1.

2 PARTS OF CONTROL SYSTEMS

• Elements in control system
i. Measurement element – Sensor Transmitter
ii. Decision – Controller
iii. Action (Final Control Element) – Control valve, pump etc.
• Basic terminologies in process control
i. Set point,
ii. Manipulated variables,
iii. controlled variables,
iv. Disturbances
v. Error
• Symbols Used In Control System Configuration
• Types of controller
i. Analog controller
ii. Digital controller
• Analog & digital processing
• Case studies
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Introduction
• Normally a chemical process has numerous inputs and
many output. Consider the diagram below :
 Elements Control System

D
e=r-b
r co Final M c
Controller control Process
Set point V v
element

b Measurement
element

Figure 1.3: General block diagram of closed loop control in process control
 Process

 The material equipment

along with the physical Mixer
and/or chemical operations
which take place.

 Continuous operation that

transform input to the
output

Boiler 6
 Measurement Element

 Measured the output signal

(physical and/or chemical
variables) and send the
signal to the controller for
corrective action

 Also known as sensor

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 Controller

Device which valuates error of

the controlled variable and
initiates corrective action to the
final control element.

DETECTIN
G
ELEMENT
6
 Manual Valve

Final Control Element

Control Valve

 Manipulates the manipulated

variables to affect the output
under command of controller

DC motor

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Basic Terminologies in Process Control
Set point

 Input representing the desired value of a system.

 Set point value is compared with output to actuate
the controller.

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Manipulated Variable

• Quantity or condition which is varied by the controller

to affect the value of controlled variable.
• On a typical chemical process there are generally any
controlled variable and manipulated variable.

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 Disturbance

 Unwanted signal that tends to affect the output value:

Internal: Generate within the system

External: Generate outside the system

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 Variables
that fluctuate and cause the process output to
move from the desired operating value (set point).

 Can be a change in flow, temperature of the

surroundings, pressure etc.

 Canbe further classified in terms of measured or

unmeasured signals.

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 Controlled Variable

 Variables of quantity or condition which are measured

and controlled
 System output

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 Error

 The difference value between the set point and output

and serve as input to the feedback control

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Naming Used In Control System
Configuration
Controller Sensor/transmitter

TC Temperature Controller FC TT Temperature transmitter

Flow Controller FT Flow transmitter

LC Level Controller PCPC LT Level transmitter

PC Pressure Controller PT Pressure transmitter

FFC Feed-forward Controller

FRC Ratio Controller

Types of Controller
1. Analog controller
◦ Used of continuously (time) varying control signal.

◦ Example :
 1) On-off controller (2-position mode controller)
 2) Proportional controller
 3) Proportional + Integral controller
 4) Proportional + Derivative controller
 5) Proportional + Integral + Derivative controller

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2. Digital or Discrete Controller
◦ Used digital concept (1/0) to control the
system.

◦ Example :
 1) Programmable Logic Controller (PLC)

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Analog & Digital Processing
 Analog ~ continuous
 Digital  computer ~ discrete
 On/Off Control – majority
 Smart sensor

◦ device with small housing contains complete set of

measurement and control including analog – digital or
digital – analog converter.

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 Data represetation

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 Analog signal Digital signal
ADVANTAGES
Simple Can be very immune to noise
Inexpensive Signal can be transmitted over
Do not require high accuracy long distances.
and flexibility
DISADVANTAGES
Noise – Output subject to quantity errors
i.e., random unwanted variation from sampling

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 Case Study and Exercises
Case Study 1 Heating system:

Suppose that it is desired to maintain the temperature of the home at 72ºF. This
temperature is the desired value or setpoint. A thermostat is installed on an inside wall of the
home and measures an existing room temperature. This temperature is to be the controlled
variable. A person watching the thermostat notes the temperature is 69ºF and is therefore less
than the desired value. The actuating signal (error) is 3ºF. An action is then taken to reduce
this difference by ON the switch that turns on the fuel gas to the furnace burner. The flow of
the fuel gas is the manipulated variable. As the furnace heats, warm air is delivered to the
room and the temperature will presently increase. In a short time the temperature becomes
too high, and the whole sequence must be repeated in
the opposite direction. 20
 Solution 1

