Introduction to Control

System
Part 2
Dr. S. Thangalakshmi
EXAMPLES - TEMPERATURE CONTROL SYSTEM (Open Loop)
EXAMPLES - TEMPERATURE CONTROL SYSTEM (Closed Loop)
What is control loop?
A Control loop is the fundamental building block of the industrial control system or
industrial automation. It is a group of components working together as a system to
achieve and maintain the desired value of a system variable by manipulating the value
of another variable in the control loop. An instrumentation control loop consists of a
controller that can adjust the process variable equal to set-point by measuring the
current process variable using sensors.
Process Variable – Measured or Actual Value
Set-Point – Desired Output

Components of a Control loop: There are different types of

Sensors are the first element in the control loop which measures the change in the process and

reporting the process variable so they are also called as the primary element. Sensors are devices

which cause change when affected by a change in the process variable. There are different types of

sensors for measuring variables like Pressure, Temperature, Flow, Level, pH, Vibration etc.,

There are different types of sensors available for various process variable:

• Thermocouples, RTD for Temperature measurement

• Strain gauge, Pressure sensing diaphragm, capacitive cells for pressure measurement

• Orifice plate, Pitot tube, Magnetic flow tube etc., for flow measurement

There are so many other sensors used to measure different variables like vibration, pH, force,

weight etc..
Transducers:

A transducer converts any form of energy

into another form. In electrical

instrumentation field Transducers are

devices which converts a physical variable

into electrical signals. Another name

transducers are Pick-ups.

In process control, a converter used to

convert a 4–20 mA current signal into a 3–

15 psi pneumatic signal is called a current-

to-pressure converter. There are different

types of transducer classified based on their

Transmitters are devices that convert the signal into a standard signal that can be

transmittable through the control loop and the parameters can be monitored remotely.

• Pressure transmitters

• Flow transmitters

• Temperature transmitters

• Level transmitters

• Analytic transmitters
Signals:

Signals are used to transmit process variable from transmitter to the controller and sent back the

feedback signal from the controller to the final control elements. There are three types of signal in

industrial automation:

Pneumatic signal: Air pressure in the pneumatic pipeline change according to the change in the

process variable. The standard pneumatic pressure in the signal pipe in industries are in a range of 3-

15psi.

Analog signal: Analog signals are mostly used control signals, the transmitter sends the signal

through a set of electrical wire. The standard signal range is within 4-20mA, for LRV valve a 4mA

signal is produced and for URV it is 20mA.Other common standard electrical signals include the 1–5 V

(volts) signal and the pulse output.

Digital signal: Digital signals are special protocols used for communication in industries. All protocol
Indicators:

An indicator is human readable devices that display the process variable. There are analog

indicators such as used in pressure, temperature gauges and there are digital indicators that

display process variables as the digits. Even though the process variable is connected to the

controller, the indicators are used industries for different purposes.

Recorder:

Recorders are used in industries to provide history on the process and to be submitted to regulatory

agencies for verification. By recording the readings of critical measurement points and comparing

those readings over time with the results of the process, the process can be improved.
Controllers:

Controllers are the centre of process control, which receives process variable then compare with

setpoint stored in the controller and sends a feedback as the controller output to control the final

control element. There are pneumatic and electronic or programmable such as DCS, PLC uses a

complex mathematical algorithm to perform the control action.

PLC (Programmable Logic Controller): PLCs are usually computers connected to a set of

input/output (I/O) devices. The computers are programmed to respond to inputs by sending outputs

to maintain all processes at setpoint.

DCS (Distributed Control Signal): DCSs are controllers that, in addition to performing control

functions, provide readings of the status of the process, maintain databases and advanced man-

machine-interface.
Final control element:

Final control elements are the correcting elements that receives signal from the controller and

make a change in process to adjust the process variable at the desired parameter. In any control

loop, the speed with which a final control element reacts to correct a variable that is out of setpoint

is very important. Many of the technological improvements in final control elements are related to

improving their response time.

For example:

Pumps and Control valves – Final control devices of Flow control system

Heaters and Boilers – Final control devices of temperature control system

Compressor and Valves: Final control devices of pressure control system

An actuator is the most important part of the final control element, a device that causes physical

change in the final control element. For a valve, actuator is the valve stem actuator and for a

heater, it is the heating coil. An actuator can be controlled by pneumatically, Hydraulically,

Electrically.