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control
ET ZC 341
Swapna Kulkarni
BITS Pilani Lecturer,
Pilani Campus
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Course Overview
The course provides a fundamental knowledge to
instrumentation engineer regarding the implementation
of process control techniques in the process industries
The course also provides a basic knowledge about process
& instrumentation drawing symbols and diagrams.
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BITS Pilani, Pilani Campus
Course Objective
To make instrumentation technology students to become
familiar with process control techniques & tools.
At the end of this course you will be in a position to
measure,acquire. Control & tune the process parameters
in process industries.
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06-01-2012 ETZC341 Instrumentation and control BITS Pilani, Pilani Campus
BITS Pilani
Pilani Campus
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06-01-2012 ETZC341 Instrumentation and control
Contents
Introduction
Definitions
Process Control Principles
Human Aided Control
Automatic Control
Servomechanisms
Discrete State Control Systems
Process Control Block Diagram
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Introduction to process control
Process:
In general, process constitutes a sequence of events in
which a raw material will be converted into finished
product.
Any system composed of dynamic variables, usually
involved in manufacturing & production operations.
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Introduction
What means Control?
The methods/techniques to force parameters or
variables in the environment/ process to have specific
values
Control Systems:
All the elements necessary to accomplish the control
objective i.e. regulation of some parameters to have
specific or desired values.
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06-01-2012 ETZC341 Instrumentation and control BITS Pilani, Pilani Campus
Process Control
Process Control:
It deals with the elements and methods of control system
operation used in industry to control industrial
processes.
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06-01-2012 ETZC341 Instrumentation and control BITS Pilani, Pilani Campus
Control Systems
Process Control Principles:
Basic objective is to regulate the value of some quantity
Regulation: It means to maintain a quantity or variable at
some desired value regardless of external influences
Reference value or setpoint :It is the desired value which is
used to maintain the particular quantity regardless of
external influences.
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Explanation Process
Liquid is flowing into a tank at Figure 1.1 The objective is to regulate the level of
liquid in the tank, h, to the value H
the rate , Qin, and out of the
tank at some rate , Qout.
h= tank height or level
Qout=Kh;K is the constant
Higher the level, faster
flows out
If Qout Qin ,
1)Qout> Qin,the level will drop
2)Qout<Qin,the level will rise
This process is called as self-
regulation
Copyright 2006 by Pearson Education, Inc.
Upper Saddle River, New Jersey 07458
All rights reserved.
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06-01-2012 ETZC341 Instrumentation and control BITS Pilani, Pilani Campus
Self regulation Process
For some input flow rate , the liquid height will rise until it
reaches a height for which the output flow rate matches
the input flow rate
It does not provide regulation of a variable to any
particular reference value.
In Fig 1.1,if Qout =Qin , then the liquid level will maintain
the particular value. But if Qin changed, level will also
change.
So, it is not regulated to a reference value.
To maintain the level at some particular value (say
H),regardless of the input flow rate , some control
principles is needed
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Human Aided Control
Figure 1.2 A human can regulate the level using a
sight tube, S, to compare the level, h, to the
objective, H , and adjust a valve to change the
Explanation level.
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06-01-2012 ETZC341 Instrumentation and control BITS Pilani, Pilani Campus
Human Aided Control
The actual liquid level or height is called the controlled
variable.
The output flow rate is called the manipulated variable or
controlling variable.
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Automatic Control
Fig 1.3 An automatic level control system
Explanation replaces the human with a controller and
uses a sensor to measure the level.
An instrument called a sensor is added
that is able to measure the value of the
level and convert it into a proportional
signal, s.
This signal is provided as input to a
machine, electronic circuit , or computer
called the controller.
The controller performs the function of
the human in evaluating the
measurement and providing an output
signal, u, to change the valve setting via
an actuator connected to valve by a
mechanical linkage.
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06-01-2012 ETZC341 Instrumentation and control BITS Pilani, Pilani Campus
Discrete State Control Systems
A type of control system concerned with controlling a
sequence of events rather than regulation or variation of
individual variables.
Ex. The manufacture of paint might involve the
regulation of many variables, such as mixing temp.,flow
rate of liquids into mixing tanks,speed of mixing and so
on.
Each of these might be expected to be regulated by
process control loops.
There is also a sequence of events that must occur in
overall process.
This sequence is described in terms of events like
started or stopped on a specific schedule.
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Discrete State Control Systems
The starting and stopping of events is a discrete
based system because the event is either true or
false,(i.e. on or off).
This type of control system can also be made
automatic and is perfectly suited to computer
based controllers.
These discrete state control systems are often
implemented using specialized computer based
equipment called programmable logic
controllers(PLCs).
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Some definitions related to process
control
Controlled variable: The process variable regulates
by process control loop.
Controlling variable: The process variable changes
by the final control element under the command
of controller to effect regulation of controlled
variable.
Setpoint: The desired value of a controlled variable
in process control loop.
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Error: The algebraic difference between the
measured value of variable and setpoint.
