CLL361 M A Shaik

CLL 361
Instrumentation & Automation
Munawar A. Shaik
Associate Professor
Department of Chemical Engineering

http://privateweb.iitd.ac.in/~munawar/CLL361.pdf

CLL361 M A Shaik

CLL361 M A Shaik

Introduction
Process Engineers are responsible for Design and Operation of
Chemical Processes
For large and complex processes process automation becomes
more important from the view point of:
Safety
Environmental aspects
Economic aspects
Ensuring uninterrupted operation of the plant with
minimum human intervention
Ex: Boiler - controllers for water level and steam pressure

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Taking a Shower

Manual Vs Automatic Control

Heat Exchanger

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Process Control
Three Main Tasks:
Measurement
Comparison
Adjustment

Development of Control Scheme:

- Control Objective
- Input and Output variables
- Constraints
- Operating Characteristics
- Safety, environmental and
economic aspects
- Control structure

Tank Level Problem

Development of Control Scheme:
- Control Objective
- Input and Output variables
- Constraints
- Operating Characteristics
- Safety, environmental and
economic aspects
- Control structure

Feedback Control Strategy 1:

The level is measured and the inlet
flow rate (valve position) is
manipulated

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Tank Level Problem

Feedback Control Strategy 2:
The level is measured and the
outlet flow rate (valve position) is
manipulated

Feed-forward Control Strategy:

Inlet flow rate is measured and
outlet flow rate is manipulated

Taking a Shower
Input Variables: Manipulated input
variables are HW and CW valve
positions, body position. Disturbance
inputs include a drop in water pressure
and changes to HW temp.
Output Variables: Measured output
variables are temp and flow rate of
mixed stream as it contacts your body.

Control Objective: to become clean, to

become refreshed, to be comfortable
(correct temp. and water velocity as it
contacts the body)

Constraints: Min and Max valve

positions on both streams. Min and
Max flow rates (hard constraints).
Mixed water temp (soft constraint).
Control Structure: Adjusting either
valve affects both temp and flow rate
Feedback / Feed-forward control

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Process Control Loop

Controller Tuning Parameters: When there is an error, the controller takes

corrective action (changes its output)
It determines: How much ? Proportional mode (P)
How long ? Integral mode (I)
How Fast ?

Derivative mode (D)

Control Valve Placement

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Elements of a Control Loop

Instrumentation

Elements of a Control Loop (Instrumentation)

Primary elements/sensors: first element in the control loop to measure the process
variables (flow, pressure, temp, level, composition, pH, humidity, viscosity etc.)
Transducer: A device that translates a mechanical signal into an electrical signal. E.g.
pressure transducer
Converter: A device that converts one type of signal into another type. E.g.: analog
to digital, current-to-pressure (4-20mA electric signal to 3-15 psig pneumatic signal)
Transmitter: A device that converts a reading from a sensor or a transducer into a
standard signal and transmits that signal to a controller or monitor (PT, LT, FT, TT,
AT etc.)
Controller: device that receives data from a sensor, compares it with set point and
takes corrective action by sending signals to the control element (PLC, DCS etc.)
Controlling element / final controlling element: part of the control system that
physically changes the manipulated variable (e.g. control valve)
Actuator: part of the control element that physically changes the final control
element when signalled to do so. (pneumatically, hydraulically, electrically)

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Pressure Sensors

Bourdon-Tube pressure gauges (a) negative (b) positive pressures

Bourdon-Tube

Helical Bourdon-Tube

Pressure sensing elements

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Differential Pressure Transducer

Position & Motion Measuring Devices

Potentiometers convert displacement in a sensor to an electric signal

(a) LVDT: Linear Variable

Differential Transformer with
movable core and three windings

(b) Secondary voltage vs

core displacement

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Level sensors
Sight glass

Simple float

Angular float

Capacitive Level Measurement

Conductive Probe
For conductive & nonvolatile liquids (as
a spark can occur)

Capacitive Probe
For nonconductive liquids with high
dielectric constant
Liquid increases capacitance between
plates

