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Process Control Fundamentals

Process Control Fundamentals

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Published by murio

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Published by: murio on Jul 21, 2009
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Table of Contents
Fundamentalsof Controlii
©
2006 PAControl.com
 Introduction..................................................................................................................................................... 1
 Performance Objective............................................................................................................................. 1
The Importance of Process Control............................................................................................................... 1
 Learning Objectives.................................................................................................................................. 1The Importance of Process Control................................................................................................................. 2 Process...................................................................................................................................................... 2 Process Control........................................................................................................................................ 2 Reduce Variability............................................................................................................................. 2 Increase Efficiency ............................................................................................................................ 3 Ensure Safety..................................................................................................................................... 3
Control Theory Basics .................................................................................................................................... 4 
 Learning Objectives.................................................................................................................................. 4The Control Loop............................................................................................................................................. 5Three Tasks...............................................................................................................................................5 Process Control Terms ....................................................................................................................................6  Process Variable.......................................................................................................................................6 Setpoint.....................................................................................................................................................6 Measured Variables, Process Variables, and Manipulated Variables.....................................................7  Error.........................................................................................................................................................7 Offset.........................................................................................................................................................8 Load Disturbance.....................................................................................................................................8Control Algorithm.....................................................................................................................................8Manual and Automatic Control................................................................................................................9Closed and Open Control Loops ..............................................................................................................10
Components of Control Loops and ISA Symbology...................................................................................... 11
 Learning Objectives.................................................................................................................................. 11Control Loop Equipment and Technology....................................................................................................... 12 Primary Elements/Sensors........................................................................................................................ 12Transducers and Converters..................................................................................................................... 13Transmitters.............................................................................................................................................. 13Signals ...................................................................................................................................................... 14 Pneumatic Signals............................................................................................................................. 14 Analog Signals................................................................................................................................... 14 Digital Signals................................................................................................................................... 15 Indicators.................................................................................................................................................. 15 Recorders.................................................................................................................................................. 16 Controllers................................................................................................................................................ 16 Correcting Elements/Final Control Elements.......................................................................................... 18 Actuators................................................................................................................................................... 18
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Table of Contents
iiiFundamentalsofControl
©
2006 PAControl.com
 ISA Symbology.................................................................................................................................................19Symbols................................................................................................................................................... 20 Pumps.............................................................................................................................................. 21 Piping and Connections .................................................................................................................. 22 Identification Letters............................................................................................................................... 23Tag Numbers........................................................................................................................................... 23 ISA Symbology Review ........................................................................................................................... 26 
Controller Algorithms and Tuning ...............................................................................................................27 
 Learning Objectives.................................................................................................................................27 Controller Algorithms.....................................................................................................................................28 Discrete Controllers................................................................................................................................28Multistep Controllers................................................................................................................................29Continuous Controllers ............................................................................................................................29Why controllers need tuning?...........................................................................................................................31Gain..........................................................................................................................................................31 Proportional Mode ..........................................................................................................................................33 Proportional Gain ....................................................................................................................................33 Proportional Band....................................................................................................................................33 Limits of Proportional action...................................................................................................................34 Determining the Controller Output..........................................................................................................34 Proportional Action- Closed Loop........................................................................................................... 35 . Integral Mode................................................................................................................................................. 37  Integral Action........................................................................................................................................ 37 Open Loop Analysis................................................................................................................................ 37 Closed Loop Analysis ............................................................................................................................. 38 Reset Windup.......................................................................................................................................... 39Summary................................................................................................................................................. 40 Derivative Mode.............................................................................................................................................. 41 Derivative Action.................................................................................................................................... 41 Rate Summary......................................................................................................................................... 44
 Process Control Loops.....................................................................................................................................46 
 Learning Objectives..................................................................................................................................46 Single Control Loops.......................................................................................................................................47  Feedback Control .....................................................................................................................................47  Examples Of Single Control Loops..................................................................................................................48 Pressure Control Loops............................................................................................................................49 Flow Control Loops..................................................................................................................................49 Level Control Loops .................................................................................................................................50Temperature Control Loops .....................................................................................................................51
www.PAControl.com

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