Instrumentation & Process

Control Fundamentals
Designed by:
Hossam A. Hassanein

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Goals
 Basic understanding of process control

 Important process control terminology

 Major components of a process loop

 Instrumentation P&ID symbols

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Instrumentation
Definition

The use of
measuring
instruments to
monitor and
control a process
variables

Instrumentation

Variables such as
temperature,
pressure, flow,
level, speed
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Process Control
Definition

Engineering
discipline that;
deals with
architecture and,
algorithms for
maintaining the
output of a
specific process
with a desired
range

Process
Control

Output such as
temperature,
pressure, flow,
level, speed
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Why Process Control

Accuracy

Stability

Safety
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Process Control Basics

and
Terminology
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Process Control Basics
and
Terminology

Control Loop

It is a cold winter night. You are sitting in front of a small fire but; you feel
uncomfortable. You start to throw another log on the fire.

This is a simple example of a control loop where:

- Variable is the Temperature
- Set point is your comfort level
- Action bring the process back into desired condition by
adding more fuel to the fire

Measurement

In industry it works the same and it requires Comparison

Adjustment
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Process Control Basics
and
Terminology

Simple Control Loop

-In the Figure a lev el

transmitter (LT) measures the
lev el in the tank and transmits
a signal associated with the
lev el reading to a controller
(LIC).
-The controller compares the
reading to a predetermined
v alue, The controller then
sends a signal to the dev ice
that can bring the tank lev el
back to a lower lev el
-The v alve at the bottom of
the tank opens to let some
liquid out of the tank.
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Process Control Basics
and
Terminology

Process Variables

Is a condition of the process fluid that; can change the manufacturing

process in some way.

Process variables such as:

▪ Pressure
▪ Flow
▪ Level
▪ Temperature
▪ Density
▪ pH
▪ Mass
▪ Conductivity
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Process Control Basics
and
Terminology

Controller
Is a device that receives data from a measurement instrument, compares that
data to a programmed set point, and, if necessary, signals a control element to
take corrective action.
For example A process fluid tank is to be
maintained at a constant temperature 100 °C .
The tank is heated by a helical pipe through
which steam flows through a control v alve.
- A sensor to measure the process
temperature
- A controller to compare the temperature
reading from the sensor to the set point
- If temperature reaches 110 °C
- The controller determines that, process
temperature is abov e the set point
- The controller signals the control v alve to
close slightly until process temperature cools
to 100 °C
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Process Control Basics
and
Terminology

Set point
Is the value for a process variable is desired to be maintained .

Also known as Reference Variable.

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Process Control Basics
and
Terminology

Measured Variables, Process Variables, and

Manipulated Variables
In the previous temperature If we measure the flow into
loop example the measured and out of a storage tank to
variable is temperature which determine tank level
must be near to 100 oC

The measured variable is also The measured variable (flow) is

process variable not process variable (level)
Measured Variable Manipulated Variable
is the condition of the process The factor that is changed to
fluid that must be kept at the keep the process variable at set
designated set point. point. (Flow in this example)
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Process Control Basics
and
Terminology

Error
Is the difference between the measured variable and the set point and
can be either positive or negative

Magnitude
Is the deviation between the values of the set point and the process
variable

Duration
Duration refers to the length of time that an error condition has existed.
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Process Control Basics
and
Terminology

Rate of Change
The rate of change is shown by the slope of the error plot.
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Process Control Basics
and
Terminology

Offset
Is a sustained deviation of the process variable from the set point.

Load Disturbance
Is an undesired change in one of the factors that can affect the process
variable.
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Process Control Basics
and
Terminology

Control Algorithm
Is a mathematical expression of a control function.
Using the temperature control
loop example, V in the
equation below is the steam
valve position, and e is the
error. The relationship in a
control algorithm can be
expressed as:

V = f(±e)
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Process Control Basics
and
Terminology

Open Control Loop

Exists where the process
variable is not compared,
and action is taken not in
response to
feedback on the condition of
the process variable
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Process Control Basics
and
Terminology

Closed Control Loop

Exists where a process

variable is measured,
compared to a set point, and
action is taken to correct any
deviation from set point.
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Components
of
Control Loops
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Components
of
Control Loops

Primary Elements (Sensors)

Devices that cause some change in their property with changes in
process fluid conditions that can then be measured and, they are the
first element in the control loop to measure the process variable

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
-Coriolis flow tubes
-Radar emitters and receiv ers
-Ultrasonic emitters and receiv ers
-Annular flow elements
-Vortex shedder
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Components
of
Control Loops

Transducers
Device that translates a mechanical signal into an electrical signal.

Converters
Device that converts one type of signal into another type of signal.

Transmitters
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 -Lev el transmitters
-Analytic (O2 [oxygen], CO [carbon monoxide], and pH) transmitters
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Components
of
Control Loops

Signals

Divided Into Three Types

Pneumatic Signals Analog Signals Digital Signals

Are signals produced by The most common standard Are discrete levels or values that
changing the air pressure in a electrical signal is the 4–20 mA are combined in specific ways to
signal pipe in proportion to the current signal. represent process variables and
measured change in a process also carry other information,
variable. - 4 mA-------- Represents lowest
The common industry standard possible measurement, or zero.
pneumatic signal range is
- 20 mA-------- Represents highest
- 3 psig -------- Corresponds to possible measurement .
Lower Range Value (LRV)

- 15 psig -------- Corresponds to

Higher Range Value (HRV)
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Components
of
Control Loops

Indicators
Is a human-readable device that displays information about the process
like pressure gauge.

