C4-System Components-EN

Process Control
Chapter 4: System Components Properties

Contents
4.1 Process Measuring Instruments
– Basic structure
– Properties of measuring instrument
4.2 Actuator and controlled valve
– Basic structure
– Properties of controlled valve
– Valve positioner
4.3 Controller
– Industrial Controller
– On/Off Controller
– P/PI/PID Controller
11/7/2017 Chapter 4: System Components HMS 2006-2016 2

Basic structure of Process Control System
Operating and
Monitoring System

Parameters States
Input Controller Output
MEASURING ACTUATOR
INSTRUMENT
TECHNICAL PROCESS

Example: Temperature Control System
Actuator
Probe
Air Thermo-
couple
Signal
DCS Transmitter
Controller
Sensor
Operation
Station

System Components Properties
Manipulated Controlled
Control signal
Set point r variable variables
(CO)
Actuator (MV) (CV)
Controller Process
Measured signal Measured

(PM) Measuring variable
instrument
 Set Point (SP), Set Value (SV)

 Control Signal, Controller Output (CO)
 Control Variable, Manipulated Variable (MV)
 Controlled Variable (CV)
 Measured Variable, Process Value (PV)
 Measured Signal, Process Measurement (PM)

Signal standards
 Analog signal:
– Electric: 0-20mA, 4-20mA, 10-50mA, 0-5V, 1-5V...
– Pneumatic: 0.2-1bar (3-15 psig)
 Logical signal
– 0-5 VDC, 0-24 VDC, 110/120 VAC, 220/230 VAC,...
 Pulse/Digital signal
– Pulse width modulation, pulse frequency modulation signal
– Fieldbus standard: Foundation Fieldbus, Profibus-PA...
– Common serial standard: RS-485, RS-422

6.1 Process Measurement Device
Sensor Measurement device Transmitter
Measured variable Standard signal

(Temperature, Sensor Transmitter (4-20mA, 0-10V,...)
Pressure, Level, Flow...) Bus signal
Transducer Indicator
Indicator
 Measurement device
 Sensor: Sensor (Thermocouple, Venturi tube, Ultrasonic...)
 Sensor element: Sensor element
 Signal conditioning: Signal conditioning
 Transmitter
 Transducer

Flow meter
Transmitter
Pressure meter
sensor
sensor

6.1.1 Operation properties
 Measuring range & measuring span
 Resolution, dead band and sensitivity
 Reliability
 Affected by environmental impacts

Measuring range and measuring span
Tm [mA]
20
16
12
4
Measuring span = 300oC
0 T [oC]
0 100 200 300 400
Low limit High limit
(Zero point)
Example:
Measuring range (input range) 100-400oC
Measuring span (input span) 300oC
Output range 4-20mA
Output signal span (output span): 16mA
6.1.2 Static properties
 Error and accuracy
 Dead band and hysteresis
 Repeatability
 Linearity
 Sensitivity

Measuring error, accuracy and resolution
 Measuring error: the error between measured value and ideal
value of measured variable
– System error
– Random error
 Accuracy: suitable level between a measurement device output
and the real value (ideal value) of a measured variable, determined
by some standards
– According to measured variable, example: +1°C/-2°C
– Percentage ratio of measuring span, example: ±0.5% measuring span
– Percentage ratio of output, example: ±1% output
 Calibration: the process of determining the accuracy of a
measurement device and perform calibration to suit the
application

Calibration graph
v
100
90
80
70
Output [%]
60
50
40
30
20
Hysteresis +
10 deadband
0 y
0 10 20 30 40 50 60 70 80 90 100
Input [%]
 Dead band: the smallest variation of measured value that measurement

device can respond to the output signal change
 Hysteresis: differences in response to input changes in two different
directions
Repeatability
 Repeatability: The largest deviation of the observed values
after many repetitions compared to the average value of a
measure
 Repeatability ≠ Accuracy
x x
x Observed value x
Observed value
xx xx
Observed value
x
x x x xx
x x xx
x x x
x x
xx x
x x x x x
x
Real value Real value Real value

Low repeatability High repeatability High repeatability
Low accuracy Low accuracy High accuracy

Linearity
 Linear characteristic y – measured variable (input)
y0 – input zero point

