Module 1 Students

EE09 L23
PROCESS CONTROL INSTRUMENTATION

Module I
Akhil A. Balakrishnan 1
1
Assistant Professor
Department of Electrical & Electronics Engineering
Jyothi Engineering College, Cheruthuruthy
akhilbalakrishnan@jecc.ac.in
As on July 7, 2015
Module I Signal Conditioning Process Control Principles
We will go through...
1 Signal Conditioning
Introduction
Analog Signal Conditioning
Digital Signal Conditioning
2 Process Control Principles

Introduction
Process Control Block Diagram
Control System Evaluation
Akhil A. Balakrishnan (JECC ) EE09 L23 PCI As on July 7, 2015 2 / 56

OBJECTIVES
*
To create an awareness of the different transducers used in
industry and signal conditioning.
*
To familiarize the process control elements and their control
characteristics.

REFERENCES
Text Books
1 Curtis D. Johnson,Process Control Instrumentation Technology,
Pearson Educations.
Reference Books
1 Curtis D. Johnson, Microprocessors in Process Control, PHI.
2 George Stephanopoulis, Chemical Process Control.
3 Caughner, Process Analysis and Control.
4 Deshpande and Ash, Elements of computer process control
of Industrial processes, ISA.
5 Jayantha K. Paul, Real-Time microcomputer control of
Industrial processes Kluwer Publications, Netherlands.
6 S. K. Singh, Computer Aided Process Control, PHI2.
7 Dale E. Seborg, Thomas F. Edgar, Duncan A. Mekkichamp,
Process Dynamics and Control, Wiley India.
SYLLABUS
Module I (8 Hours)
Signal Conditioning - Analog - Digital -
Signal conversions - Process Control
Principles - Identification of elements,
Block diagram, the loop, Control system
evaluation, Stability, Regulation,
Evaluation criteria, and Cyclic response.

Introduction
Introduction

Introduction

Introduction
A signal as referred to in communication systems, signal processing, and

electrical engineering ”is a function that conveys information about the
behavior or attributes of some phenomenon”.
Signal Conditioning
Signal Conditioning refers to operations
performed on signals to convert them to a
form suitable for interfacing with other
elements in the process control loop[1].
Two types:

Introduction

Introduction

Principles of Analog Signal Conditioning
Analog Signal Conditioning provides the operations necessary to

transform a sensor output into a form necessary to interface with
other elements of the process control loop.
Effect of signal conditioning is also described by the term
transfer function. Ex:- Simple Voltage Amplifier
Signal conditioning can be categorized into several general
types:
• Signal Level & Bias Changes
• Linearization
• Conversions
• Filtering & Impedance Matching
• Concept of Loading

1. Signal Level & Bias Changes
Signal Conditioning involves adjusting the level (magnitude) and

bias (zero value) of some voltage representing a process variable.
Example:

1. Signal Level & Bias Changes
12.5 is called the gain. This is called amplification.

Attenuation
An Amplifier can perform both.
Amplifier operation (amplification / attenuation) can be
distinguished by noting whether the gain is greater than or
less than unity.

2. Linearization
Linearization is necessary to provide an output that varies linearly

with some variable even if the sensor output does not.
[1]
Analog circuits are difficult to design and usually operate only
within narrow limits.
Modern approach is to provide the nonlinear signal as input
to the computer and perform the linearization using software.

3. Conversions
Signal Conditioning is used to convert one type of electrical

variation into another.
A large class of sensors exhibit change of resistance with
changes in a dynamic variable.
It’s necessary to provide a circuit to convert this resistance
changes either to a voltage or a current signal.
Generally accomplished by bridges when the fractional
resistance change is small and/or by amplifiers whose gain
varies with resistance.

