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PIONEERS IN TECHNOLOGY TRANSFER

Process Control & Instrumentation

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 Process Control & Instrumentation

Section 1
Introduction

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Theory & Application

Topics

 Control History
 Basic Measurement Definitions
 Performance Terms and Specification
 P&ID Symbols
 Typical Applications
 Basic Control Concepts

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 Process Control & Instrumentation

Theory & Application

Control History

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 Process Control & Instrumentation

Theory & Application

CONTROL HISTORY
 Early development of feedback control by James Watt
in Scotland using a governor on a steam engine in
about 1775. (flywheel principle)
 Broader use of automatic control began to be made in
the late 1920’s and the first general, theoretical,
treatment of automatic control was published in 1932.
 New technologies have created a transformation in
control engineering with the advent of DCS and PLC
systems.
 The theory of automatic control has also developed in
parallel with these new technologies.
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 Process Control & Instrumentation

Theory & Application

CONTROL HISTORY

AN EXAMPLE OF WATTS STEAM GOVERNOR

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 Process Control & Instrumentation

Theory & Application

P & ID Symbols

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 Process Control & Instrumentation

P & ID Symbols

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 Process Control & Instrumentation

Theory & Application

P & ID SYMBOLS

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 Process Control & Instrumentation

Theory & Application

P&ID SYMBOLS

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 Process Control & Instrumentation

Theory & Application

P&ID SYMBOLS

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 Process Control & Instrumentation

Theory & Application

P&ID SYMBOLS

Control Valve

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 Process Control & Instrumentation

Theory & Application

Typical Applications

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Theory & Application

APPLICATIONS

A TYPICAL HOME HEATING SYSTEM

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APPLICATION

EXAMPLE - PROCESS LEVEL CONTROL

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Theory & Application

APPLICATIONS

EXAMPLE - PROCESS FLOW CONTROL

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Theory & Application

APPLICATIONS

INSTRUMENTS AND CONTROL VALVES IN THE

OVERALL CONTROL SYSTEM
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 Process Control & Instrumentation

Theory & Application

Basic Control Concepts

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 Process Control & Instrumentation

Theory & Application

BASIC CONTROL CONCEPTS

 This section introduces the basic concepts

encountered in Process Control.
 Some of the basic terminology is also presented.

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BASIC CONTROL CONCEPTS

Elements of a Process Control System

 A control loop is a self-contained system
 Purpose is to maintain a process at a given value
 Usually consists of a transmitter for measurement
 A controller to evaluate
 A control valve which can be changed by the
controller

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 Process Control & Instrumentation

Theory & Application

BASIC CONTROL THEORY

TRADITIONAL SINGLE LOOP CONTROLLER

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BASIC CONTROL THEORY
 For each controlled variable the control system
operator selects a manipulated variable which can be
paired with a controlled variable
 Often the choice is obvious, such as manipulating the
flow of fuel to a home furnace to control the
temperature of a house
 Sometimes the choice is not so obvious and can only be
determined by someone who understands the process
under control
 The pairing of manipulated and controlled variables is
performed as part of the process
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Theory & Application

BASIC CONTROL THEORY
Variables Involved
There are three main terms to consider
1. Controlled Quantities/Variables
2. Manipulated Quantities/Variables
3. Disturbances

Disturbances

Manipulated Controlled
Variables Variables

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BASIC CONTROL THEORY
Controlled Quantities
 Also referred to as Controlled Variables
 These are the streams or conditions which the
operator wishes to control or maintain at some level
 Controlled variables include such parameters as
temperature, pH, moisture, level, position, flow
weight and speed etc.
 For each controlled variable, there must be a desired
value known as a SET-POINT or reference value

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BASIC CONTROL THEORY

Manipulated Quantities
 For each controlled variable there is a manipulated
variable such as a flow rate
 This manipulated variable is usually controlled through
the use of a control valve

