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PIONEERS IN TECHNOLOGY TRANSFER
Process Control & Instrumentation
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Process Control & Instrumentation
Section 1
Introduction
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Process Control & Instrumentation
Theory & Application
Topics
Control History
Basic Measurement Definitions
Performance Terms and Specification
P&ID Symbols
Typical Applications
Basic Control Concepts
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Process Control & Instrumentation
Theory & Application
Control History
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Process Control & Instrumentation
Theory & Application
CONTROL HISTORY
Early development of feedback control by James Watt
in Scotland using a governor on a steam engine in
about 1775. (flywheel principle)
Broader use of automatic control began to be made in
the late 1920’s and the first general, theoretical,
treatment of automatic control was published in 1932.
New technologies have created a transformation in
control engineering with the advent of DCS and PLC
systems.
The theory of automatic control has also developed in
parallel with these new technologies.
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Process Control & Instrumentation
Theory & Application
CONTROL HISTORY
AN EXAMPLE OF WATTS STEAM GOVERNOR
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Process Control & Instrumentation
Theory & Application
P & ID Symbols
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Process Control & Instrumentation
P & ID Symbols
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Process Control & Instrumentation
Theory & Application
P & ID SYMBOLS
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Process Control & Instrumentation
Theory & Application
P&ID SYMBOLS
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Process Control & Instrumentation
Theory & Application
P&ID SYMBOLS
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Process Control & Instrumentation
Theory & Application
P&ID SYMBOLS
Control Valve
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Process Control & Instrumentation
Theory & Application
Typical Applications
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Process Control & Instrumentation
Theory & Application
APPLICATIONS
A TYPICAL HOME HEATING SYSTEM
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Process Control & Instrumentation
Theory & Application
APPLICATION
EXAMPLE - PROCESS LEVEL CONTROL
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Process Control & Instrumentation
Theory & Application
APPLICATIONS
EXAMPLE - PROCESS FLOW CONTROL
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Process Control & Instrumentation
Theory & Application
APPLICATIONS
INSTRUMENTS AND CONTROL VALVES IN THE
OVERALL CONTROL SYSTEM
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Process Control & Instrumentation
Theory & Application
Basic Control Concepts
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Process Control & Instrumentation
Theory & Application
BASIC CONTROL CONCEPTS
This section introduces the basic concepts
encountered in Process Control.
Some of the basic terminology is also presented.
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Process Control & Instrumentation
Theory & Application
BASIC CONTROL CONCEPTS
Elements of a Process Control System
A control loop is a self-contained system
Purpose is to maintain a process at a given value
Usually consists of a transmitter for measurement
A controller to evaluate
A control valve which can be changed by the
controller
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Process Control & Instrumentation
Theory & Application
BASIC CONTROL THEORY
TRADITIONAL SINGLE LOOP CONTROLLER
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Process Control & Instrumentation
Theory & Application
BASIC CONTROL THEORY
For each controlled variable the control system
operator selects a manipulated variable which can be
paired with a controlled variable
Often the choice is obvious, such as manipulating the
flow of fuel to a home furnace to control the
temperature of a house
Sometimes the choice is not so obvious and can only be
determined by someone who understands the process
under control
The pairing of manipulated and controlled variables is
performed as part of the process
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Process Control & Instrumentation
Theory & Application
BASIC CONTROL THEORY
Variables Involved
There are three main terms to consider
1. Controlled Quantities/Variables
2. Manipulated Quantities/Variables
3. Disturbances
Disturbances
Manipulated Controlled
Variables Variables
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Process Control & Instrumentation
Theory & Application
BASIC CONTROL THEORY
Controlled Quantities
Also referred to as Controlled Variables
These are the streams or conditions which the
operator wishes to control or maintain at some level
Controlled variables include such parameters as
temperature, pH, moisture, level, position, flow
weight and speed etc.
