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Introduction to Process Control

FG05W1 Version 1.3 2010
Standards Certification Education & Training Publishing Conferences & Exhibits

2010 ISA FG05W1 (1.3)

Seminar Logistics
Seminar materials
Downloadable presentation Question and Answer session (audio and email) Survey Earn 1.5 Professional Development Hours (PDH)

Seminar length
90 minute total presentation Three approximately 20 minute instructional presentations Three approximately 10-minute question and answer sessions

Audio Instructions
Please note the following during the seminar: As a participant, you are in a listen-only mode. You may ask questions via the internet, using your keyboard, at any time during the presentation. However, the presenter may decide to wait to answer your question until the next Q&A Session.

2010 ISA FG05W1 (1.3)

Audio Instructions for Q & A Sessions

Questions may be asked via your telephone line. Press the *1 key on your telephone key-pad. If there are no other callers on the line, the operator will announce your name and affiliation to the audience and then ask for your question. If other participants are asking questions, you will be placed into a queue until you are first in line. While in the queue, you will be in a listen-only mode until the operator indicates that your phone has been activated. The operator will announce your name and affiliation and then ask for your question.

Introduction of Presenter
Instructor
Name: William (Tim) Shaw PhD, CISSP Background/experience: Over 30 years of experience with computer based automation systems including developing three generations of DCS systems and two generations of SCADA systems. Former Adjunct Professor in the Graduate Engineering department of Loyola College in Baltimore. Authored books on Batch Process Control and on SCADA Cyber Security. Currently the Senior Consultant for Cyber SECurity Consulting, an industrial automation cyber security firm. Tim periodically teaches courses for ISA and IEEE. Email: timshaw4@verizon.net

2010 ISA FG05W1 (1.3)

Goals of this training session

Discuss the operation and components of a feedback control loop Explain the role of measurement and control in industrial processes Interpret measurement and control technology Discuss the fundamental concepts of controller tuning

Section 1: Basics of Process Control

Process/Process Control Defined Process Control Loop Measurement Loop Control Loop Setpoint Steps
Measure Compare Decide Action

P&ID drawings

2010 ISA FG05W1 (1.3)

Definition of a Process
A process is a part of a manufacturing plant in which material or energy is converted to other forms of material or energy
Change in pressure, temperature, speed, electrical potential, etc.

Basic Feedback Loop

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2010 ISA FG05W1 (1.3)

Process Control Loop

Process Control: the regulation or manipulation of variables influencing the conduct of a process in such a way as to obtain a product of desired quality and quantity in an efficient manner

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Control Steps

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Process Pictorial

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Another Pictorial View

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2010 ISA FG05W1 (1.3)

Control Loop on a P & I D

Steps Again
Measure
Quantify Standardize

Compare
To Desired Value (Setpoint)

Decide
How much How long How quickly

Action
Manipulate Variable

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2010 ISA FG05W1 (1.3)

Feedback
Because you take information about a process output and use it to control a process input (feedback) Process must be upset before deviation can be measured Always a lag in action due to steps

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Review of Key Items

Process/Process Control Defined Process Control Loop Measurement Side Control Side Setpoint Steps
Measure Compare Decide Action

P&ID drawings

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2010 ISA FG05W1 (1.3)

Question and Answer Session

During Q&A, questions may be asked via your telephone line. Press the *1 key on your telephone key-pad. If there are no other callers on the line, the operator will announce your name and affiliation to the audience and then ask for your question. If other participants are asking questions, you will be placed into a queue until you are first in line. While in the queue, you will be in a listen-only mode until the operator indicates that your phone has been activated. The operator will announce your name and affiliation and then ask for your question.

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Section 2: The Measurement Loop

Process Variables Instrument Zero Instrument Full Scale Standard Signals Engineering vs. Percent Accuracy Repeatability Other Measurement Terminologies Ranging and Calibration

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2010 ISA FG05W1 (1.3)

Process Variables
The following variables (one or more) will be found in the majority of process control applications:
Flow Level Pressure Temperature

There are many others, yet those above are found most often.

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Flow Measurement Volumetric

Positive Displacement
(gallons per minute, cubic feet per minute, liters per minute, etc.)

Mass
Coriolis Mass Thermal
(pounds per hour, kilograms per hour, etc.)

Velocity
Magnetic Oscillatory Turbine Ultrasonic

Inferential
Differential Pressure Target Variable Area

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2010 ISA FG05W1 (1.3)

Pressure
Pressure Is Force Per Unit Area

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Level Measurement
WHERE

HOW MUCH

How far from full How far from empty How much material
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2010 ISA FG05W1 (1.3)

Temperature Measurement
How much heat energy?

