Simple Process
Control Loop
Simple process control loop (with negative feedback)
Load or disturbance u
Controller
+
Set
point
or
Demand
Error
_
Final control
element
Controller output
+
Actuating
signal
cm
Measured output
Measuring element
Transducer + transmitter
Process
Output
c
Simple process control loop (with negative feedback)
Load or disturbance u
Controller
+
Set
point
or
Demand
Error
_
Final control
element
Controller output
+
Actuating
signal
cm
Measured output
Measuring element
Transducer + transmitter
Independent variables:
set point r
load u
Manipulated variable: actuating signal v
Controlled variable: output c
Feed back variable: measured output cm
Process
Output
c
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 transducer
Transmitter gain
100%
Kt =
span of the transducer
Example: If a temperature transducer produces a full scale change in
output for a change in temperature from 20C to 150C, the gain of the
transmitter is
Kt = 100%/(150C -20C) = 100%/130C = 0.77%/C
Transmitter gain
100%
Kt =
span of the transducer
Example: If a temperature transducer produces a full scale change in
output for a change in temperature from 20C to 150C, the gain of the
transmitter is
Kt = 100%/(150C -20C) = 100%/130C = 0.77%/C
For a 4-20mA output, 0% means 4 mA and 100% means 20 mA.
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
Two state with or without hysteresis:
100%
0
Without hysteresis
100%
0
With hysteresis
On/Off controllers
100%
Two state with or without hysteresis:
Without hysteresis
Set point
Controller output
Process output
Measured output
Without hysteresis
100%
0
With hysteresis
On/Off controllers
100%
Two state with or without hysteresis:
Without hysteresis
100%
0
With hysteresis
Set point
Controller output
Process output
Measured output
Without hysteresis
With hysteresis
On/Off controllers
Two state with or without hysteresis:
100%
0
Without hysteresis
100%
0
With hysteresis
100%
100%
Three state with or without hysteresis:
-100%
Without hysteresis
-100%
With hysteresis
On/Off controllers
Two state with or without hysteresis:
100%
100%
0
Without hysteresis
With hysteresis
100%
100%
Three state with or without hysteresis:
-100%
Without hysteresis
-100%
With hysteresis
one
cycle
Proportional time using PWM:
on off
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
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
Motorized rotary actuator
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
Motorized linear actuator
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
Solenoid operated actuator
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
Pneumatic actuator
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
Pneumatic actuator
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
Hydraulic piston actuator
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
Diaphragm control valve
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
Diaphragm control valve
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
Direction control valve
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
Direction control valve
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
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
Oil fired burner
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
Centrifugal pump
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
Centrifugal pump
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
Type-0
Non-linear
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
Self-regulation type processes
Heated oil bath
Liquid level in a tank
Non-self regulation type processes
Metering Pump
Out
In
Different types of processes
Electrical
Mechanical
Thermal
Liquid
Gas
In combination of above types
Process parameters
Resistance or restriction
Capacitance or capacity
T
R
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%
%
=
dimension o
Kt
o
100 C
C
10 KW
W
=
Kv
100%
%
o
o
C 100 C
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
supply
Control
valve
Thermostat for water heating
Thermocouple
Desired
temp
Error
Mixer
Heater
50
25
75
Difference
Measurement
Power
amplifier
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
Multiplier
Square-root extractor
<
Low selector
>
High selector
Divider
Common Symbols
Absolute value
Saturation
V
I
Voltage-to-current or current-to-voltage converters
Voltage isolator
Current isolator
Process instrumentation diagrams
Liquid level control with a local pneumatic level controller
control
valve
pneumatic
controlsignal
Fi
LC
Local mounted
level controller
Sensor/transducer
Fo
Manual valve
Process instrumentation diagrams
Flow control system with electronic flow controller
square root
extractor
electrical control
signal
FC
board mounted flow
controller
differential pressure
transmitter
DP
Fi
Fo
control valve
orifice
Process instrumentation diagrams
Flow control with a turbine flow meter
FC
Flow
transmitter
Fi
FT
Fo
Process instrumentation diagrams
Temperature controlled stirred tank
motor stirrer
temperature
transmitter
TT
TC
board mounted
temperature
controller
Heat input
thermocouple/RTD/thermistor
References
1.
2.
3.
4.
5.
6.
7.
8.
9.
Process Control Systems by Shinskey
Automatic Process Control by Eckman
Principles of Process Control by Patranabis
Process Control by Harriott
Process Systems Analysis and Control by Coughanowr and Koppel
Process Control by Pollard
Chemical Process Control by Stephanopoulos
Modern Control Engineering by Ogata
Applied Process Control by Chidambaram