1 v – measured signal (output)
v = km ( y − y0 ) + v0 = km y + vc
2
v0 – output zero point
km – sensitivity
Example: A thermistor changes its resistor linearly from 100 to 180 when the
temperature T changes from 20o to120oC. Linear characteristic function:
80
R= (T − 20) + 100 = 0.8T + 84
100
 Linearity: the proximity with linear characteristic

Sensitivity
v
100
90
80
70
Output [%]
60
∆v ∆v v − vs
50
=
km =
40 ∆y ys y − ys
∆y
30
20
10
y
0
0 10 20 30 40 50 60 70 80 90 100
Input [%]

Measured signal normalization
 Normally to percentage of output range or unit normalization
 Example: A pressure meter have linear characteristic, measuring
range is from 20 to 220 psig and output range from 4 to 20 mA
Input-output equation for unnormalized signal is:
16
=
y[mA] ( P − 20) +=
4 0.08 P + 5.6
200
( km = 0.08 [mA/psig])
 Normalizing measured signal according to percentage of output
signal:
100
y [%] = ( P − 20) = 0.5 P − 10
200
km = 0.5 [%/psig]
 Unit normalization:
km = 0.005 [psig -1 ]
Static characteristic linearization
 Partial linearization: calibration curve is approximated by a
broken line.
 Independent linearization: calibration curve is approximated by a
straight line so that the absolute value of the largest error is
minimized.
 Linearization at zero point: The approximated line goes through
the first point of the calibration curve (the zero point) and slopes
so that the absolute value of the largest error is minimized.
 Star point –End point Linearization : The approximated line goes
through the first and the last point of the calibration curve.
 Least-square linearization: the approximated line is determined so
that the summary of all errors is minimum.

Linearization
100 100
Start point-End
Output [%]
Independent
Output [%]
point Linearization
linearization
50 50
Zero point
Linearization
Segment
Linearization
0 0
0 50 100 0 50 100
Input [%] Input [%]

Dynamic characteristic
 Dynamic characteristic of most of the instrumentation can be
represented by a first-order inertia
km
Gm ( s ) =
1 +τ s
or stable second order inertia

kmω0 km
=Gm ( s ) = , ζ >0
ω0 + 2ζ s + s τ + 2τζ s + s
2 2 2 2
 If the dynamic characteristic of the measurement device can not

be ignored:
– Included in the control object model, or
– Still using the static model of measurement device, presume the measuring
error (dynamic) as measurement noise.

Step response
Dynamic error

Slope response

6.1.4 Representative Process Sensors
 Selection criterias
– Operation characteristic: measuring range, measuring span,
operation reliability, dead band, sensitivity
– Static characteristic: Accuracy, repeatability, linearity
– Dynamic characteristic: Hysteresis, response speed, frequency
characteristic...
– Manufactured material: suitable for the working environment
(temperature, pressure, cavitation, corrosion...)
– Using experience
– Electromechanical characteristic: Explosive proof rating, weather
proof rating, enclosure.
– The degree of process intervention (reduced accuracy)

Temperature sensor
 Thermometer A material expansion with temperature
changes the length, volume or pressure, for example in
mercury thermometers and bimetallic thermometers
 Resistor changes with temperature, is used in Resistive
Thermal Device or Thermistor
 The voltage changes with temperature at the junction point
of two different metal, applied in Thermocouple
 Thermal radiation, thermal radiation wavelengths vary with
temperature, e.g. pyrometers, applied to high temperature
measurement (combustion)

Pressure sensor
 Elastic sensor element: Bourdon tube, diaphragm
 Moving sensor element:
– Resistor changing (Strain gauge, potentiometer)
– Capacitive changing (Capacitive sensor)
– Inductive changing (Inductive sensor)
– Magnetic flux changing (linear variable differential transformer)
 Piezo sensor:
 Vacuum sensor
– Pirani gauge
– Ionization gauge

Flow sensor
 Venturi flow meter
 Turbine flow meter
 Vortex -shedding flow meter
 Magnetic flow meter
 Ultrasonic flow meter
 Thermal mass flow meter

Level Sensor
 Surface contact method
 Electrical: Resistor, capacitive
 Differential Pressure
 Ultrasonic
 Optic
 Mass
 Etc.,

Concentration and composition sensor
 This measurement is the most complex, the most expensive,
has biggest delay, low reliability, and can adversely impact the
quality control
 Many measurement methods: Gas-liquid chromatography
(GLC), spectroscopy (Ultraviolet, ultrasonic, Raman) is the
most common methods
 Method choosing is depend on the characteristics of the fluid
 Many analytical measurements required the coordination of
many different methods

