Instrumentation & Control

Process Control Fundamentals

Table of Contents
Introduction..................................................................................................................................................... 1
Performance Objective ............................................................................................................................. 1

The Importance of Process Control ............................................................................................................... 1

Learning Objectives.................................................................................................................................. 1
The Importance of Process Control................................................................................................................. 2
Process...................................................................................................................................................... 2
Process Control ........................................................................................................................................ 2
Reduce Variability ............................................................................................................................. 2
Increase Efficiency ............................................................................................................................ 3
Ensure Safety ..................................................................................................................................... 3

Control Theory Basics .................................................................................................................................... 4

Learning Objectives.................................................................................................................................. 4
The Control Loop............................................................................................................................................. 5
Three Tasks...............................................................................................................................................5
Process Control Terms ....................................................................................................................................6
Process Variable.......................................................................................................................................6
Setpoint .....................................................................................................................................................6
Measured Variables, Process Variables, and Manipulated Variables.....................................................7
Error .........................................................................................................................................................7
Offset.........................................................................................................................................................8
Load Disturbance .....................................................................................................................................8
Control Algorithm.....................................................................................................................................8
Manual and Automatic Control ................................................................................................................9
Closed and Open Control Loops ..............................................................................................................10

Components of Control Loops and ISA Symbology ...................................................................................... 11

Learning Objectives.................................................................................................................................. 11
Control Loop Equipment and Technology....................................................................................................... 12
Primary Elements/Sensors........................................................................................................................ 12
Transducers and Converters..................................................................................................................... 13
Transmitters.............................................................................................................................................. 13
Signals ...................................................................................................................................................... 14
Pneumatic Signals ............................................................................................................................. 14
Analog Signals................................................................................................................................... 14
Digital Signals ................................................................................................................................... 15
Indicators.................................................................................................................................................. 15
Recorders.................................................................................................................................................. 16
Controllers................................................................................................................................................ 16
Correcting Elements/Final Control Elements .......................................................................................... 18
Actuators................................................................................................................................................... 18

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 Table of Contents
ISA Symbology .................................................................................................................................................19
Symbols ................................................................................................................................................... 20
Pumps .............................................................................................................................................. 21
Piping and Connections .................................................................................................................. 22
Identification Letters............................................................................................................................... 23
Tag Numbers........................................................................................................................................... 23
ISA Symbology Review ........................................................................................................................... 26

Controller Algorithms and Tuning ...............................................................................................................27

Learning Objectives.................................................................................................................................27
Controller Algorithms.....................................................................................................................................28
Discrete Controllers ................................................................................................................................28
Multistep Controllers................................................................................................................................29
Continuous Controllers ............................................................................................................................29
Why controllers need tuning?...........................................................................................................................31
Gain ..........................................................................................................................................................31
Proportional Mode ..........................................................................................................................................33
Proportional Gain ....................................................................................................................................33
Proportional Band ....................................................................................................................................33
Limits of Proportional action ...................................................................................................................34
Determining the Controller Output..........................................................................................................34
Proportional Action- Closed Loop........................................................................................................... 35 .
Integral Mode ................................................................................................................................................. 37
Integral Action ........................................................................................................................................ 37
Open Loop Analysis................................................................................................................................ 37
Closed Loop Analysis ............................................................................................................................. 38
Reset Windup .......................................................................................................................................... 39
Summary ................................................................................................................................................. 40
Derivative Mode .............................................................................................................................................. 41
Derivative Action .................................................................................................................................... 41
Rate Summary......................................................................................................................................... 44

Process Control Loops.....................................................................................................................................46

Learning Objectives..................................................................................................................................46
Single Control Loops .......................................................................................................................................47
Feedback Control .....................................................................................................................................47
Examples Of Single Control Loops..................................................................................................................48
Pressure Control Loops............................................................................................................................49
Flow Control Loops..................................................................................................................................49
Level Control Loops .................................................................................................................................50
Temperature Control Loops .....................................................................................................................51

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Multi-Variable / Advanced Control Loops ......................................................................................................52
Multivariable Loops .................................................................................................................................52
Feedforward Control ................................................................................................................................53
Feedforward plus Feedback .....................................................................................................................54
Cascade Control ..................................................................................................................................... 55
Batch Control ......................................................................................................................................... 56
Ratio Control .......................................................................................................................................... 56
Selective Control..................................................................................................................................... 57
Fuzzy Control ......................................................................................................................................... 57

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Introduction
Control in process industries refers to the regulation of all aspects of the process. Precise control of level,
temperature, pressure and flow is important in many process applications. This module introduces you to
control in process industries, explains why control is important, and identifies different ways in which
precise control is ensured.
The following five sections are included in this module:
❑ The importance of process control
❑ Control theory basics
❑ Components of control loops and ISA symbology
❑ Controller algorithms and tuning
❑ Process control systems
As you proceed through the module, answer the questions in the activities column on the right side of each
page. Also, note the application boxes (double-bordered boxes) located throughout the module. Application
boxes provide key information about how you may use your baseline knowledge in the field. When you see the
workbook exercise graphic at the bottom of a page, go to the workbook to complete the designated exercise
before moving on in the module. Workbook exercises help you measure your progress toward meeting each
section’s learning objectives.

PERFORMANCE OBJECTIVE
After completing this module, you will be able to determine needed control loop components in specific
process control applications.

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The Importance of Process Control
Refining, combining, handling, and otherwise manipulating fluids to profitably produce end products can be a
precise, demanding, and potentially hazardous process. Small changes in a process can have a large impact
on the end result. Variations in proportions, temperature, flow, turbulence, and many other factors must be
carefully and consistently controlled to produce the desired end product with a minimum of raw materials and
energy. Process control technology is the tool that enables manufacturers to keep their operations running
within specified limits and to set more precise limits to maximize profitability, ensure quality and safety.

LEARNING OBJECTIVES
After completing this section, you will be able to:
❑ Define process
❑ Define process control
❑ Describe the importance of process control in terms of variability, efficiency, and safety
Note: To answer the activity questions the Hand Tool (H) should be activated.

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 The Importance of Process Control

The Importance of Process Control

PROCESS Activities
Process as used in the terms process control and process industry, 1. Process is defined as the
refers to the methods of changing or refining raw materials to create changing or refining of raw materials
end products. The raw materials, which either pass through or remain
that pass through or remain in a
in a liquid, gaseous, or slurry (a mix of solids and liquids) state
liquid, gaseous, or slurry state to
during the process, are transferred, measured, mixed, heated or
to create end products.
cooled, filtered, stored, or handled in some other way to produce the
end product.
Process industries include the chemical industry, the oil and gas
industry, the food and beverage industry, the pharmaceutical industry,
the water treatment industry, and the power industry.

PROCESS CONTROL
Process control refers to the methods that are used to control process
variables when manufacturing a product. For example, factors such
as the proportion of one ingredient to another, the temperature of the
materials, how well the ingredients are mixed, and the pressure under 2. Which of these industries are examples
which the materials are held can significantly impact the quality of of the process industry?
an end product. Manufacturers control the production process for Select all options that apply.
three reasons:
❑ Reduce variability 1 Pharmaceutical
❑ Increase efficiency 2 Satellite
❑ Ensure safety 3 Oil and Gas
4 Cement
Reduce Variability 5 Power
Process control can reduce variability in the end product, which
ensures a consistently high-quality product. Manufacturers can also
save money by reducing variability. For example, in a gasoline
blending process, as many as 12 or more different components
may be blended to make a specific grade of gasoline. If the refinery
does not have precise control over the flow of the separate
components, the gasoline may get too much of the high-octane
components. As a result, customers would receive a higher grade
and more expensive gasoline than they paid for, and the refinery
would lose money. The opposite situation would be customers
receiving a lower grade at a higher price.

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The Importance of Process Control

The Importance of Process Control

Reducing variability can also save money by reducing the need for Activities
product padding to meet required product specifications. Padding
refers to the process of making a product of higher-quality than it 3. What are the main reasons for
needs to be to meet specifications. When there is variability in the end manufacturers to control a process?
product (i.e., when process control is poor), manufacturers are forced Select all options that apply.
to pad the product to ensure that specifications are met, which adds
to the cost. With accurate, dependable process control, the setpoint 1 Reduce variability
(desired or optimal point) can be moved closer to the actual product
specification and thus save the manufacturer money. 2 Ensure safety
3 Reduce costs
4 Increase efficiency
PV limit to ensure quality PV limit to ensure quality
5 Increase productivity
PV Setpoint

Low Variability

PV Setpoint

High Variability

Increase Efficiency
Some processes need to be maintained at a specific point to maximize
efficiency. For example, a control point might be the temperature at
which a chemical reaction takes place. Accurate control of temperature
ensures process efficiency. Manufacturers save money by minimizing
the resources required to produce the end product.

Ensure Safety
A run-away process, such as an out-of-control nuclear or chemical
reaction, may result if manufacturers do not maintain precise control
of all of the processg variables. The consequences of a run-away
process can be catastrophic.
Precise process control may also be required to ensure safety. For
example, maintaining proper boiler pressure by controlling the inflow
of air used in combustion and the outflow of exhaust gases is crucial
in preventing boiler implosions that can clearly threaten the safety of
workers.

COMPLETE WORKBOOK EXERCISE - THE IMPORTANCE OF PROCESS CONTROL

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Control Theory Basics
This section presents some of the basic concepts of control and provides a foundation from which to
understand more complex control processes and algorithms later described in this module. Common terms and
concepts relating to process control are defined in this section.

