Basic Instrumentation Systems

Content
1.1 Introduction to Process control
1.2 Basic component of process control
1.3 Basic Block Diagram 1
1.4 Control System Strategies

C
 1.1 Introduction
General production systems are categorized by their type of industrial production which will be
considered by their process behavior. Basically, the industry is divided into 3 categories:

- "Process Control": continuous processes control a variable in the process continuously

and precisely. Such as pressure control systems, temperature control systems, level control
1
systems which can be found in power plants, refinery industries or petrochemical industries.

- "Manufacturing": discrete processes are productions of distinct items. The production is

controlled as a sequence, which characteristic is typically “ON-OFF”. Such as the automobile
industries, electronics industry, etc. production control in a sequence of work, which is a typical
characteristic On-Off by example in this industry include automobile industry. Electronics, etc.

- "Batch Control": semi-continuous processes include both continuous process and

discrete process. Such as the food industry, pharmaceutical industry, etc.

Automotive
Manufacturing
Electronics
Machinery
Textiles
Pharmaceuticals
Fine Chemical
Food & Beverage
Metals & Mining
Water & Waste
Pulp & Paper
Vehicles 1
Petrochemicals
Oil & Gas
Electrical Power

Figure 1. shows the types of manufacturing processes

This teaching material will focus on process controlling, where the word process means
converting raw materials into different types of products used.

Process
Raw Material Product
2
Figure 2. Definition of Process

To make the production meet its objective, we need to control variables. Automation is
therefore used in industrial applications to control these variables. As a result, process control
systems are focused on the closed loop control, which measures the output and compares it to
the set point. This will generate a signal for controlling the device as shown in the picture below.

SP + %CO MV PV
Controller Final Process
control
- element

%TO
Measurin
g device
2

Figure 3. The physical picture of the devices in relative to their position in the block diagram
 Large control system
hierarchy

Management ERP
Plant MES 3
Field SCADA DCS Large PLC
Process Manufacturing
Batch
Control
Figure 4. shows the level of management and control

Figure 4 shows the entire system of an organization - from the production sector to the
management sector - based on the standard ISA 95. Present organization have a management
system called ERP (Enterprise Resource Planning), which will manage human resources, finance,
accounting, human assets and important economic information for the organization. The ERP is
linked to the MES (Manufacturing Execution System), which is a management and planning
system for the production sector. It will make the process of production appropriate to the laid
out policies. The organization’s factory will manage to fulfil the plan from the MES.

Figure 5. layers of production management and control, according to the ISA

95
 Level
Planning ERP
Level (Enterprise Resource Planning)
MES
Execution (Manufacturing Execution System)
Level SCADA
Supervisory
(Supervisory Control
and Data Acquisition)
4
Level DCS
(Distributed
Control System)
Control PLC
Level (Programmable
Logic Controller)
Time
ms seconds hours days weeks month years
Figure 6. Response time and hierarchical level
As shown in Figure 6, information management is related between the vertical axis that
represents the levels and the horizontal axis that represents the time to deal with the data. It is
demonstrated that the data in the process control requires less time to manage the production
control. Managing production planning (MES) will require more time. But the last level will be
about managing the enterprise (ERP), which requires a lot of time and which might take up to
years.

P&ID (Piping and Instrumentation Diagram) is widely used when it comes to process control. It
shows the details of the manufacturing’s processes and the equipment used in the production
process. For example, Figure 7.

