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Professor Robert L. Heider, PE

This document provides an overview of a lecture on process control by Professor Robert L. Heider. The key points covered include: definitions of process control and related terms, common process measurement instruments like temperature, pressure, level, and flow transmitters, control valves, statistical process control techniques, and discussion topics around these areas. Measurement transducers, transmitters, controllers, and process manipulation are also defined as the basic components of a process control loop.

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Rachidh Uverkane
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70 views

Professor Robert L. Heider, PE

This document provides an overview of a lecture on process control by Professor Robert L. Heider. The key points covered include: definitions of process control and related terms, common process measurement instruments like temperature, pressure, level, and flow transmitters, control valves, statistical process control techniques, and discussion topics around these areas. Measurement transducers, transmitters, controllers, and process manipulation are also defined as the basic components of a process control loop.

Uploaded by

Rachidh Uverkane
Copyright
© © All Rights Reserved
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Professor Robert L.

Heider, PE

Adjunct Professor, ChE, Washington


University

~45 years experience doing “Process Control”

Professor for the DPCL, ChE433


Lecture Includes:
• What is "process control"? Hardware and
Software (firmware)
• Process measurement instruments;
transmitters, transducers, sensor elements,
control valves
– Flow
– Level
– Pressure
– Temperature
– pH
• Comments on topics in text
Process Control
• Macro vs. micro and nano
• Process Control views the process in
macro terms
• Concerned with interactions of all process
variables rather than exact solution of the
details of one variable
• Can use simulations but does not
necessarily require it
Just what is “Process Control?”
“Operating a processing plant or facility such
that the product quality and production rate
specifications are met in a safe and
reliable manor.”

Involves both hardware and software or


firmware functioning together.
Process Control is a general term
for the whole plant.
Control Loop is the term used to
define a single process parameter.
• Measurement
• Controller
• Process Manipulation
• Connections or communication between them
Process Control - SPC
• Statistical Process Control (SPC) is a
technique where the process output or PV
is monitored in order to detect an out of
control process.
• Frequently done with Control Charts
• More processes are batch rather than
continuous, discrete batches or things
properties are controlled through SPC
Process Control - SPC
• Shewhart control chart, X-BAR R chart
used to detect out of control process
• CUSUM and EWMA Charts
• SPC does not dictate how much to move
or change the process, only that it is out of
control
• Run-by-Run control is frequently used in
semiconductor manufacturing
Measurement
• Devices that convert a physical or
chemical plant condition to a usable
signal.
Process Manipulation
Moves or changes the process

• Control Valve
• Adjustable Speed Drive
Controller
• The device or software (firmware) that
moves the process to keep the
measurement where we want it.
Process Instrumentation Diagram:
Feedback Control – Basic Format
CONTROLLER

TE Temperature
Temp. 101 Element
TC
Set 101
Point
TT Temperature
Current to pneumatic TT
101 Transmitter
TRANSMITTER
(I/P) converter 101

TC Temperature (line in middle indicates


101 Controller remote control)
FY
ACTUATOR 101
TE
101
SENSOR FE Flow
Cooling
101 Element
Manual
Water
AFC Valve
Pneumatic Valve (automatic valve)
Valve failure
position chosen Electrical Signal (4-20 mA)
for safety and Pneumatic Signal (3-15 psig)
operability (arrow indicates flow/signal direction)
Material Flow Line
Often the sensor is integrated into the transmitter and the I/P converter is integrated into a
position controller or “valve positioner” on the actuator that is also not shown on the P&ID.
Process Instrumentation Diagrams:
Standard Control Instrumentation Symbols
Preceded by area or plant number
H X Y Z

XYZ Measurement (optional) Instrument

T– I – Indicator C – Controller
Temperature
nnn P – Pressure R – Recorder T – Transmitter
L
F – Flow E – Sensor V – Valve
Low Alarm
C- Y– Z – Actuator
nnn Composition Composition
# that uniquely L – Level A - Alarm H – High
identifies instrument W – Weight L – Low

D - Density
Lecture Topics
• Terminology
• Instruments
– Temperature
– Pressure, level, flow
• Control Valves
• Transducer – Element; Latin word
From Latin trānsdūcere, to transfer : trāns-, trans- + dūcere, to lead

A device that converts one type of energy or physical


attribute to another for various purposes including
measurement or information transfer
Also called an “Element”
• Transmitter
A transducer which responds to a measured variable by
means of a sensing element, and converts it to a
standardized transmission signal which is a function only
of the measured variable.
Discussion Items
• Pressure Flow
• Level
• Control Valves
• Temperature Instrumentation
Text Comments, Chapter 9
Output final element linearity – usually is not, consider:
SCR Silicon Controlled Rectifier – AC power phase control
SCR phase controlled load results in non-linear output
Instrument Selection
• Page 209 of Seborg text
• Point 4 MOC, Instruments require better
service requirements than pipe or vessel
MOC, thin diaphragms, etc
• Add point 9, International Codes and
Standards as well as special instructions
for service requirements
– Oxygen cleaning
– Nuclear service
Manufacture Support

ABB Siemens

• Most major companies now rely on instrument and


control system manufactures for their technical support.
• Users groups now substitute for technical societies

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