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Basics of Control Engineering

This document provides an introduction to the basics of control engineering. It discusses two main topics: process control and heating, ventilating, and air conditioning (HVAC) control. Process control involves regulating variables like temperature, pressure, flow, level, and speed. HVAC control ranges from domestic appliances to large industrial systems. The document outlines some key terms used in control engineering and provides a simple example to illustrate concepts like the controlled condition, manipulated variable, controlled device, and more. It also discusses the need for automatic controls in terms of safety, stability, and accuracy.

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80 views

Basics of Control Engineering

This document provides an introduction to the basics of control engineering. It discusses two main topics: process control and heating, ventilating, and air conditioning (HVAC) control. Process control involves regulating variables like temperature, pressure, flow, level, and speed. HVAC control ranges from domestic appliances to large industrial systems. The document outlines some key terms used in control engineering and provides a simple example to illustrate concepts like the controlled condition, manipulated variable, controlled device, and more. It also discusses the need for automatic controls in terms of safety, stability, and accuracy.

Uploaded by

brian qlp
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Basics of Control Engineering

The subject of automatic controls is enormous, covering the control of variables such as
temperature, pressure, flow, level, and speed
The objective of this Block is to provide an introduction to automatic controls. This too can
be divided into two parts:

 Process control and.


 The control of Heating, Ventilating and Air Conditioning systems (commonly known
as HVAC);

Both are immense subjects, the latter ranging from the control of a simple domestic cooker to
a complete production system or process, as may be found in a large petrochemical complex.

The Controls Engineer needs to have various skills at his command - knowledge of
mechanical engineering, electrical engineering, electronics and pneumatic systems, a working
understanding of HVAC design and process applications and, increasingly today, an
understanding of computers and digital communications.

The intention of this Block is to provide a basic insight into the practical and theoretical
facets of automatic control, to which other skills can be added in the future, not to transform
an individual into a Controls Engineer.

This Block is confined to the control of processes that utilise the following fluids: steam,
water, compressed air and hot oils.

Control is generally achieved by varying fluid flow using actuated valves. For the fluids
mentioned above, the usual requirement is to measure and respond to changes in temperature,
pressure, level, humidity and flowrate. Almost always, the response to changes in these
physical properties
must be within a given time. The combined manipulation of the valve and its actuator with
time, and the close control of the measured variable, will be explained later in this Block.

The control of fluids is not confined to valves. Some process streams are manipulated by the
action of variable speed pumps or fans.

The need for automatic controls


There are three major reasons why process plant or buildings require automatic controls:

 Safety - The plant or process must be safe to operate.


The more complex or dangerous the plant or process, the greater is the need for
automatic controls and safeguard protocol.
 Stability - The plant or processes should work steadily, predictably and repeatably,
without fluctuations or unplanned shutdowns.
 Accuracy - This is a primary requirement in factories and buildings to prevent
spoilage, increase quality and production rates, and maintain comfort. These are the
fundamentals of economic efficiency.
Other desirable benefits such as economy, speed, and reliability are also important, but it is
against the three major parameters of safety, stability and accuracy that each control
application will be measured.
Automatic control terminology
Specific terms are used within the controls industry, primarily to avoid confusion. The same
words and phrases come together in all aspects of controls, and when used correctly, their
meaning is universal.

The simple manual system described in Example 5.1.1 and illustrated in Figure 5.1.1 is used
to introduce some standard terms used in control engineering.
Example 5.1.1 A simple analogy of a control system
In the process example shown (Figure 5.1.1), 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.

Fig 5.1.1
Manual control of a simple process
The Example (Figure 5.1.1) demonstrates that:

1. The operator is aiming to maintain the water in the vessel between levels 1 and 2. The
water level is called the Controlled condition.
2. The controlled condition is achieved by controlling the flow of water through the
valve in the inlet pipe. The flow is known as the Manipulated Variable, and the
valve 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 level of water in the tank is altered.
The change in water level is known as the Controlled Variable.
5. Once the water is in the tank it is known as the Controlled Medium.
6. The level of water trying to be maintained on the visual indicator is known as the Set
Value (also known as the Set Point).
7. The water level can be maintained at any point between 1 and 2 on the visual
indicator and still meet the control parameters such that the bottom of the tank is
covered and there is no overflow. Any value within this range is known as the
Desired Value.
8. Assume the level is strictly maintained at any point between 1 and 2. This is the water
level at steady state conditions, referred to as the Control Value or Actual Value.

Note: With reference to (7) and (8) above, the ideal level of water to be maintained
was at point 3. But if the actual level 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 valve is closed to a new position, the water level will drop and the
deviation will change. A sustained deviation is known as Offset.

Elements of automatic control

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