3. Conversions (cont...)
Conversions are required in
Signal Transmission
Standard of transmitting signals : 4-20mA current levels in wire.
Signals in current transmission are independent of load
variations other than accidental shunt conditions that may
draw off some current.
Hence, voltage-to-current and current-to-voltage converters are
often required.
Digital Interface
Requires conversion of analog data into a digital format by
integrated circuit devices called analog-to-digital converters
(ADC’s).
Analog signal conversion circuits can be developed to
interface the analog measurement signal (sensor output) to
match the i/p requirements of the ADC. Example.
4. Filtering & Impedance Matching

Why we need filtering...???
Interference from the surroundings.
Motor start transients may cause pulses and other unwanted
signals in the process control loop.
To eliminate unwanted signals high-pass, low-pass, or notch
filter are used.
Passive filters - Using only resistors, capacitors, and inductors.
Active filters - Using gain and feedback.
Impedance matching.
Transducer internal impedance or line impedance can cause
errors in measurement of a dynamic variable.
Both, active and passive networks are employed to provide
such matching.

5. Concept of Loading
One of the most important concerns in analog signal
conditioning is the loading of one circuit by another.
It introduces uncertainty in the amplitude of voltage as it is
passed through the measurement process.

Rx
Vy = Vx 1−
RL + Rx
Equation shows how the effects of loading can be reduced.
The objective is to make RL much greater than Rx , ie, RL Rx
Loading is important mostly when signal amplitudes are
important. Frequency is not affected.
Example

Assignment
Write short notes on the “Different types of Passive Circuits”

Divider Circuits
Bridge Circuits
RC Filter Circuits
Op-amp Circuits

Introduction

Introduction

Digital Fundamentals
Digital Information
2 state (binary) levels
High state(H or 1) or a Low state(L or 0)
Digital Words
Bits
Binary Number or Word
Decimal Whole Numbers
Base 10
Octal & Hex Numbers
Base 8
Base 16 Hexadecimal
Fractional Binary Numbers

Example

Boolean Algebra
[1]
Alarm conditions.
1 Low level with High pressure
2 High level with High temperature
3 High level with Low temperature and High pressure
D =A·B+A·C+A·B·C
Digital Electronic Building Blocks
AND Gate
NAND Gate
OR Gate
NOR Gate
NOT Gate
XNOR Gate
XOR Gate

[1]

Programmable Logic Controllers
PLCs or simply Programmable Controller(PCs) is a computer

based solid state device that controls industrial equipment
and process.
Used for solutions of problems associated with boolean
equations and binary logic problems.
PLCs are computer-based outgrowth of relay sequence
controllers.
Programming PLCs is done using Ladder Logic.

Basic Structure of PLCs
[1]
Basic elements are: the processor, the input/output modules and

the software.
Basic Structure of PLCs (cont...)

Processor
Processor is a computer that executes a program to perform
the operations specified in a ladder diagram or a set of
boolean equations.
Input Modules
Input modules examine the state of physical switches and
other input devices and put their state into a form suitable for
the processor.
The PLC is able to accommodate a no of inputs, called as
channels.
Output Modules
The objective is to supply power to an external device such as
motor, light, solenoid and so on, as required by the ladder
diagram.
Advantages of PLCs
Advantages of computer based controllers over conventional

relay logic controllers are:
The input and output variables of discrete-state control
systems are binary in nature, just as in a computer.
Many of the “control relays” of the ladder diagram can be
replaced by software, which means less hardware problems.
Easy to make changes in a programmed sequence of events
when it is only a change in the software.
Special functions, such as time-delay actions and counters,
are easy to implement in software.
Development of new solid-state devices such as SCRs and
TRIACs, that can control high power ac/dc in response to
low-level commands from a computer.

Computer Interface
[1]
3 parallel sets of digital lines, together called as Bus.

Data Lines : Carry data to and from the processor.
Address Lines : Select external locations for input and output.
Control Lines : Carry information to and from the computer
related to operations such as reading, writing, interrupts , etc.
Tri-State Buffers
Data Acquisition Systems
PC’s connects the bus lines to no. of Printed Circuit

Board(PCB) sockets.
These sockets are referred to as expansion slots.
Special PCBs called as Data Acquisition Systems (DASs)

Data Acquisition Systems (cont...)
DAS Hardware - Typical Layout
[1]

Data Acquisition Systems (cont...)
DAS Hardware
ADC and S/H
Analog Multiplexer (MUX)
Address Decoder/Command Processor
DAC and Latch
DAS Software
Interfaces the computer and the DAS

Converters
Comparators
DACs
ADCs
DAC: A Unipolar DAC converts a digital word into an analog

voltage by scaling the analog output to be zero when all the bits
are zero and some maximum value when all bits are one. where
as in a Bipolar DAC the output ranges from minus to plus some
maximum values.