Actuator
Actuator
Control signal Actuator Control Manipulated
The output of system element variable
the controller
 Actuator system (final control element): Changes the controlled

quantity according to the control signal, e.g.: control valves,
pumps, fans, conveyors
 Control element: Acting directly to controlled quantity, e.g.:
proportional solenoid valves, on/off valves, contractor, heating
coil, conveyors
 Actuator (actuating element) The dynamic or energy transferring
structure to the acting element, e.g: motor, coil, pneumatic
mechanism

Control valve and accessories
 Control valve
– An important and common actuator in the process control system, allowing to
adjust the fluid flow through the pipelines
– Consist of a valve body connected to an actuator (with related accessories) that
has the ability to adjust the opening of the valve according to the signal from
the controller
 Actuator
– A pneumatic, hydraulic or electric transmission mechanism to position the
valve opening element
 Valve's accessories:
– Transducer
– Positioner
– Booster relay
– Limit switches
– Solenoid valve
– ...

The basic parts of control valve:
Pneumatic input
Valve actuator
Stem
Valve body
Fluid input Fluid output
Closer member Valve seat

Example: Parts and Accessories of Globe
valve
Actuator
Positioner
Digital Controller
Valve body
Example: Block Diagram of a Control Valve

Control Valve Classification
 Classified by transmission type:
– Electromechanical: Using servo motor or step motor
– Hydraulic: Using oil pump in combination with a diaphragm or piston
– Pneumatic Using pneumatic in combination with a diaphragm or piston
– Combined electrohydraulic, electro - pneumatic
– Magnetic: Using coil with springs
 Classified by moving characteristic:
– Linear valve: the stem moves linearly
– Rotary valve: The valve stem rotates
 Classified by closer member design:
– Globe valve: Globe/cone sliding closer member
– Plug valve: Cylinder rotating closer member
– Ball valve: Globe/Part-of-globe rotating closer member
– Butterfly valve: Dished rotating closer member
 Classified by input signal type:
– Analogue valve: 4 - 20 mA, 3 - 15 psi input
– Digital valve: Direct digital input or via fieldbus

Example: Globe valve (Fisher Controls)
Embedded digital control positioner Embedded I/P conversion

(Pneumatic transmission) (electropneumatic transmission)

Example: Ball valve (Fisher Controls)
V-ball

Example: Butterfly valve (Baumann)

Actuator classifying
 Classified by transmission energy type (electric, hydraulic,
pneumatic, electro-pneumatic, electrohydraulic)
 Classified by transmission mechanism:
– Bellow (màng rung)
– Diaphragm (màng chắn)
– Piston
– Vane
 Classified by acting type:
– Single-acting: a device in which the power supply acts in only one
direction, e.g., a spring diaphragm actuator or a spring return piston
actuator
– Double-acting: a device in which power is supplied in either direction

Pneumatic acting: Spring/Diaphragm
Mechanism
Air input
Diaphragm
Air input
Spring
Stem
Valve position indicator
A) Fail-Open or Air-to-Close (FO, AC) b) Fail-Closed or Air-to-Open (FC, AO)

(Fail-Open hay Air-to-Close) (Fail-Closed hay Air-to-Open)

Pneumatic acting: Piston mechanism
Spring
Cylinder
Piston
Stem Safe position
Double-acting Double-acting or single-acting Double-acting or single-acting

with a Fail-Close spring with a Fail-Open spring
6.2.2 Valve acting type
 Fail-Closed (FC) or Air-to-Open (AO)
 Fail-Open (FO) or Air-to-Close (AC)
 Choosing the valve acting type depends on the system safety
requirement
Fail-Closed Valve Fail-Open Valve

Cold Water
Feed
Top product
Steam
Bottom Product

4.2.3 Flow characteristic
 Valve characteristic: The relation between the flow through
valve and the opening of the valve
 Flow characteristic (Static Characteristic)
– Inherent flow characteristic: The static characteristic of a valve in
the condition that pressure drop across the valve is constant
– Installed flow characteristic: The static characteristic of valve after
was installed

