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Process Controls consists of two parts :

The Process

The Control E!ipments

The Control E!ipments broa"l# consists of

Meas!rement S#stem

Comparator

$ee"bac% &nit

Controller

$inal Controllin' Elements

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AUTO CONTROL TERMINOLOGY.
Measured value: The actual value of process
parameter measured ! a measur"#$ eleme#t.
%et &o"#t: The po"#t at 'h"ch the co#troller "s
ad(usted to re$ulate the process.
Co#troller: A dev"ce 'h"ch measure the value of a
var"ale a#d operate to correct or l"m"t the dev"at"o#
of measured value from a selected refere#ce.
)ev"at"o#: The departure from the des"red value .
)ead a#d: The cha#$e throu$h 'h"ch the "#put to
a# "#strume#t ca# e var"ed '"thout "#"t"at"#$
"#strume#t respo#se.
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$inal control Element: Component of a control s#stem

which "irectl# re'!late the "esire" process*

$ee" bac%: In a control loop, it is information abo!t the

stat!s the controlle" variable which is compare" with
that which is "esire"*

Sensitivit#: The minim!m chan'e of inp!t to which the

s#stem is capable to respon"*

Repeatabilit#* The closeness of a'reement amon' a

n!mber of consec!tive meas!rement of an o!tp!t for
the same val!e of the meas!re" si'nal*

+!ntin' : ,scillation or c#clin' of a meas!re" variable

ca!se" b# the control s#stem*
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Co#troller Comparator
Actuator &rocess
*eedac+
Measureme#t
%et &o"#t
*eedac+
Error
,
-
r
e
m
c
u
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,n/off Control

Time 0 Proportion Control

Proportional Control

Proportional/Inte'ral 1 P/I 2 Control

Proportional 0 3erivative 1 P/3 2 Control

Proportional/Inte'ral/3erivative 1 PI3 2 Control

Ratio Control

Spilt Ran'e Control

Casca"e Control

$ee"/forwar" Control
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M!lti/variable State Control*

Pro'ramme Control

5"aptive Control
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T7PE ,$ C,8TR,9 9,,PS
O&EN LOO& CONTROL %Y%TEM .OLC%/
Ope# co#f"$urat"o#0 s!stem do #ot ta+e a#! feedac+ from
process. E1ample ru##"#$ a fa#0 pump0 ope#"#$ or clos"#$ a
valve2damper etc.
CLO%E) LOO& CONTROL %Y%TEM .CLC%/
The s!stem has feed ac+ from the process. The co#trolled
var"ale "s co#sta#tl! measured0 a#d "f0 dev"at"o# from
prescr"ed set po"#t0 correct"ve act"o# "s appl"ed to the f"#al
eleme#t so as to retur# the co#trolled var"ale to the des"red
value.
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ON-O** CONTROL .T3O &O%ITION CONTROL/
The co#trol mecha#"sm hav"#$ o#l! t'o d"screte values of
output0 full! ON or full! O**.
&RO&ORTIONAL CONTROL:
The co#troller output "s proport"o#al to the d"ffere#ce
et'ee#
the measured var"ale a#d set po"#t ".e. error s"$#al.
RE%ET OR INTEGRAL CONTROL:
Reset act"o# "s def"#ed as a co#troller respo#se0 'h"ch "s
proport"o#al to the e1te#t a#d durat"o# of the s"$#al
dev"at"o#.
The reset act"o# "s used to$ether '"th proport"o#al act"o#
.&,I/
RATE OR )E4IATION CONTROL:
It "s def"#ed as the part of the co#troller respo#se0 'h"ch "s
proport"o#al to the rate of cha#$e of "#put. &,) or &,I,).

