Simple process control loop (with negative feedback)
Load or disturbance
u
+ Output
r e m Final control v c
+ Controller element + Process
Set Error
point Actuating
_ Controller output
or signal
Demand
cm
Measuring element
Measured output
Transducer + transmitter
Simple process control loop (with negative feedback)
Load or disturbance
u
+ Output
r e m Final control v c
+ Controller element + Process
Set Error
point Actuating
_ Controller output
or signal
Demand
cm
Measuring element
Measured output
Transducer + transmitter
Independent variables:
• set point ‘r’
• load ‘u’
Manipulated variable: actuating signal ‘v’
Controlled variable: output ‘c’
Feed back variable: measured output ‘cm’
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 transduce r
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
100% 100%
Two state with or without hysteresis:
0 0
Without hysteresis With hysteresis
On/Off controllers
100% 100%
Two state with or without hysteresis:
0 0
Without hysteresis With hysteresis
Set point
Controller output
Process output
Measured output
Without hysteresis
On/Off controllers
100% 100%
Two state with or without hysteresis:
0 0
Without hysteresis With hysteresis
Set point
Controller output
Process output
Measured output
Without hysteresis With hysteresis
On/Off controllers
100% 100%
Two state with or without hysteresis:
0 0
Without hysteresis With hysteresis
100% 100%
Three state with or without hysteresis:
-100% -100%
Without hysteresis With hysteresis
On/Off controllers
100% 100%
Two state with or without hysteresis:
0 0
Without hysteresis With hysteresis
100% 100%
Three state with or without hysteresis:
-100% -100%
Without hysteresis With hysteresis
one
cycle
Proportional time using PWM:
on off t
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
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 Non-linear
Type-0 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
Non-self regulation type processes
Different types of processes
Electrical
Mechanical
Thermal
Liquid
Gas
In combination of above types
Process parameters
Resistance or restriction T
R
Capacitance or capacity C
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% %
Kt o
dimension o
100 C C
10 KW W
Kv
100% %
C 100 C o o
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 Control
supply valve
Thermostat for water heating
Thermocouple
Desired
Mixer
temp Error Heater
50
75
Power
25 Difference
amplifier
Measurement
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
X Multiplier
Square-root extractor
< Low selector
> High selector
Divider
Common Symbols
Absolute value
Saturation
V
I Voltage-to-current or current-to-voltage converters
V
V Voltage isolator
I
I Current isolator
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
Process instrumentation diagrams
Flow control system with electronic flow controller
square root
extractor
electrical control FC board mounted flow
signal
controller
differential pressure
transmitter
DP
Fi Fo
control valve
orifice
Process instrumentation diagrams
Flow control with a turbine flow meter
FC
Flow
transmitter
FT
Fi Fo
Process instrumentation diagrams
Temperature controlled stirred tank
temperature
board mounted
motor stirrer transmitter
temperature
TT TC controller
Heat input
thermocouple/RTD/thermistor
