PROCESS CONTROL

SUBMITTED TO:- SUBMITTED BY:-

MR.INDERJIT SINGH AYAAN PATTI
PGM-1901
 What is Process Control?

Activities involved in ensuring a process is

predictable, stable, and consistently operating at
the target level of performance with only normal
variations.
 Why do we need process control?

• Increase in productivity:
• Helps to increase the efficiency of both men and machine.

• Improvement in quality of products by meeting the product specifications

overcoming operational constraints.

• Ensure the stability of the process

• Optimize the performance of the process.

• Minimize /suppress the influence of external disturbances on the

process.
 Automatic process control

Automatic control is the maintenance of a desired value of a

quantity or condition by measuring the existing value,
comparing it to the desired value, and employing the difference
to initiate action for reducing this difference. Thus automatic
control requires a closed loop of action and reaction operating
without human aid.
 Variables of Automatic Process Control

• Set point variable : is the one that is set by the operator, master controller
or computer as a desired value for a ‘controlled variable’. It is also called
sometimes as ‘reference value’.

• Controlled variable : is the one that must be maintained precisely at the set
point. Typically, the variable chosen to represent the state of the system is
termed the ‘controlled variable’.

• Manipulated variable : is the one that can be changed in order to maintain

the controlled variable at the set point value.

• Load variables : are those variables that cause disturbances in the process.
They are also called as load disturbances.
The Control Loop

Imagine you are sitting in a cabin in front of a small fire on a cold

winter evening. You feel uncomfortably cold, so you throw another
log on the fire. This is an example of a control loop. In the control
loop, a variable (temperature) fell below the set-point (your comfort
level), and you took action to bring the process back into the desired
condition by adding fuel to the fire. The control loop will now remain
static until the temperature again rises above or falls below your
comfort level.
THREE TASKS

Control loops in the process control industry work in the same way,
requiring three tasks to occur:
• Measurement
• Comparison
• Adjustment
Example:-

• In Figure, a level transmitter (LT) measures the level in the tank and
transmits a signal associated with the level reading to a controller
(LIC). The controller compares the reading to a predetermined
value, in this case, the maximum tank level established by the plant
operator, and finds that the values are equal. The controller then
sends a signal to the device that can bring the tank level back to a
lower level—a valve at the bottom of the tank. The valve opens to let
some liquid out of the tank.
 Figure:-

Controlle
r

L
T
Maximum level
 What is HART ?

• Nowadays all the smart field devices works on HART.

• It is Highway Addressable Remote Transducer.
• It is global protocol for sending and receiving information between
field devices and Host system.
• HART protocol uses frequency shift keying for digital communication
of signals.
 TRANSMITTERS

A transmitter is a device that converts a reading from a sensor or

transducer into a standard signal and transmits that signal to a
monitor or controller. Transmitter types include:
• Pressure transmitters
• Flow transmitters
• Temperature transmitters
• Level transmitters
• Analytic (O2 [oxygen], CO [carbon monoxide], and pH) transmitters
 Temperature Transmitter

Rosemount 648 Wireless Temperature Transmitter

 Specifications

• Electrical Temp. Sensors such as RTDs and thermocouples produce

low-level signals proportional to their sensed temperatures. The 648
converts the low –level signal to a wireless enabled signal.
• Operated on 2’c’ size primary lithium/thionyl chloride batteries.
• Temperature range: -40 to 85º C
• Thermocouple can be directly connected.
• Transmitter will accept a variety of RTD, whether it is 2-wire, 3-wire
or 4-wire.
3144P Temperature Transmitter
 Specifications

• It provides superior accuracy, stability, and reliability. it has the

capability to accept either single sensor or dual sensor input.
Compatible with RTDs and thermocouple.
• Dual sensor input capability allows the transmitter to accept
simultaneous inputs from 2 different sensors, enabling the
measurement of differential temperature, average temperature.
• It is self calibrated.
• Operates on 42 V DC and generates the output 4-20 mA.
Wireless Gateway
 Wireless Gateway