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BASIC CONTROL THEORY
Disturbances
 Disturbances enter the process and cause a change
away from the set-point
 Typical disturbances include change in temperature or
pressure or feed-stock
 The automatic control system must therefore alter the
manipulated variable so that the set point is
maintained in spite of these disturbances
 Also, the set point may be moved, in which case the
manipulated variable will need to be changed to
adjust the process to the new value
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BASIC CONTROL THEORY
Elements of a Process Control System
There are four essential elements in any process control
system:
1. Process
2. Measurement
3. Evaluation
4. Control

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BASIC CONTROL THEORY

Process

 In general, a process is an assembly of equipment and

material and is related to some manufacturing
operation or sequence
 In the case of a tank with a liquid, the level of this
liquid is influenced by the flow into and out of the tank.
 Any given process can involve dynamic variables and it
may be desirable to control all of them
 In most cases, controlling one variable would be
sufficient to control the process within acceptable
limits
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 Process Control & Instrumentation

Theory & Application

BASIC CONTROL THEORY
Process

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BASIC CONTROL THEORY

Measurement
To control any process it first has to be measured
 Measurement means the conversion of a process
variable into an analogue or digital signal by means of
a sensor or transmitter or both.
 The result of any measurement is the conversion of a
dynamic variable into some proportional information
which is required by some other elements in the
process control loop or sequence.

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BASIC CONTROL THEORY
Evaluation
 In the evaluation step of a process control sequence, the
measurement is examined and compared with the
desired value or set-point.
 The amount of corrective action required to maintain
proper control is determined.
 A controller is used for this evaluation. This controller
can be pneumatic, mechanical or electronic and would
be mounted in a panel.
 It can also be part of a computer control system, in
which case the control function is performed by
software.
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BASIC CONTROL THEORY
Control
 The control element in a control loop has the most
direct effect on the process.
 Receives a signal from the controller and transforms
this to a proportional operation which is performed on
the process.
 In most cases, the final element is a control valve
which adjusts a flow in a pipeline.
 Other final elements include: electrical motors, pumps
and dampers.
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BASIC CONTROL THEORY
Control (continued)
 In a typical home heating system, the controlled variable
is the room temperature.
 A number of disturbances cause the room temperature to
vary, e.g., outside ambient temp., the number of people
in the room or the activity taking place inside the room.
 The automatic control system is designed to manipulate
the fuel flow to the furnace in order to maintain room
temperature at the desired set-point.
 Note: Temperature is being controlled and flow rate is
being varied.

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BASIC CONTROL THEORY

Typical Manual Control

IT IS CONSIDERED USEFUL TO REVIEW THE MANUAL
CONTROL OF A PROCESS AT THIS STAGE.
 There must be an indication of the process which can
be used as a measurement
 The operator uses this indication to decide what
change is required
 The set-point is in the mind of the operator
 The operator compares these two values and changes
the final element accordingly
 There are many problems associated with this form of
control
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 Process Control & Instrumentation

Theory & Application

BASIC CONTROL THEORY

TYPICAL MANUAL CONTROL

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Theory & Application

BASIC CONTROL THEORY
Feedback Control
THE SIMPLEST WAY TO AUTOMATE THE CONTROL OF A
PROCESS IS THROUGH FEEDBACK CONTROL.
 Sensors are used to measure the actual value of the
controlled variable
 This value is transmitted to the feedback controller
 The controller makes a comparison between this
measurement and the desired value which has already
been established.
 Based on the difference (error) between these two
values, the controller sends a proportional output to
the control value.
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Theory & Application

BASIC CONTROL THEORY

FEEDBACK CONTROL CONCEPT

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Theory & Application

BASIC CONTROL THEORY
Feedback Control ( continued)
ADVANTAGES OF FEEDBACK CONTROL
 It is not essential to know what disturbances will affect
the process
 Also, the relationship between the final control element
and the process is not an issue
 Standard hardware can be used for almost any
application
 The principles of feedback control apply to all types of
process control instrumentation.
 Traditional, stand-alone feedback controllers offer the
simplest approach to automatic control.
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