Controller TC

Final control
element
Steam 4
TT
Process Process Transmitter
Fluid in Fluid out

Sensor

Condensate Process
return

Figure 7. P & ID for Heat exchange process

Figure 8 shows that the process is connected to the control system. For example, the DCS which
stands for Distributed Control System. The DCS is similar to a PLC, but larger and more capable
than a PLC. It can either do batch control, sequential control, analog control or advance control.
Moreover it can have an user interface and keep history data. The DCS has been brought in to
monitor various parameter values within the production process, including the ability to adjust
these parameters as needed. 5

การควบคุมระบบในส่ วนของ DCS

Figure 8. shows the control of the whole system

Aside from the DCS, the SCADA system has been brought in to be used in analysing values. From
analysing, signals will be generated for adjusting various parameters at a different place. These
data will be sent to the MES (Manufacture Execution System) for further production planning.
Then these data will be sent to the ERP (Enterprise Resource Planning) to analyse economic data.
6

Figure 9. shows an example of the SCADA system

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 1.2 Basic components of
Instrumentation Disturbance

SP + %CO MV PV 7
Controller Final Process
control
- element

%TO
Measurin
g device

Figure 10. shows a general block diagram of a process

From the figure above, we can see that the process has various disturbances. This prevents the
output to be unlike the set point. The sensor or transmitter’s main work is to measure the output
of the process and compare the output with the set point. So that the controller is able to find an
error percentage and process the data it got in order to send signals to the control valve. Where
the control valve’s main work is to control the process input to meet the desired output.

Basic components in a control loop includes:

1. Sensor/Transmitter
2. Final control element
3. Controller
4. Process

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 1.2.1
Sensor/Transmitter
SP + %CO MV PV
Controller Final Process
-
control
element
8
%TO
Measurin
g device

Figure 11. The physical picture of the sensor in relative to their position in the block
diagram

A sensor or transmitter serves to measure process variables or also called output such as
temperature, pressure, flow and liquid level. These devices will convert the process variable
value into a signal (% TO) which will then be used for the controller. Good sensors and
transmitter should have faster response time the process itself. Standard signals of that are
used are given below.

 Pneumatic signal (3-15 psi, 0.2-1.0 kg/cm2)

 Analog signal (4-20 mA, 1-5 V)
 Fieldbus signal (digital signal ex. HART, Profibus, etc.) 8
The physical characteristics of these devices are:
1.1 Temperatures sensor/transmitter 1.2 Level sensor/transmitter
such as RTD and Thermocouple

1.3 Pressure sensor/transmitter 1.4 Flow sensor/transmitter

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 1.2.2 Final control element

Here we will focus specifically on the control valve, which is commonly used in process
control.

10

SP + %CO MV PV
Controller Final Process
control
- element

%TO
Measurin
g device

Figure 12. The physical picture of the control valve in relative to their position in the block diagram

Components of the control valve

A control valve is a device that controls the flow of a fluid in the process. Where the valve stem
will be controlled by the signals received from the controller.

10

Figure 13. working principle of a control valve

  Valve Actuator is the mechanism for opening and closing a valve. It consists of a
diaphragm that gets actuated by air pressure.
 Valve Stem connects the actuator with the valve.
 Valve Body has a stem inside of it for allowing or preventing fluid flowing through the
valve. 11

Figure 14. components within a control valve

The image above shows the components within a control valve. It includes a diaphragm,
which is a main component of the valve mechanism. When air pressure acts on the diaphragm,
the diaphragm’s spring will deform. While the spring expands the valve stem will move.

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Valve Flow Characteristics
generally, control valves are divided into three types according to their behaviour.
• Equal Percentage are widely used, because it is a linear valve.
• Used in processes with heavy pressure change.
• Used in processes related to pressure and temperature.
12
• Linear
• Used in processes related to level and flow.
• Used in processes with regular pressure change.
• Quick Opening
• Commonly used for On-Off processes.
• Suitable for processes that require significant changes.

