Polymer Technology DKK2413Process Instrumentation and Control e-learning notes lecture notes

CHAPTER 1: INTRODUCTION MEASUREMENT AND CONTROL 1.0 Definition of Process Control Process = a single stage or series of stage of manufacturing, which could be either mechanical, electrical, physical, chemical, or a combination of all these, that the feed material or materials would have to undergo to be transformed into the desired end products. Control = implies regulation or manipulation of the variable influencing a process in order to achieve a desired result. Instrumentation = a specific device or groups of related devices that measure, monitor, and/or control a process. Measurement = the conversion of the variable into some corresponding analog of the variable, such as pneumatic pressure, an electrical voltage or current, or a digitally encoded signal. 1.1 Control System TO PROCESS

a)

Process-Control Principles *

The basic objective to regulate the value of some quantity. The Process Human-Aided Control Automatic Control b) Servomechanism The basic objective to force some parameter to vary in a specific manner.

c)

Discrete-State Control System *

The basic objective to control a sequence of events rather than regulation or variation of individual variables. Commonly used in product packaging, utility plant and mechanical moving component where involves PLC.

1.2 The Process-Control Block Diagram

p

Final Control element

u

Transmitter

e=r-b

Controller

Process
c

Measurement

The four fundamentals components of a control loop (physical diagram) are:-

a)

The primary element/ sensor/ measurement Detect and convert energy from the process variable into a quantitative value suitable for measurement. b) Transmitter Receive and interpret the

Polymer Technology DKK2413Process Instrumentation and Control e-learning notes lecture notes
measurement value from the primary element, convert it into a standardized signal of representative value and transmit the standardized signal to the controller. c) Controller Receives the transmitter signal, operating automatically applies preset algorithm to create a correction signal. d) Final control element Receives the correction signal and changes the value of the manipulated variable. Typical manipulated variable include flow, temperature, pressure and level.

Open- Loop and Closed- Loop Control a) Closed- Loop Control

Any control system that has a feedback system. Feedback is the ability to monitor the results of a control action and determine if additional correction is required. b) Binary Logic A mathematical application that interprets, represent and determines all possible value, states or conditions based on a successive progression of TRUE/FALSE statements. a) Inverter Truth Table b) AND/ NAND Gate Truth Table c) OR/NOR Gate truth Table Open- Loop Control A control system operating without feedback.

1.3 Analog and Digital Processing In the past, analog processing was applied for the function of the controller in a control system, which was performed by sophisticated electronic circuit. Now, digital processing was mostly implemented, which is often interrelated with the analog processing. This digital processing represents data in binary numbers consisting of specific number of bits. a) Data representation Analog data Digital data

Analog data forms as nonlinear line profile whereas digital data forms the laddered line profile. Special devices are employed to convert analog voltages into a digital representation, called analog-todigital converters (ADCs). Sensor (measurement) often produces an analog output ie voltage. Digital-to-analog converters (DACs) are to inverse the

Polymer Technology DKK2413Process Instrumentation and Control e-learning notes lecture notes
direction of paragraph. b) ON/OFF control Before the advent of the computer, the on/off control became the element of digital control. The command are just on and off c) Analog control True analog control exists when all variables in the system are analog representations of another variable. d) Digital control Supervisory digital the computer monitors measurements and updates setpoints, but the loops are still in nature (analog). Direct digital control (DDC) the computer performs the error detection and the controller functions. Smart sensor the controller device which contains the sensor, signal conditioning, ADC, and computer controller in a sensor housing case. Networked control systems DDC in plant connected to personnel computer thru local area network (LAN). conversion mentioned in the above

e)

Programmable logic controllers used for discrete-state control and also for DDC.

1.4 Piping and Instrumentation Diagram (P&ID)

An illustration that displays the actual equipments and instruments associated with the flow path of the process. The American National Standards Institute (ANSI) and The Instrument Society of America (ISA) publish the complete industrial standard for instrument symbols and tags. a) Essential elements The P&ID depicts the entire plant and associated control. There are specific symbols and tags of equipments, instruments and lines. b) Instrument Line Symbols Different function of line is for different symbol. Signal differentiation: current, pneumatic, hydraulic, electrical, and internal system link (digital data/ computer signal). Process line differentiation: common connection of pipe and capillary tube. c) Instrument symbol The instrument associated with the control systems varies from sensors and transmitters to controllers, computers, an PLCs. These are drawn as bubbles with or without rectangles. Each has its own special symbol and designation.