Basics of Control Theories

HEAT EXCHANGER
Steam in

Fluid in

Fluid out
Heat Exchanger

Ti

T desired
Steam out

HEAT EXCHANGER
Steam in
(Manipulated variables)
(Controlled variables)
Fluid out

Fluid in
Heat Exchanger
Ti
(Load disturbances )

T desired
Steam out
(Uncontrolled variables)

THREE BASIC COMPONENT OF

CONTROL SYSTEM

Measurement (M)

measure the variable to be controlled.

Decision (D)

Controller decides what to do to maintain the variables at its

desired value

sensor-transmitter combination

Single control loop (feedback control loop)

Multi-variable control loop/ advanced control loop

Action (A)

System must take an action based on controllers decision

control valve (final control element)

Process Control Terms

Process Variables (PV) condition of the process fluid (a liquid

or gas) that can change the manufacturing process.

Measured Variables - condition of the process fluid that must be

kept at the designated set point

Set point (SP)- desired value of the control variable.

Manipulated Variables - The factor that is changed to keep the

measured variable at set point

Process Control Terms .

Error - difference between the measured variable and the set point
and can be either positive or negative

Offset sustained deviation of the process variable from the set point

Open loop system - The behavior with no controllers in the system

Closed loop system A closed control loop exists where a process

variable is measured, compared to a set point, and action is taken to
correct any deviation from set point.

Question of the day ..

Is process variable is the same as measured
variable ?
Why and how?

Action

Steam in

SP

Decide

TC
TT

Fluid in

Fluid out
Heat Exchanger

Ti

T desired
Steam out

Measured = T desired (sensor transmitter)

Control = Steam in
Action = valve (final control element)

Measure

SP
Steam in
(Manipulated variables)

TC
TT

Fluid in

Fluid out
Heat Exchanger

Ti

(Load disturbances )

T desired

(Controlled variables)
Steam out
(Uncontrolled variables)

Question
How to ensure that L (level) remains at or near the set
point?
- List all the variables
-

BASIC COMPONENTS OF CONTROL SYSTEM

Measurement

(M) sensor-transmitter

combination
Decision

Action

(D)

(A)

controller
control valve

Process & Instrumentation Diagram

Purpose
1. To indicate the instruments or control devices attached to the process.
2. To indicate the control system architecture associated with the process.

How it is done?
Standard symbols and notations representing instruments or control devices are placed to
the pipings and vessels.Standard symbols and notations are available from ISA-5.1(1984)
standard.

Methodology?
Process piping and sub-piping

A thick straight line represent main process piping

A thin straight line represent process sub-piping either
to instruments or by-pass process line.

Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

PG

Unit 1: Process & Instrumentation Diagram

Symbols
Instruments / control devices:

A circle representing locally

mounted instrument

A circle with horizontal line

representing control room
panel mounted instrument.

Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

A circle with horizontal line

inside a square representing
its function in DCS.

P&ID: Function Devices

Function devices

<

Integrator

Low selector

Square root
extractor

Current to Pneumatic
Converter

Signals
Electrical signal (low current
or low voltage e.g. 4-20 mA).
Straight dashed line

//

//

//

//

Pneumatic signal e.g.

3-15 psig or 0-60 psig.
Straight line with //

Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

Unit 1: Process & Instrumentation Diagram

Final control elements

Control
valves

Manual
valve

O
R

Manual

O
R

valve

Solenoid
valve

Not darkened
Always open

Darkened Always
closed

Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

P&ID: Notations

Naming rule
Instruments or devices are noted by 2 to 4 letters.

1st

2nd

3rd

4th

Measurement

Control device

Device/ Condition

Condition

Common
measurement:
P = Pressure
T = Temperature
L = Level
F = Flow

Common control
devices:
I = Indicator
C = Controller
R = Recorder
T = Transmitter
A = Alarm
S = Switch
G = Gauge

Common condition:
H = High
L = Low

Common condition:
H = High
L = Low

Examples

See Smith & Corripio (2006) as in Appendix A, Table A-1

LT
120
Level transmitter no. 120
installed to vessel

LT
120
Level transmitter no. 120
panel mounted, control room.
Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

LC
120
Level controller no. 120
in DCS, control room.

Unit 1: Process & Instrumentation Diagram

Naming rule

P
T
L
F
A

Measurement

Device

Device / Condition

Condition

Pressure
Temperature
Level
Flow
Analysis

C
T
R
I
A
S
G

Controller
Transmitter
Recorder
Indicator
Alarm
Switch /
Safety
Gauge

C
T
R
H
L
V

Controller
Transmitter
Recorder
High
Low
Valve

H
L

High
Low

Complete guide on P&ID symbols & notations are available from ISA 5.1 (R1984)
Examples

PC
PIC
LG
FR
TAL
TALL
TAHL

Pressure Controller
Pressure Indicating Controller
Level Gauge
Flow Recorder
Temperature Alarm Low
Temperature Alarm Low Low
Temperature Alarm High Low

PCC
PTC
PTR
PIR
TRR
TRA
TAV

No such
devices yet.

Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

Unit 1: Process & Instrumentation Diagram

Examples

Unit 1: Process & Instrumentation Diagram

Examples

Instrument piping - thin line

LT
120

Unit 1: Process & Instrumentation Diagram

Examples

Instrument piping + field instrument thin line + circle

LT
120

P&ID

Examples

thin process line

LT
120

thick process line

Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

TRANSMISSION SIGNAL

3 principle type of signals in in in process industries

Signal

Range

Pneumatic

3 15 psig

Electrical

4 20 mA
1 to 5 V

Digital/discrete

Usually signal is in percent

Example 0-100% = 3-15 psig

Symbol

 Signal

are used by devices transmitters,

controllers, final control element to
communicate.

Change type of signal using transducer /

converter
Example of transducer
Current to pneumatic (I/P)
Digital-to-analog (D to A)
Pneumatic to current (P/I)

Steam in
(Manipulated variables)

I/P

TC
TT

Fluid in

Fluid out
Heat Exchanger

Ti

(Load disturbances )

T desired

(Controlled variables)
Steam out
(Uncontrolled variables)

P&ID: Process Control Loop

Process control loop

Process

Transmitter

Controller

Transducer

I/P

Control Valve

Unit 1: Process Control Loop

Process control loop

Process

Sensor

Transmitter

Controller

Transducer

Control valve

Pressure
Flow
Level
Temperature
pH
dP cell
Capacitance
Radar, Sonic
Magnetic
Resistance
IR/Laser
4-20 mA
1-5 Vdc

PID
Fuzzy logic

4-20 mA
3-15 psig

Linear
Equal percentage

Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

I/P

P& ID OF SIMPLE CONTROL LOOP

EXAMPLE OF P& ID

EXAMPLE OF P&ID