EPC503: Process Control III

Electrical and Electronic Engineering

Ahram Canadian University

Dr. Sayed Ahmed Zaki

Assistant Prof. in Electrical Engineering
Faculty of Engineering
Cairo University
 Industrial Control
)Selected Topics(

? Your Expectation
Overview on control system components and Process,
Instrumentation Diagrams P&ID, Discrete and Continuous
controllers design, PID industrial controller design, tuning, and
implementation, Introduction and structure to Programing Logic
Controller PLC.
 Textbook
Textbook:
1. Curtis D. Johnson, Process Control
Instrumentation Technology, by Prentice Hall, 7th
edition, 2003
2. Steven LeBlanc, Donald R. C., Process Systems
Analysis And Control, McGraw-Hill, 2009
3. K Astrom, Automatic tuning of PID Controllers,
ISA, 1998
 Course ILOs
1) To be introduced to Process Control Concepts & definitions,
P&ID diagrams
2) Learn some examples on Process control
3) Understand controllers implementation in discontinuous /
continuous forms
4) Know the effect of process nonlinearity on controller
performance
5) To understand PID tuning techniques
6) To understand the structure, and design concept of PLC control
Introduction to Process
Control
Chapter 1:
Curtis D. Johnson, Process Control Instrumentation
Technology, by Prentice Hall, 7th edition, 2003
 Elements of Process Control
Process
Process Variable (PV)
Measurements
(Sensors/Transducer/
Transmitters)
Set point (SP) Error SP e=r-b P CO PV
Detector
(Circuits Op-Amps )
Controller
( Electrical, Mechanical,
pneumatic, hydraulic)

Control Element Block Diagram

Control Output (CO)
Example of open and closed loop
process control
Reasons for using Industrial Automatic Control
(Industrial automation)

Computer
Controlled
System

Electronic
Mechanical
Hydraulic
Pneumatic
Combination of the above
 Process Control Principles
The basic objective of the process control is to regulate
(maintain) certain variable value at some desired value
(reference/setpoint) regardless of external influence.
A process example
Qin

H Qout
-►

Level control
 Process Example
❖ The objective is to regulate the
level of liquid in the tank, h, to the
value H.
❖ If the output flow rate is not exactly
equal to the input flow rate, the tank
will either
- empty if Qout > Qin, or

- overflow, if Qout < Qin.

❖ This process has not a self-

regulation property .

A self-regulating process is its inherent ability to settle at a new

process variable value without any corrective action on the part of
the controller.
 Process Example
❖ This means that for some
input flow rate, the liquid
height will rise until it
reaches a height for which
the output flow rate matches
the input flow rate.
 Human-Aided Control
❖ To regulate the level so that it
maintains the value H, it will
be necessary to employ a
sensor to measure the level.
❖ This has been provided via a
“sight tube” S.
❖ The actual liquid level or
height h is called the
controlled variable.
❖ In addition, a valve has been
added so the output flow rate
can be changed by the human.
❖
The output flow rate is called
the manipulated variable or
controlling variable.
 Human-Aided Control
❖ The human can bring
the level to the setpoint
value H and maintain it
there by continuous
monitoring of the sight
tube and adjustment of
the valve.
 Automatic Control
❖ Machines, electronics, or
computers replace the operations
of the human.
❖ An instrument called a sensor
is added that is able to measure
the value and convert it into a
proportional signal s.
❖ This signal is provided as input
to a machine, electronic circuit,
or computer, called the controller.

PI&D structure
 Servomechanisms control
❖ Servomechanisms
force the robot arm to
follow a path from point
A to point B.
❖ This is done by
controlling the speed of
motors driving the arm
and the angles of the arm
parts

❖ Instead of regulating a variable value to a setpoint, the

servomechanism forces the controlled variable value to
follow variation of the reference value
Regulatory versus Servo Control
 Discrete-State Control Systems
❖ Control a sequence of events rather than regulation
or variation of individual variables.
❖ There is also a sequence of events: mixture needs to
be heated with a regulated temperature for a certain
length of time and then perhaps pumped into a
different tank and stirred for another period.
❖ These discrete-state control systems are often
implemented using PLCs.