Chapter 1

Introduction to Process Control

Chapter 1 Introduction to Process Control

1.1 Introduction
1.2 Control Systems
1.3 Process-Control Block Diagram
1.4 Control System Evaluation
1.5 Analog and Digital Processing
1.6 Units, Standards, And Definitions
1.7 Sensor Time Response
 1.1 Introduction

(1) Control

(2) Control system

(3) Process control system

 1.2 Control systems

(1) Process control systems

(2) Servomechanisms

(3) Discrete-state control systems

 1.2 Control systems
1.2.1 Process control principles

(1) The Process

 1.2 Control systems
1.2.1 Process control principles

(1) The Process

Property: self-regulation
For some input flow rate, the
liquid height will rise until it reaches a
height for which the output flow rate
matches the input flow rate.

A self-regulation system does not

provide a regulation of a variable to
any particular reference value.
Non-self-regulation
 1.2 Control systems
1.2.1 Process control principles
(2) Human-aided control, artificial regulation

To maintain a value, a sensor is necessary to provide a sight tube. The actual

liquid level is called controlled variable.
A valve has been added to the output flow rate can be changed by the human.
The output flow is called manipulated variable or Controlling variable.
Disadvantages: tired, human cost, etc.
 1.2 Control systems
1.2.1 Process control principles
(3) Automatic control

Sensor: a floating ball mechanism, human eyes

Controller: a machines , electronic circuits or computer , human brain
Final control operation: actuator and valve, human hands
1.3 Process-control block diagram
1.3.1 Identification of elements

(1) Process: single-variable process, multi-variable process

(perhaps interrelated)
(2) Measurement: sensor, transducer. All sensors are transducers,
but not all transducers are sensors.
(3) Error detector the difference between the actual process
value and setpoint.
(4) Controller - to examine the error and determine what action
should be taken.
(5) Control Element (final control element): refers to the device
that exerts a direct influence on the process. e.g. valve,
actuator etc.
1.3 Process-control block diagram
1.3.2 Block Diagram

Chap. 7

Chap. 8, 9, 10, 11

Chap. 1, 12
Chap. 2, 3: transducers
Chap 4, 5, 6: sensors
1.3 Process-control block diagram
1.3.2 Block Diagram

Physical diagram of a process-control loop

1.3 Process-control block diagram
1.3.2 Block Diagram

Physical diagram of a
process-control loop

Block diagram of the

process-control loop
1.4 Control System Evaluation
e(t ) r c(t ) (1.1)

Control system objective:

(1) The system should be stable.
(2) The system should provide the best possible steady-state regulation.
(3) The system should provide the best possible transient regulation.
1.4 Control System Evaluation
1.4 Control System Evaluation

A e(t ) dt min imum

Minimium area

a 2 a1 / 4
a3 a 2 / 4

Quarter amplitude
1.5 Analog and Digital Processing
1.5.1 Data Representation
1.5 Analog and Digital Processing
1.5.2 ON/OFF Control
1.5 Analog and Digital Processing
1.5.2 ON/OFF Control

Deadband - a range, of temperature in this case, wherein

no action will occur.
Hysteresis - the behavior of the system is difference at the
same value depending on whether the temperature is
increasing or decreasing.
1.5 Analog and Digital Processing
1.5.3 Analog Control
1.5 Analog and Digital Processing
1.5.4 Digital Control

Supervisory control
1.5 Analog and Digital Processing
1.5.4 Digital Control

Direct Digital Control (DDC)

1.5 Analog and Digital Processing
1.5.4 Digital Control

Smart Sensor
1.5 Analog and Digital Processing
1.5.4 Digital Control

Networked Control System

1.6 Units, Standards, and Definitions
1.6.1 Units
1.6 Units, Standards, and Definitions
1.6.1 Units

English system, Appendix p600

1.6 Units, Standards, and Definitions
1.6.1 Units

CGS---centimeter-gram-second system, Appendix p601

1.6 Units, Standards, and Definitions
1.6.2 Analog Data Representation

3-15psi(pound/inch2) , 20~100kPa
4~20mA
1.6 Units, Standards, and Definitions
1.6.2 Analog Data Representation

