PROCESS CONTROL INSTRUMENTS

Mokhamad Abrar 9:33 PM

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This article to introduce you to Process Control Instruments. To give an understanding of the
terms used in instrumentation and to introduce you to basic process variables.
Instrumentation plays an important part in the efficient operation of any processing or production
plant. Instruments enable the plant to operate smoothly and safely with a minimum of operating
staff. Instruments help the operator to perform his duties. This course will give you a basic
understanding of how the instruments function. A process is the changing of raw materials into a
finished product. As raw materials flow through the process equipment they are subjected to
various conditions. These conditions alter the raw material composition and chemical structure.
It is important that these process conditions be accurately controlled at all times. The controlling
is done by instruments. It is the operators that tell the instruments what to do. The operator who
knows his instruments is the master. The instruments are his slaves or servants. When the
instruments are properly used the process equipment operates correctly. When the process
equipment operates correctly the finished products are up to specification.
We will give a simple example of process control, as following:
Manual Control

The diagram above (see Figure) shows what is called MANUAL control. The process is
temperature control. The indicator is a thermometer. The correcting unit is the gas control valve.
The controller is the operator who uses his own judgement to keep the water temperature
constant. Manual control has its uses as it is cheap to install and maintain, and simple to operate.
However, it is very seldom used in industry because:

The operator must remain in position at all times.

It cannot be used if the operator is placed in a dangerous area.

The process changes faster than the operator can react.

A mistake by the operator can have dangerous results.

These problems are avoided by using automatic control.

Modern household appliances now use automatic control to make work easier. For example:

Refrigerators and air conditioners use automatic temperature control.

Washing machines use automatic heating and water control.

Automatic Control

The above diagram (see Figure) shows a simple

automatic controller. The boiler now has the loop closed and no operator is required. The
following items are added:

The temperature transmitter (T.T) which measures (senses) the temperature of the hot
water and changes it to a standard signal.

A signal line from the transmitter to the controller, the signal may be either pneumatic or
electrical.

A controller which keeps the temperature of the hot water at a position set by the operator
(set point)

The controller adjusts the correcting unit (automatic control valve) using an output signal
line similar to the input line from the transmitter.

The controller may provide alarm signals to alert the operator if the system fails. It may
also shut off the gas if the water starts to boil.

This is a very simple example of automatic control.

Process Control Instruments can be very complex.

If we take each part or device that is in a complex unit one by one the system is easy to
understand.

Instrumentation uses a lot of words which need to be explained. Before we can talk about
instrumentation and process control you need to understand the following words.
Instrument

Any device for measuring, indicating, controlling, recording, and adjusting a

physical or chemical property e.g. flow, pressure, acidity, weight, gas,
concentration, etc

Instrumentation

A complete set of instruments used to control a process, e.g. refining,

oil/gas production. LNG, LPG, etc

Indicator

A device which shows a measured value to the operator

Recorder

A device which continuously records measurements, either electronically or

on an ink chart. It is used to show production figures, etc.

Process Loop

A group of instruments used to control a single process variable e.g.

pressure, flow, level, etc.

Process

The operators word for a manufacturing unit e.g. refining, liquefying gas,
etc.

Measured Variable or
Process Variable (MV)

The value of the property being controlled by single process loop e.g.
pressure, flow, level, etc.

Desired Value or Set Point

The value required by the operator
(SP)
Error Signal (ER)

The difference between the measured variable and the set point should be
zero for good control

Controller

A device, either pneumatic or electrical/ electronic, which adjusts the error

signal to zero

Correcting Unit
(Final Control Element)

A device which works on the command of the controller. It is used to adjust

the measured value to obtain a zero error signal, e.g. control valve, etc.

Transmission

A method of standardizing signal sent from various parts of the plant

Transmitter

A device which takes a measurement and changes it into a standard signal

Transducer

A device which changes one form of energy to another; particularly from

electrical to pneumatic

Note:
The instruments in use are very varied, depending on how old the installation is. They may be air
(pneumatic), liquid (hydraulic) or electric / electronic in operation. The way the information is
shown or recorded may be simple, like a clock or thermometer. It may use the latest information
technology to display information on a personal computer screen (video display unit).