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Load or disturbance u

Simple process control loop (with negative feedback)

r Set point or Demand

Controller

Error

Final control element

Process

Output c

Controller output

Actuating signal

cm

Measuring element g

Measured output

Transducer + transmitter

Independentvariables: Independent variables: setpointr loadu Manipulatedvariable:actuatingsignalv Controlledvariable:output c Controlled variable: output c Feedbackvariable:measuredoutputcm

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Output Set point Load or disturbance

Servo problem

Itistheabilityofoutputtrackingthegivensetpointchanges

Itistheabilitytocontroltheoutputatthedesiredlevelinthefaceof disturbancesenteringtheprocess di t b t i th

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Regulatory problem
Set point Load or disturbance Output

Temperature, Temperature pressure, flow, pH

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Measuring element
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 3 15psi

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Transmitter gain

100% Kt = span of th t f the transduce r d

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Temperature transmitters
Indicating t I di ti transmitter itt

Non-indicating (blind) transmitters N i di ti (bli d) t itt

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Controller
Electronic Pneumatic Analog Digital

Depending on construction controllers may be classified as

Depending on operation controllers may be classified as

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Different types of Controllers Proportional (P) controllers P ti l t ll Proportional-integral (PI) controllers Proportional-derivative (PD) controllers On/Off controllers

Proportional-integral-derivative (PID) controllers

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P-control P control

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PI-control PI control

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PD-control PD control

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PID-control PID control

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

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Controller symbol

Kc = Change in controller output

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Controller gain

Error

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PID temperature controller

Twostatewithorwithouthysteresis: ih ih h i

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On/Off controllers
Withouthysteresis

Withhysteresis

Set point

Controller output

Process output

Measured output

Withouthysteresis

Withhysteresis

Twostatewithorwithouthysteresis: ih ih h i

Threestatewithorwithouthysteresis: Three state with or without hysteresis

ProportionaltimeusingPWM: i l i i

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On/Off controllers
Withouthysteresis Withouthysteresis Without hysteresis

Withhysteresis

Withhysteresis With hysteresis

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Final control element
Itisthemechanismwhichaltersthevalueofthe manipulatedvariableinresponsetotheoutputsignal i l t d i bl i t th t t i l fromthecontroller
Electric actuators Motorized rotary or linear Solenoid operated Pneumatic actuators Electro-pneumatic actuators Hydraulic actuators Piston Diaphragm Control valves Heaters Burners Pumps

span of th fi l control element f the final t l l t Kv = 100% 00%

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Gain of the final control element

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Type-0 Linear A process may be characterized by its input-output relationship Type-1 Non-linear

Process

Process

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Process
Process Self-regulation type process

A process may be characterized by its natural form of feedback

Non-self regulation type process

Heated oil bath

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Liquid l Li id level in a tank li t k

Self-regulation type processes

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Non-self Non self regulation type processes

Electrical

Thermal Th l

Gas

Liquid

Mechanical

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In combination of above types Different types of processes

Resistance or restriction Capacitance or capacity C it it

Dead time or transportation lag

Lag due to combination of resistance and capacitance Inductance due to mass of fluid or liquid

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Process parameters
T R

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Steady state gain of a process

The Th product (Kt.Kv.Kp) is a dimension less parameter. It i related t the d t K K i di i l t is l t d to th gain of the controller which is again dimensionless.

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Loop gain

In a temperature control system (0-100oC), 10 KW:

100% % Kt = dim ension o o 100 C C 10 K W W Kv = 100% % o C 100 o C C Kp = = V 10 K W W

Process Examples

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h=Rm h=p1 p2

R h = m sT + 1 T = RC

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Boiler drum level control (inverse response)
level transmitter LT Boiler drum level controller LC Feed water supply Control valve

Steam discharge

check valve

25

50

75

Desired D i d temp

Difference

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Measurement Power amplifier

Thermostat for water heating

Error

Heater

Mixer

Thermocouple p

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Common Symbols
Pneumatic control signal g Capillary control signal

_____

Electrical control signal Gas / liquid pipeline Restriction

or

Manual valve

Control valve

On Off On-Off or solenoid type valve

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Common Symbols
XC

Locally mounted controller y

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 Transmitter, Transmitter X: pH T L P F S pH, T, L, P, F, Switch, X: pH, T, L, P, F, S

XT

XS

DP

Differential pressure transmitter

XRC

Recorder controller, X: pH, T, L, P, F, S

Common Symbols

Orifice

Relief valve

Check valve

Nozzle or venturi

Controlled damper

Magnetic f flow meter

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Turbine type flow meter

Common Symbols

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Pump Oil-burner Oil burner Motor stirrer Vessel / reactor V l t Heat H t exchanger h Sensor / transducer

>

<

Summer

Common Symbols

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Divider Multiplier Low selector High selector Square-root extractor

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Common Symbols
Absolute l Ab l t value Saturation
V I
V V

Voltage-to-current or current-to-voltage converters

Voltage isolator

Current isolator

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Process instrumentation diagrams
Liquid level control with a local pneumatic level controller

control valve

pneumatic controlsignal

Fi

LC

Sensor/transducer

Local mounted level controller

Fo

Manual valve

differential pressure transmitter Fi

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Process instrumentation diagrams
Flow control system with electronic flow controller
square root extractor electrical control signal FC DP Fo control valve orifice

board mounted flow controller

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Fi Flow transmitter FC

Flow control with a turbine flow meter

FT

Process instrumentation diagrams

Fo

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Process instrumentation diagrams
Temperature controlled stirred tank