For each controlled variable, there must be a desired
value known as a SET-POINT or reference value
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Process Control & Instrumentation
Theory & Application
BASIC CONTROL THEORY
Manipulated Quantities
For each controlled variable there is a manipulated
variable such as a flow rate
This manipulated variable is usually controlled through
the use of a control valve
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Process Control & Instrumentation
Theory & Application
BASIC CONTROL THEORY
Disturbances
Disturbances enter the process and cause a change
away from the set-point
Typical disturbances include change in temperature or
pressure or feed-stock
The automatic control system must therefore alter the
manipulated variable so that the set point is
maintained in spite of these disturbances
Also, the set point may be moved, in which case the
manipulated variable will need to be changed to
adjust the process to the new value
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Process Control & Instrumentation
Theory & Application
BASIC CONTROL THEORY
Elements of a Process Control System
There are four essential elements in any process control
system:
1. Process
2. Measurement
3. Evaluation
4. Control
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Process Control & Instrumentation
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BASIC CONTROL THEORY
Process
In general, a process is an assembly of equipment and
material and is related to some manufacturing
operation or sequence
In the case of a tank with a liquid, the level of this
liquid is influenced by the flow into and out of the tank.
Any given process can involve dynamic variables and it
may be desirable to control all of them
In most cases, controlling one variable would be
sufficient to control the process within acceptable
limits
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Process Control & Instrumentation
Theory & Application
BASIC CONTROL THEORY
Process
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Process Control & Instrumentation
Theory & Application
BASIC CONTROL THEORY
Measurement
To control any process it first has to be measured
Measurement means the conversion of a process
variable into an analogue or digital signal by means of
a sensor or transmitter or both.
The result of any measurement is the conversion of a
dynamic variable into some proportional information
which is required by some other elements in the
process control loop or sequence.
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Process Control & Instrumentation
Theory & Application
BASIC CONTROL THEORY
Evaluation
In the evaluation step of a process control sequence, the
measurement is examined and compared with the
desired value or set-point.
The amount of corrective action required to maintain
proper control is determined.
A controller is used for this evaluation. This controller
can be pneumatic, mechanical or electronic and would
be mounted in a panel.
It can also be part of a computer control system, in
which case the control function is performed by
software.
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Process Control & Instrumentation
Theory & Application
BASIC CONTROL THEORY
Control
The control element in a control loop has the most
direct effect on the process.
Receives a signal from the controller and transforms
this to a proportional operation which is performed on
the process.
In most cases, the final element is a control valve
which adjusts a flow in a pipeline.
Other final elements include: electrical motors, pumps
and dampers.
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Process Control & Instrumentation
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BASIC CONTROL THEORY
Control (continued)
In a typical home heating system, the controlled variable
is the room temperature.
A number of disturbances cause the room temperature to
vary, e.g., outside ambient temp., the number of people
in the room or the activity taking place inside the room.
The automatic control system is designed to manipulate
the fuel flow to the furnace in order to maintain room
temperature at the desired set-point.
Note: Temperature is being controlled and flow rate is
being varied.
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Process Control & Instrumentation
Theory & Application
BASIC CONTROL THEORY
Typical Manual Control
IT IS CONSIDERED USEFUL TO REVIEW THE MANUAL
CONTROL OF A PROCESS AT THIS STAGE.
There must be an indication of the process which can
be used as a measurement
The operator uses this indication to decide what
change is required
The set-point is in the mind of the operator
The operator compares these two values and changes
the final element accordingly
There are many problems associated with this form of
control
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Process Control & Instrumentation
Theory & Application
BASIC CONTROL THEORY
TYPICAL MANUAL CONTROL
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Process Control & Instrumentation
Theory & Application
BASIC CONTROL THEORY
Feedback Control
THE SIMPLEST WAY TO AUTOMATE THE CONTROL OF A
PROCESS IS THROUGH FEEDBACK CONTROL.
Sensors are used to measure the actual value of the
controlled variable
This value is transmitted to the feedback controller
The controller makes a comparison between this
measurement and the desired value which has already
been established.
Based on the difference (error) between these two
values, the controller sends a proportional output to
the control value.
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Process Control & Instrumentation
Theory & Application
BASIC CONTROL THEORY
FEEDBACK CONTROL CONCEPT
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Process Control & Instrumentation
Theory & Application
BASIC CONTROL THEORY
Feedback Control ( continued)
ADVANTAGES OF FEEDBACK CONTROL
It is not essential to know what disturbances will affect
the process
Also, the relationship between the final control element
and the process is not an issue
Standard hardware can be used for almost any
application
The principles of feedback control apply to all types of
process control instrumentation.
Traditional, stand-alone feedback controllers offer the
simplest approach to automatic control.
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