LEARNING OBJECTIVES
After completing this section, you will be able to:
❑ Define control loop
❑ Describe the three tasks necessary for process control to occur:
• Measure
• Compare
• Adjust
❑ Define the following terms:
• Process variable
• Setpoint
• Manipulated variable
• Measured variable
• Error
• Offset
• Load disturbance
• Control algorithm
❑ List at least five process variables that are commonly controlled in process measurement industries
❑ At a high level, differentiate the following types of control:
• Manual versus automatic feedback control
• Closed-loop versus open-loop control
Note: To answer the activity questions the Hand Tool (H) should be activated.

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 Control Theory Basics

The Control Loop

Imagine you are sitting in a cabin in front of a small fire on a cold Activities
winter evening. You feel uncomfortably cold, so you throw another
log on the fire. Thisis an example of a control loop. In the 1. The three tasks associated with any
control loop, a variable (temperature) fell below the setpoint (your control loop are measurement,
comfort level), and you took action to bring the process back into the comparison, and adjustment. Is this
desired condition by adding fuel to the fire. The control loop will statement true or false?
now remain static until the temperature again rises above or falls
below your comfort level.

THREE TASKS
Control loops in the process control industry work in the same way,
requiring three tasks to occur:
❑ Measurement
❑ Comparison
❑ Adjustment
In Figure 7.1, a level transmitter (LT) measures the level in the tank
and transmits a signal associated with the level reading to a controller
(LIC). The controller compares the reading to a predetermined value,
in this case, the maximum tank level established by the plant
operator, and finds that the values are equal. The controller then
sends a signal to the device that can bring the tank level back to a
lower level—a valve at the bottom of the tank. The valve opens to let
some liquid out of the tank.
Many different instruments and devices may or may not be used in
control loops (e.g., transmitters, sensors, controllers, valves, pumps),
but the three tasks of measurement, comparison, and adjustment are
always present.

LIC

LT
Maximum
level

A Simple Control Loop

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Control Theory Basics

Process Control Terms

As in any field, process control has its own set of common terms that
you should be familiar with and that you will use when talking about
Activities
control technology. 2. A process variable is a
condition that can change
PROCESS VARIABLE the process in some way.

A process variable is a condition of the process fluid (a liquid or gas)

that can change the manufacturing process in some way. In the
example of you sitting by the fire, the process variable was
temperature. In the example of the tank in Figure 7.1, the process
variable is level. Common process variables include:
❑ Pressure
❑ Flow
❑ Level
❑ Temperature
❑ Density 3. Imagine you are in a cabin in
❑ Ph (acidity or alkalinity) front of a small fire on a cold
❑ Liquid interface (the relative amounts of different liquids that are winter evening. You feel
combined in a vessel) uncomfortably cold, so you
❑ Mass throw another log into the fire.
❑ Conductivity In this scenario, the process
variable is temperature. Is this
true or false?
SETPOINT
The setpoint is a value for a process variable that is desired to be
maintained. For example, if a process temperature needs to kept
within 5 °C of 100 °C, then the setpoint is 100 °C. A temperature
sensor can be used to help maintain the temperature at setpoint.
The sensor is inserted into the process, and a contoller compares the
temperature reading from the sensor to the setpoint. If the temperature
reading is 110 °C, then the controller determines that the process is
above setpoint and signals the fuel valve of the burner to close slightly 4. If the level of a liquid in a tank
until the process cools to 100 °C. Set points can also be maximum or must be maintained within 5 ft
minimum values. For example, level in tank cannot exceed 20 feet. of 50 ft, what is the liquid’s
setpoint?

1 45 ft
2 55 ft
3 5 ft
4 50 ft

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Process Control Terms

MEASURED VARIABLES, PROCESS VARIABLES, AND Activities
MANIPULATED VARIABLES
5. ____________________ is a
In the temperature control loop example, the measured variable is sustained deviation of the process
temperature, which must be held close to 100 °C. In this example and variable from the setpoint.
in most instances, the measured variable is also the process variable.
The measured variable is the condition of the process fluid that must
be kept at the designated setpoint.
Sometimes the measured variable is not the same as the process
variable. For example, a manufacturer may measure flow into and out
of a storage tank to determine tank level. In this scenario, flow is the
measured variable, and the process fluid level is the process variable.
The factor that is changed to keep the measured variable at setpoint is
called the manipulated variable. In the example described, the 6. A load disturbance is an undesired
manipulated variable would also be flow (Figure 7.2). change in one of the factors that can
Setpoint affect the setpoint. Is this statement
true or false?
Process Manipulated
variable or Controller variable
measured
variable

Variables

ERROR
Error is the difference between the measured variable and the
setpoint and can be either positive or negative. In the temperature
control loop example, the error is the difference between the 110 °C
measured variable and the 100 °C setpoint—that is, the error is +10
°C.
The objective of any control scheme is to minimize or eliminate error.
Therefore, it is imperative that error be well understood. Any error
can be seen as having three major components. These three
components are shown in the figure on the folowing page

Magnitude
The magnitude of the error is simply the deviation between the values
of the setpoint and the process variable. The magnitude of error at any
point in time compared to the previous error provides the basis for
determining the change in error. The change in error is also an
important value.

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Control Theory Basics

Process Control Terms

Activities
Duration
Duration refers to the length of time that an error condition has
existed.

Rate Of Change
The rate of change is shown by the slope of the error plot.

Rate of Change of Error

(Slope of Error Plot)
PV

Magnitude of Error

Duration SP

Components of Error

OFFSET
Offset is a sustained deviation of the process variable from the
setpoint. In the temperature control loop example, if the control
system held the process fluid at 100.5 °C consistently, even though
the setpoint is 100 °C, then an offset of 0.5 °C exists.

LOAD DISTURBANCE
A load disturbance is an undesired change in one of the factors that
can affect the process variable. In the temperature control loop
example, adding cold process fluid to the vessel would be a load
disturbance because it would lower the temperature of the process
fluid.

CONTROL ALGORITHM
A control algorithm is a mathematical expression of a control
function. Using the temperature control loop example, V in the
equation below is the fuel valve position, and e is the error. The
relationship in a control algorithm can be expressed as:

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 Control Theory Basics

Process Control Terms

V = f ( ± e)
Activities
7. Automatic control systems are
The fuel valve position (V) is a function (f) of the sign (positive or control operations that involve
negative) of the error (Figure 7.3). human action to make adjustment.
Is this statement true or false?
Summing
block
Process Error Manipulated
variable variable
Valve
f(e) position

Feedback

Algorithm Example
Control algorithms can be used to calculate the requirements of much
more complex control loops than the one described here. In more
complex control loops, questions such as “How far should the valve
be opened or closed in response to a given change in setpoint?” and
“How long should the valve be held in the new position after the
process variable moves back toward setpoint?” need to be answered.

MANUAL AND AUTOMATIC CONTROL

Before process automation, people, rather than machines, performed
many of the process control tasks. For example, a human operator
might have watched a level gauge and closed a valve when the level
reached the setpoint. Control operations that involve human
action to make an adjustment are called manual control systems.
Conversely, control operations in which no human intervention is
required, such as an automatic valve actuator that responds to a level
controller, are called automatic control systems.

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Process Control Terms

CLOSED AND OPEN CONTROL LOOPS Activities
A closed control loop exists where a process variable is measured, 8. Under what circumstances does
compared to a setpoint, and action is taken to correct any deviation an open control loop exist?
from setpoint. An open control loop exists where the process variable Select all options that apply.
is not compared, and action is taken not in response to
feedback on the condition of the process variable, but is instead taken 1 Process variable is not measured
without regard to process variable conditions. For example, a water 2 Process variable is not compared
valve may be opened to add cooling water to a process to prevent the 3 Process variable is measured
process fluid from getting too hot, based on a pre-set time interval, and compared to a setpoint
regardless of the actual temperature of the process fluid. 4 Action is taken without regard
to process variable conditions
5 Action is taken with regard
to process variable conditions

COMPLETE WORKBOOK EXERCISE - CONTROL THEORY BASICS

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Components of Control Loops and ISA
Symbology
This section describes the instruments, technologies, and equipment used to develop and maintain process
control loops. In addition, this section describes how process control equipment is represented in technical
drawings of control loops.

LEARNING OBJECTIVES
After completing this section, you will be able to:
❑ Describe the basic function of and, where appropriate, the basic method of operation for the following
control loop components:
• Primary element/sensor
• Transducer
• Converter
• Transmitter
• Signal
• Indicator
• Recorder
• Controller
• Correcting element/final control element
• Actuator
❑ List examples of each type of control loop component listed above
❑ State the advantages of 4–20 mA current signals when compared with other types of signals
❑ List at least three types of final control elements, and for each one:
• Provide a brief explanation of its method of operation
• Describe its impact on the control loop
• List common applications in which it is used
❑ Given a piping and instrumentation drawing (P&ID), correctly label the:
• Instrument symbols (e.g., control valves, pumps, transmitters)
• Location symbols (e.g., local, panel-front)
• Signal type symbols (e.g., pneumatic, electrical)
❑ Accurately interpret instrument letter designations used on P&IDs

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 Components of Control Loops and ISA Symbology

Control Loop Equipment and Technology

The previous section described the basic elements of control as Activities
measurement, comparison, and adjustment. In practice, there are
instruments and strategies to accomplish each of these essential 1. Identify three examples of a primary
tasks. In some cases, a single process control instrument, such as a element/sensors in process control?
modern pressure transmitter, may perform more than one of the basic Select all options that apply.
control functions. Other technologies have been developed so that
communication can occur among the components that measure, 1 Resistance Temperature Detectors
compare, and adjust.
2 Thermocouples
3 Control Valve
PRIMARY ELEMENTS/SENSORS 4 Converter
In all cases, some kind of instrument is measuring changes in the 5 Pitot tubes
process and reporting a process variable measurement. Some of the
greatest ingenuity in the process control field is apparent in sensing
devices. Because sensing devices are the first element in the control
loop to measure the process variable, they are also called primary
elements. Examples of primary elements include:
❑ Pressure sensing diaphragms, strain gauges, capacitance cells
❑ Resistance temperature detectors (RTDs)
❑ Thermocouples
❑ Orifice plates
❑ Pitot tubes
2. Primary elements will not make direct
contact with the process fluid. Is this
❑ Venturi tubes
statement true or false?
❑ Magnetic flow tubes
❑ Coriolis flow tubes
❑ Radar emitters and receivers
❑ Ultrasonic emitters and receivers
❑ Annubar flow elements
❑ Vortex sheddar

Primary elements are devices that cause some change in their

property with changes in process fluid conditions that can then be
measured. For example, when a conductive fluid passes through the
magnetic field in a magnetic flow tube, the fluid generates a voltage
that is directly proportional to the velocity of the process fluid. The
primary element (magnetic flow tube) outputs a voltage that can be
measured and used to calculate the fluid’s flow rate. With an RTD, as
the temperature of a process fluid surrounding the RTD rises or falls,
the electrical resistance of the RTD increases or decreases a
proportional amount. The resistance is measured, and from this
measurement, temperature is determined.