Converters
Digital-to-Analog-Converters
[1]
Converters
DAC Characteristics
Digital Input : Digital input is a parallel binary word; TTL logic
levels.
Power Supply: It is bipolar at a level of ±12 to ±18 as required
for internal amplifiers.
Reference Supply: Required to establish the range of output
voltage and resolution of the converter. Stable and Low
ripple source.
Output : Voltage representing the digital input.
Offset : Op-amps used in DAC’s produce typical output offset
voltage with a zero input.
Data Latch: When logic command is given to latch data,
data on the input bus will be latched into the DAC, & analog
output will be updated.
Conversion Time: Instantaneously convert the digital input to
analog output. Propagation time of the signal through the
internal amplifiers, order of few microseconds.
Converters
DAC Structure: Binary Weighted Resistor Network

Converters
DAC Structure: R-2R Ladder Network
[1]
Converters
DAC Structure: R-2R Ladder Network

1 Vb1 Vb2 Vb3 Vb4
i= { + + + } (1)
R 2 4 8 16
Vout = −i ∗ Rf (2)
−Rf Vb1 Vb2 Vb3 Vb4
Vout = { + + + } (3)
R 2 4 8 16

Converters
Analog-to-Digital Converters
[1]
Converters
ADC Characteristics
Analog Voltage Input : Voltage to be converted.
Power Supply: Requires bipolar supply voltage for internal
op-amps, and a digital logic supply connection.
Reference Voltage: Must be stable, well regulated.
Digital outputs: n-output lines, TTL values for logic high & low.
Control Lines: Single bit digital input and output lines.
SC(Start Convert): Input that starts the conversion process.
(Conversion starts on a Falling Edge)
EOC(End of Convert): Digital output from ADC to receiving
device(computer). High during conversion and low when
conversion completes.
RD(Read): Receiving device must take this line low to enable
the tri-states(buffer) & place the data on the output lines.
Conversion Time: ADC does not produce the digital o/p
instantaneously. Hence, Handshaking lines are required.
(Timing Diagram)
Converters
Flash Type / Simultaneous ADC
[3] [4]
Converters
Parallel-Feedback ADC
[1]
Introduction
Introduction

Introduction

Introduction
Systems
2 types of systems
Open Loop System - Manual Control System
Simple to operate, cheap, linear relationship, easily effected
by the disturbance and causes error.
Closed Loop System - Automatic Control System
Accurate, self adjusting, noise reduction stability.

Introduction
Open Loop & Closed Loop Control Systems
[5]

Introduction
Control : Methods to force parameters to a specific value.

Control System : All the elements necessary to accomplish
the control objective.
Process : Sequence of actions performed to achieve the
defined objective.
Process Control
• Natural Process Control
• Artificial Process Control
• Automatic Process Control

Introduction
Process Control Principles

Basic objective is to regulate the value of some quantity.
Regulate means to maintain that quantity at some desired
value regardless of external influences.
The desired value is called reference value or set-point.
Manipulated variable: Variable used for controlling. Also
known as Controlling variable.
Controlled variable: Variables which are affected by the
adjustments.

Introduction
Process
[1]

Introduction
Process
[1]

Introduction
Process
[1]

Introduction

Introduction

Process Control Elements

Process: Consists of a complex assembly of phenomena that
regulate to some manufacturing sequence.
Also called as Plant. Single-variable, Multivariable process.
Measurement: Representation of the variable value in some
form required by the other elements in the process-control
operation.
Sensors.
Error Detector: Difference between the actual and reference
values of a variable.
Magnitude and Polarity.
Controller: Depending upon the error value, corrective
actions are adopted in the next stage.
Compensator, filter, etc... Commonly called as Controller.
Control Element: Exerts a direct influence on the process.
Also called as Final Control Element.
Actuator: Uses the control signal to actuate the final control
element.
Block Diagram
[1]

Example
[1]

Example
[1]

Introduction

Introduction

Control System Objective
Objective of a process control system is to regulate the value

of some process variable.
Variable used to measure performance of the control system
is the error signal.
e(t) = r - c(t)
The objective of the control system is to make the error
exactly equal to zero.
Practical requirements of a control system are:
• The system should be stable.
• The system should provide the best possible steady-state
regulation.
• The system should provide the best possible transient regulation.