Inherent flow characteristic
 Distinguish 3 types:
– Linear valve
– Quick Opening valve
– Equal Percentage valve
 Example: the flow of a fluid
∆P
= F C= v f ( p ) , f ( p) F / Fmax
gs
– F is the flow rate
– ∆P is the pressure drop across the valve
– Cv is valve coefficient (depends on design and the size of valves)
– gs is the specific gravity of the fluid (=1 with water at 15oC)
– The function f ( p)shows the valve presentation
 Linear valve
 Quick Opening valve f =p
 Equal Percentage valve f = p
=f α p −1 (20 ≤ α ≤ 50)

Typical inherent flow characteristic
Flow proportional to the
square root of the valve
opening
Quick
Opening
Adjust the flow in
percentage according to
the valve opening
Linear
Equal
Percentage
(α = 50)

Installed flow characteristic
 Example:
 Linear valve
Choose the valve coefficient Cv so that the valve opening p = 0.5 corresponds
with the design flow rate 200 gal/min:
F 200
=Cv = = 126.5
p ∆Pv 0.5 10

When the flow F decreases to 25% (50 gal/min)
30 × (0.25)2 =
∆Ps ( F ) = 1.875[psi]
∆Pv ( F ) =
40 − 1.875 = 38.125[psi]
F 50
= p = = 0.064
Cv ∆Pv ( F ) 126.5 × 38.125
(Not 0.5/4 = 0.125 as expected)
 Equal Percentage valve ( α = 50)
F 200
= Cv = p −1
= −0.5
44.7
α ∆Pv 0.5 10
To decrease the flow F to 50 gal/min
 F   50  + 1 ≈ 0.1
p log α  =  + 1 log 50  
C
 v ∆Pv ( F )   44.7 × 38.125 
Common fluid system 25
Pump Head
Pressure Drop (psi)

20
C.W.
Valve DP
15
10
Line Losses
5
0
0 50 100 150 200
FT
Flow Rate (GPM)
200 Linear Valve
Installed Flow Rate (GPM)
150
Equal Percentage valve has 100

=% Valve
installed flow
characteristic that is more 50
linear than linear valve 0

0 20 40 60 80 100
Stem Position (% Open)

System with few changes in pressure drop 15
Hydrostatic Head
Pressure Drop (psi)

10 Valve DP
Line Losses
FT 30 ft
0
0 100 200 300 400 500 600
Flow Rate (GPM)
600
Installed Flow Rate (GPM) 500
400 Linear Valve
Linear valve has

300
better installed flow

200
=% Valve
characteristic
100
0
0 20 40 60 80 100
Stem Position (% Open)

Select control valve characteristic
 Quick Opening: Used for safety valve, need fast open/close
operation
 Linear: used when the pressure drop across the valve is almost
constant
 Equal Percentage: Accounting for about 90% of control valve
applications because of the near-linear installed flow
characteristic When the valve pressure drop ratio with the
highest and lowest flow is bigger than 5 → should choose
Equal Percentage valve

4.2.3 The dynamic characteristic of controlled
valve:
Control Valve
Manipulated Valve
Signal Opening
Valve Flow
Valve
Actuator body
 The dynamic behavior of the control valve (and valve positioner) can be
approximated by a first-order transfer function
F ( s) kv dF dF dp
G=
v ( s) = =
kv =
u( s ) τ v s + 1 du dp du
 tv : 3-15 seconds
Simplify  dF
dp
, for valve FC
For the actuator → kv =  dF
 − dp , for valve FO
Valve Positioner
 Problem: A controlled valve often has a not-high accuracy
(the position error can reach 5%) because:
– Deadband and hysteresis
– Friction altered because of dust, lack of lubrication, and rust
– Flow rate loading
– Nonlinear characteristic of the actuator
 Positioner Using the real valve opening position and control
the actuating element to adjust the valve opening more
accurate according to the control signal
– In face, it is an inside control loop, in an cascade control
– Often use the ratio method with the huge proportional (10-200)
– Can reduce the position error to 0.5%

When to use the Valve Positioner?
 Should use when:
– Need high accuracy or increase the acting speed.
– The dynamic of process is significantly slower than the valve (the
time coefficient is more than 3 times higher the valve's), e.g.:
reaction, thermal, stirring etc.,
 Should not use when:
– The dynamic of the process is fast (the time coefficient is not more
than 3 times higher the valve's): the positioner can slow down and
reduce the quality of outside control loop
– Already used a local digital controller (embedded in valve), the
digital controller take the positioning role