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Components of Control Loops and ISA Symbology

Control Loop Equipment and Technology

TRANSDUCERS AND CONVERTERS Activities
A transducer is a device that translates a mechanical signal into an 3. A ____________ is a device
electrical signal. For example, inside a capacitance pressure device, a
that translates a mechanical signal
transducer converts changes in pressure into a proportional change in
into an electrical signal.
capacitance.
A converter is a device that converts one type of signal into another
type of signal. For example, a converter may convert current into
voltage or an analog signal into a digital signal. In process control, a
converter used to convert a 4–20 mA current signal into a 3–15 psig
pneumatic signal (commonly used by valve actuators) is called a
current-to-pressure converter.

TRANSMITTERS
A transmitter is a device that converts a reading from a sensor
or transducer into a standard signal and transmits that signal 4. A transmitter is a device that converts
to a monitor or controller. Transmitter types include: a reading from a transducer into a
❑ Pressure transmitters standard signal and transmits that signal
❑ Flow transmitters to a monitor or controller. Is this
❑ Temperature transmitters statement true or false?
❑ Level transmitters
❑ Analytic (O2 [oxygen], CO [carbon monoxide], and pH)
transmitters

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Control Loop Equipment and Technology

SIGNALS Activities
There are three kinds of signals that exist for the process industry to 5. Identify the signal types that are
transmit the process variable measurement from the instrument to a used in the process control
centralized control system. industry?
Select all options that apply.
1. Pneumatic signal
2. Analog signal
3. Digital signal
1 Hydraulic signals
2 Digital signals
Pneumatic Signals 3 Analog signals
4 Pneumatic signals
Pneumatic signals are signals produced by changing the air pressure
in a signal pipe in proportion to the measured change in a process 5 Electro-magnetic signals
variable. The common industry standard pneumatic signal range is
3–15 psig. The 3 corresponds to the lower range value (LRV) and the
15 corresponds to the upper range value (URV). Pneumatic signalling
is still common. However, since the advent of electronic instruments
in the 1960s, the lower costs involved in running electrical signal wire
through a plant as opposed to running pressurized air tubes has made
pneumatic signal technology less attractive.

Analog Signals
The most common standard electrical signal is the 4–20 mA current
signal. With this signal, a transmitter sends a small current through a
set of wires. The current signal is a kind of gauge in which
4 mA represents the lowest possible measurement, or zero, and 20
mA represents the highest possible measurement.
For example, imagine a process that must be maintained at 100 °C.
An RTD temperature sensor and transmitter are installed in the
process vessel, and the transmitter is set to produce a 4 mA signal
when the process temperature is at 95 °C and a 20 mA signal
when the process temperature is at 105 °C. The transmitter will
transmit a 12 mA signal when the temperature is at the 100 °C
setpoint. As the sensor’s resistance property changes in
response to changes in temperature, the transmitter outputs a
4–20 mA signal that is proportionate to the temperature changes. This
signal can be converted to a temperature reading or an
input to a control device, such as a burner fuel valve.
Other common standard electrical signals include the 1–5 V (volts)
signal and the pulse output.

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 Components of Control Loops and ISA Symbology

Control Loop Equipment and Technology

Digital Signals Activities
Digital signals are the most recent addition to process control signal
technology. Digital signals are discrete levels or values that are 6. The ___________ is a
combined in specific ways to represent process variables and also carry human-readable device that
other information, such as diagnostic information. The methodology displays information about the
used to combine the digital signals is referred to as protocol. process or the instrument it is
connected to.
Manufacturers may use either an open or a proprietary digital
protocol. Open protocols are those that anyone who is developing a
control device can use. Proprietary protocols are owned by specific
companies and may be used only with their permission. Open digital
protocols include the HART® (highway addressable remote
transducer) protocol, FOUNDATION™ Fieldbus, Profibus, DeviceNet,
and the Modbus® protocol.
(See Module 8: Communication Technologies for more information
on digital communication protocols.)

INDICATORS
While most instruments are connected to a control system, operators
sometimes need to check a measurement on the factory floor at the 7. Which of the following are examples
measurement point. An indictor makes this reading possible. An of a digital signal?
indicator is a human-readable device that displays information about Select all options that apply.
the process. Indicators may be as simple as a pressure or temperature
gauge or more complex, such as a digital read-out device. Some 1 Profibus
indicators simply display the measured variable, while others have 2 4 - 20 mA
control buttons that enable operators to change settings in the field. 3 1-5v
4 Fieldbus
5 3 - 15 psig

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Control Loop Equipment and Technology

RECORDERS Activities
A recorder is a device that records the output of a measurement 8. A recorder is a device that records
devices. Many process manufacturers are required by law to provide a the ________________ of a
process history to regulatory agencies, and manufacturers use measurement or control device.
recorders to help meet these regulatory requirements. In addition,
manufacturers often use recorders to gather data for trend analyses.
By recording the readings of critical measurement points and
comparing those readings over time with the results of the process,
the process can be improved.
Different recorders display the data they collect differently. Some
recorders list a set of readings and the times the readings were taken;
others create a chart or graph of the readings. Recorders that create
charts or graphs are called chart recorders.

CONTROLLERS

A controller is a device that receives data from a measurement

instrument, compares that data to a programmed setpoint, and, if
necessary, signals a control element to take corrective action.
Local controllers are usually one of the three types: pneumatic,
electronic or programmable. Contollers also commonly reside
in a digital control system.

Computer-based Pneumatic, electronic, or

central controller programmable local controller

DCS

Transmitter Single-loop Valve

controller

Power I/O card

supply Controller
(CPU)

Controllers

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Control Loop Equipment and Technology

Controllers may perform complex mathematical functions to compare Activities
a set of data to setpoint or they may perform simple addition or
subtraction functions to make comparisons. Controllers always have 9. Which of the following have the
an ability to receive input, to perform a mathematical function with ability to receive input, to perform
the input, and to produce an output signal. Common examples of a mathematical function with the
controllers include: input, and produce an output signal?
❑ Programmable logic controllers (PLCs)—PLCs are usually
computers connected to a set of input/output (I/O) devices. The
computers are programmed to respond to inputs by sending 1 Actuators
outputs to maintain all processes at setpoint. 2 Transmitters
3 Transducers
❑ Distributed control systems (DCSs)—DCSs are controllers that,
4 Controllers
in addition to performing control functions, provide readings of
the status of the process, maintain databases and advanced
man-machine-interface.

10. Which of the following is the most

Setpoint
common final control element in
process control industries?
P I D

Pipestand Controller Analog Rack Mount Controller 1 Agitator

(Pneumatic or Electronic) (Electronic) 2 Pump motor
3 Valve
4 Louver

Single Loop Digital Converter Distributed Control System

(Electronic) (Electronic)

Types of Process Controllers

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 Components of Control Loops and ISA Symbology

Control Loop Equipment and Technology

Activities
11. _______________ is a part
final control device that causes a
physical change in the final control
device when signaled to do so.

Smart
Transmitter

Smart Transmitter
Digital Valve Controller (Provides PID Output)
(Smart Positioner)
Types of Process Controllers

CORRECTING ELEMENTS/FINAL CONTROL ELEMENTS

The correcting or final control element is the part of the control
system that acts to physically change the manipulated variable. In
most cases, the final control element is a valve used to restrict or cut
off fluid flow, but pump motors, louvers (typically used to regulate air
flow), solenoids, and other devices can also be final control elements.
Final control elements are typically used to increase or decrease fluid
flow. For example, a final control element may regulate the flow of
fuel to a burner to control temperature, the flow of a catalyst into a
reactor to control a chemical reaction, or the flow of air into a boiler
to control boiler combustion.
In any control loop, the speed with which a final control element
reacts to correct a variable that is out of setpoint is very important.
Many of the technological improvements in final control elements are
related to improving their response time.

ACTUATORS
An actuator is the part of a final control device that causes a physical
change in the final control device when signalled to do so. The most
common example of an actuator is a valve actuator, which opens or
closes a valve in response to control signals from a controller.
Actuators are often powered pneumatically, hydraulically, or
electrically. Diaphragms, bellows, springs, gears, hydraulic pilot
valves, pistons, or electric motors are often parts of an actuator system.

