ELEMENT OF PROCESS CONTROL

LEARNING OUTCOME

• Explain the required instrumentation and final elements to

ensure that well-tuned control is achieved
• Draw a PID (Process & Instrumentation Diagram)
WHAT ARE THE BASIC ELEMENTS OF PROCESS
CONTROL?
• PROCESS
• Processes have a DYNAMIC BEHAVIOR thas
is determined by physical properties which
PROCESS cannot be altered without making a physical
change to the process
• SENSOR
• Measure the value of the process output (PV)
FINAL such as temp, press, mass, flow and level
CONTROL SENSOR • CONTROLLER
ELEMENT • Elaborate the process output (PV) with the
target (SP)
• Provides the signal to the final element

CONTR • FINAL CONTROL ELEMENT

OLLER TARGET (SP) • The physical device that receives commands
from the controller that manipulate the
resources
SENSOR  Measure the value of the process
output
TEMPERATURE PRESSURE FLOW LEVEL OTHER

Resistance
Thermometer Manometers Var. Head Gauge glass pH
(RTD)

Chain and tape

Thermocouple Bourdon Tubes Var. Area Moisture
float gauges

Bimetalic Lever and shaft

Bellows Turbine meters Gas Analyzers
Thermometer float gauges

Filled system Positive

Diaphragm Other
Thermometer displacement

Glass stem
Electromagnetic
Thermometer

Ultrasonic
SENSOR

TEMPERATURE SENSOR PRESSURE SENSOR

https://www.slideshare.net/HassanElBanhawi
SENSOR

FLOW SENSOR
SENSOR

LEVEL SENSOR pH SENSOR

CLOSED LOOP DIAGRAM

R
IITE
M
A NS
TR
TRANSMITTER
• A device that converts the signal • EXAMPLE:
produced by a sensor into a
• Consider a pressure
standardized instrumentation signal
such as 3-15 PSI air pressure, 4-20
sensor/transmitter that has been
mA DC electric current, Fieldbus calibrated to measure a process
digital signal etc. pressure between the values of
20 psig and 50 psig.
• The span of the instrument is the
difference between the high and low • THE SPAN = ???
values of the range. • THE ZERO = ???
• The low value of the range is often
referred to as the zero of the
instrument.
CONTROLLER  Elaborate the process output (PV) with the target (SP)
and Provides the signal to the final element

ON – OFF CONTROLLER
[DISCRETE CONTROLLER]
• Controller that have only two mode or
positions, on and off
• Example:
CONTROLLER  Elaborate the process output (PV) with the target (SP)
and Provides the signal to the final element

CONTINOUS CONTROLLER
[PID CONTROLLER]
• Controllers automatically compare the
value of the PV to the SP to determine if
an error exists.
• Modes of PID Controllers
• Proportional [P] Controllers
• Proportional + Integral [PI]
Controllers
• Proportional + Derivative [PD]
Controllers
• Proportional + Integral + Derivaitve
[PID] Controllers
FINAL CONTROL ELEMENT  The device that
actually adjust the manipulated variable
• Actuator Types :
• Manual
• Pneumatic
• Hydraulic
• Electric
• Spring
• Valve bodies Types :
• Globe
• Ball
• Butterfly
• Diaphragm
• Gate
FCE : TYPE OF PNEUMATIC CONTROL VALVE
ATO [AIR TO CLOSE]  FAIL CLOSE
• Air to open valves are normally held
closed by the spring and require air
pressure (a control signal) to open
them - they open progressively as the
air pressure increases.
ATC [AIR TO CLOSE]  FAIL OPEN
• Air to close valves are valves which
are held open by the valve spring and
require air pressure to move them
towards the closed position.
PNEUMATIC VALVE IN CAMPUS LABORATORY
FCE  VALVE CHARACTERISTIC
CLOSED LOOP DIAGRAM

I/P TRANSDUCER
TRANSDUCER
• A transducer is any device or
component that is capable of
converting one form of energy to a
different form of energy.
• DIFFERENCE BETWEEN
TRANSDUCER VS TRANSMITTER :
• The transmitter is also a type of
transducers.
• Transducers in general can be
used as measurement devices,
but transmitters cannot be used
as measuring devices.
• Transmitters do not have any
mechanical movements, but
transducers in general can have
mechanical movements.
PROCESS  Dynamic behavior
P&ID DIAGRAM  Piping and instrumentation
diagram
• Diagram in the process industry which shows the Piping of the process flow together with
the installaed equipment and instrumentation
• P&ID Content:
• Equipment
• Piping
• Instrumentation
P&ID CONTENT

EQUIPMENT PIPING
P&ID CONTENT

INSTRUMENTATION
P&ID DIAGRAM