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Anjan Rakshit and Amitava Chatterjee Electrical Engineering Department Jadavpur University Kolkata, India

The document describes the basic components and functions of a process control loop, including: - A controller that receives an error signal from the difference between a setpoint and measured process variable and outputs a control signal. - A final control element, such as a valve, that receives the control signal and actuates to alter the manipulated process variable. - A process with inputs, outputs, and dynamic behavior that is being controlled. - Measuring elements that provide feedback of the controlled process variable to the controller to close the loop.

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92 views

Anjan Rakshit and Amitava Chatterjee Electrical Engineering Department Jadavpur University Kolkata, India

The document describes the basic components and functions of a process control loop, including: - A controller that receives an error signal from the difference between a setpoint and measured process variable and outputs a control signal. - A final control element, such as a valve, that receives the control signal and actuates to alter the manipulated process variable. - A process with inputs, outputs, and dynamic behavior that is being controlled. - Measuring elements that provide feedback of the controlled process variable to the controller to close the loop.

Uploaded by

sourav
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PDF, TXT or read online on Scribd
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AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T

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

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
Output Set point Load or disturbance

Servo problem

Itistheabilityofoutputtrackingthegivensetpointchanges

Itistheabilitytocontroltheoutputatthedesiredlevelinthefaceof disturbancesenteringtheprocess di t b t i th

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
Regulatory problem
Set point Load or disturbance Output

Temperature, Temperature pressure, flow, pH

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
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

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
Transmitter gain

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

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
Temperature transmitters
Indicating t I di ti transmitter itt

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

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
Controller
Electronic Pneumatic Analog Digital

Depending on construction controllers may be classified as

Depending on operation controllers may be classified as

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
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

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
P-control P control

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
PI-control PI control

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
PD-control PD control

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
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

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
Controller symbol

Kc = Change in controller output

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
Controller gain

Error

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
PID temperature controller

Twostatewithorwithouthysteresis: ih ih h i

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
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

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
On/Off controllers
Withouthysteresis Withouthysteresis Without hysteresis

Withhysteresis

Withhysteresis With hysteresis

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
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%

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
Gain of the final control element

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
Type-0 Linear A process may be characterized by its input-output relationship Type-1 Non-linear

Process

Process

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
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

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
Liquid l Li id level in a tank li t k

Self-regulation type processes

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
Non-self Non self regulation type processes

Electrical

Thermal Th l

Gas

Liquid

Mechanical

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
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

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
Process parameters
T R

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
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.

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
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

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
h=Rm h=p1 p2

R h = m sT + 1 T = RC

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
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

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
Measurement Power amplifier

Thermostat for water heating

Error

Heater

Mixer

Thermocouple p

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
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

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
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

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
Turbine type flow meter

Common Symbols

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
Pump Oil-burner Oil burner Motor stirrer Vessel / reactor V l t Heat H t exchanger h Sensor / transducer

>

<

Summer

Common Symbols

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
Divider Multiplier Low selector High selector Square-root extractor

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
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

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
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

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
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

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
Fi Flow transmitter FC

Flow control with a turbine flow meter

FT

Process instrumentation diagrams

Fo

AN EL JAN EC R TR AK IC SH JA AL IT D E an KO AV NG d A LK PU INE MI AT R U ER TA A, NI IN VA IN VE G C D R DE HA IA S P T IT A T Y R E TM RJ E N EE T
Process instrumentation diagrams
Temperature controlled stirred tank

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