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Flow measurement

Orifice Plate

Venturi Tube

Flow Nozzle

Temperature measurement
Bimetallic Strip

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Thermocouples

(a) Thermocouple Circuit

(b) thermocouples connected to

form a Thermopile
(c) Pyrometer
Thermopile: no of thermocouples connected in series to increase sensitivity and
accuracy for low temp differences
Pyrometer: by sensing heat radiated from a hot a body through a lens on to a
thermopile (non contact device, e.g. furnace temp through a small hole in furnace wall)

Resistance Temperature Detectors (RTD)

RTD connections using (a) common supply and meter leads (b) directly
connected meter
RTDs measure the change in electrical resistance of a wire-wound resistor with temp.
Typically platinum resistance element is used with 100

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Hygrometer/ Psychrometer

Hydrometer

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Viscometer

pH meter

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Regulators and Safety Valves

Self-compensating pressure regulators (a) Spring loaded (b) weight loaded

(c) Automatic pressure

safety valve (PSV)

Level Regulators

(a) Automatic fluid

level controller

(b) Automatic emptying of

a storage tank when full

(c) Means of detecting full

level or empty level in a fluid
reservoir

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Flow control actuators: Globe Valve

(a) Cross section of

Globe valve with linear
flow control plug

(b) Different flow

patterns for various
plugs vs plug travel

Actuator determines the speed of travel and distance the valve shaft travels

Flow control actuators: Butterfly Valve

(a) Cross section of a

butterfly valve

(b) Flow vs travel

characteristic

The relation between flow and lift is approximately equal % up to 50% open after
which it is linear. Butterfly valves offer high capacity at low cost.

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Flow control actuators: different valves

(a) Diaphragm

(b) One-piece ball valve

Diaphragm valves & ball

valves are good for slurries &
liquids with suspended solids

(c) Rotary plug valve

Rotary plug valve can be used with

corrosive liquids for forward and
reverse flow.

Valve Fail Safe

(a) Fail Open

(b) Fail Close

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A to D & D to A converters

Smart Sensor Block Diagram

Smart sensor: Integration of sensor with ADC, processor, and DAC for
actuator control.
Smart sensor contains all necessary circuits to interface to the sensor, amplify
the signal, apply PID control, ADC to convert signal into digital format for
internal processor, DAC to convert signal back into analog format for actuator
control.

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Analog vs Digital control loop

Voltage signal

Supervisory control using an analog control loop

Digital temperature signal

Pulse Width Modulated

Supervisory control using a digital control loop

Digital to Analog Conversion

Two methods of converting digital to analog signals:
(i) DAC converter (ii) Pulse Width Modulation (PWM)

(a) 1 kHz sine wave form reproduced

from a DAC

(b) Commercial 8-bit DAC

Digital signal is converted to a voltage

every 0.042 ms giving step wave form.
Finer time grid will give better approx.
4 bit binary coding

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Pulse Width Modulation (PWM signal)

PWM signal to give a 1 kHz sine wave using positive and negative supplies
PWM changes the duration for which voltage is applied going
from narrow to wide and back to narrow.
If the voltage pulses are averaged it gives a half-sine wave.
The other half is generated using negative supply

Programmable Logic Controllers (PLC)

PLC can be configured to receive a small number of inputs (both
analog and digital) & control a small number of outputs
PLC can be expanded with plug-in modules to receive a large
number of signals and control a large number of actuators
Block diagram of a control loop:

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Programmable Logic Controllers (PLC)

I/O Scan Mode: the output control signal is updated based on the
information received from previous I/O scan cycle
Execution Mode: In this mode the processor evaluates input data
stored in memory against the data programmed into the CPU.
The programs are set up using ladder network (series of
steps/instructions to be executed sequentially)
Ladder diagram: symbolic and schematic way to represent the
interconnections between the elements of a PLC.