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Standard Signal Concept

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2010 ISA FG05W1 (1.3)

Standard Signal for Flow

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Repeatability vs. Accuracy

2010 ISA FG05W1 (1.3)

Zero & Span Errors

100% MEASURED VALUE ERROR CAUSED BY INCORRECT ZERO 0 100% TRUE VALUE HIGH SPAN 100% IDEAL SPAN LOW SPAN ERROR CAUSED BY SPAN

MEASURED VALUE

TRUE VALUE

100%
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Non-linearity Error

100%

MEASURED VALUE

ERROR CAUSED BY NONLINEARITY

TRUE VALUE

100%

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2010 ISA FG05W1 (1.3)

Other Terminologies
Resolution
Smallest scale increments

Sensitivity
Smallest detectable change

Hysteresis
Difference in measurement output when measuring input ascending and descending

Dead band
Range in which input signal may change upon reversal of direction without causing measurable change in output
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Ranging (or Scaling) vs. Calibration

Ranging changes the Instrument zero and/or Instrument Span Range is always given as from , to
Instrument zero is set to lower range value Instrument span is set so 100% = upper range value

Modern Instruments do not have to be calibrated upon a range change. Calibration means to compare this instruments readings for a selected set to a measurement standard in a standardized environment. And adjust if necessary Some of the more modern test instruments are shop standards Smart Instruments have their own built in standards, or at least characterization curves for sensor linearization.
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2010 ISA FG05W1 (1.3)

Review of Key Points

Process Variables Instrument Zero Instrument Full Scale Standard Signals Engineering vs. Percent Accuracy Repeatability Other Measurement Terminologies Ranging (Scaling) and Calibration

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Question and Answer Session

During Q&A, questions may be asked via your telephone line. Press the *1 key on your telephone key-pad. If there are no other callers on the line, the operator will announce your name and affiliation to the audience and then ask for your question. If other participants are asking questions, you will be placed into a queue until you are first in line. While in the queue, you will be in a listen-only mode until the operator indicates that your phone has been activated. The operator will announce your name and affiliation and then ask for your question.

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2010 ISA FG05W1 (1.3)

Section 3: Control Loop/Controllers

Two Wire Loops Output Signals Transducers Valves Actuators Controller Action On-Off Proportional Only Proportional-Integral Proportional-Integral-Derivative Tuning
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Two Wire Loop

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2010 ISA FG05W1 (1.3)

Transducers
Many Final Control Elements in continuous control are valves, and valves use a pneumatic actuator. Most controllers are electronic and have an electronic output. A transducer (I/P) is used to provide an interface.

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Current to Pneumatic (I/P) Transducer

Used to convert current signal to pressure signal

2010 ISA FG05W1 (1.3)

Control Valves

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Typical Pneumatic Actuator

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2010 ISA FG05W1 (1.3)

Typical Pneumatic Valve Positioner

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Controller Action

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2010 ISA FG05W1 (1.3)

On-Off Control

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Proportional Control Algorithm

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2010 ISA FG05W1 (1.3)

PI Algorithm
Integral action also known as reset average error over time

m = Kc e +
Gain adjustment

1 edt Ti
(minutes per repeat)

Integral Time Adjustment

Integral action is used to eliminate the offset that occurs in a proportional controlled process when a load change or continuing error to one side of set point occurs. Operates on duration of error
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PID Algorithm
Derivative action also known as rate Rate of error change over time

=
gain adjustment

+
derivative time adjustment (minutes)

integral time adjustment Derivative is used on slow processes to reduce over/undershoot, providing less excursion from setpoint and a quicker first return to setpoint. Operates of the rate of error change.

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2010 ISA FG05W1 (1.3)

Tuning Objectives
Adjustment of gain, reset, and rate to achieve good process control

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Action Summary

ACTION On-Off Proportional Integral Derivative

OPERATES ON Presence of error Magnitude of error Duration of error Rate of Change of error

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2010 ISA FG05W1 (1.3)

Review of Key Steps

Two Wire Loops Output Signals Transducers Actuators Valves Controller Action On-Off Proportional Only Proportional-Integral Proportional-Integral-Derivative Tuning
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How Many People Are at Your Site?

Poll Slide Click on the appropriate number indicating the number of people that are at your site.

2010 ISA FG05W1 (1.3)

Question & Answer Session

During Q&A, questions may be asked via your telephone line. Press the *1 key on your telephone key-pad. If there are no other callers on the line, the operator will announce your name and affiliation to the audience and then ask for your question. If other participants are asking questions, you will be placed into a queue until you are first in line. While in the queue, you will be in a listen-only mode until the operator indicates that your phone has been activated. The operator will announce your name and affiliation and then ask for your question.

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Related ISA Courses

FG07 Introduction to Industrial Automation and Control TC05 Tuning Control Loops TS00 CCST Review Course

All ISA courses are available any time as on-site training For more information: www.isa.org/training or (919) 549-8411

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2010 ISA FG05W1 (1.3)

ISA Certifications
Certified Automation Professionals (CAP )
www.isa.org/CAP

Certified Control Systems Technician (CCST)

www.isa.org/CCST

Please visit us online for more information on any of these programs, or call (919) 549-8411.

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Please take our Web Seminar Survey via Zoomerang The seminar survey was sent to you via email during the seminar. Please do not forget to complete the Zoomerang survey.

2010 ISA FG05W1 (1.3)

Conclusion
This is the end of: Introduction to Process Control

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2010 ISA FG05W1 (1.3)