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Chapter 1 Introduction To Process Control

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Megha Raj
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9 views

Chapter 1 Introduction To Process Control

Uploaded by

Megha Raj
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 13

Module 1

Introduction to Process Control

Syllabus: block diagram of process control loop, definition of elements. Sensor time response - first
and second order responses. Review of Transducers: Characteristics and Choice of transducer-
factors influencing choice of transducer

Text books:
1. Curtis D Johnson ,” Process Control Instrumentation Technology”, PHI, 1986

1.1 Block diagram of process control loop

Block diagram – process control system

The figure shows the block diagram of close loop system or process control system.
The process control system consists of process or plant, feedback elements, error detector,
automatic controller, actuator or control element.

Plant or Process:
Plant or process is an important element of process control system in which variable of process is
to be controlled. The Process means some manufacturing sequence. It has one variable or
multivariable output.

Feedback element or Sensor:


The feedback element or sensor is the device which converts the output variable into another
suitable variable which can acceptable by error detector.

Error detector:
The error detector compares between actual signal and reference input i.e. set point. The error
detector is subtract summing points whose output is an error signal to controller for comparison
and for the corrective action.

Automatic controller:
The controller detects the actuating error signal, which is usually at a very low power level,
and amplifies it to a sufficiently high level i.e. means automatic controller comprises an error
detector and amplifier.

Actuator or control element:


The actuator is nothing but pneumatic or valve, a hydraulic motor or an electric motor, which
produces an input to the plant according to the control signal getting from the controller.

1.2 Sensor time responses


1.3 Review of Transducers:

A device which converts a physical quantity into the proportional electrical signal is called a
transducer. The electrical signal produced may be a voltage, current or frequency. A transducer
uses many effects to produce such conversion. The process of transforming signal from one form
to other is called transduction. A transducer is also called pick up. The transduction element
transforms the output of the sensor to an electrical output, as shown in the Fig.

A transducer will have basically two main components. They are

1. Sensing Element

The physical quantity or its rate of change is sensed and responded to by this part of the
transistor.

2. Transduction Element

The output of the sensing element is passed on to the transduction element. This element is
responsible for converting the non-electrical signal into its proportional electrical signal.
There may be cases when the transduction element performs the action of both transduction and
sensing. The best example of such a transducer is a thermocouple. A thermocouple is used to
generate a voltage corresponding to the heat that is generated at the junction of two dissimilar
metals.

1.3.1 Characteristics of Transducer


1. Accuracy: It is defined as the closeness with which the reading approaches an accepted
standard value or ideal value or true value, of the variable being measured.
2. Ruggedness: The transducer should be mechanically rugged to withstand overloads. It
should have overload protection.
3. Linearity: The output of the transducer should be linearly proportional to the input
quantity under measurement. It should have linear input - output characteristic.
4. Repeatability: The output of the transducer must be exactly the same, under same
environmental conditions, when the same quantity is applied at the input repeatedly.
5. High output: The transducer should give reasonably high output signal so that it can be
easily processed and measured. The output must be much larger than noise. Now-a-days, digital
output is preferred in many applications;
6. High Stability and Reliability: The output of the transducer should be highly stable and
reliable so that there will be minimum error in measurement. The output must remain unaffected
by environmental conditions such as change in temperature, pressure, etc.
7. Sensitivity: The sensitivity of the electrical transducer is defined as the electrical
output obtained per unit change in the physical parameter of the input quantity. For example, for
a transducer used for temperature measurement. A high sensitivity is always desirable for a given
transducer.
8. Dynamic Range: For a transducer, the operating range should be wide, so that it can be
used over a wide range of measurement conditions.
9. Size: The transducer should have smallest possible size and shape with minimal weight and
volume. This will make the measurement system very compact.
10. Speed of Response: It is the rapidity with which the transducer responds to changes in
the measured quantity. The speed of response of the transducer should be as high as practicable.

1.3.2 Selection criteria of transducer

o Operating Principle: The transducers are selected on the basis of operating principle it may
be resistive, inductive, capacitive, optical etc.
o Operating range: The range of transducer should be appropriate for measurement to get a
good resolution.
o Accuracy: The accuracy should be as high as possible or as per the measurement.
o Range: The transducer can give good result within its specified range, so select transducer
as per the operating range.
o Sensitivity: The transducer should be more sensitive to produce the output or sensitivity
should be as per requirement.
o Loading effect: The transducer’s input impedance should be high and output impedance
should be low to avoid loading effect.
o Errors: The error produced by the transducer should be low as possible.
o Environmental compatibility: The transducer should maintain input and output
characteristic for the selected environmental condition.

1.3.3 Factor to be considered while selecting transducer:


o It should have high input impedance and low output impedance, to avoid loading effect.
o It should have good resolution over is entire selected range.
o It must be highly sensitive to desired signal and insensitive to unwanted signal.
o Preferably small in size.
o It should be able to work n corrosive environment.
o It should be able to withstand pressure, shocks, vibrations etc..
o It must have high degree of accuracy and repeatability.
o Selected transducer must be free from errors.
o The transducer circuit should have overload protection so that it will withstand overloads.

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