12

Figure 15. valve characteristic shown in a graph

Valve Type
Ball Valve
Best Suited Control: Quick opening, linear
Recommended Uses:
1. Fully open/closed, limited-throttling 13
2. Higher temperature fluids

Applications: Most liquids, high temperatures, slurries

Advantages: Disadvantages:
1. Low cost 1. Poor throttling characteristics
2. High capacity 2. Prone to cavitation
3. Low leakage and maint.
4. Tight sealing with low torque

Globe Valve
Best Suited Control: Linear and Equal percentage
Recommended Uses:
1. Throttling service/flow regulation
2. Frequent operation

Applications: Liquids, vapors, gases, corrosive substances, slurries

Advantages: Disadvantages: 13
1. Efficient throttling 1. High pressure drop
2. Accurate flow control 2. More expensive than
3. Available in multiple ports other valves
Butterfly Valve
Best Suited Control: Linear, Equal percentage
Recommended Uses: 14
1. Fully open/closed or throttling services
2. Frequent operation
3. Minimal fluid trapping in line

Applications: Liquids, gases, slurries,

liquids with suspended solids
Advantages: Disadvantages:
1. Low cost and maint. 1. High torque required for control
2. High capacity 2. Prone to cavitation at lower flows
3. Good flow control
4. Low pressure drop

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 1.2.3. Controller

Here we will introduce a controller by showing the function of this controller. The controller we
will be using is a FUJI PXT Series.
15

SP + %CO MV PV
Controller Final control Process
element
-

%TO
Measuring
device

Figure 16. physical picture of the controller according to its position in the block
diagram of the process

15
16

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1.3 Block Diagram Analysis

Steam

Process
Fluid in
Process
Fluid out
17

Condensate
return

MV
(Flow of steam) PV
(Process fluid out)
Process
Disturbance
(Process fluid in)
Figure 17. shows the P & ID and Block diagram of a heat exchange process.

We can look at a system process simply in the way of a block diagram like the example of a
heat exchange process. In which the process, can have a defined input that is able to set or
change the value of ‘MV’ or an undefined input that is called disturbance.

Terminology of the block diagram

• Set point (SP) represents the desired value.
• Manipulated variable (MV) represents the variable that can be adjusted
dynamically to keep the controlled variables at their set points or make the output
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variable (PV) change.
• Process variable (PV) represents the output variable of the process that has to
be controlled.
• Disturbance represents the input variables that cause the output variable (PV) to
differ from their respective set points.
 We need to have the system built up in the form of an automation control. Which means that we
need to use a controller to adjust the system. We commonly use block diagrams to analyze the
system. Such as the temperature control of the heat exchange process.

SP
18
Controller TC

Final control
element
Steam

TT
Process Process Transmitter
Fluid in Fluid out

Sensor

Condensate Process
return

SP + %CO MV PV
Controller Final Process
control
- element

%TO
Measurin
g device 18

Figure 18. shows P & ID and Block diagram of the heat exchange process in the form of automation
control.
Hand From P & ID given, try to Identify the variables into the blank space.
on SP

PV = ____________________
PC 19
PT
MV = ____________________
Gas
Disturbance = ______________

SP

TC TT
PV = ____________________

Steam
MV = ____________________

Feed
Disturbance = ______________

Product 19
Liquid

PV = ____________________
20
LT LC MV = ____________________

Disturbance = ______________

SP

PV = ____________________ TT TC
Preheater
furnace
MV = ____________________

Disturbance = ______________

Reactant A

20

Fuel
1.4 Control System Strategies
The objective of controlling a process system is to maintain the process variable as close as
possible to the required set point, where the process variable might be stable or deviating. We
can separate the word control into a basic control model and complex control model. The basic
principle is Feedback and Feedforward. 21
1.4.1 Feedback Control
Controlling the variable MV in a process to get the desired variable PV is shown in Figure 19.
The output of the process will be measured by a sensor or transmitter and compares it to the
set point. The controller will then adjust the variable MV until the desired variable PV is
reached. This is the most common type of control, it is called Feedback control.