• 1420 wireless gateway allows wireless, self - organising devices to

communicate with each other and manages security and
connectivity.
• It is the entry point of wireless device that collects the data converts
into the other format that is compatible with another system.
• Works on modbus, TCP/IP via Ethernet/serial connections.
 Specifications

Functional Specifications:

Power Input Options:

24 V dc
500 milliamps required to power the 1420 Wireless Gateway.

Environmental:

Operating Temperature Range:

-40 to 60°C (-40 to 158°F)

Operating Humidity Range:

0-95% relative humidity (non-condensing)

THUM Adapter
 THUM Adapter

• Smart wireless THUM adapter is a device that can retrofit on any

existing 2 or 4 wire HART devices.
• Key benefits:
• Makes any HART device wireless to enable new measurement
points
• Gain access to advanced instrument diagnostics.
• Remotely manages devices and monitors device health.
• Effectively gathers data from multi-variable devices.
• Extend predictive intelligence to area not possible before due to
technical/economical reasons
Dual input analyzer
(MODEL 1056)
 Dual input analyzer
(MODEL 1056)
• Multi parameter instrument: Single or dual input. Choose from
pH/ORP, resistivity/conductivity, %age concentration, chlorine,
oxygen, ozone, temperature, turbidity, flow and 4-20 mA current
input.
• Large display: large easy to read process measurements.
• EASY TO INSTALL – modular boards, removable connectors, easy
to wire power, sensors, and outputs.

• FEATURES AND APPLICATIONS

The Model 1056 dual-input analyzer offers single or dual sensor
input with an unrestricted choice of dual measurements. This multi-
parameter instrument offers a wide range of measurement choices
supporting most industrial, commercial, and municipal applications.
The modular design allows signal input boards to be field replaced
making configuration changes easy. Conveniently, live process
values are always displayed during programming and calibration
routines
Orifice plate
 Orifice plate

• Device used for measuring the flow rate. Based upon Bernoulli's
principle that when the velocity of the fluid increases, its pressure
decreases.
• Differential Pressure is directly proportional to the square of the
velocity of the fluid.
• Orifice plate is a thin plate with a hole in the middle, placed in a pipe
in which fluid flows.
 Mass flow meter

• Measures mass flow rate of a fluid travelling through a tube.

• Mass flow rate is the mass of the fluid travelling past a fixed point
per tube.
• Unit: kg/sec.
• Based upon Coriolis Principle.
Fieldvue DVC 6000 SIS
 Fieldvue DVC 6000 SIS
• Digital valve controllers are communicating micro-processor based
current to pneumatic instruments.
• Primary function is to actuate its pneumatic outputs in response to a
demand signal from a logic solver which moves the valve to a
configured safe state.
 Principle of Operation
• The input signal provides electrical power and set point
simultaneously.
• Input signal is directed to the micro-processor and it runs a digital
algorithm resulting in a drive signal to the I-P convertor.
• I-P output is sent to the pneumatic relay assembly. The relay is
connected to the supply pressure and amplifies the small pneumatic
signal from I-P convertor into a single larger pneumatic output signal
used by single acting actuator.
• The change in relay output pressure to actuator, causes the valve to
move.
• Valve position is sensed through the feedback linkage by the
instrument’s travel sensor. The travel sensor is electrically
connected to the printed wiring board to provide a travel feedback
signal used in the control algorithm
• Valve continues to move until the correct position is attained.
DP type flow meter
 Differential pressure flow meter

• Working principle:
Differential pressure flow meters use Bernoulli's principle to
measure the flow of fluid in pipe. D.P flow-meters introduce a
constriction in the pipe that creates a pressure drop across the flow-
meter. When the flow increases, more pressure drop is created.
Impulse piping route the upstream and downstream pressures of the
flow-meter to the transmitter that measures the differential pressure
to determine the fluid flow.
 DCS (Distributed Control System)
• A distributed control system (DCS) is a computerised control system
for a process or plant usually with a large number of control loops, in
which autonomous controllers are distributed throughout the system,
but there is central operator supervisory control.