SV – home temperature at 72ºF Process – ON the switch that turns on the

CV – home temperature fuel gas to the furnace burner
MV – flow of the fuel gas Controller – A person
D – Temperature of fuel gas, flow of the fuel Actuator – Solenoid valve
gas. Sensor – Regulator / thermostat

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 Case Study 2 Consider the stirred tank shown below:

• Identify the four components of

control system in the above process.
• Draw its functional block diagram.
• Identify the following:
- controlled variable
- manipulated variable
- setpoint
- disturbance

The temperature of the stream leaving the stirred tank is the controlled variable. Many
other output variables exist such as the output flow rate and the exit heating oil temperature. A
manipulated variable is selected for adjustment in a control strategy to achieve the desired
performance in the controlled variable. The valve position in the heating oil pipe is the
manipulated variable, since opening the valve increase the flow of heating oil and results is
greater heat transfer to the fluid in the tank. A feedback control system is needed to achieve
the desired behavior of the output variable. The output is
measured using thermometer for corrective action. 22
 Solution 2

SV – Desired temperature of the stream

CV – Temperature of the stream Process – Maintain temperature of the
MV – valve position in the heating oil pipe stream leaving the stirred tank
D – Output flow rate, exit heating oil Controller – A person
temperature Actuator – Valve
Sensor – Thermometer

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CASE STUDY 3 Water heater system:

The purpose of the heater is to maintain a supply of heated water. The variable most
indicative of this purpose is the temperature of water at the outlet; this temperature is
called the controlled variable. The heat flow rate must be manipulated by the
controller. The incoming water temperature is the load variable. It is expected that the
automatic controller will correct for fluctuations in load variables and maintain the
controlled variable at the desired value.
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 SOLUTION 3 Draw Block diagrDam:

SV – Desired water temperature Process – Maintain a supply of heated water

CV – temperature of water at the outlet at desired temperature in a tank (Tank)
MV – heat flowrate Controller – Automatic controller
D – Fluid flowrate, heat flowrate, Actuator – Water heater
ambient temperature Sensor – RTD (resistance temperature
detector)
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 Case Study 4 Temperature control of continuous stirred tank reactor:

• Identify the four components of

control system in the above
process.
• Draw its functional block
diagram.
• Identify
the
following:
- controlled
variable
-
manipulate
d variable
-- setpoint
The temperature of the reactor is to be controlled to pre-specified value. Cooling water runs
- disturbanc
through the cooling jacket to remove heat generated by the reaction.
e The mixed raw material
fed to the reactor may be of variable flow rate and temperature. The generated product is
withdrawn at such a rate as to keep the amount of material in the reactor unchanged. The
temperature of the reactor is measured by a thermocouple and the measurement signal is
transmitted to a comparator and send to the controller. The signal is compared with the
desired value. The difference between them is calculated, amplified and used to adjust the
control valve, thereby changing the flow rate of cooling water to the jacket. In this way, the
temperature of the reactor may be kept at or near its target value.
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SOLUTION 4

Process – The heat transfer between the reactor and cooling jacket.
Controller – The comparator and the amplifier
Actuator – The flow control valve
Sensor – The thermocouple

SV – prespecified reactor temperature

CV – temperature of the reactor
MV – flowrate of cooling water
E – Difference between prespecified and measured temperature
D – Inlet water flowrate, outlet water flowrate, ambient temperature, cooling
water flowrate.
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EXERCISE 1
Figure Q1 below show a heating system for a stirred tank.Water is heated to
the reference temperature of 100 ºC by mixing with steam.Assume that the
inflow rate of cold water and the heated water overflows into an outlet pipe at
top of the tank, so that there is no accumulation. Identify:
• Components
• Controlled variables (CV), manipulated variables (MV) and disturbances
(D).
Main steam
supply

Set point

Rela
Heated y
Water

RTD Voltage source

Cold
Water

Control
steam Solenoid
Valve
Figure Q1 28
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REFERENCES

1. Curtis, D. Johnson, Process Control Instrumentation Technology, Prentice

Hall, 2000.

2. Thomas E. Marlin, Process Control, McGraw Hill, 2nd Edition 2000.

3. Harriot, P.Process Control, McGraw Hill,1986
4. Dale E. Sebog,Thomas F. Edgar, Duncan A. Melichamp, Process Dynamics
Control,Wiley, 1st Edition, 1989.
5. http://blog.opticontrols.com/site-map

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