I kVB

RL
V VB V IRL
R RL
V kRLVB
1.6 Units, Standards, and Definitions
1.6.2 Analog Data Representation

Example 1.7 Suppose the temperature range 20 to 120 is

linearly converted to the standard current range 4 to 20mA.
What current will result from 66? What temperature does
6.5mA represent?
1.6 Units, Standards, and Definitions
1.6.3 Definitions

1) Error
2) Block definitions
3) Transfer function (T. F.)
(1) Static
Q 119.5 P
(2) Dynamic
1.6 Units, Standards, and Definitions
1.6.3 Definitions

4) Accuracy - specify the maximum overall ever of a device, usually

expressed as inaccuracy. Several forms:
(1) Measured variable. e.g. 2 -uncertainty of 2 in any value of
temperature measured
(2) Percentage of the instrument full-scale (FS) reading. e.g. 0.5% FS in
a 5-V full-scale range meter, the accuracy would be 0.5%FS5V=
0.025V
(3) Percentage of instrument span, i.e. percentage of the range. e.g. 3%
of span for a 20 to 50 psi range, the accuracy would be (0.03 )(50-
20)= 0.9psi
(4) Percentage of the actual reading. e.g. 2% of reading 2V, the accuracy
would be 0.04V
1.6 Units, Standards, and Definitions
1.6.3 Definitions

5) System accuracy the overall accuracy of many elements in a

process control loop to represent a process variable.
The best way is in the terms of the T. F.

V K G
2%
V K G

V
[ ]rms (0.015) 2 (0.005) 2 0.0158
V
1.6 Units, Standards, and Definitions
1.6.3 Definitions

6) Sensitivity - a measurement of the change in output of an

instrument for a change in input.
High sensitivity is desirable, e.g. 10mV/ is higher than 5mV/
evaluated together with other parameters (linearity, range, accuracy)
Generally indicated by the T. F.
e.g. 5mV/ means:
(1) T. F., i.e. when input is 1 , output is 5mV.
(2) sensitivity, i.e. if input change by 1, output change 5mV.
1.6 Units, Standards, and Definitions
1.6.3 Definitions

7) Hysteresis and Reproducibility

8) Resolution
1.6 Units, Standards, and Definitions
1.6.3 Definitions

Comparing Sensitivity and Resolution

Sensitivity: refers to the output when input change by one unit.
Resolution: refers to the input which causes the minimum
recognized output.
1.6 Units, Standards, and Definitions
1.6.3 Definitions

9) Linearity cm mc c0

EXAMPLE 1.14 A sensor resistance changes linearly from 100 to

180 Ohm as temperature changes from 20 to 120. Find a
linear equation relating resistance and temperature.
Solution:
The desired equation would be of the form
R mT R0 m 0.8 / o C

R0 84
100 (20o Cm R0 )
R 0.8T 84
180 (120o
Cm R0 )
1.6 Units, Standards, and Definitions
1.6.4 Process-Control Drawings

P&ID: Piping and Instrumentation Diagram Page 622

1.6 Units, Standards, and Definitions
1.6.4 Process-Control Drawings

P&ID: Piping and Instrumentation Diagram Page 622

1.7 Sensor Time Response

Perfect sensor: b(t) reaches the final

value with no lag.
However, all sensors will exhibit
some lag between the output and the
input and some characteristic variation
in time before settling on the final value.
1.7 Sensor Time Response
1.7.1 First-Order Response

b(t ) bi (b f bi )[1 e t / ]
1.7 Sensor Time Response
1.7.1 First-Order Response

EXAMPLE 1.15 A sensor measures temperature linearly with a

static transfer function of 33mV/ and has a 1.5-s time
constant. Find the output 0.75s after the input change from 20
to 41. Find the error in temperature this represents.
1.7 Sensor Time Response
1.7.2 Second-Order Response

This is called second-order because the time response is determined

by the solution of a second-order differential equation.
The general form :
a - output damping constant
fn - natural frequency
R0 amplitude

R(t ) R0 e at sin(2 f n t )
 Homework

1.3, 1.8, 1.10, 1.26