4.3 Control equipment
Control Equipment
Measured signal Control Algorithm Control

signal
Set point
Dominant signal
 Control equipment: PLC, IPC, Digital Controller, DCS

Controller...
 Controller: can be understand as
– The whole control equipment
– Only the control computing module, e.g.: PI, PID, FLC, On/Off

Process control Discrete control
(Processing industry, mining industry) (Manufacturing industry, assembly industry)
Mechanical controllers Mechanical equipments
PID pneumatic controller (1920-1930) Electric-mechanical relay

(1920)
Programmable Logic Device

PID electronic controller (1940-1950) (PLD, 1960)
Direct Digital Controller Programmable Logic Controller

(DDC, 1965-1975) (PLC, 1970)
Compact Digital Controller Distributed Control System

(CDC, 1980) (DCS, 1975)
Industrial PC (IPC) PLC-based DCS

PC-104, CompactPCI, SBC Soft-PLC
(PC-based Control) (1996)
PC-based DCS
Hybrid control system
Field control system (FCS, 2000)
The Structure of Feedback Controllers
Analogue Controller
Manipulated
Set point Set Signal Signal
Set Signal Controller
Creator Element
Measure Signal
Digital Controller
Manipulated
Set point Error Signal
Controller Scale
Element Converter
Scale
Measure Signal
Converter

4.3.1 Two-position Controller
 Also called On/Off control or Bang-bang control
 The control signal can only be one of two values
 Is a static nonlinear controller.
u(t)
Ideal situation
umax
 umin , e < 0 “ON”
u(t ) = 
 umax , e ≥ 0 “OFF”
umin
0 e

Real Two-position Controller
 Use the dead band to eliminate the “bang-bang” phenomena
 Advantage: Simple, low price
 Disadvantage: Low quality
u(t)
umax
 umin , e < −δ
umin 
=u(t )  umax , e > +δ
 u(t ), −δ ≤ e ≤ +δ

0 e
deadband
4.3.2 Ideal PID controller
 The control algorithm P, PI, PD, and PID (collectively, PID)
were most used in process control system
 The controller structure and operation principle is simple,
easy to understand and use for the real working people
 There are a lot of methods and strong tools to help tuning
the digital parameters of the controller
 PID algorithm is suitable for almost industrial process

Proportional Control (P)
u u umax
Bias, control value
u at working point u
e umin e
Ideally case Real case

u(t )= u + kc e(t ) Ratio range definition
=
PB (umax − umin ) / kc
 Simple, fast response
 Unavoidable steady-state error with the process without
integrated characteristic
 Best suitable for Integrator plus First -Order

Proportional-integral (PI) controller
1
u + kc  e(t ) + 
t
u(t ) =
 τi ∫0 e(τ )dτ 

u( s ) 1 
K PI=
( s) = kc  1 + 
e( s )  τis 
 Most used (> 90%) in all PID controllers

 The integral component eliminates the steady-state error
when the set point has step changes
 The integral component worsens the dynamic characteristic
of system: Low response, easy to oscillate and easy to unstable
 Best suite for first or second order characteristics

The frequency characteristic of PI controller

Proportional-Integral-Derivative Control
 1 t de(t ) 
u(t ) =u + kc  e(t ) + ∫ e(τ )dτ + τ d
 τi 0 dt 
u( s ) 1
K PID ( s ) = = kc  1 + + τ d s 
e( s )  τis 
 The derivative component improve the response speed and stabilizes

some oscillatory
 The derivative component is high sensitive with measurement noise
 The derivative component is also sensitive with set point change
→ Improved algorithm
 1 dy(t ) 
u(t ) =K  e(t ) + ∫ e(t )dt − Td 
 Ti dt 

The frequency characteristic of PID controller

Three forms of PID control
 Standard form:
1 t de(t ) 
u(t ) =u + kc  e(t ) + ∫ e(τ )dτ + τ d 
 τ i 0 dt 
u( s ) 1
K PID ( s ) = = kc  1 + + τ d s 
e( s )  τis 
 Parallel form
t de(t )
u(t ) =u + k p e(t ) + ki ∫ e(τ )dτ + kd
0 dt
ki ki + k p s + kd s 2
K PID ( s ) = k p + + kd s =
s s
 Series form
1 
K PID ( s ) =kc′  1 +  ( 1 + τ d′ s )
 τ ′ s
i 

a) Standard Form b) Parallel Form
c) Series Form

4.3.3 Real PID Controller
 Derivative approximation algorithm
 Anti-reset windup
 2 DOF controller
 Digital Algorithm
 Auto-Manual mode
 Noise filtering

