1.

LEVEL CONTROL LOOP:

Block diagram:

Figure #1 block diagram of level control loop

P&ID Diagram:

Sensor: ULTRA SONIC SENSOR IS USED TO MEASURE THE LEVEL OF TANK.

Controlled variable: LIQUID LEVEL IN TANK

Manipulated variable: FLOW RATE OF LIQUID

Final control element: MOTORIZE VALVE

Controller: P&I CONTROLLER

Process: FILLING UP OF A TANK TO CERTAIN HEIGHT

Working:

In level-control systems, fluid flow rates are controlled by varying the degree of opening of a gate-
type valve. Because of the forces involved, a pneumatic ‘actuator’ is normally employed, working off
a controlled pressure in the range between 3-15 pounds per square inch (i.e. psi). An applied
pressure of 3 psi is equivalent to the valve being fully open, 15 psi corresponds to the valve being
fully closed.

Most flow control valves are fitted with a ‘positioner’, which operates off a current signal in the
range 4-20 mA. The current range generally corresponds on a linearly proportional basis to the
pressure range. Since the computer interface usually involves a HMI, then an additional element (a
voltage-to-current converter) is required to interface between the DAC and the valve positioner. 

2. PRESSURE CONTROL LOOP:

Block diagram:

P&ID Diagram:

Sensor: Pressure gauge

Controlled variable: Pressure inside a tank.

Manipulated variable: flow of Air introduced in the tank

Final control element: solenoid valve

Controller: P&I and P&Id controller

Process: filling up of tank with certain air pressure.

Working:

The outlet air flow rate is controlled using pneumatically operated control valve. The orifice plate
and differential cell are used to measure the pressure of the outlet air from the pressure vessel. Also,
an orifice element and differential cell are used to measure the flow rate of the outlet air from the
system. The pressure and flow rate of the air transmitted whose output is a current in the range of
4-20 mA. This current is fed to an electronic controller where the signal current is compared with a
value set up on the controller. A control signal in the range 4-20 mA resulting from this comparison
is supplied to an auto/manual station and hence, as a 4-20 mA signal, to a current/pressure (I/P)
converter which in turn supplies an air pressure signal in the range 3-15 psig to operate the control
valve. The air used for the instruments is filtered and regulated by air filter/regulator with pressure
gauge. The maximum pressure of air inlet to the filter 150 psig and the maximum pressure of the air
outlet were 20 psig and then the air entered the transducer (I/P)

3. FLOW CONTROL LOOP:

Block Diagram:

P&ID Diagram:

Sensor:

Controlled variable: flow of liquid

Manipulated variable: flow of liquid

Final control element: control valve

Controller : P&ID controller

Process: measuring the flow of liquid

Working:

Control loops are added to a process to control the process. In control loops, flow control loops are
laster loops among them.

A valve is used in a control system to control the flow of the fluid inside the pipe system. So valves
are the control element in flow control system.

The flow inside the pipeline is measured using flow measurement devices such as an orifice, venturi,
ultrasonic flow measuring devices. The measured value is transmitted using the flow transmitter to
the controller.

The controller compares the measured value with the setpoint value. The setpoint is the preset
value which is the required flow value. The difference in the value is given to the control device,
which is valve here to take a proper control action.

If the measured value is greater than the setpoint then the value is controlled to close and block the
flow so that flows set to required flow.

If the measured value is less than the setpoint, then the valve open further to maintain the required
flow.

Signals:

Every control loop uses the pneumatic and electric signals.

The flow transmitter sends 4-20mA signal which indicates the flow parameter and acceptable to the
controller. The controller sends the control action through pneumatic signal within 3-15 psi pressure
standard. Valve actuators move according to the pneumatic signal send by the controller.

4. TEMPERATURE CONTROL LOOP:

Block diagram:
P&ID Diagram:

Sensor: thermocouple

Controlled variable: temperature of liquid or any substance

Manipulated variable: voltage or current through solid state relay.

Final control element:

Controller: P&I controller

Process: Temperature control of the oven or water

Working:

To understand how a temperature loop is work in a real life. Consider the temperature mechanism
above diagram, a thermocouple sensor/transmitter measures the temperature of the process and
sends a signal to the temperature controller. Based on whether the temperature of the oven is
above or below a pre-determined set point , the controller initiates a control action to either put on
the heater (final control Element) to add more heat or turn off the heater to remove the heat.

5. PH CONTROL LOOP:

Block diagram:
P&ID Diagram:

Sensor: pH meter

Controlled variable: pH of system

Manipulated variable: flow of acid or base

Final control element: control valve

Controller: P&ID controller

Process: control the PH of system

Working:

To control the pH of the system , the pH meter act as an sensor and forward the signal to the
controller to variate the manipulated variable to get the desire output , if the the system is too
alkaline then the controller get signals from the sensors and acid valve is open to maintain the pH of
the process on the other hand if the system is acidic the valve from alkaline solution to maintain the
desire pH , when the system achieve the desired set the sensor send the signal to controller and the
controller immediately took action and stop the flow of either acid or base by fully closed the
control valve with the help of actuator.
6. DISTRIBUTION CONTROL SYSTEM:
P&ID Diagram:

Sensor: ultrasonic sensor level sensor, RTD sensor

Controlled variable: level of tank and temperature of water

Manipulated variable: flow of water

Final control element: Motorized valve

Controller: P&ID controller

Process: To control control the temperature of final product

Working:

Sensors in a DCS control system senses the process information and then send it to the local I/O
modules. The actuators connected with these modules control the process parameters. The
collected information is used to the process control unit via field bus.

This information is processed further and analyzed to produce the output results. The control
logic implemented in the controller are used in this process. The control actions as per the
output results are then carried to the actuator devices via field bus. At the engineering station,
the DCS configuring, commissioning and control logic implementation are carried out.