E.g. Liquid heating system

Symbols used in Ladder Diagrams

NO: Normally Open
Push to close

NC: Normally Close

Push to open

Position

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Ladder diagram for liquid heating system

Alarm will remain enabled
until turned Off by switch 3PB
Switch 3PB ON de-energizes
Red light control
2CR then alarm is OFF
1CR can also be turned off by
Green light control
switch 2PB
Power on Relay

Heater control
Temp sense &
Control Relay
Alarm Control

The first three rungs S1,S2, and S3 are used for control of indicator lights and
the power to the rest of the circuit.
Closure of switch 1PB will energize control relay 1CR, which in turn closes
1CR NO (red light ON); opens 1CR NC (green light OFF); heater is turned ON
In rung S5 when temp reaches desired level it will energize 2CR which in turn
sets alarm ON in rung S6
In rung S1 2CR will turn OFF and de-energizes 1CR, turns lights red to green
and turns off heater.

Different Control Modes

On/Off action: Simplest form of control
E.g. Room heating system: reference temp is 75o F

Simple On/Off action

(considering only inertia)

Differential or Delayed On/Off action

When heating, the temp in the center of

(considering dead time & inertia)
room has already reached 77o F before the
The switching points for thermostat are
temp at sensor reaches 75o F
delayed by 3o F
As the room cools, the temp in the room will
Temp varies between 70o F to 80o F
drop to 73o F before the temp at sensor
reaches 75o F
Temp varies between 72o F to 78o F due to
inertia of system

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Different Control Modes

Proportional action
Disturbance 1: more demand for wash water

Water heater (a) showing a feedback loop for constant temp output and (b)
effect of load changes on the temperature of the water from water heater

Different Control Modes

Proportional action
Disturbance 2: increase in water inlet temp

(system has too little gain)

(system has large gain)

Effect of loop gain on correction time using proportional action with over
correction and under correction
Over corrected signal has oscillatory response (like underdamped) with longer
settling time; and under corrected signal is non-oscillatory (like over damped system
with lesser settling time; optimum corrected signal is like critically damped

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Different Control Modes

Proportional & Derivative action
PD action was developed to reduce the correction time relative to proportional
action alone. Derivative action senses the rate of change of the measured variable
and a correction signal is applied proportional to rate of change only.
Disturbance 2: increase in water inlet temp

PD action (a) variable change with resulting slope and (b) effect of
proportional & derivative action on a variable

Different Control Modes

Proportional & Integral action
PI action was developed to correct for long-term loads and applies a correction
proportional to the area under the change in variable curve.
Disturbance 2: increase in water inlet temp

PI action (a) variable change with area under the graph and (b) effect of
proportional & integral action on a variable

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Different Control Modes

Proportional, Integral & Derivate action
General guidelines:
1. Pressure control requires P&I.
D is normally not required
2. Level control uses P and
sometimes I. D is normally not
required
3. Flow control uses P&I. D is
normally not required
4. Temp control uses PID with
integral set for a long time
period.

Implementation of control loops

Implementation of pneumatic control loops can be achieved using Pneumatic,
Analog, Digital electronics. Initially process controllers were pneumatics based,
now they are replaced by electronic systems.

On/Off Action Pneumatic Controller: Furnace

Furnace temp sensor moves a flapper that

controls the air flow from a nozzle.

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Implementation of control loops

On/Off Action Electrical Controller: Room Heating
(Mercury in
glass bulb)

Example of the use of On/Off controls used for Carton Filling

Implementation of control loops

Pneumatic PID Controller

The pressure from the sensing device (Pin) is compared to a setpoint (Pref) to generate
differential force (error signal) on the flapper in relation to the nozzle giving an output
pressure proportional to error.
System gain is adjusted by moving the position of bellows along the flapper arm, .i.e the
closer the bellows is positioned to the pivot the greater the movement of the flappe arm.

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Implementation of control loops

Schematic of a PID analog electronic controller

Comparator

Summing
circuit

Digital Controllers
Computer based Digital Controller Process

Fig shows Processor controlling two digital loops.

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