Detailed Notes: Unit I - Fundamentals of Process Control
1. Components of Process Control Loop
A process control loop is designed to maintain a process variable (PV) at a desired set point
(SP) despite disturbances. The key components are:
1. Sensor/Transmitter: Measures the process variable (e.g., temperature, pressure, flow)
and transmits the data to the controller.
2. Controller: Compares the measured PV with the desired SP and computes the required
correction to minimize the error.
3. Final Control Element: Executes the corrective action determined by the controller (e.g.,
control valves, pumps).
4. Actuator: Converts the electrical signal from the controller into mechanical motion to
adjust the final control element.
2. Examples of Process Loops
Examples of common process loops include:
1. Temperature Control Loop: PV = Temperature; SP = Desired temperature; Final Control
Element = Control valve.
2. Flow Control Loop: PV = Flow rate; SP = Desired flow rate; Final Control Element = Pump
or valve.
3. Level Control Loop: PV = Liquid level; SP = Desired level; Final Control Element =
Inflow/outflow valve.
4. Pressure Control Loop: PV = Pressure; SP = Desired pressure; Final Control Element =
Relief valve or compressor.
3. Process Variables
Process variables are measurable quantities in a process. They include:
1. Controlled Variable: The variable the system aims to maintain (e.g., temperature,
pressure).
2. Manipulated Variable: The variable adjusted to achieve the desired control.
3. Disturbance Variable: External factors that cause deviations from the set point.
4. Signal Line Symbols and Instrumentation Symbols
Signal line symbols and instrument symbols are used in P&IDs.
1. Signal Line Symbols: Solid = Pneumatic; Dashed = Electrical; Dotted = Hydraulic.
2. Instrumentation Symbols: Circle = Field-mounted instruments; Hexagon = Control room
instruments.
5. Field and Control Room Area
1. Field Area: Location of on-site instruments like sensors and actuators.
2. Control Room Area: Centralized location for controllers and monitoring systems.
6. Standard Signals
1. 4-20 mA Current Signal: Standardized for process control. Live Zero (4 mA) indicates 0%
of range; Dead Zero (0 mA) indicates fault.
2. Voltage Signals (1-5 V): Common for short-distance signal transmission.
7. Process Characteristics
1. Process Equation: Mathematical relationship between input and output.
2. Capacity: Process's ability to store energy or material.
3. Self-Regulation: Inherent ability to stabilize without external control.
4. Control Lag: Delay between control action and its effect.
5. Process Lag: Time to reach a new steady state after a disturbance.
6. Dead Time: Delay between input change and observable output effect.
How to Prepare
1. Understand Core Concepts: Learn the roles of components in a control loop.
2. Practice Diagrams: Draw and annotate process control diagrams.
3. Review Examples: Study real-world applications of process loops.
4. Memorize Standards: Focus on standard signal ranges like 4-20 mA and their importance.
5. Solve Problems: Apply theoretical knowledge to practice questions.