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Components of Control Loops and ISA Symbology

ISA Symbology
The Instrumentation, Systems, and Automation Society (ISA) is one of
the leading process control trade and standards organizations. The ISA
Activities
has developed a set of symbols for use in engineering drawings and 12. What does the acronym P&ID
designs of control loops (ISA S5.1 instrumentation symbol stand for?
specification). You should be familiar with ISA symbology so that you
can demonstrate possible process control loop solutions on paper to
your customer. Figure 7.5 shows a control loop using ISA symbology. 1 Piping and Instrument Designing
Drawings of this kind are known as piping and instrumentation 2 Piping and Instrumentation
drawings (P&ID). Drawing
3 Process Control and Installation
SP Drawing
FIC TIC 4 Proportional, Intergral and
123 123 Derivative control

YIC
TY 123
123

TT
123
FT
123

Piping and Instrumentation Drawing

(P&ID)

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 Components of Control Loops and ISA Symbology

ISA Symbology
SYMBOLS Activities
In a P&ID, a circle represents individual measurement instruments, 13. Which of the following is a symbol of
such as transmitters, sensors, and detectors (Figure 7.6). a transmitter in an auxiliary
LOCATION location?

1
Control Room Auxiliary Field Not Accessible
Figure 7.6: Discrete Instruments
A single horizontal line running across the center of the shape 2
indicates that the instrument or function is located in a primary
location (e.g., a control room). A double line indicates that the
3
function is in an auxiliary location (e.g., an instrument rack). The
absence of a line indicates that the function is field mounted, and a
dotted line indicates that the function or instrument is inaccessible
(e.g., located behind a panel board). 4

A square with a circle inside represents instruments that both display

measurement readings and perform some control function
(Figure 7.7). Many modern transmitters are equipped with
microprocessors that perform control calculations and send control
output signals to final control elements.
DISPLAY AND CONTROL TYPES
14. Which of the following is a symbol of
a field-mounted control/display
element?
Flow/
Square
Control Room Not Accessible Root
Field

1
Shared Control/Display Elements

A hexagon represents computer functions, such as those carried out 2

by a controller (Figure 7.8).
Control Types
3

4
Control Room Auxiliary Field Not Accessible

Computer Functions (Controllers)

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Components of Control Loops and ISA Symbology

ISA Symbology
Activities
15. Which of the following is a symbol of
a controller located behind a
panel?

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Components of Control Loops and ISA Symbology

ISA Symbology
A square with a diamond inside represents PLCs (Figure 7.9). Activities
PLC Types
16. The symbol displayed below denotes
a PLC in a primary location.
Is this statement true or false?

Control Room Auxiliary Field Not accessible

PLCs

Two triangles with their apexes contacting each other (a “bow tie”
shape) represent a valve in the piping. An actuator is always drawn
above the valve (Figure 7.10).

Pneumatic valve Manual valve Electric valve

17. Which of the following is a symbol

of a pneumatic valve?

Valves 1

Pumps
2
Directional arrows showing the flow direction represent a pump
(Figure 7.11).
3

Pumps

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 Components of Control Loops and ISA Symbology

ISA Symbology
Piping and Connections Activities
Piping and connections are represented with several different symbols
(Figure 7.12): 18. The symbols displayed below represent
a data link and a process connection.
❑ A heavy solid line represents piping
Is this statement true or false?
❑ A thin solid line represents process connections to instruments
(e.g., impulse piping)
❑ A dashed line represents electrical signals (e.g., 4–20 mA
connections)
❑ A slashed line represents pneumatic signal tubes
❑ A line with circles on it represents data links
Other connection symbols include capillary tubing for filled systems
(e.g., remote diaphragm seals), hydraulic signal lines, and guided
electromagnetic or sonic signals.

Piping

Process
connection

Electrical
signal

Pneumatic
signal

Data
link

Capillary tubing for

filled systems

Hydraulic
signal line

Guided
electromagnetic
or sonic signal

Piping and Connection Symbols

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Components of Control Loops and ISA Symbology

ISA Symbology
IDENTIFICATION LETTERS Activities
Identification letters on the ISA symbols (e.g., TT for temperature 19. The initial letter on an ISA symbol
transmitter) indicate: indicates the measured variable. Is
❑ The variable being measured (e.g., flow, pressure, temperature) this statement true or false?
❑ The device’s function (e.g., transmitter, switch, valve, sensor,
indicator)
❑ Some modifiers (e.g., high, low, multifunction)
Table 7.1 on page 26 shows the ISA identification letter designations.
The initial letter indicates the measured variable. The second letter
indicates a modifier, readout, or device function. The third letter
usually indicates either a device function or a modifier.
For example, “FIC” on an instrument tag represents a flow indicating
controller. “PT” represents a pressure transmitter. You can find
identification letter symbology information on the ISA Web site at
http://www.isa.org. 20. What does the third letter on an ISA
symbol indicate?
TAG NUMBERS
Numbers on P&ID symbols represent instrument tag numbers. Often
1 Device function or a modifier
these numbers are associated with a particular control loop (e.g., flow
transmitter 123). See Figure 7.13.
2 Measured variable
3 Readout
Identification 4 Type of process fluid
letters
FIC
123
Tag number

Identification Letters and Tag Number

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 Components of Control Loops and ISA Symbology

ISA Symbology
Measured Variable Modifier Readout Device Function Activities
Modifier
A Analysis Alarm
B Burner, combustion User’s choice User’s choice User’s choice
C User’s choice Control
D User’s choice Differential
Sensor (primary
E Voltage
element)
F Flow rate Ration (fraction)
G User’s choice Glass, viewing device
H Hand High
I Electrical Current Indication
J Power Scan
K Time, time schedule Time rate of change Control station
L Level Light Low
M User’s choice Momentary Middle, intermediate
N User’s choice User’s choice User’s choice User’s choice
O User’s choice Orifice, restriction
P Pressure, vacuum Point, test connection
Q Quantity Integrate, totalizer
R Radiation Record
S Speed, frequency Safety Switch
T Temperature Transmit
U Multivariable Multifunction Multifunction Multifunction
Vibration, mechanical
V Valve, damper, louver
analysis
W Weight, force Well
X Unclassified X axis Unclassified Unclassified Unclassified
Event, state, or
Relay, compute,
Y presence Y axis
convert

Z Position, dimension Z axis Driver, actuator

ISA Identification Letters

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ISA Symbology
ISA SYMBOLOGY REVIEW Activities
Figure 7.14 shows the elements of ISA symbology used in a P&ID. 21.. In Figure 7.14, what kind of
signal is transmitted out from the
Flow indicating controller that
performs a square root flow temperature transmitter?
calculation (primary location) Temperature
indicating
controller (field
mounted)
1 Data link
FIC SP
TIC 2 Mechanical signal
123 Data link 123 3 Electrical signal
Electrical PLC 4 Pneumatic signal
signal
YIC
TY 123
Flow 123
transmitter Pneumatic
line
Temperature TT
computer
123
FT
123 Temperature
transmitter
Impulse
Tubing

Pipe

Pneumatically Electrically
actuated valve actuated valve

P&ID with ISA Symbology

COMPLETE WORKBOOK EXERCISE - COMPONENTS OF CONTROL LOOPS AND

ISA SYMBOLOGY

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Controller Algorithms and Tuning
The previous sections of this module described the purpose of control, defined individual elements within
control loops, and demonstrated the symbology used to represent those elements in an engineering drawing.
The examples of control loops used thus far have been very basic. In practice, control loops can be fairly
complex. The strategies used to hold a process at setpoint are not always simple, and the interaction of
numerous setpoints in an overall process control plan can be subtle and complex. In this section, you will be
introduced to some of the strategies and methods used in complex process control loops.

LEARNING OBJECTIVES
After completing this section, you will be able to:
❑ Differentiate between discrete, multistep, and continuous controllers
❑ Describe the general goal of controller tuning.
❑ Describe the basic mechanism, advantages and disadvantages of the following mode of controller action:
• Proportional action
• Intergral action
• Derivative action
❑ Give examples of typical applications or situations in which each mode of controller action would be
used.
❑ Identify the basic implementation of P, PI and PID control in the following types of loops:
• Pressure loop
• Flow loop
• Level loop
• Temperature loop
Note: To answer the activity questions the Hand Tool (H) should be activated.

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 Controller Algorithms and Tuning

Controller Algorithms
The actions of controllers can be divided into groups based upon the Activities
functions of their control mechanism. Each type of contoller has
advantages and disadvantages and will meet the needs of different 1. Which one of the following is an
applications. Grouped by control mechanism function, the three everyday example of a discrete
types of controllers are: controller?
❑ Discrete controllers Select the options that apply.
❑ Multistep controllers
1 Refrigerator
❑ Continuous controllers 2 Electric iron
3 Air conditioner
DISCRETE CONTROLLERS 4 Rice cooker

Discrete controllers are controllers that have only two modes or

positions: on and off. A common example of a discrete controller is a
home hot water heater. When the temperature of the water in the tank
falls below setpoint, the burner turns on. When the water in the tank
reaches setpoint, the burner turns off. Because the water starts
cooling again when the burner turns off, it is only a matter of time
before the cycle begins again. This type of control doesn’t actually
hold the variable at setpoint, but keeps the variable within proximity
of setpoint in what is known as a dead zone (Figure 7.15).

Dead
zone

Process variable action

Control action

Discrete Control

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Controller Algorithms and Tuning

Controller Algorithms
MULTISTEP CONTROLLERS Activities
Multistep controllers are controllers that have at least one other 2. A controller with three or more
possible position in addition to on and off. Multistep controllers set positions is called a continuous
operate similarly to discrete controllers, but as setpoint is approached, controller. Is this statement true or
the multistep controller takes intermediate steps. Therefore, the false?
oscillation around setpoint can be less dramatic when multistep
controllers are employed than when discrete controllers are used
(Figure 7.16).

