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LEC# 12-Process Control2020 PDF

The document discusses control loop components and equipment used in process control systems. It describes common elements like sensors, transmitters, signals, controllers, final control elements, and actuators. It also discusses process control drawings standards and piping and instrumentation diagrams, explaining various symbols used to represent components.

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Shahidan Kirkuky
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107 views

LEC# 12-Process Control2020 PDF

The document discusses control loop components and equipment used in process control systems. It describes common elements like sensors, transmitters, signals, controllers, final control elements, and actuators. It also discusses process control drawings standards and piping and instrumentation diagrams, explaining various symbols used to represent components.

Uploaded by

Shahidan Kirkuky
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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PROCESS CONTROLLERS 2

From Books

CH5
Programmable Controllers Theory and
Implementation
CH1
Instrumentation & Control
Process Control Fundamentals

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Controller output current loops

The simplest form of 4-20 mA current loop is the type


used to represent the output of a process controller,
sending a command signal to a final control element.
Here, the controller both supplies
the electrical power and regulates the DC current to the
final control element, which acts as an electrical load. To
illustrate, consider the example of a controller sending a
4-20 mA signal to an I/P (current-to-pressure) signal
converter, which then pneumatically drives a control
valve:

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Control Loop Equipment and Technology
Control loop components:
• Primary element/sensor
• Transducer
• Converter
• Transmitter
• Signal
• Indicator
• Recorder
• Controller
• Correcting element/final control element
• Actuator
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Primary element/sensor
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
 Venturi tubes
 Magnetic flow tubes
 Ultrasonic emitters and receivers
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TRANSMITTERS
A transmitter is a device that converts a reading from a sensor
or transducer into a standard signal and transmits that signal
to a monitor or controller. Transmitter types include:
 Pressure transmitters
 Flow transmitters
 Temperature transmitters
 Level transmitters
SIGNALS
There are three kinds of signals that exist for the process
industry to transmit the process variable measurement from the
instrument to a
centralized control system.
1. Pneumatic signal
2. Analog signal
3. Digital signal
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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. Common examples of controllers
include:
 Programmable logic controllers (PLCs)
 Distributed control systems (DCSs)

Controllers may perform complex mathematical functions to


compare a set of data to setpoint or they may perform simple
addition or subtraction functions to make comparisons. Controllers
always have an ability to receive input, to perform a mathematical
function with the input, and to produce an output signal.

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Process-Control Drawings
process control employs a standard set of symbols and definitions to
represent a plant and its associated control systems. This standard
was developed and approved by a collaboration between the American
National Standards Institute (ANSI) and the Instrumentation, Systems,
and Automation (ISA) society. The standard is designated ANSI/ISA
S5.1-1984 (R1992) Instrumentation Symbols and Identification.
This standard is used for the early design phases of a plant control
system to construct simplified process-control diagrams and then to
render the final, detailed plant design as a piping and instrumentation
diagram (P&ID).
You should be familiar with ISA Symbology so that you can
demonstrate possible process control loop solutions on paper to your
customer. PID ( piping and instrumentation diagram ) drawing is
shown below

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A P&ID uses special symbols and lines to show the devices and
interconnections in a process-control system.
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ISA Symbology
In a P&ID, a circle represents individual measurement
instruments, such as transmitters, sensors, and detectors

Discrete Instruments
A square with a circle inside represents instruments that both
display measurement readings and perform some control function
.

Shared Control/Display Elements


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A hexagon represents computer functions, such as those carried
out by a controller

Computer Functions (Controllers)


A square with a diamond inside represents PLCs

PLC
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Piping and Connections
Piping and connections are represented with several different
symbols
Piping

Process connection

Electrical signal

Pneumatic signal

Data link
Capillary tubing for
filled systems
Hydraulic signal line

Guided electromagnetic
or sonic signal
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Exercise Problem:
1- The temperature of water in a tank is controlled by a two- position controller.
When the heater is off the temperature drops at 2 K per minute. When the
heater is on the temperature
rises at 4 K per minute. The setpoint is 323 K and the neutral zone is 4% of
the setpoint. There is a 0.5-min lag at both the on and off switch points. Find
the period of oscillation and
plot the water temperature versus time.
Solution
The neutral zone in temperature is T = 4% (323 K) = 12.92 K. Therefore, the
switching temperatures are about 336 K and 310 K. When the system is cooling
the temperature can be written,
Tc(t) = T(t0) - 2(t - t0) (1)
where t0 is the starting time and T(t0) is the temperature at that time. Similarly,
when heating the temperature rises according to the relation,
Th(t) = T(t1) + 4(t - t1) (2)

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The effect of the overshoot is found as follows. Suppose the heater is
on and the upper trip point, 336 K, was reached at some time t. The
system will continue to heat for another 0.5 min at 4 K/min (i.e.,
another 2 K). Therefore, when the system really starts cooling the
temperature is 338 K. In the same sense, when cooling to 310 K the
system will continue to cool for another 0.5 min at -2 K/min or -1 K, so
the actual heating starts from 309 K.
Suppose at t = 0 the temperature has reached the “real” upper trip
point of 338 K and is now cooling. It will then drop according to
Equation (1), T c(t) = 338 - 2t. We can find the time when it reaches
309 K by solving, 309 = 338 - 2t1, so t1 = 14.5 min. Therefore, at 14.5
min. it starts heating. We can find the time it reaches 338 K again from
Equation (2), for heating, 338 = 309 + 4(t2 - 14.5), so t2= 21.75 min.
Thus, the total time for one cycle, which is the period, is 21.75 min.
Below figure shows a plot of the temperature variation. (The plot was
constructed with a starting point of the setpoint, 323 K and
cooling, instead of the upper trip point used in the previous
calculations.)
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2- A 5-m-diameter cylindrical tank is emptied by a constant outflow
of . A two-position controller is used to open and close a fill valve
with an open flow of
.For level control, the neutral zone is 1 m and the setpoint is 12 m.
a. Calculate the cycling period.
b. Plot the level versus time.

3- For Exercise 1, verify that a neutral zone produces the results of


limits of oscillation and period given in the text.

4- A floating controller with a rate gain of 6%/min and has a


deadband. Plot the controller output for an input given by Figure 25.
The setpoint is 60 gal/min.

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4. Identify the signal types that are used in the process control
industry?
Hydraulic signals
Digital signals
Analog signals
Pneumatic signals
Electro-magnetic signals
5-Which of the following have the ability to receive input, to
perform a mathematical function with the input, and produce an
output signal?
Actuators
Transmitters
Transducers
Controllers

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6- Which of the following is the most common final control element
in process control industries?
Agitator
Pump motor
Valve
Louver
7- _______________ is a part final control device that causes a
physical change in the final control device when signaled to do
so.
8- Which of the following is a symbol of a transmitter in an
auxiliary location?

1 2 3 4
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9- Identify three examples of a primary element/sensors in
process control?.
Resistance Temperature Detectors
Control Valve
Thermocouples
Converter
Pitot tubes

10- Primary elements will not make direct contact with the process
fluid. Is this statement true or false?

11- A transmitter is a device that converts a reading from a


transducer into a standard signal and transmits that signal to a
monitor or controller. Is this statement true or false?

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