Records
Is a device that records the output of a measurement devices.
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Components
of
Control Loops

Controllers

Process variable controller divided Into Two Types

Continuous Action Controller Non Continuous Action Controller

The manipulated v ariable of the The manipulated v ariable of a
continuous action controller non-continuous-action controller
changes continuously dependent can only be changed in set steps.
on the system dev iation

Centrifugal Thermostat of an
Governor iron
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Components
of
Control Loops

Controller

Controllers always have an ability to receive input, to perform a

mathematical function with the input, and to produce an output signal.

Programmable logic controllers Distributed control systems (DCSs)

(PLCs) Are controllers that, in addition to
Are usually computers connected performing control functions,
to a set of input/output (I/O) prov ide readings of the status of
dev ices. The computers are the process, maintain databases
programmed to respond to inputs and adv anced man-machine-
by sending outputs to maintain all interface.
processes at set point.
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Components
of
Control Loops

Correcting Elements (Final Control Elements)

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.

ACTUATORS
Is the part of a final control device that causes a physical change in the
final control device when signaled to do so. The most common example
of an actuator is a valve actuator
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Components
of
Control Loops
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Instrumentation, Systems,
and Automation
(ISA) Symbols
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Instrumentation, Systems,
and Automation
(ISA) Symbols

The figure shows a control

loop using ISA symbology.
Drawings of this kind are
known as piping and
instrumentation drawings
(P&ID).
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Instrumentation, Systems,
and Automation
(ISA) Symbols
Signal Lines
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Instrumentation, Systems,
and Automation
(ISA) Symbols

Control Room Not accessible Auxiliary

Function
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Instrumentation, Systems,
and Automation
(ISA) Symbols

Actuator
Symbols
Control Valves

Self Actuated
Regulators
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Instrumentation, Systems,
and Automation
(ISA) Symbols

▪ Status of valves (default position) is shown below the valve

symbol:
▪ NO = Normally Open
▪ NC = Normally Closed
Control Valves

▪ LO = Locked Open
▪ LC = Locked Closed

▪ Status of valves (fail position) is shown below the valve symbol:

▪ FO = Fail Open
▪ FC = Fail Closed
▪ FL = Fail Last or Locked
▪ FI = Fail Indeterminate
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Instrumentation, Systems,
and Automation
(ISA) Symbols
Tag Number
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Instrumentation, Systems,
and Automation
(ISA) Symbols
Tag Number

EMCS = Electronic Measuring Control System

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Instrumentation & Process

Control Fundamentals
Summary
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Instrumentation & Process
Control Fundamentals
Summary
In the process example shown (Figure5.1.1),
the operator manually varies the flow of
water by opening or closing an inlet valve to
ensure that:
-The water level is not too high; or it will run
to waste via the overflow.
- The water level is not too low; or it will not
cover the bottom of the tank.
The outcome of this is that the water runs out
of the tank at a rate within a required range.
If the water runs out at too high or too low a
rate, the process it is feeding cannot
operate properly.
At an initial stage, the outlet valve in the
discharge pipe is fixed at a certain position.
The operator has marked three lines on the
side of the tank to enable him to manipulate
the water supply via the inlet valve. The 3
levels represent:
1. The lowest allowable water level to ensure
the bottom of the tank is covered.
2. The highest allowable water level to
ensure there is no discharge through the
overflow.
3. The ideal level between 1 and 2.
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Instrumentation & Process
Control Fundamentals
Summary

1. The operator is aiming to maintain the water in the v essel between lev els 1 and 2. The water
lev el is called the Controlled condition.
2. The controlled condition is achiev ed by controlling the flow of water through the v alve in the inlet
pipe. The flow is known as the Manipulated Variable, and the v alve is referred to as the Controlled
Device.
3. The water itself is known as the Control Agent.
4. By controlling the flow of water into the tank, the lev el of water in the tank is altered. The change
in water lev el is known as the Controlled Variable.
5. Once the water is in the tank it is known as the Controlled Medium.
6. The lev el of water trying to be maintained on the v isual indicator is known as the Set Point.
7. The water lev el can be maintained at any point between 1 and 2 on the v isual indicator and still
meet the control parameters such that the bottom of the tank is cov ered and there is no ov erflow.
Any v alue within this range is known as the Desired Value.
8. Assume the lev el is strictly maintained at any point between 1 and 2. This is the water lev el at
steady state conditions, referred to as the Control Value or Actual Value.
Note: With reference to (7) and (8) abov e, the ideal lev el of water to be maintained was at point 3.
But if the actual lev el is at any point between 1 and 2, then that is still satisfactory. The difference
between the Set Point and the Actual Value is known as Deviation.
9. If the inlet v alve is closed to a new position, the water lev el will drop and the dev iation will
change. A sustained dev iation is known as Offset.
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Instrumentation & Process
Control Fundamentals

The End of The Session

QUESTIONS??