1 Process Control

Introduction to
Instrumentation and
Control Systems
Introduction to Instrumentation and Control
Systems
– Manipulated variable
– Controlled variable
– Disturbance variable
• Describe simple process control loop using
block diagram
• Explain the two (2) general types of control
loop
– Manual or open loop
– Automatic or close loop
Introduction to Instrumentation and Control
Systems
• Sketch a simple automatic control loop, using block

diagram showing the principal elements in the system.
• Explain the three (3) elements involve in a typical process
control loop:
– Primary element
– Secondary element
– Final control element
• Explain the four (4) functions of the elements in the loop
– Measuring - Computation
– Comparison - Correction
What is INSTRUMENTATION?
“ A collection of instruments or their application for the
purpose of observation, measurement or control.”
Instrumentation is defined as the art and science of

measurement and control of process variables
within a production, or manufacturing area. it is
also defined as instrumentation is a device or
group of device that is measure the process
variable and control them as per the requirement
for the process.[1]wikipedia
What is AUTOMATION?
- is the use of machines, control

systems and information
technologies to optimize productivity in
the production of goods and delivery of
services.
Automation…
The correct incentive for applying
automation is to increase productivity,
and/or quality beyond that possible with
current human labor levels so as to
realize economies of scale, and/or realize
predictable quality levels.
The incorrect application of automation,
which occurs most often, is an effort to
eliminate or replace human labor.
What is PROCESS CONTROL?
a statistics and engineering discipline
that deals with the architectures,
mechanism, and algorithm for
maintaining the output of a specific
process within the desired range.
PROCESS CONTROL…
Process control is extensively used in industry and enables
mass production of continuous processes such as oil
refining, paper manufacturing, chemicals, power plants and
many other industries. Process control enables automation,
with which a small staff of operating personnel can operate
a complex process from a central control room.
CONTROL LOOP
- Is the fundamental building block of industrial
control systems. It consist of all the physical
components and control functions necessary to
automatically adjust the value of a measured
process variable (PV) to equal the value of a
desired set-point (SP).
It includes the process sensor, the controller

function, ant the final control element (FCE) which
are all required for automatic control
Two General Types of Control Loop
Open Loop System Closed Loop System
The terms manual mode & auto mode are

sometimes used in place of open loop & closed
loop. When the system control is placed in manual
mode, the loop is in open-loop operation, & when
the system control is placed in auto mode, the loop
is in closed-loop operation.
Open Loop System (feedforward system)
Open loop systems do not have access to the real time

data about the performance of the system and therefore
no immediate corrective action can be taken in case of
system disturbance. This system is only applied
normally to the case where the output is almost
constant and predictable.
Open loop control is by far the more
simple of the two types of control theory.
In open loop control, there is some sort of
input signal (digital or analog), which then
passes through amplifiers to produce the
proper output, and is then passed out of
the system.
MANUAL CONTROL
Above: An example of an open-loop water-level control system. The

operator controls the opening & closing of the water valve when
the system is operated in manual mode. (*NOTE: Operator must
visually check water level when system is in manual control)
MANUAL CONTROL
HOT H2O
STM HEATER
Cold H2O
Advantages:
Simplicity and stability: they are simpler in their
layout and hence are economical and stable too due
to their simplicity.
Construction: Since these are having a simple layout
so are easier to construct.
Disadvantages:
Accuracy and Reliability: since these systems do not
have a feedback mechanism, so they are very
inaccurate in terms of result output and hence they
are unreliable too.
Due to the absence of a feedback mechanism, they
are unable to remove the disturbances occurring
from external sources.
Open-loop systems tend to be very simple
& used frequently in industrial
applications because they are inexpensive
to operate.
Closed-Loop System
Feed back devices closely monitor the output and any

disturbance will be corrected in the first instance in a
close loop system. Therefore high system accuracy is
achievable. This close loop system is more powerful than
the open loop system and can be applied to the case
where the output is subjected to frequent change.
AUTOMATIC CONTROL
HOT H2O
STM HEATER
COLD H2O
Closed Loop System:
Advantages:
Accuracy: They are more accurate than open

loop system due to their complex construction. They
are equally accurate and are not disturbed in the
presence of non-linearities.
Noise reduction ability: Since they are composed of a

feedback mechanism, so they clear out the errors
between input and output signals, and hence remain
unaffected to the external noise sources.
Closed Loop System:
Disadvantages:
Construction: They are relatively more complex in

construction and hence it adds up to the cost making it
costlier than open loop system.
Since it consists of feedback loop, it may create
oscillatory response of the system and it also reduces
the overall gain of the system.
Stability: It is less stable than open loop system but

this disadvantage can be striked off since we can make
the sensitivity of the system very small so as to make
thesystem as stable as possible.
Closed-loop control systems are the
type most commonly used in the Navy
because they respond and move the
loads they are controlling quicker and
with greater accuracy than open-loop
systems
The Process Control Loop
DISTURBANCE
VARIABLE
MANIPULATED CONTROLLED
VARIABLE VARIABLE
PROCESS
PROCESS CONTROL VARIABLES

Basic Concepts of Process Control
 Control Loop Variables

 Control Loop Elements
 Control Loop Elements Functions
 Sample Processes
FINAL SECONDARY
CONTROL ELEMENT
ELEMENT
PRIMARY
ELEMENT
PROCESS
PROCESS CONTROL ELEMENTS AND THEIR FUNCTIONS

SET VALUE
(SV)
MANIPULATED
VALUE
(MV) PROCESS
VALUE
(PV)
PROCESS
PROCESS CONTROL ELEMENTS AND THEIR FUNCTIONS

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Introduction to

• Sketch a simple automatic control loop, using block

Instrumentation is defined as the art and science of

- is the use of machines, control

It includes the process sensor, the controller

Open Loop System Closed Loop System

The terms manual mode & auto mode are

Open loop systems do not have access to the real time

Above: An example of an open-loop water-level control system. The

Feed back devices closely monitor the output and any

Accuracy: They are more accurate than open

Noise reduction ability: Since they are composed of a

Construction: They are relatively more complex in

Stability: It is less stable than open loop system but

PROCESS CONTROL VARIABLES

 Control Loop Variables

PROCESS CONTROL ELEMENTS AND THEIR FUNCTIONS

PROCESS CONTROL ELEMENTS AND THEIR FUNCTIONS

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