Process variable action

Control action

Figure 7.16: Multistep Control Profile

CONTINUOUS CONTROLLERS
Controllers automatically compare the value of the PV to the SP to
determine if an error exists. If there is an error, the controller adjusts
its output according to the parameters that have been set in the
controller. The tuning parameters essentially determine:
How much correction should be made? The magnitude of the
correction( change in controller output) is determined by the
proportional mode of the controller.

How long should the correction be applied? The duration of the

adjustment to the controller output is determined by the integral mode
of the controller
How fast should the correction be applied? The speed at which a
correction is made is determined by the derivative mode of the
controller.

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Controller Algorithms and Tuning

Controller Algorithms
When there is an error, the controller SP PV Activities
makes a change in its output.
It determines:
How much? Proportional Mode
How long? Integral Mode
How fast? Derivative Mode

Setpoint

LIC I/P
P I D

Controller

LT

PV

SP

Load

Automatic Feedback Control

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 Controller Algorithms and Tuning

Why Controllers Need Tuning?

Controllers are tuned in an effort to match the characteristics of the Activities
control equipment to the process so that two goals are achieved: 3. The change in the controller output
is the foundation of process control measurement in that electricity: divided by the change in the input to the
❑ The system responds quickly to errors. controller is known as __________ .
❑ The system remains stable (PV does not oscillate around
the SP).

GAIN
Controller tuning is performed to adjust the manner in which a control
valve (or other final control element) responds to a change in error.
In particular, we are interested in adjusting the gain of the controller
such that a change in controller input will result in a change in
controller output that will, in turn, cause sufficient change in
valve position to eliminate error, but not so great a change as
to cause instability or cycling.
Gain is defined simply as the change in output divided by the change
in input.

Examples:
Change in Input to Controller - 10%
Change in Controller Output - 20%
Gain = 20% / 10% = 2

Change in Input to Controller - 10%

Change in Controller Output - 5%
Gain = 5% / 10% = 0.5
convey measurements and instructions to other instruments in a
control loop to maintain the highest level of safety and efficiency.
The next three sections in this module discuss electricity, circuits,
transmitters, and signals in greater detail so you can understand the
importance of electricity in process control.

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 Controller Algorithms and Tuning

Why Controllers Need Tuning?

Gain Plot - The Figure below is simply another graphical way of Activities
representing the concept of gain.
4. Fast or slow processes have no impact
Gain Kc =∆ Output % / ∆ Input %
on controller gain settings. Is this
statement true or false?
100 Gain=2 Gain=1

Output %
50 Gain=0.5

0
0 50 100
Input %
Graphical Representaion of Gain Concept

Examples - The following examples help to illustrate the purpose of

setting the controller gain to different values.

LIC I/P LIC I/P

LT LT

Controllers May be Tuned to Help Match the Valve to the Process

Fast Process May Require Less Gain To Achieve Stability

Small volume liquid process

Slow Process May Require Higher Gain To Achieve Responsiveness

Large volume gas process

Fast and Slow Processes May Require Different Controller Gain Settings

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 Controller Algorithms and Tuning

Proportional Mode
PROPORTIONAL ACTION Activities
The proportional mode is used to set the basic gain value of the 5. Identify the major disadvantage
controller. The setting for the proportional mode may be expressed of proportional action.
as either:
1. Proportional Gain
2. Proportional Band 1 Tends to leave an offset
2 Reset Windup during shutdown
PROPORTIONAL GAIN 3 Possible overshoot during
In electronic controllers, proportional action is typically expressed as startup
proportional gain. Proportional Gain (Kc) answers the question: 4 Can cause cycling in fast process
"What is the percentage change of the controller output relative to the by amplifying noisy signals
percentage change in controller input?"
Proportional Gain is expressed as:
Gain, (Kc) = ∆Output% /∆Input %

PROPORTIONAL BAND
Proportional Band (PB) is another way of representing the same
information and answers this question:
"What percentage of change of the controller input span will cause a
100% change in controller output?"

PB = ∆Input (% Span) For 100%∆Output

Converting Between PB and Gain

A simple equation converts gain to proportional Band:

added.
PB = 100/Gain
Also recall that:
Gain = 100%/PB
Proportional Gain, (Kc) = ∆Output% / ∆Input %

PB= ∆Input(%Span) For 100%∆Output

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 Controller Algorithms and Tuning

Proportional Mode
Gain=2
PB= 50%
Gain=1
PB=100%
Gain=0.5
PB=200%
Activities
100
6. If proportional gain is 0.5, and a
level reading is 5% above setpoint,
Output %
a proportional controller will signal
50
the outflow control valve to open
by <1 / 2.5 / 5> % of its full range.

0
0 50 100 150 200
Input %

Relationship of Proportional Gain and Proportional Band

LIMITS OF PROPORTIONAL ACTION

Responds Only to a Change in error - Proportional action responds
only to a change in the magnitude of the error.
Does Not Return the PV to Setpoint - Proportional action will not
return the PV to setpoint. It will, however, return the PV to a value
that is within a defined span (PB) around the PV.

DETERMINING THE CONTROLLER OUTPUT

Controller Output - In a proportional only controller, the output is a
function of the change in error and controller gain.
Output Change, % = (Error Change, %) (Gain)
Example: If the setpoint is suddenly changed 10% with a proportional
band setting of 50%, the output will change as follows:

Calculating Controller Output

∆Controller Output = ∆Input, % X Gain
Gain = 100%/PB
EXAMPLE
∆Input = 10%
PB = 50%, so Gain = 100%/50% = 2

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 Controller Algorithms and Tuning

Proportional Mode
∆Controller Output = ∆ Input X Gain Activities
∆Controller Output = 10% X 2 = 20%

Expressed in Units:
Controller Output Change = (0.2)(12 psi span) = 2.4 psi OR
(0.2)(16 mA span) = 3.2 mA

PROPORTIONAL ACTION - CLOSED LOOP

Loop Gain - Every loop has a critical or natural frequency. This is the
frequency at which cycling may exist. This critical frequency is
determined by all of the loop components. If the loop gain is too high
at this frequency, the PV will cycle around the SP; i.e., the process
will become unstable.
Low Gain Example - In the example below, the proportional band is
high (gain is low). The loop is very stable, but an error remains between
SP and PV.
10
9
8
7
% 6
SP
5
4 PV
3
2 IVP
1
PB= 200%
0 Time
0 1 2 3 4 5 6 7 8 9 10
Proportional Control Closed Loop - Low Gain Example

High Gain Example - In the example, the proportional band is

small resulting in high gain, which is causing instability. Notice that
the process variable is still not on set point.

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 Controller Algorithms and Tuning

Proportional Mode
10
IVP
Activities
9

8 7. What will be the result if the

7 proportional gain is set too high?
SP
6 Select all options that apply.
%5
4 PV 1 Large offset
3 2 Minimized offset
2 3 Possible cycling
1 PB=10%
4 Stable loop
0 TIME
0 1 2 3 4 5 6 7 8 9 10

Proportional Control Closed Loop - High Gain example

Proportional Summary - For the proportional mode, controller output

is a function of a change in error. Proportional band is expressed in
terms of the percentage change in error that will cause 100% change in
controller output. Proportional gain is expressed as the percentage
change in output divided by the percentage change in input.

PB = (∆Input, % / ∆Output, % ) x 100 = 100/Gain

Gain= ∆Input % / ∆Output %

∆ Controller Output = (Change in Error)(Gain)

1. Proportional Mode Responds only to a change in error
2. Proportional mode alone will not return the PV to SP.
Advantages - Simple
Disadvantages - Error
Settings - PB settings have the following effects:
Small PB (%) Minimize Offset
High Gain (%) Possible cycling

Large PB (%) Large Offset

Low Gain Stable Loop
Tuning - reduce PB (increase gain) until the process cycles following
a disturbance, then double the PB (reduce gain by 50%).

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Integral Mode
INTEGRAL ACTION Activities
Duration of Error and Integral Mode - Another component of error 8. _____________ action is the type of
is the duration of the error, i.e., how long has the error existed? control algorithm that eliminates offset.
The controller output from the integral or reset mode is a function of
the duration of the error.
100

90
80

70
60
PV
% 50
40
30
20 SP
Duration
10

0
0 1 2 3 4 5 6 7 8 9 10

INTEGRAL(RESET)

OPEN LOOP ANALYSIS

Purpose- The purpose of integral action is to return the PV to SP. This is
accomplished by repeating the action of the proportional mode as
long as an error exists. With the exception of some electronic
controllers, the integral or reset mode is always used with the
proportional mode.
Setting - Integral, or reset action, may be expressed in terms of:
Repeats Per Minute - How many times the proportional
action is repeated each minute.
Minutes Per Repeat - How many minutes are required for
1 repeat to occur.

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Integral Mode
CLOSED LOOP ANALYSIS Activities
Closed Loop With Reset - Adding reset to the controller adds one more 9. Which of the following are integral
gain component to the loop. The faster the reset action, the greater or reset actions expressed in
the gain. terms of?
Slow Reset Example - In this example the loop is stable because Select all options that apply.
the total loop gain is not too high at the loop critical frequency.
1 Repeats per setting
Notice thatthe process variable does reach set point due to the reset
action. 2 Repeats per minute
3 Repeats per loop
100
90
4 Minutes per repeat
80
SP
70

60
50
% PV
40
30

20 IVP
PB=80%
10
Repeat=2.0 Repeats/min
0 TIME
0 1 2 3 4 5 6 7 8 9 10

SLOW RESET, CLOSED LOOP

Fast Reset Example - In the example the rest is too fast and the PV is
cycling around the SP.