Derivative approximation
 Common approximation algorithm
τd s
=ud ( s ) kc (r( s ) − y( s ))
τd s
1+
N
– N becomes a parameter of PID controller (N will increase the
integrated affect)
– N is in range 3 - 30
 Use setpoint weight c (to avoid the setpoint changing
sensitivity)
τd s
=ud ( s ) kc (cr( s ) − y( s ))
τd s
1+
N

Reset windup
 When the output of the controller still increase while the error was zero
 Reset windup can happen when:
– The controller consist of integral component and
– The control signal is limited

a) Unlimited manipulated signal b) Limited manipulated signal

Anti-reset windup
1. Turn off the integral component after the controlled signal
reached the set point, completely eliminate the reset windup
2. Decrease the proportional gain so the output of controller stays in
allowed limit, avoid the reset windup
3. Monitoring the real value of the limited control signal and
feedback to controller in order to reduce the integral components,
limit the reset windup
dui kc 1
= e+ (ub − u)
dt τ i τ t
4. Put a limiter at the output of PID controller to simulate the
nonlinear characteristic of actuator, using the compensation
algorithm like in the method 3

Anti-reset windup
Actuator or
actuator model
dui kc 1
= e+ (ub − u)
dt τ i τ t

2 DOF Controller – setpoint weight
 2 DOF
Controller
 b was used to
soften the
transition process
1 τd s
u = kc (b − 1)r + kc  1+ +  (r − y )

 τi s 1 +τd s / N 
 1 τd s
= kc  br − y + (r − y) + (r − y) 
 τis 1 +τd s / N 

Real PID controller structure in ISA standard
Controller
Process
1 τd s
u kc  br − y + (r − y) +
= (cr − y) 
 τis 1 +τd s / N 
1 τd s
K ( s ) = kc  1 + + 

 τ i s 1 + τ d s / N 
1 + ( bτ i + τ d N ) s + τ iτ d ( c + b N ) s 2
P( s ) =
1 + ( τ i + τ d N ) s + τ iτ d ( 1 + 1 N ) s 2

Notice: PID controller in ISA standard
 The ISA structure equivalent with the structure in case c = 1
 K(s) is the transfer function of 1-DOF real PID controller.
So, the parameters can be tuning using a lot of researched
methods
 P (s) acts as a pre-filter that helps softening the transition
with the set point
– If N was fixed after tuning K(s) then b and c can only change the
zero point(s) of P(s)
– When K(s) was well tuned for the system stabilizing purpose, we
can tune the b and c parameters to improve the response quality to
the set point
 When b = 1 and c = 1, P(s) becomes a unit proportional

Digital PID algorithm
 Proportional: =u p (t ) kc (br(t ) − y(t ))
 Approximate the Integral (T is sample time)
kc t kcT
=
ui (t )
τi ∫0 e(τ ) dτ ≈ ui (t − T ) +
τi
e(t )
or kcT
( e(t ) + e(t − T ) ) a
ui (t ) ≈ ui (t − T ) +
2ti
 Approximate the improved Integral τ d dud dy
+ ud = − kcτ d
N dt dt
d u(t ) u(t ) − e(t − T )
≈
dt T
τd kτ N
= ud (t ) ud (t − T ) − c d ( y(t ) − y(t − T ))
τ d + NT τ d + NT
 Control Algorithm u(t ) =

u + u p (t ) + ui (t ) + ud (t )

Auto-Manual Mode Switching
 Problem: When switching from Manual to Auto mode and
vice versa, the major change in control signal will cause
fluctuating
→ Require bumpless transfer
 In Manual mode, the PID controller working but in tracking
mode, update the state of controller → the computing result
will approximate the manual value and the switch from
Manual mode to Auto mode will take place entirely smooth.
 Before switch for Auto mode to Manual mode, set the
manual value equal to the current control signal