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ON-O** CONTROL OR T3O &O%ITION CONTROL
5eater Co#troller
Temp.
%e#sor
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%ET &OINT
Co#troller
Co#trol 4alve
Level Tra#sm"tter
IN
OUT
&I) LE4EL CONTROLLER
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CA%CA)E CONTROL:
Cascade co#trol "s a tech#"6ue that uses t'o
measureme#t a#d co#trol to ma#"pulate a s"#$le f"#al
co#trol eleme#t. Its purpose "s to prov"de "#creased
sta"l"t! of process co#trol. The relat"o#sh"p that e1"sts
et'ee# co#trollers "s referred to as a master-slave or
pr"mar!-seco#dar! relat"o#sh"p. The master or pr"mar! "s
the co#troller of the var"ale 'hose value "s pr"mar!
"mporta#ce. The slave or seco#dar! co#troller has var"ale
'hose value "s "mporta#t o#l! as "t affects o# the pr"mar!
var"ale.
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Master Co#troller
%lave Co#troller
%team I#let
*eed 3ater
&roduct Out
Co#trol 4alve
*lo' Measureme#t
CA%A)E CONTROL
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RATIO CONTROL:
The co#troller ma"#ta"#s a f"1ed rat"o et'ee# t'o
var"ales. *or e1ample ma"#ta"#"#$ a relat"o#sh"p
et'ee# t'o flo's0 such as a"r-fuel rat"o "# fur#ace0 feed
a#d catal!sts "# reactors a#d m"1 t"me of t'o or more
ra' mater"als "# le#d"#$ operat"o#.
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U#co#trolled *lo'
Co#trolled *lo'
&ROCE%%
Co#trol 4alve
Rat"o
Co#troller
RATIO CONTROL
September 11, 2012 PMI Revision 00 1.
TYPES OF CONTROLLER

Pne!matic Controller

+#"ra!lic Controller

Electronic Controller

5nalo' Controls

3i'ital Controls

Comp!ter base" Controllers

Centralise" Comp!ter Controls

3istrib!te" Comp!terise" Controls 1 33CMIS 2

September 11, 2012 PMI Revision 00 14
*actors to e co#s"dered 'h"le
select"#$ su"tale co#trol s!stem.

3h"ch var"ale "s to e co#trolled7

3h"ch detect"o# method "s to e used.

Ra#$e of the pr"mar! measur"#$ u#"t.

3here the measureme#t "s to e ta+e#.

3hat t!pe of f"#al co#trol eleme#t "s used7

The process la$.

5o' f"#e co#trol "s re6u"red

5o' much s!stem cost versus s!stem eff"c"e#c!

e evaluated
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Presentation o!tline

5!to loop s#mbols

$ee" water;"r!m level controls

$!rnace press!re Controls

P5 +E53ER PRESS&RE C,8TR,9S

Mill 5ir flow an" temp controls

Comb!stion controls

5ir flow controls

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COMPONENTS OF A CONTROL LOOP
se#sor &rocess
%et po"#t

.%&/
&rocess
value
.&4/
*"#al
Co#trol
Eleme#t

)"stura#ce
Controller
/ Pr T<r
/ 3P T<r
/ RT3, TC
/ +all probe
/ Ran'e
/ Select
/ Compensate
/ $ilter
/ $i<e"
/ Trac%in'
/ 5!to
/ Rate limit
/ Clampin'
/ P / PI
/ P3
/ 3
/ PI3
/ =alves, "ampers
/ =ane, >la"e, =$3
/ ?overnor, scoop
/ Temp
/ Press
/ 9vl
/ $low
/ Spee"
se#so
r
$EE3>5C@
C,8TR,9
$EE3$A3
C,8TR,9
September 11, 2012 PMI Revision 00 )-
LOOP TUNING
PR,P ?5I8 0 base" on ma'nit!"e of ma<im!m error P=/SP
I8TER?R59 5CTI,8 0 base" on process la'
3ERI=5TI=E 5CTI,8 0 consi"er ma< rate of chan'e

$IRST 583 $,REM,ST B*

/ Sensor Inte'rit#
/ $inal Control Element Inte'rit#
/ 3irection of Controller: 3irect ,R Reverse
?oo" Stea"# State Response 9on'er life of final control element
?oo" Transient Response >etter process stabilit#
September 11, 2012 PMI Revision 00 ).
LOOP TUNING
9,,P CR,SS C,&P9I8?
5ir $low S53C $!rnace Press!re
S+ Temp 3r!m 9evel
Mill air flow P5 hea"er press!re
+P+ .5 level +P+ -5 9evel
T&8I8? STR5TE?IES:
/ 5''ressive, best possible performance
/ Mo"erate, C!st optim!m performance
September 11, 2012 PMI Revision 00 )4
EXAMPLES OF CONTROLLERS IN
PLANT
PRESS&RE
$!rnace Press!re
?lan" Steam Press!re
P5 +ea"er Press!re
T!rbine Throttle Press!re
9E=E9
3r!m level
3eaerator 9evel
+otwell 9evel
+P+;9P+ 9evel
$9,A
Total 5ir $low
CEP Min Recirc $low
Mill 5ir $low
?SC Min $low
TEMPER5T&RE
S+ Temp
R+ Temp
Mill ,;9 Temp
+P>P Temp
SPEE3
T!rbine, >$P, I3 $an
3I$$ PRESS
S53C, $RS/3P
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CONTROL SYSTEM
PROGRAMMING & MMIPIS M & S
CONFIGURATION SYSTEM CLOCK
SG- C&I BOP- C&I TG- C&I
SYSTEM SYSTEM SYSTEM
3CS
September 11, 2012 PMI Revision 00 -.