100
90
80

70 SP
60
50
% PV
40
30
IVP
20
PB=80%
10 Repeat=10 Repeats/min
0 TIME
0 1 2 3 4 5 6 7 8 9 10

FAST RESET, CLOSED LOOP

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Integral Mode
RESET WINDUP Activities
Defined - Reset windup is described as a situation where the controller 10. Identify the major disadvantages
output is driven from a desired output level because of a large of integral action.
difference between the set point and the process variable. Select all options that apply.
100
1 Tends to leave an offset
2 Reset windup during shutdown
3 Possible overshoot during start up
4 Can cause cycling in fast process
Output% by amplifying noisy signals
IVP

ARW

0
INPUT(ERROR)

Reset Windup - Ant-Reset Windup

Shutdown - Reset windup is common on shut down because the

process variable may go to zero but the set point has not changed,
therefore this large error will drive the output to one extreme.

100

SP

Input %

PV
ARW

0
Shutdown Input(Error) Startup
Reset Windup - Shutdown and Startup

Startup - At start up, large process variable overshoot may occur

because the reset speed prevents the output from reaching its desired
value fast enough.

Anti Reset Windup - Controllers can be modified with an anti-reset

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 Controller Algorithms and Tuning

Integral Mode
windup (ARW) device. The purpose of an anti-reset option is to allow Activities
the output to reach its desired value quicker, therefore minimizing
the overshoot.
SUMMARY
Integral (Reset) Summary - Output is a repeat of the proportional
action as long as error exists. The units are in terms of repeats per
minute or minutes per repeat.
Advantages - Eliminates error
Disadvantages - Reset windup and possible overshoot

Fast Reset 1.High Gain

(Large Repeats/Min.,Small Min./Repeat) 2.Fast Return To Setpoint
3.Possible Cycling
Slow Reset 1.Low Gain
(Small Repeats/Min.,Large Min./Repeats) 2.Slow Return To Setpoint
3.Stable Loop

Trailing and Error Tuning - Increase repeats per minute until the
PV cycles following a disturbance, then slow the reset action to a
value that is 1/3 of the initial setting.

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Derivative Mode
DERIVATIVE ACTION Activities
Derivative Mode Basics - Some large and/or slow process do not 11. ___________ action is a control
respond well to small changes in controller output. For example, algorithm that is tied to the rate of
a large liquid level process or a large thermal change in the error.
process (a heat exchanger) may react very slowly to a small change
in controller output. To improve response, a large initial change in
controller output may be applied. This action is the role of the
derivative mode.

The derivative action is initiated whenever there is a change in the

rate of change of the error (the slope of the PV). The magnitude of
the derivative action is determined by the setting of the derivative . The
mode of a PID controller and the rate of change of the PV. The
Derivative setting is expressed in terms of minutes. In oper ation, the
the controller first compares the current PV with the last value of the
PV. If there is a change in the slope of the PV, the controller
etermines what its output would be at a future point in time 12. Which of the following are derivative or
(the future point in time is determined by the value of the derivative rate actions expressed in terms of?
setting, in minutes). The derivative mode immediately increases
the output by that amount.
1 Repeats per minute
100
2 Hours
90
80
3 Seconds
Slope= Rate of Error Change(Y/X)
70
4 Minutes
60
5 Milliseconds
50 PV
%
Y
40
X
30

20
SP
10
0 TIME
0 1 2 3 4 5 6 7 8 9 10

Derivative Action is based on the rate of change in Error (Y/X)

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Derivative Mode
Example - Let's start a closed loop example by looking at a Activities
temperature control system. IN this example, the time scale has been
13. The addition of derivative or rate alone
lengthened to help illustrate controller actions in a slow process.
to a close loop control can cause the
Assume a proportional band settingof 50%. There is no reset at
process variable to match the set point.
this time. The proportional gain of 2 acting on a 10% change in set
Is this statement true or false?
pint results in a change in controller output of 20%. Because
temperature is a slow process the setting time after a change in error
is quite long. And, in this example, the PV never becomes equal to
the SP because there is no reset.

Rate Effect - To illustrate the effect of rate action, we will add the
are mode with a setting of 1 minute. Notice the very large controller
output at time 0. The output spike is the result of rate action. Recall
that the change in output due to rate action is a function of the speed
(rate) of change of error, which in a step is nearly infinite. The
addition of rate alone will not cause the process variable to match the
set point.
100

90
80
IVP
70
60 SP

50

40 PV
30

20 PB=50%
10 Reset=0
Rate=0
0 TIME

0 100 200 300 400

100
IVP
90

80

70
PV
60 SP

50

40 PV
30
20 PB=50%
10 Reset=0
Rate=1 min
0 TIME
0 100 200 300 400
No Rate, Small Rate examples, Closed Loop
42 Fundamentals of Control
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 Controller Algorithms and Tuning

Derivative Mode
Effect of Fast Rate - Let's now increase the rate setting to 10 minutes. Activities
The controller gain is now much higher. As a result, both the IVP
(controller output) and the PV are cycling. The point here is that
increasing the rate setting will not cause the PV to settle at the SP.
100 IVP
90
80

70 SP
60
50
PV
40

30

20 PB= 50%
10 Reset=0
Rate= 10 min
0 TIME
0 100 200 300 400
P+D, High Rate Setting, Closed Loop Analysis
Need for Reset Action - It is now clear that reset must be added to
bring process variable back to set point.

Applications - Because this component of the controller output is

dependent on the speed of change of the input or error, the output
will be very erratic if rate is used on fast process or one with noisy
signals. The controller output, as a result of rate, will have the
greatest change when the input changes rapidly.

Controller Option to Ignore Change in SP - Many controllers,

especially digital types, are designed to respond to changes in the PV
only, and to ignore changes in SP. This feature eliminates a major upset
upset that would occur following a change in the setpoint.

43 Fundamentals of Control
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 Controller Algorithms and Tuning

Derivative Mode
SUMMARY Activities
Derivative (Rate) Sumary - Rate action is a function of the speed of
change of the error. The units are minutes. The action is to apply an
immediate response that is equal to the proportional plus reset action
that would have occurred some number of minutes I the future.

Advantages - Rapid output reduces the time that is required to return

PV to SP in slow process.

Disadvantage - Dramatically amplifies noisy signals; can cause

cycling in fast processes.

Settings
Large (Minutes) 1.High Gain
2.Large Output Change
3.Possible Cycling
Small (Minutes) 1.Low Gain
2.Small Output Change
3.Stable Loop

Trial-and-Error Tuning
Increase the rate setting until the process cycles following a
disturbance, then reduce the rate setting to one-third of the initial
value.

44 Fundamentals of Control
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Controller Algorithms and Tuning

Controller Algorithms
Proportional, PI, and PID Control Activities
By using all three control algorithms together, process operators can:
14. What type of control is used in
❑ Achieve rapid response to major disturbances with derivative
an application where noise is
control
present, but where no offset can
❑ Hold the process near setpoint without major fluctuations with be tolerated?
proportional control
❑ Eliminate offset with integral control

Not every process requires a full PID control strategy. If a small offset 1 P only
has no impact on the process, then proportional control alone may be 2 PD
sufficient. 3 PI
PI control is used where no offset can be tolerated, where noise 4 PID
(temporary error readings that do not reflect the true process variable
condition) may be present, and where excessive dead time (time after
a disturbance before control action takes place) is not a problem.
In processes where no offset can be tolerated, no noise is present, and
where dead time is an issue, customers can use full PID control.
Table 7.2 shows common types of control loops and which types of
control algorithms are typically used.
Controlled Proportional
Variable Control PI Control PID Control
Flow Yes Yes No
Level Yes Yes Rare
Temperature Yes Yes Yes
Pressure Yes Yes Rare
Analytical Yes Yes Rare

Table 7.2: Control Loops and Control Algorithms

COMPLETE WORKBOOK EXERCISE - CONTROLLER ALGORITHMS AND TUNING

Fundamentals of Control 45
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Process Control Loops
In this section, you will learn about how control components and control algorithms are integrated to create a
process control system. Because in some processes many variables must be controlled, and each variable can
have an impact on the entire system, control systems must be designed to respond to disturbances at any point
in the system and to mitigate the effect of those disturbances throughout the system.

LEARNING OBJECTIVES
After completing this section, you will be able to:
❑ Explain how a multivariable loop is different from a single loop.
❑ Differentiate feedback and feedforward control loops in terms of their operation, design, benefits, and
limitations
❑ Perform the following functions for each type of standard process control loop (i.e., pressure, flow, level,
and temperature):
• State the type of control typically used and explain why it is used
• Identify and describe considerations for equipment selection (e.g., speed, noise)
• Identify typical equipment requirements
• Diagram the loop using ISA symbology
❑ Explain the basic implementation process, including a description of equipment requirements and
considerations, for each of the following types of control:
• Cascade control
• Batch control
• Ratio control
• Selective control
• Fuzzy control
❑ Describe benefits and limitations of each type of control listed above
❑ Give examples of process applications in which each type of control described in this section might be
used
Note: To answer the activity questions the Hand Tool (H) should be activated.

Fundamentals of Control 46
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 Process Control Loops

Single Control Loops

Control loops can be divided into two categories: Single variable Activities
loops and multi-variable loops.
1. What type of control loop takes
FEEDBACK CONTROL action in response to measured
deviation from setpoint?
A feedback loop measures a process variable and sends the
measurement to a controller for comparison to setpoint. If the
process variable is not at setpoint, control action is taken to return the 1 Discrete control loop
process variable to setpoint. Figure 7.18 illustrates a feedback loop in 2 Multi-step control loop
which a transmitter measures the temperature of a fluid and, if 3 Open loop
necessary, opens or closes a hot steam valve to adjust the fluid’s 4 Feedback control loop
temperature.