Noise filtering (digital filtering)
y f (=
t) f y(t ) + (1 − f ) y f (t − h)
 Noise filtering reduces the affect of measured noise by taking

the average of approximation
 The dynamic characteristic of noise filter must be considered
in control loop
 Use the filter as needed by changing the coefficient
f(0-1)

Illustrating the response of an open-loop
system to a filter
Filtered Temperature
f=0.3
f=0.1
f=0.2
0 20 40 60 80 100
Time (seconds)
Control characteristic without filter
Product Temperature
Manipulated Variable
Time

Control characteristic with filter
Product Temperature
Manipulated Variable
Time

C4-System Components-EN

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

C4-System Components-EN

Uploaded by

Copyright:

Available Formats

Process Control

Chapter 4: System Components Properties

11/7/2017 Chapter 4: System Components HMS 2006-2016 2

Input Controller Output

11/7/2017 Chapter 4: System Components HMS 2006-2016 3

11/7/2017 Chapter 4: System Components HMS 2006-2016 4

Measured signal Measured

 Set Point (SP), Set Value (SV)

11/7/2017 Chapter 4: System Components HMS 2006-2016 5

11/7/2017 Chapter 4: System Components HMS 2006-2016 6

Sensor Measurement device Transmitter

Measured variable Standard signal

11/7/2017 Chapter 4: System Components HMS 2006-2016 7

11/7/2017 Chapter 4: System Components HMS 2006-2016 8

11/7/2017 Chapter 4: System Components HMS 2006-2016 9

11/7/2017 Chapter 4: System Components HMS 2006-2016 11

11/7/2017 Chapter 4: System Components HMS 2006-2016 12

 Dead band: the smallest variation of measured value that measurement

Real value Real value Real value

11/7/2017 Chapter 4: System Components HMS 2006-2016 14

y0 – input zero point

11/7/2017 Chapter 4: System Components HMS 2006-2016 15

11/7/2017 Chapter 4: System Components HMS 2006-2016 16

11/7/2017 Chapter 4: System Components HMS 2006-2016 18

11/7/2017 Chapter 4: System Components HMS 2006-2016 19

or stable second order inertia

 If the dynamic characteristic of the measurement device can not

11/7/2017 Chapter 4: System Components HMS 2006-2016 20

11/7/2017 Chapter 4: System Components HMS 2006-2016 21

11/7/2017 Chapter 4: System Components HMS 2006-2016 22

11/7/2017 Chapter 4: System Components HMS 2006-2016 23

11/7/2017 Chapter 4: System Components HMS 2006-2016 24

11/7/2017 Chapter 4: System Components HMS 2006-2016 25

11/7/2017 Chapter 4: System Components HMS 2006-2016 26

11/7/2017 Chapter 4: System Components HMS 2006-2016 27

11/7/2017 Chapter 4: System Components HMS 2006-2016 28

 Actuator system (final control element): Changes the controlled

11/7/2017 Chapter 4: System Components HMS 2006-2016 29

11/7/2017 Chapter 4: System Components HMS 2006-2016 30

Closer member Valve seat

11/7/2017 Chapter 4: System Components HMS 2006-2016 33

11/7/2017 Chapter 4: System Components HMS 2006-2016 34

Embedded digital control positioner Embedded I/P conversion

11/7/2017 Chapter 4: System Components HMS 2006-2016 35

11/7/2017 Chapter 4: System Components HMS 2006-2016 36

11/7/2017 Chapter 4: System Components HMS 2006-2016 37

11/7/2017 Chapter 4: System Components HMS 2006-2016 38

Valve position indicator

A) Fail-Open or Air-to-Close (FO, AC) b) Fail-Closed or Air-to-Open (FC, AO)

11/7/2017 Chapter 4: System Components HMS 2006-2016 39

Stem Safe position

Double-acting Double-acting or single-acting Double-acting or single-acting

Fail-Closed Valve Fail-Open Valve

11/7/2017 Chapter 4: System Components HMS 2006-2016 41

11/7/2017 Chapter 4: System Components HMS 2006-2016 42

11/7/2017 Chapter 4: System Components HMS 2006-2016 43

11/7/2017 Chapter 4: System Components HMS 2006-2016 44

11/7/2017 Chapter 4: System Components HMS 2006-2016 45

11/7/2017 Chapter 4: System Components HMS 2006-2016 46

Pressure Drop (psi)

200 Linear Valve

Installed Flow Rate (GPM)

Equal Percentage valve has 100