Training Program on

Instrumentation & Controls

Basic Concept of Process Controls

Basic Concept of Instrumentation &
Controls

CONTENTS:-

 Basic Control System-Concept

 Open Loop Control System
 Closed Loop Control System
 Process Characteristics
 Current Scenario – PLC and DCS
 Q&A
Basic Concept of Instrumentation &
Controls

Basic Control System- Block Diagram

Basic Concept of Instrumentation &
Controls
Classification of Control System:

 Open Loop Control System:

 Closed Loop Control System:

Basic Concept of Instrumentation &
Controls

Open Loop Control System: Control Action is

independent of the Output

Contd..
Basic Concept of Instrumentation &
Controls

Closed Loop Control System: Control Action is related to

the Output
Basic Concept of Instrumentation &
Controls

Closed Loop Control System

Basic Concept of Instrumentation &
Controls
Elements of Control Systems:
 Sensors: Pressure, Temp, Flow,
Level, etc.
 Controller: P, PI, PID- Including
comparator unit
 Actuators: Converts controller output to
Mechanical Energy to regulate final control
element.
 Final Control Element: Control Valves, etc.
Basic Concept of Instrumentation &
Controls
Process Characteristics:
 Resistance Type Processes

 Capacitance Type Processes

 Transportation Time
Basic Concept of Instrumentation &
Controls
Example showing Process Characteristics:
Heat Exchanger
Basic Concept of Instrumentation &
Controls
Resistance Type Processes:
Those parts of the process which resist
transfer of energy ( or materials) are
called resistances.
e.g. Walls of the steam coil
Basic Concept of Instrumentation &
Controls
Capacitance Type Process:
Those parts of the process which have
ability to store energy (or materials)
are called Capacitances.
e.g.
 Walls of the steam coils

 Water in the tank

Basic Concept of Instrumentation &
Controls
Transportation Time:
Time required to carry a change from
one point to another point in the
process.

e.g. Time taken at the change in inlet

water temp and the measurement
point.
PLC & DCS Systems
1. What is a PLC?
2. Why PLC ?
3. Benefits of Automation
4. PLC or DCS ?
5. Continuous & Discrete Signal
1. What is a PLC?

1. PLC stands for Programmable Logic

Controller

2. A Programmable Logic Controller is an electronic device

used for automation of industrial processes, such as
control of machinery on factory assembly lines.

3. A typical PLC system consists of a central processing unit

(CPU), a power supply, input modules, and output
modules. PLC executes the logic program based on data
received from input modules and/or operator
commands, processes this information and sends signals
to output modules to control field devices
Why PLC ?
 Before the PLC, Control, Sequencing, and
Safety Interlock logic for manufacturing
automobiles was accomplished using relays,
timers and dedicated closed-loop controllers.
The process for updating such facilities for the
yearly model change-over was very time
consuming and expensive, as the relay systems
needed to be rewired by skilled electricians.
Before PLC ….
1. Sequencing & Control was complex & any change in
the sequence would take lot of time.
2. Providing interlocks after certain stage was
complicated & time taking.
3. Troubleshooting was not easy & small faults would
take enough time thus large downtimes.
4. Keeping records of Faults was tedious job.
5. Keeping track of progress also was tiresome.
6. It was hard Keep track of Production, MIS report
generation was ineffective.
After PLC ….
1. Sequencing has become too easy.
2. Providing interlocks is no more
complicated.
3. Troubleshooting is painless.
4. Keeping records of Faults was simple.
5. Keeping track of Production & MIS
report generation is simple, effective
& informative.
Benefits of Automation ….
In Summary, the benefits of Automation
include
1. Engineering for Maximum Performance
2. Continuous Productivity Improvements
3. Reduced Downtime
4. Integrating Information for Improved
Visibility
Common terms associated with PLC
1. Scan Time / Rate
2. Node
3. Chassis
4. SCADA & HMI
5. PLC System Architecture
6. Baud Rate
7. Bit / Byte
8. I/O Address
9. Remote I/O
Continuous & Discrete Signal
 Continuous Signals or the Analog
signals are like volume controls,
with a range of values between zero
and full-scale.
 Pressure transmitters, temperature
transmitters, flow rate, and weight
are often represented by analog
signals.
Continuous Signal (..contd..)

Analog signals can use voltage or current with a

magnitude proportional to
the value of the process signal. (4-20 mA or 0 -
10 V)
Continuous & Discrete Signal
1. Digital or discrete signals behave as
binary switches, yielding simply an
On or Off signal (1 or 0, True or
False, respectively).
2. Pushbuttons, limit switches, Pressure
switches, Temperature switches and
photoelectric sensors are examples
of devices providing a discrete signal.
Continuous & Discrete Signal
Discrete signals are sent using either
voltage or current, where a specific
range is designated as On and
another as Off.
DCS
A Distributed control system (DCS)
refers to a control system in which
the controller elements are not
central in location (like the brain) but
are distributed throughout the system
with each component sub-system
controlled by one or more controllers.
The entire system may be networked
for communication and monitoring.
History of DCS
 The DCS was introduced in 1975.
 Both Honeywell and Japanese
electrical engineering firm Yokogawa
introduced their own independently
produced DCS at roughly the same
time, with the TDC 2000 and CENTUM
systems, respectively.
PLC or DCS ?
1. The programmable logic controller (PLC) is king of machine
control while the distributed control system (DCS)
dominates process control. If you manufacture automobiles,
you speak PLC. If you produce chemicals, you speak DCS

2. PLCs and DCS overlap in their features, but also have

distinct strengths and weaknesses

3. DCS have been used primarily in process industries such as

oil and gas production and transport; refining; chemical
processes; food and beverage; power generation; water

PLC have been used in discrete industries such as

automotive; electronic assembly; bottling facilities; machine
parts manufacturing; conveyor belt sorting and material
movement; and skid mounted process equipment.
Q&A