Controller
Process
fluid

Steam valve
Transmitter

Feedback Loop
An everyday example of a feedback loop is the cruise control system
in an automobile. A setpoint is established for speed. When the car
begins to climb a hill, the speed drops below setpoint and the
controller adjusts the throttle to return the car’s speed to setpoint.
Feedback loops are commonly used in the process control industry.
The advantage of a feedback loop is that it directly controls the
desired process variable. The disadvantage to feedback loops is that
the process variable must leave setpoint for action to be taken.

47 Fundamentals of Control
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Process Control Loops

Examples of Single Control Loops

While each application has its own characteristics, some general
statements can be made about pressure, flow, level, and temperature
Activities
loops. 2. How does a high-volume pressure
control loop react as compared to a
PRESSURE CONTROL LOOPS small-volume pressure control loop?

Pressure control loops vary in speed—that is, they can respond to

changes in load or to control action slowly or quickly. The speed 1 Same rate
required in a pressure control loop may be dictated by the volume of 2 Quicker
the process fluid. High-volume systems (e.g., large natural gas storage 3 Slower
facilities) tend to change more slowly than low-volume systems
4 Extremely fast
(Figure 7.21).

Pneumatic
controller

Relief
valve
Pressure
transmitter

Process
fluid

Fluid
pump

A Pressure Loop

Fundamentals of Control 48
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 Process Control Loops

Examples of Single Control Loops

FLOW CONTROL LOOPS Activities
Generally, flow control loops are regarded as fast loops that respond 3. Flow control loops are generally
to changes quickly. Therefore, flow control equipment must have fast considered to be slow responding
sampling and response times. Because flow transmitters tend to be loops. Is this statement true or false?
rather sensitive devices, they can produce rapid fluctuations or noise
in the control signal. To compensate for noise, many flow transmitters
have a damping function that filters out noise. Sometimes, filters are
added between the transmitter and the control system. Because the
temperature of the process fluid affects its density, temperature
measurements are often taken with flow measurements and
compensation for temperature is accounted for in the flow
calculation. Typically, a flow sensor, a transmitter, a controller, and a
valve or pump are used in flow control loops (Figure 7.22).

Pneumatic
controller

Flow
transmitter
Valve

Process
fluid

Fluid
pump

A Flow Loop

49 Fundamentals of Control
© 2006 PAControl.com.
Process Control Loops

Examples of Single Control Loops

LEVEL CONTROL LOOPS Activities
The speed of changes in a level control loop largely depends on the 4. Redundant control systems are
size and shape of the process vessel (e.g., larger vessels take longer to sometimes used in level applications
fill than smaller ones) and the flow rate of the input and outflow because preventing tank overflow is
pipes. Manufacturers may use one of many different measurement
often critically important. Is this
technologies to determine level, including radar, ultrasonic, float
statement true or false?
gauge, and pressure measurement. The final control element in a level
control loop is usually a valve on the input and/or outflow
connections to the tank (Figure 7.23). Because it is often critical to
avoid tank overflow, redundant level control systems are sometimes
employed.

Converter

Level
controller

Differential
pressure
transmitter

A Level Loop

Fundamentals of Control 50
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 Process Control Loops

Examples of Single Control Loops

TEMPERATURE CONTROL LOOPS Activities
Because of the time required to change the temperature of a process 5. What type of control strategy is
fluid, temperature loops tend to be relatively slow. Feedforward often used to increase the speed
control strategies are often used to increase the speed of the of a temperature control loop?
temperature loop response. RTDs or thermocouples are typical
temperature sensors. Temperature transmitters and controllers are
used, although it is not uncommon to see temperature sensors wired
directly to the input interface of a controller. The final control element 1 Feedforward control
for a temperature loop is usually the fuel valve to a burner or a valve 2 Feedback control
to some kind of heat exchanger. Sometimes, cool process fluid is 3 Cascade control
added to the mix to maintain temperature (Figure 7.24). 4 Ratio control

Controller

Process
fluid Temperature
transmitter
Valve

A Temperature Loop

51 Fundamentals of Control
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 Process Control Loops

Multi-Variable / Advanced Control Loops

MULTIVARIABLE LOOPS Activities
Multivariable loops are control loops in which a primary controller 6. A multivariable control loop
controls one process variable by sending signals to a controller of a contains a primary and
different loop that impacts the process variable of the primary loop. secondary controller assigned
For example, the primary process variable may be the temperature of to different process variables? Is
the fluid in a tank that is heated by a steam jacket (a pressurized steam this statement true or false?
chamber surrounding the tank). To control the primary variable
(temperature), the primary (master) controller signals the secondary
(slave) controller that is controlling steam pressure. The primary
controller will manipulate the setpoint of the secondary controller to
maintain the setpoint temperature of the primary process variable
(Figure 7.17).
.

Primary
controller
Transmitter

SP
Secondary
controller Valve
Transmitter

Multivariable Loop
When tuning a control loop, it is important to take into account the
presence of multivariable loops. The standard procedure is to tune the
secondary loop before tuning the primary loop because adjustments
to the secondary loop impact the primary loop. Tuning the primary
loop will not impact the secondary loop tuning.

52 Fundamentals of Control
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Process Control Loops

Multi-Variable / Advanced Control Loops

FEEDFORWARD CONTROL Activities
Feedforward control is a control system that anticipates load 7. What type of control loop
disturbances and controls them before they can impact the process anticipates and controls load
variable. For feedforward control to work, the user must have a disturbances before they can
mathematical understanding of how the manipulated variables will impact the process variable?
impact the process variable. Figure 7.19 shows a feedforward loop in
which a flow transmitter opens or closes a hot steam valve based on
how much cold fluid passes through the flow sensor.
1 Feedback control loop
2 Feedforward control loop
Flow
transmitter Controller
3 Ratio control loop
4 Single variable loop
Cold
process
fluid

Steam valve

Feedforward Control
An advantage of feedforward control is that error is prevented, rather
than corrected. However, it is difficult to account for all possible load
disturbances in a system through feedforward control. Factors such as
outside temperature, buildup in pipes, consistency of raw materials,
humidity, and moisture content can all become load disturbances and
cannot always be effectively accounted for in a feedforward system.
In general, feedforward systems should be used in cases where the
controlled variable has the potential of being a major load disturbance
on the process variable ultimately being controlled. The added
complexity and expense of feedforward control may not be equal to
the benefits of increased control in the case of a variable that causes
only a small load disturbance.

Fundamentals of Control 53
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 Process Control Loops

Multi-Variable / Advanced Control Loops

FEEDFORWARD PLUS FEEDBACK Activities
Because of the difficulty of accounting for every possible load 8. A controller with a summing function
disturbance in a feedforward system, feedforward systems are often totals the input from both the
combined with feedback systems. Controllers with summing feedforward loop and the feedback
functions are used in these combined systems to total the input from loop and sends a unified signal to
both the feedforward loop and the feedback loop, and send a unified the final control element. This is
signal to the final control element. Figure 7.20 shows a
how a single control signal is sent to
feedforward-plus-feedback loop in which both a flow transmitter and
the final control element in a
a temperature transmitter provide information for controlling a hot
feedforward plus feedback system.
steam valve.
Is this statement true or false?

Feedforward
controller Summing Feedback
controller controller

Flow
transmitter

Process
fluid Temperature
transmitter
Steam valve

Feedforward Plus Feedback Control

System

54 Fundamentals of Control
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Process Control Loops

Multi-Variable / Advanced Control Loops

This module has discussed specific types of control loops, what
components are used in them, and some of the applications (e.g., flow,
Activities
pressure, temperature) they are applied to. In practice, however, many 9. Ratio control is the term used to
independent and interconnected loops are combined to control the describe a system in which the
workings of a typical plant. This section will acquaint you with some controller of the primary loop determines
of the methods of control currently being used in process industries. the setpoint of a secondary loop. Is
this statement true or false?
CASCADE CONTROL
Cascade control is a control system in which a secondary (slave)
control loop is set up to control a variable that is a major source of load
disturbance for another primary (master) control loop. The controller
of the primary loop determines the setpoint of the summing contoller in
the secondary loop (Figure 7.25).

Secondary Primary
controller controller

Process
fluid

Temperature
Flow transmitter
transmitter

Valve

Cascade Control

Fundamentals of Control 55
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 Process Control Loops

Multi-Variable / Advanced Control Loops

BATCH CONTROL Activities
Batch processes are those processes that are taken from start to finish 10. Which term describes a control
in batches. For example, mixing the ingredients for a juice drinks is system in which controlled
often a batch process. Typically, a limited amount of one flavor (e.g., flow is added proportionately to
orange drink or apple drink) is mixed at a time. For these reasons, it is an uncontrolled flow?
not practical to have a continuous process running. Batch processes
often involve getting the correct proportion of ingredients into the
batch. Level, flow, pressure, temperature, and often mass
measurements are used at various stages of batch processes. 1 Selective control
2 Cascade control
A disadvantage of batch control is that the process must be frequently
3 Ratio control
restarted. Start-up presents control problems because, typically, all
measurements in the system are below setpoint at start-up. Another 4 Fuzzy control
disadvantage is that as recipes change, control instruments may need
to be recalibrated.