Fig:- distributed control system (DCS

 Which cable to be used for HART signal

• HART devices use the conventional 4–20 mA current signal cable path
to send the HART FSK signal. Thus, no extra communication paths are
required to send HART signals that use existing signal cables for
communication. There are several ways to calculate HART cable
lengths, which depend on the quality of cables used and consequently
on the capacitance— the lower the cable capacitance, the longer would
be the cable run. Capacitance limitation imposed by intrinsic safety
considerations further puts a limit on the maximum cable run in such
cases.
 3 wire RTD using to the wheatstone bridge

• To compensate for lead wire resistance, 3 wire RTDs have a third wire that provides a
measurement of the resistance of the lead wire and subtracts this resistance from the
read value. This correction compensates for the effect of the resistance of the long
lead wires on the temperature measurement and results in improved accuracy.
Because 3 wire RTDs are so effective and affordable, they have become the industry
standard. They are used in a variety of industrial applications and processes,
especially in refineries and chemical and petrochemical plants where temperature
monitoring and control is of extrememportance. The 3 wire RTDs provide good
accuracy and repeatability at reasonable cost and have been adopted by all major
temperature transmitter manufacturers as the standard type of sensor for most
applications.

Fig:- 3 wire RTD using to the wheatstone bridge

 TCP/IP and RS-485 serial communication

• TCP/IP - The Internet works by using a protocol called TCP/IP, or

Transmission Control Protocol/Internet Protocol. TCP/IP is the
underlying communication language of the Internet. In base terms,
TCP/IP allows one computer to talk to another computer via the Internet
through compiling packets of data and sending them to right location.
• For those who don’t know, a packet, sometimes more formally referred
to as a network packet, is a unit of data transmitted from one location to
another. Much like the atom is the smallest unit of a cell, a packet is the
smallest unit of transmitted information over the Internet.
• RS-485 - RS485 is the most versatile communication standard in the
standard series defined by the EIA, as it performs well on all four points.
That is why RS485 is currently a widely used communication interface in
data acquisition and control applications where multiple
nodes communicate with each other.
•
2/3/4 wire HART transmitter

•
 2 wire- The figure above shows the wiring diagram of the two-wire
transmitter.
• Two wire transducer as shown in the above,
• the power supply is 24 VDC, output signal for the DC4-20 ma,
• the load resistance is 250 Ω,
• lowest negative line voltage of 24 v power supply, it is the public line
signal.

3 wire- The figure above shows the wiring diagram of the three-wire
transmitter.
The so-called three-wire system is that the positive end of the power supply
USES one line,
the positive end of the signal output USES one line,
and the negative end of the power supply and the negative end of the signal
share one line.
Its power supply mostly DC 24V, DC 4 ~ 20 ma output signals,
and the load resistance is 250 Ω or DC0-10 ma,
load resistance to 0-1.5 K Ω;
Some also have mA and mV signals,
but the load resistance or input resistance,
depending on the output circuit form and different values.
4 wire- The figure above shows the wiring diagram of the four-wire transmitter.
• Most of the power supply is AC 220V,
• and some are DC 24V. DC4 ~ 20 ma output signals and the load resistance is
250 Ω,
• or DC0-10 ma, load resistance to 0-1.5 K Ω;
• Some also have mA and mV signals,
• but the load resistance or input resistance,
• depending on the output circuit form and different values.

• Foundation fieldbus (FF)

• A fieldbus trunk or segment—either FOUNDATION fieldbus H1 or PROFIBUS

PA—is a single twisted pair wire carrying both a digital signal and DC power that
connects up to 32 fieldbus devices (temperature, flow, level and pressure
transmitters, smart valves, actuators, etc.) to a DCS or similar control system.
Most devices are two-wire bus-powered units requiring 10 to 20mA, but it is also
possible to have 4-wire fieldbus devices, typically where a device has a
particularly high current draw.

•
• The fieldbus segment begins at an interface device at the control
system. On a FOUNDATION fieldbus H1 (FF) system, the interface
is called an H1 card; on a PROFIBUS PA system (PA), it is a
PROFIBUS DP/PA segment coupler. In terms of signal wiring and
power requirements for the segment, FF and PA are identical:
• Minimum device operating voltage of 9V
• Maximum bus voltage of 32V
• Maximum cable length of 1900m (shielded twisted pair)
Thank you