C,8SISTS ,$ :

>&R8ER M585?EME8T S7STEM 1>MS2,

S,,T >9,AER C,8TR,9 S7STEM 1S>C2,

SEC,835R7 5IR 35MPER C,8TR,9 S7STEM

1S53C2,

5&DI9I5R7 PR3S C,8TR,9S 15PR3S2

$,R >MS, ES5$ET7 S7STEMF +5R3A5RE IS

SPECI$IE3, i*e* T+E +5R3A5RE , A+IC+ MEETS T+E
REG&IREME8T ,$ RE9E=58T 8$P5 583 =3E
ST5835R3SH
September 11, 2012 PMI Revision 00 -4

TRIP9E RE3&8358T C,8$I?&R5TI,8 $,R T+E

$&R85CE 2 ,&T ,$ ( PR,TECTI,8 1M$T2 P,RTI,8
,$ >&R8ER M585?EME8T S7STEM 1>MS2

$,R S>C, S53C, 5PR3S,MI99 I ,I9 E9E=*

SEG&E8CE, I8TER9,C@ 583 PR,TECTI,8,
C,8$I?&R5TI,8 SIMI95R T, ,9CS;C9CS*

$,R MI99 I ,I9 E9E=* 9,?ICS, S5$ET7 S7STEM

+5R3A5RE 5S PER ST5835R3 S+599 >E &SE3*
September 11, 2012 PMI Revision 00 -6
C,8SISTS ,$ :/

T&R>I8E PR,TECTI,8 S7STEM 1TPS2,

5&T,M5TIC T&R>I8E R&8/&P S7STEM 15TRS2,

5&T,M5TIC T&R>I8E TESTI8? S7STEM 15TT2,

E9ECTR,/ +73R5&9IC T&R>I8E C,8TR,9

S7STEM 1E+TC2 $,R M5I8 I >$P T&R>I8E,

T&R>I8E STRESS C,8TR,9 S7STEM 1TSCS2,

?9583 STE5M PRESS&RE C,8TR,9

?E8ER5T,R SE59 ,I9, PRIM5R7 A5TER I

+73R,?E8 C,8TR,9 S7STEM
September 11, 2012 PMI Revision 00 -:

TRIP9E RE3&8358T ,R 2 D 100 J REPE5TE3 TAICE

C,8$I?&R5TI,8 $,R T+E T&R>I8E PR,TECTI,8
S7STEM 1TPS2*

$,R TPSS, S5$ET7 S7STEM +5R3A5RE ; $5I9/S5$E

+5R3A5RE S+599 >E &SE3 A+IC+ MEETS T+E
REG&IREME8T ,$ RE9E=58T 8$P5 583 =3E
ST5835R3SH

$,R ,T+ERS, C,8$I?&R5TI,8 SIMI95R T,

,9CS;C9CS T, >E &SE3
September 11, 2012 PMI Revision 00 .0

C,8SISTS ,$ ,PE8 9,,P C,8TR,9 S7STEM

1,9CS2 583 C9,SE3 9,,P C,8TR,9 S7STEM
1C9CS2

,9CS /T+E SEG&E8CE C,8TR,9, I8TER9,C@ ,$

599 T+E P958T S7STEMS A+IC+ 5RE 8,T
C,=ERE3 I8 T+E S?/CII 583 T?/CII* T+IS
I8C9&3ES M5K,R 5&DI9I5RIES 9I@E $3;I3;P5 $58S,
5IR/PRE+E5TER, >$P;CEP;CAP; >CAP ,
3MCAP;C9CAP 583 E9ECTRIC59 >RE5@ERS*
September 11, 2012 PMI Revision 00 .1

1C9CS2 /T+E M,3&95TI8? C,8TR,9 $,R =5RI,&S

IMP,RT58T P958T P5R5METERS, 9I@E $A $9,A
13R&M 9E=E92, $&R85CE 3R5$T, C,M>&STI,8
C,8TR,9 1$&E9 $9,A 583 5IR $9,A2, P5 +3R
PRESS&RE C,8TR,9, 3E5ER5T,R ; +,TAE99 ;
+E5TER 9E=E9 C,8TR,9S ETC*
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