Controller: The element in a process control loop
that evaluates error of the controlled variable
and initiates corrective action by a signal to
controlling variable.
Dynamic variable: The process variable that can
change from moment to moment because of
unknown sources.
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BITS Pilani
Pilani Campus
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06-01-2012 ETZC341 Instrumentation and control
Process Control Introduction
In Process control system , it is useful to
describe the elements and operations involved
and should be independent of a particular
application.
It is applicable to all control situations.
A model can be constructed using blocks to
represent each distinctive elements.
The characteristics of control operation then may
be developed from a consideration of the
properties and interfacing of these elements.
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Identification of elements
The elements of a process control system are
defined in terms of separate functional parts of
the system.
Elements
1. Process
2. Measurement
3. Error Detector
4. Controller
5. Control Element
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1. Process
A process can consist of a complex assembly of
phenomena that relate to some manufacturing
sequence.
Many variables may be involved in such a
process, and it may be desirable to control all
these variables at the same time.
There are single-variable processes as well as
multi-variable processes (variables may be
interrelated) may require regulation.
The processes is often also called the plant.
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2 Measurement (1/2)
It refers to the conversion of the variable into some
corresponding analog of the variable or a digitally
encoded signal.
A sensor is a device that performs the initial
measurement and energy conversion of a variable
into analogous digital , electrical, or pneumatic
information.
Signal conditioning may be required to complete the
measurement function.
The result of measurement is a representation of the
variable value in some form required by the other
elements in the process control operation.
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2. Measurement (2/2)
Fig 1.3An automatic level control system replaces the human witha The sensor is also called
controller and uses a sensor to measure the level. Transducer.
The sensor is preferred
for the initial
measurement device.
Transducer represents a
device that converts any
signal from one form to
another.
All sensors are
transducers but not all
transducers are sensors.
Copyright 2006 by Pearson Education, Inc.
Upper Saddle River, New Jersey 07458
All rights reserved.
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3. Error Detector
Some kind of error determination must be made
before any control action an be taken by the
controller.
Ex. In Human aided control (refer fig. 1.2),
human will detect the error (between h and
H).This error has both a magnitude and polarity.
In Automatic control, although error detector is
often a physical part of the controller device, it is
important to keep clear distinction between the
two.
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4 Controller
The next step in the process control sequence, is to examine
the error and determine what action, if any, should be taken.
The evaluation may be performed by an operator ,by
electronic signal processing , or by a computer.
In modern control systems, the operations of controller are
typically performed by microprocessor based computers.
The controller requires an input of both a measured indication
of the controlled variable and a representation of the
reference value of the variable, expressed in the same terms
as measured value.
Evaluation consists of determining the action required to drive
the controlled variable to the setpoint value.
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5. Control Element (1/2)
The final element in the process control operation
is the device that exerts a direct influences on the
process
It provides those required changes in the
controlled variable to bring it to a setpoint.
This element accepts the input from controller,
which is then transferred into some proportional
operation performed on the process.
Ex. Valve in fig. 1.2 and 1.3 acts as final control
element which controls the output flow rate of
liquid
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5. Control Element (2/2)
Often an intermediate operation is required
between controller o/p and the final control
element.
This operation is refereed as actuator because it
uses the controller signal to actuate the final
control element.
The actuator translates the small energy signal
of the controller into a larger energy action on
the process.
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BITS Pilani
Pilani Campus
Fig. 1.8 One of the measures of control system performance is how the
system responds to changes of setpoint or a transient disturbance
Note that the error is of only one polarity(i.e. it never oscillates about
the setpoint).
For this case , measures of quality are the duration, tD , of the
excursion and, for the transient, the maximum error, rmax, for a given
input.
The duration is usually defined as the time taken for the controlled
variable to go from 10% of the change to 90% of the change
following setpoint change.
In case of transient , the duration is often defined as the time from
the start of the disturbance until the controlled variable is again
within 4% of the reference.
Different tuning will provide different values of emax And tD for the
same excitation.
It is up to the process designers to decide whether the best control is
larger duration with smaller peak error, or vice versa, or something
in between.
06-01-2012 ETZC341 Instrumentation and control BITS Pilani, Pilani Campus
Cyclic Response (1/4)
b3
Analog b2
Vin ADC b1
b0
Fig. 1.13 This ON/OFF control system Objective: to maintain the temp. in
can either heat or cool or do neither. No a system at some reference value,
Tref.
variation of the degree of heating or
A sensor converts temp. value into
cooling is possible. a resistance in an analog fashion.
i.e. R varies smoothly and
continuously with T.
Signal conditioning converts the
variable R into an analog voltage ,V.
Thus V is an analog of T as well.
The differential amplifier multiplies
the difference between V and a
reference value , Vref, by a gain K to
produce an error voltage, Ve.
Ve= K(Vref-V)
Vref is simply defined as the voltage
from the converter that would be
produced by Tref.
Copyright 2006 by Pearson Education, Inc.
Upper Saddle River, New Jersey 07458
All rights reserved.