Simple process control loop (with negative feedback)

Load or disturbance
u

+ Output
r e m Final control v c
+ Controller element + Process
Set Error
point Actuating
_ Controller output
or signal
Demand
cm
Measuring element
Measured output
Transducer + transmitter
 Simple process control loop (with negative feedback)

Load or disturbance
u

+ Output
r e m Final control v c
+ Controller element + Process
Set Error
point Actuating
_ Controller output
or signal
Demand
cm
Measuring element
Measured output
Transducer + transmitter

 Independent variables:
• set point ‘r’
• load ‘u’
 Manipulated variable: actuating signal ‘v’
 Controlled variable: output ‘c’
 Feed back variable: measured output ‘cm’
 Servo problem

It is the ability of output tracking the given set point changes

 Servo problem

It is the ability of output tracking the given set point changes

Set point

Load or
disturbance

Output
 Regulatory problem

It is the ability to control the output at the desired level in the face of
disturbances entering the process
 Regulatory problem

It is the ability to control the output at the desired level in the face of
disturbances entering the process

Set point

Load or
disturbance

Output
 Measuring element

Temperature,
pressure, flow, pH
 Measuring element

Temperature,
pressure, flow, pH

 Electrical output signal range:

• Voltage: 0-1V, 0-5V, 0-10V, 1-5V
• Current: 0-1mA, 0-5mA, 0-10mA, 0-20mA, 4-20mA
 Pneumatic output signal range: 3-15psi
 Transmitter gain

100%
Kt 
span of the transduce r
 Temperature transmitters

Non-indicating (blind) transmitters Indicating transmitter

 Controller

Depending on construction controllers may be classified as

 Electronic

 Pneumatic
 Controller

Depending on construction controllers may be classified as

 Electronic

 Pneumatic

Depending on operation controllers may be classified as

 Analog

 Digital
 Different types of Controllers

 Proportional (P) controllers

 Proportional-integral (PI) controllers

 Proportional-derivative (PD) controllers

 Proportional-integral-derivative (PID) controllers

 On/Off controllers
P-control
PI-control
PD-control
PID-control
 Controller symbol

P – controller – for a step change in error 


 Controller symbol

P – controller – for a step change in error 

PI – controller – for a step change in error 


 Controller symbol

P – controller – for a step change in error 

PI – controller – for a step change in error 

PD – controller – for a step change in error 


 Controller symbol

P – controller – for a step change in error 

PI – controller – for a step change in error 

PD – controller – for a step change in error 

PID – controller – for a step change in error 

 Controller gain

Change in controller output

Kc =
Error
PID temperature controller
 On/Off controllers

100% 100%
Two state with or without hysteresis:
0 0

Without hysteresis With hysteresis

 On/Off controllers

100% 100%
Two state with or without hysteresis:
0 0

Without hysteresis With hysteresis

Set point

Controller output

Process output

Measured output

Without hysteresis
 On/Off controllers

100% 100%
Two state with or without hysteresis:
0 0

Without hysteresis With hysteresis

Set point

Controller output

Process output

Measured output

Without hysteresis With hysteresis

 On/Off controllers

100% 100%
Two state with or without hysteresis:
0 0

Without hysteresis With hysteresis

100% 100%

Three state with or without hysteresis:

-100% -100%

Without hysteresis With hysteresis

 On/Off controllers

100% 100%
Two state with or without hysteresis:
0 0

Without hysteresis With hysteresis

100% 100%

Three state with or without hysteresis:

-100% -100%

Without hysteresis With hysteresis

one
cycle

Proportional time using PWM:

on off t
 Final control element

It is the mechanism which alters the value of the

manipulated variable in response to the output signal
from the controller
 Final control element

It is the mechanism which alters the value of the

manipulated variable in response to the output signal
from the controller

 Electric actuators
• Motorized – rotary or linear
• Solenoid operated
 Pneumatic actuators
 Electro-pneumatic actuators
 Hydraulic actuators
• Piston
• Diaphragm
 Control valves
 Heaters
 Burners
 Pumps
 Gain of the final control element

span of the final control element

Kv 
100%
 Process

A process may be characterized by its input-output relationship

Process

Linear Non-linear

Type-0 Type-1
 Process

A process may be characterized by its natural form of feedback

Process

Self-regulation type process Non-self regulation type process

Self-regulation type processes

Heated oil bath

Self-regulation type processes

Heated oil bath

Liquid level in a tank

Non-self regulation type processes
 Different types of processes

 Electrical

 Mechanical

 Thermal

 Liquid

 Gas

 In combination of above types

 Process parameters

 Resistance or restriction T
R

 Capacitance or capacity C

 Dead time or transportation lag

 Lag – due to combination of resistance and capacitance

 Inductance – due to mass of fluid or liquid

Steady state gain of a process
 Loop gain

The product (Kt.Kv.Kp) is a dimension less parameter. It is related to the

gain of the controller which is again dimensionless.
 Loop gain

The product (Kt.Kv.Kp) is a dimension less parameter. It is related to the

gain of the controller which is again dimensionless.

In a temperature control system (0-100oC), 10 KW:

100% %
Kt  o
 dimension o
100 C C
10 KW W
Kv  
100% %
C 100 C o o
C
Kp   
V 10 KW W
Process Examples

h = p1 – p2

h=Rm
Process Examples

h = p1 – p2

h=Rm

 R 
h  m
 sT  1 
T  RC
 Boiler drum level control
(inverse response)

Steam discharge
level
transmitter
LT
check valve

Boiler drum
level controller

LC

Feed water Control

supply valve
 Thermostat for water heating

Thermocouple
Desired
Mixer
temp Error Heater
50

75
Power
25 Difference
amplifier

Measurement
 Common Symbols

Pneumatic control signal

Capillary control signal

_____
Electrical control signal

Gas / liquid pipeline

or Restriction

Manual valve

Control valve

On-Off or solenoid type valve

 Common Symbols

XC Locally mounted controller

X: pH
X: S - speed
X: T - temperature
X: L - level
X: P - pressure
X: F - flow

XC Board mounted controller, X: pH, S, T, L, P, F

XT Transmitter, X: pH, T, L, P, F, S

XS Switch, X: pH, T, L, P, F, S

DP Differential pressure transmitter

XRC Recorder controller, X: pH, T, L, P, F, S

Common Symbols

Check valve

Relief valve

Orifice

Nozzle or venturi

Magnetic flow meter

Turbine type flow meter

Controlled damper
Common Symbols

Vessel / reactor

Heat exchanger

Oil-burner

Sensor / transducer

Motor stirrer

Pump
 Common Symbols

+ Summer

X Multiplier

Square-root extractor

< Low selector

> High selector

Divider
 Common Symbols

Absolute value

Saturation

V
I Voltage-to-current or current-to-voltage converters

V
V Voltage isolator

I
I Current isolator
 Process instrumentation diagrams

Liquid level control with a local pneumatic level controller

control
valve
pneumatic
controlsignal

Fi
LC
Sensor/transducer Local mounted
level controller
Fo
Manual valve
 Process instrumentation diagrams

Flow control system with electronic flow controller

square root
extractor
electrical control FC board mounted flow
signal
controller
differential pressure
transmitter

DP
Fi Fo

control valve
orifice
Process instrumentation diagrams

Flow control with a turbine flow meter

FC
Flow
transmitter
FT

Fi Fo
 Process instrumentation diagrams

Temperature controlled stirred tank

temperature
board mounted
motor stirrer transmitter
temperature
TT TC controller

Heat input

thermocouple/RTD/thermistor