Jan.

26, 2018

Process Control Overview

Saqib Hasnain
Staff Engineer

System Engineering Team

 Contents
1. Control System

2. Documentation Standards

3. Plot Plan

4. Types of Diagrams

5. DCS Hard-wiring Concept

6. Pump, Motor Control Philosophy

7. Types of Control System

8. Final Control Elements (FCE)

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 1. Control System
A component, or system of components functioning as a unit, which is activated
either manually or automatically to establish or maintain process performance
within specification limits.

-Failure in a control system

Distributed Control System (DCS)
-Loss of production.
-Equipment damage. -DCS concept appeared in mid-1970.
-Physically distributed throughout the
-Important aspects of a control system facility/ plant.
-Totally integrated/ linked through a
-Stable network for control, communication
-Reliable (foundation filed bus, HART, Profibus,
and Modbus), and monitoring purposes.
-Robust
-Optimal
-Integrated

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A Typical DCS Architecture

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Pyramidal Architecture of DCS

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 2. Documentation Standards
The documentation of process control and field instrumentation for a plant are
strongly influenced by and, in some cases, are required to follow codes and
standards established for the process industry.
ISA Standards
-P & ID diagrams symbols.
Some of the very common codes and Standard are,
-Control logic symbols
-HMI graphic symbols
IEC : International Electrotechnical Commission
-SAMA symbols
NEC : National Electrical Code
ANSI : American National Standards Institute (ISA)
IEEE : Institute of Electrical and Electronic Engineers
NEMA : National Electrical Manufacturers Association
API : American Petroleum Institute
NFPA : National Fire Protection Association
JEC : Japanese Electrotechnical Committee
JEM : Japanese Electrical Manufacturers Association

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 3. Plot Plan (1/2)
It is often helpful to look at the plot plan to get an overview of how a plant is
physically organized. By examining the plot plan, it is possible to get an idea
of where a piece of equipment is located in the plant.
-2D
-3D

-Transport delay
-Time required for a liquid, gas or solid material flow to move from one point
to another through the process.

-Importance from DCS prospective

-The physical layout of a plant will impact the length of wiring runs and
communication distance from the control system to the field devices; thus, it is
a good idea to use the plot plan to get a sense of the plant layout and a feel for
the location of process equipment and process areas.

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A Typical Plot Plan (2/2)

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 4. Types of Diagrams
 Process Flow Diagram (PFD)
Drawing that shows the general process flow between major pieces of
equipment of a plant and the expected operating conditions at the target
production rate.
-Control loop
-One segment of a process control system.

 Piping and Instrument Diagram (P & ID)

Drawing that shows the instrumentation and piping details for plant equipment.
The P&ID includes much more detail about the piping associated with the
process.

Details about pressure, temperature, level, flow etc. transmitters, valves,

automatic or manual control are discussed.
Tag number
-Unique identifier that is assigned to a field device. Tag number
- Field tag no. (For
construction purposes).
 Control Logic Diagram
- System tag no. (For
 Control Loop Diagram
control system purposes).

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Process Flow Diagram

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P & ID

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Control Logic Diagram

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Control Loop Diagram

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 I/O Philosophy Concept
 Digital Input (DI)
 An immediate indication to a DCS system in form of (1/0) about various
field functions like (motor running, stop, trip, fault, level high and low etc.).
 Digital Output (DO)
 An immediate command (1/0) from DCS to field devices like (on, off
pump/ motor, shutoff valve etc.).
 Analog Input (AI)
 A measurement signal of various kinds (normally 4-20mA current signal)
from the field devices to the DCS system like (pressure, temperature, flow,
level transmitters etc.).
 Analog Output (AO)
 A control output command signal (normally 4-20 mA current signal) from
the DCS system to the field devices like (control valves etc.).
 Pulse Input (PI)

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DCS Hardwiring (1/3)

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DCS Hardwiring (2/3)

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 DCS Hardwiring (3/3)

-For more information on control and instrumentation visit

https://instrumentationtools.com/how-will-a-field-jb-of-conventional-4-20ma-
connection-look-different-from-that-of-ff-jb/

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 Motor Control-an Illustration (1/2)

D
C
S
/
P
L
C

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 Motor Control (2/2)
DCS/PLC

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 Control System Types (1/3)
There are various kinds of control, depending on performance, industry usage etc.
Control type used in the process industry are,

General Common/traditional
-Open loop control Automatic Control
-DCS/PLC issue the
-Closed loop control (PID control)
commands to maintain the
-Cascade control process.

Manual Control
Less common/advanced
-Plant operator
-Model predictive control adjustment of a process
-Fuzzy control input.
-Adaptive control

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 Open Loop Control (2/3)
A type of continuous control system in which the output has no influence or effect
on the control action of the input signal.

-No feedback
-No self-correction/self-regulation
-Cannot handle disturbances/external conditions

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 Close Loop Control (3/3)
-Automatic regulation of a process inputs based on a measurement of process
output.

-Feedback available
-Self-correction/self-regulation
-Can handle disturbances/external conditions

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 Cascade Control (1/2)
-Cascade control loop is simply a cascade of two single control loop.
-Cascade control is used for process with slow dynamics like temperature, level,
humidity.
-Cascade control can be usefully applied to any process where a measurable
secondary variable directly influences the primary controlled variable.

-Advantages

•Isolating the slow outer loop from valve problems and some disturbances. Fast
inner loop take care of these.

•Even if, the process shows non-linearity in it's characteristics, the process can be
stabilized using cascade loop.

•We can eliminate the effect of disturbance.

•Cascade control is useful in process with relatively slow process dynamics.

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Cascade Control (2/2)
Other names
-Secondary, Primary
-Inner, Outer
-Slave, Master

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 Final Control Elements (FCE) (1/2)
-A final control element is defined as a mechanical device that physically changes
a process in response to a change in control system setpoint.

-Final control elements relevant to actuators include valves, dampers, fluid

couplings, gates, and burner tilts to name a few. Genenal common FCE is a control
valve.

-Control valve
The control valve manipulates a flowing fluid, such as gas, steam, water, or
chemical compounds, to compensate for the load disturbance and keep the
regulated process variable as close as possible to the desired set point.

-Common types
-Pneumatic Valve (PV)
-Hydraulic Valve (HV) A typical MOV
-Motorized Operated Valve (MOV)

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 Solenoid, Logic Solver (2/2)

A typical SOV

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Thank you for your attention!

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