Stability
Steady State Regulation - Allowable deviation.
Transient Regulation - Set point changes.
Influence of other process variable - sudden changes -
Transient Response
Tuning is used to indicate how a process control loop is
adjusted to provide best control.
Evaluation criteria
Damped response
Cyclic response - Criteria : Minimum area, Quarter-amplitude

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EE09 L23

PROCESS CONTROL INSTRUMENTATION

2 Process Control Principles

Akhil A. Balakrishnan (JECC ) EE09 L23 PCI As on July 7, 2015 2 / 56

Akhil A. Balakrishnan (JECC ) EE09 L23 PCI As on July 7, 2015 3 / 56

Akhil A. Balakrishnan (JECC ) EE09 L23 PCI As on July 7, 2015 5 / 56

2 Process Control Principles

Akhil A. Balakrishnan (JECC ) EE09 L23 PCI As on July 7, 2015 6 / 56

A signal as referred to in communication systems, signal processing, and

Akhil A. Balakrishnan (JECC ) EE09 L23 PCI As on July 7, 2015 7 / 56

Analog Signal Conditioning

2 Process Control Principles

Akhil A. Balakrishnan (JECC ) EE09 L23 PCI As on July 7, 2015 8 / 56

Analog Signal Conditioning

Principles of Analog Signal Conditioning

Analog Signal Conditioning provides the operations necessary to

Akhil A. Balakrishnan (JECC ) EE09 L23 PCI As on July 7, 2015 9 / 56

Analog Signal Conditioning

1. Signal Level & Bias Changes

Signal Conditioning involves adjusting the level (magnitude) and

Akhil A. Balakrishnan (JECC ) EE09 L23 PCI As on July 7, 2015 10 / 56

Analog Signal Conditioning

1. Signal Level & Bias Changes

12.5 is called the gain. This is called amplification.

Akhil A. Balakrishnan (JECC ) EE09 L23 PCI As on July 7, 2015 11 / 56

Analog Signal Conditioning

Linearization is necessary to provide an output that varies linearly

Akhil A. Balakrishnan (JECC ) EE09 L23 PCI As on July 7, 2015 12 / 56

Analog Signal Conditioning

Signal Conditioning is used to convert one type of electrical

Akhil A. Balakrishnan (JECC ) EE09 L23 PCI As on July 7, 2015 13 / 56

Analog Signal Conditioning

Analog Signal Conditioning

4. Filtering & Impedance Matching

Akhil A. Balakrishnan (JECC ) EE09 L23 PCI As on July 7, 2015 15 / 56

Analog Signal Conditioning

Analog Signal Conditioning

Akhil A. Balakrishnan (JECC ) EE09 L23 PCI As on July 7, 2015 17 / 56

Analog Signal Conditioning

Write short notes on the “Different types of Passive Circuits”

Akhil A. Balakrishnan (JECC ) EE09 L23 PCI As on July 7, 2015 18 / 56

Digital Signal Conditioning

2 Process Control Principles

Akhil A. Balakrishnan (JECC ) EE09 L23 PCI As on July 7, 2015 19 / 56

Digital Signal Conditioning

Akhil A. Balakrishnan (JECC ) EE09 L23 PCI As on July 7, 2015 20 / 56

Digital Signal Conditioning

Akhil A. Balakrishnan (JECC ) EE09 L23 PCI As on July 7, 2015 21 / 56

Digital Signal Conditioning

2 High level with High temperature

3 High level with Low temperature and High pressure

Digital Signal Conditioning

Akhil A. Balakrishnan (JECC ) EE09 L23 PCI As on July 7, 2015 23 / 56

Digital Signal Conditioning

Akhil A. Balakrishnan (JECC ) EE09 L23 PCI As on July 7, 2015 24 / 56

Digital Signal Conditioning

Programmable Logic Controllers

PLCs or simply Programmable Controller(PCs) is a computer

Akhil A. Balakrishnan (JECC ) EE09 L23 PCI As on July 7, 2015 25 / 56