SP

TC TT
01 01

Steam

Feed

Product

Disturbance

+
SP + + PV
PID TV-01
Temp
Process 21
-

TT-01

Figure 19. shows the P&ID and block diagram of the tank’s temperature control using
feedback control
 1.4.2 Feedforward Control
Here we are interested in controlling the disturbance in the system. A sensor or transmitter will
be measuring the disturbance for adjusting the variable MV, before the variable PV experiences
huge changes. This method is different from the feedback control, because it will wait until the
disturbance interrupts the system and then it will adjust the variable MV. Moreover we can use
this method with a system that has many disturbances.
22
Steam

L/L
FY
02

FT
02 TT
Process Process 01
Fluid in Fluid out

Condensate
return

Disturbance

FY-02
FT-02
(FFC)

Temperature
of fluid out
22
Heat
FY-01 Exchanger

Figure 20. shows the P&ID and block diagram of a Heat exchange process using feedforward control
 But in practice the feedforward control is often combined with the feedback control to optimize
performance like shown in Figure 21.

Steam

FY
L/L
FY
23
SP
02a 02b

TC
01
FT
02 TT
Process Process 01
Fluid in Fluid out

Condensate
return

Disturbance

FY-02a FT-02

+
SP + + PV
Heat
PID TY-01 Exchanger
-

TT-01
23

Figure 21. shows the P&ID and block diagram of a heat exchange process using both
feedforward and feedback control.
 Besides the 2 control methods mentioned before, they are other ways to control a complex system.
For example:

1.4.3 Cascade Control

This method was brought in with the main purpose to solve the effects of the disturbance. The
control model involves two control loops. The outer loop will be called the slave and the inner
24
loop will be called the master.

Note: Consist out of more than 1 controller and transmitter but only 1 final control element.
SP

TC
01
Process 02
TT
01
TT TC
Process 01
Preheater 02 02
Reactor
furnace

Cooling
water

Product

Fuel Disturbance

+ + + PV
PID PIC Preheater
SP TV-02 Reactor
-
[TC-01]
-
[TC-02] furnace
24
TT-02

TT-01

Figure 22. shows the P&ID and block diagram of a preheater furnace and reactor process using cascade control
1.4.4 Ratio Control
The objective of this control method is to maintain the ratio of two process variables as a
specified value. Such as to control the air and fuel ratio in a furnace or the ratio of two mixing
components. This type of system will be controlled by the ratio station.

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Fluid A

FA/FB
FT FY
01 01

FT FC
02 02

Fluid B

+
FT-01 FY-01 PID FV-02
-

FT-02

Figure 23. shows the P&ID and block diagram of a ratio control 25
1.4.5 Override Control
Override control involves 2 loops to run the final control element. It will have one selector that
will choose either the higher or lower value from the output of the two controllers used. This
method is mainly used for performance and safety.
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Hot saturated
liquid

<
LT LC FY FC
01 01 01 02

FT
02

To process

LT-01
[Level]

-
+
Level PID
Set point

Level
< Pump
Process

Flow PID
+
Set point
-

FT-02
[Flow]
26

Figure 24. shows the P&ID and block diagram of an override control
1.4.6 Selective Control
For the selective control method, we are able to choose more than one input to be used to
control. The input can be the maximum value, minimum value or average value. This method is
used to increase reliability or other
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SP

TC
01
>
TY
01

TT TT TT
01a 01b 01c

Product
Cooling
Reactants
water

SP +
PID TY-01 Reactor
-

TT-01a

> TT-01b

TT-01c
27

Figure 25. shows the P&ID and block diagram of a selective control
1.4.7 Split-range Control
Split control method requires more than one valve for adjusting the variable MV of the process.
Where those valves will respond to the control signal CO differently. This depends on the
formulation of the split-range function block.
27

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Figure 26. shows the P&ID and block diagram of a split-range control
References

1. Carlos A.Smith and Armanda Corriipio., Principles and Practice of

Automation Process Control, Wiley Asia Student Edition, 3 rd edition
,2006
2. Bela G. Liptak, Instrument engineers’ Handbook “Process Control”,
Chilton Book Company I Radnor, Pennsylvania, 3 rd edition ,1995