practicing process and control engineers, this textbook offers an alternative to traditional texts and offers a practical, hands-on approach to design of process controls.

    PowerPoint lecture slides, multiple-choice quiz questions for each chapter, and a solutions manual are available to qualifying instructors. Tutorial-style videos for most of the text examples are available for all readers to download.

    1. Processing System Fundamentals. 2. Control System Fundamentals. 3. Motive Force Unit Operations Control. 4. Heat Transfer Unit Operations Control. 5. Separation Unit Operations Controls. 6. Reaction Unit Operations Controls. 7. Other Control Paradigms. 8. Controller Theory. 9. Higher- Level Automation Techniques. 10. Instrumentation (Types and Capabilities). 11. Automation and Control System Projects. 12. Process Dynamics Analysis. Appendix A: Transform Functions and the “s” Domain. Appendix B: PID Controller Tuning. Appendix C: Controller Script. Appendix D: A Case Study of the Regulatory Controls of an Entire Process Area.


    Professor Wayne S. Seames is Distinguished Professor, Chemical Engineering, University of North Dakota (UND). He has been Director, The SUNRISE BioProducts Center of Excellence at UND since 2009 and Director, The Sustainable Energy Research Initiative and Supporting Education Research Supercluster at UND, since 2004. Before joining UND, Prof. Seames was an independent consultant at Seaway Consulting, Tucson, Arizona, and an instructor at University of Arizona. Prof Seames is also an expert in the field of Process Plant Automation. He has direct Project Management experience in the scope definition, design development, implementation, and maintenance of Process Control Systems, Integration Systems, Plant Automation, and Management Information Systems. He has also supervised the operation of an operational Refinery Management Information system and also has direct Plant Operations support experience in the Refining industry.

    Prof. Seames was awarded The Fulbright Foundation's 2014/15 Distinguished Chair Scholar at the University of Leeds; 2013 UND Faculty Scholar Award for Excellence in Teaching, Research, and Service; 2012 UND Faculty Spirit of Achievement Award; 2011 UND Chester Fritz Distinguished Professor; 2007 UND Award for Excellence in Individual Research (University Researcher of the Year); 2006 UND School of Engineering and Mines Professor of the Year (Outstanding teacher); Award for Excellence at the Student Interface from the Univ. of Arizona College of Engineering and Mines, 1999 (Outstanding Faculty Teaching Award); and 2004-2005 Olson Professor for Excellence in Research and Scholarship, UND SEM. He has published 2 invited book chapters, 47 refereed journal publications, 20 additional papers, over 100 research reports, as well 4 teaching- related publications, and over 50 proprietary industrial publications.

    "A good book that is designed keeping in view the skills set necessary for a learner to become a good process engineer. The book includes almost all the relevant information for a first course in process control. I recommend this book for adoption in process control related undergraduate courses."
    —Rakesh Mishra, University of Huddersfield, United Kingdom

    "The material is current, modern, and accessible without resorting to advanced or abstract mathematics. Instructors will appreciate the flexibility of the self-contained chapters for using the textbook customized for their own courses. Dr. Seames understands how students learn and has written a student-centered book that will serve them after graduation as practicing engineers."
    —Richard Davis, University of Minnesota Duluth, USA

    "I believe this to be an excellent resource that can serve as a good, practical text book as well as a very useful reference for the professional engineer. I believe the content flow and practical approach are quite good. I particularly like the approach to describing common unit operations and the potential control strategies associated with each. This is very valuable information. I am planning on keeping this book on my bookshelf for as long as I work in industrial automation and control."
    —Peter G. Martin, Schneider Electric, Foxboro, Massachusetts, USA

    "This is one of the very few textbooks that presents comprehensive coverage of key and important ingredients for the control of industrial processes in a very pragmatic way. It includes many insightful elements from an author who has had substantial industrial experiences on process engineering and process control, and presents some unique prospects that are essential for training modern process control engineers."
    —Kang Li, Queen’s University Belfast, Northern Ireland

    "I particularly like the conversational writing style of the author which results in a very readable book. …I believe that this text book will provide comprehensive coverage of the topics discussed, and receive immediate acceptance and use, not only for classroom training purposes but as an excellent reference book for practicing control engineers" —Martin A. Turk, Schneider Electric, Houston, Texas, USA

    "This book takes a unique, practical approach to control, emphasizing the design of control systems, what is measured and what is adjusted, for different unit operations."
    —Joseph A. Shaeiwitz, Auburn University, Alabama, USA