RATIO CONTROL
Imagine a process in which an acid must be diluted with water in the
proportion two parts water to one part acid. If a tank has an acid
supply on one side of a mixing vessel and a water supply on the other,
a control system could be developed to control the ratio of acid to
water, even though the water supply itself may not be controlled. This
type of control system is called ratio control (Figure 7.26). Ratio
control is used in many applications and involves a contoller that
receives input from a flow measurement device on the unregulated
(wild) flow. The controller performs a ratio calculation and signals the
appropriate setpoint to another controller that sets the flow of the
second fluid so that the proper proportion of the second fluid can be
added.
Ratio control might be used where a continuous process is going on
and an additive is being put into the flow (e.g., chlorination of water).

Water flow Acid flow

Ratio Control

56 Fundamentals of Control
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Process Control Loops

Multi-Variable / Advanced Control Loops

SELECTIVE CONTROL Activities
Selective control refers to a control system in which the more 11. In which type of control system
important of two variables will be maintained. For example, in a will the more important of two
boiler control system, if fuel flow outpaces air flow, then variables be maintained?
uncombusted fuel can build up in the boiler and cause an explosion.
Selective control is used to allow for an air-rich mixture, but never a
fuel-rich mixture. Selective control is most often used when
equipment must be protected or safety maintained, even at the cost of 1 Fuzzy control
not maintaining an optimal process variable setpoint. 2 Cascade control
3 Ratio control
FUZZY CONTROL 4 Selective control

Fuzzy control is a form of adaptive control in which the controller

uses fuzzy logic to make decisions about adjusting the process. Fuzzy
logic is a form of computer logic where whether something is or is
not included in a set is based on a grading scale in which multiple
factors are accounted for and rated by the computer. The essential
idea of fuzzy control is to create a kind of artificial intelligence that
will account for numerous variables, formulate a theory of how to
make improvements, adjust the process, and learn from the result.
Fuzzy control is a relatively new technology. Because a machine 12. ___________ control is the term
makes process control changes without consulting humans, fuzzy used to describe a control system in
control removes from operators some of the ability, but none of the which the controller uses computer
responsibility, to control a process. logic to make decisions about adjusting
the process.

COMPLETE WORKBOOK EXERCISE - PROCESS CONTROL LOOPS

Fundamentals of Control 57
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Module 7: Workbook Exercises
EXERCISE 7.1— THE IMPORTANCE OF PROCESS CONTROL
1. Which of the following options best represents the reasons to control a process?
(Select three options that apply)

(1) Reduce variability

(2) Increase productivity
(3) Increase efficiency
(4) Reduce cost
(5) Ensure safety

2. Process is defined as the method of changing or refining raw materials to create end
products. Is this statement true or false?

(1) True
(2) False

3. Which of the following are advantages of reducing variability in a process

application?

(1) Helps ensure a consistently high-quality end product.

(2) Helps ensure an increase in the reaction rate of the process.
(3) Helps ensure increase in efficiency of the process.
(4) Helps ensure safety

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Module 7: Workbook Exercises
EXERCISE 7.2 — CONTROL THEORY BASICS

1. Which of the following tasks is associated with process control? (Select three options
that apply)

(1) Measurement
(2) Comparison
(3) Quality Analysis
(4) Adjustment
(5) Calculation

2. Which of the following variables are commonly measured or monitored in process

control applications? (Select three options that apply)

(1) Pressure
(2) Viscosity
(3) Nitrogen content
(4) Flow rate
(5) Temperature

3. A process liquid level needs to be held within 5 ft of 150 ft in a large tank. A pressure
transmitter monitors the liquid’s level using a pressure reading and sends the result
to a controller. The controller compares the level reading to the set point and opens
or closes an inflow or outflow pipe depending on the liquid level. Keeping in mind the
given scenario, match the terms in Column A with their values in Column B.

(1) Inferred process variable (A) 150 ft

(2) Manipulated variable (B) Pressure
(3) Measured variable (C) Flow of liquid to the tank
(4) Set point (D) Level

Workbook Exercises Page 59

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Module 7: Workbook Exercises
4. Match each term to its correct definition.

(1) Load disturbance

(2) Control algorithm
(3) Manual control
(4) Manipulated variable
(5) Set point

(A) The factor that is changed to keep a measured variable at set point.
(B) An undesired change in a factor that can affect the process variable.
(C) A value or range of values for a process variable that must be maintained to
keep the process running properly.
(D) A control operation that directly involves human action.
(E) A mathematical expression of a control function

5. Match each term to its correct description.

(1) Closed-loop, automatic control _____

(2) Closed-loop, manual control _____
(3) Open-loop, automatic control _____

(A) An operator turns off the heater coil when the temperature transmitter outputs
a certain reading.
(B) A controller turns off the heater coil at set intervals, regardless of the process
temperature.
(C) A temperature sensor measures process temperature, sends the result to a
controller to compare to the setpoint, and the controller turns off the heater
coil.

6. __________ is a deviation from set point due to load disturbance.

(1) Error
(2) Offset
(3) Rate of change

7. __________ is a continuing error due to the inability of a control system to keep the
measured variable at set point.

(1) Load disturbance

(2) Offset
(3) Pressure

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Module 7: Workbook Exercises
EXERCISE 7.3 — COMPONENTS OF CONTROL LOOPS AND ISA SYMBOLOGY
1. The basic function of a __________ is to convert a reading from a transducer into a
standard signal and transmit that signal to a controller or computer monitor.

(1) recorder
(2) transmitter
(3) converter

2. 4–20 mA is the most common standard analog signal used in the process control
industry today. Is this statement true or false?

(1) True
(2) False

3. Match the signal type in Column A with its example/application in Column B.

(1) Analog signal (A) 3 –15 psig

(2) Pneumatic signal (B) Fieldbus, Profibus and Modbus
(3) Digital signal (C) 4-20 mA and 1 – 5 V

4. A customer would use __________to read the temperature of a process fluid on a

display.

(1) an indicator
(2) a volt-meter
(3) an actuator

5. Match each control loop equipment to its correct description.

(1) Recorder _____

(2) Controller _____
(3) Final control element _____
(4) Actuator _____

6. A pump motor is the most commonly used final control element. Is this statement
true or false?

(1) True
(2) False

Workbook Exercises Page 61

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Module 7: Workbook Exercises
7. Match the ISA symbols in Column A with its respective description in Column B.

(1) (A) Programmable logic control

(2) (B) Temperature transmitter

(3) (C) Pneumatically actuated valve

(4) (D) Electrically actuated valve

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Module 7: Workbook Exercises
EXERCISE 7.4 — CONTROL ALGORITHMS AND TUNING
1. Match each term to its correct definitions.

(1) Proportional band

(2) Proportional/integral (PI) control
(3) Proportional control
(4) Derivative control
(5) Integral control

(A) A type of control that corrects error and eliminates offset.

(B) A type of control that produce erratic output in noisy applications.
(C) The percent change in error that will cause a 100% change in controller
output.
(D) A type of control that is prone to leaving an offset.
(E) A type of control that repeats the action of the proportional mode as long as
an error exists.

2. Identify the two effects on a process variable if the proportional gain (Pgain) is set too
high? (Select all that apply)

(1) Minimize offset

(2) Large offset
(3) Stable loop
(4) Possible cycling

3. Derivative gain (Dgain) is typically set to zero in flow applications since flow
applications are usually noisy and derivative control will react to readings that are in
fact noise, thus preventing the process from holding set point. Is this statement true
or false?

(1) True
(2) False

Workbook Exercises Page 63

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Module 7: Workbook Exercises
EXERCISE 7.5 — PROCESS CONTROL LOOPS
1. Which control system anticipates load disturbances and controls them before they
can impact the process variable?

(1) Selective control

(2) Fuzzy control
(3) Feed forward control
(4) Cascade control

2. Match the component label in Column A to its ISA symbol representation in Column
B.

(1) Flow transmitter (A)

(2) Temperature transmitter (B)

(3) Flow controller (C)

(4) Valve (D)

3. If R1 = 60 :, R2 = 100 :, and R3 = 100 :, what is the equivalent resistance (Req) in

the circuit?

(1) slow
(2) fast
(3) variable speed

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Module 7: Workbook Exercises - Answers

Exercise 7.1 – The Importance of Process Control

1. 1, 3, 5
2. 1
3. 1

Exercise 7.2 – Control Theory Basics

1. 1, 2, 4
2. 1, 4, 5
3. D, C, B, A
4. B, E, D, A, C
5. C, A, B
6. 1
7. 2

Exercise 7.3 – Components of Control Loops and ISA Symbology

1. 2
2. 1
3. C, A, B
4. 1
5. C, D, B, A
6. 2
7. B, C, D, A

Exercise 7.4 – Control Algorithms and Tuning

1. C, A, D, B, E
2. 1, 4
3. 1

Exercise 7.5 – Process Control Loops

1. 3
2. B, C, D, A
3. 1

Workbook Exercises Page 65

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Module 7: Activity Answers
The Importance of Process Control

1. True
2. 1,3,5
3. 1,2,4

Control Theory Basics

1. True
2. True
3. True
4. 4
5. 3
6. False
7. False
8. 2,4

Components of Control Loops and ISA Symbology

1. 1,2,5
2. False
3. 3
4. True
5. 2,3,4
6. 1
7. 1,4
8. 2
9. 4
10. 3
11. 1
12. 2
13. 1
14. 2
15. 3
16. True
17. 4
18. True
19. True
20. 1
21. 3

Page 66 Activity Answers

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Module 7: Activity Answers
Controller Algorithms and Tuning

1. 1,2,3,4
2. False
3. 2
4. False
5. 1
6. 2.5
7. 2,3
8. 3
9. 2,4
10. 2,3
11. 2
12. 4
13. False
14. 3

Process Control Loops

1. 4
2. 3
3. False
4. True
5. 1
6. True
7. 2
8. True
9. False
10. 3
11. 4
12. 1

Activity Answers Page 67

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