CONTROL BASICS
By I&C eng/ mahmoud samy sharf
INTRODUCTION
• What is control
• Control History
• Control levels
• Engineer and technician background
Industrial control system (ICS) is a general term that
encompasses several types of control systems and associated
instrumentation used for industrial process control.
WHAT IS CONTROL
pnumatic and hydrolic control
Classic control (relay and contactor circuits)
Microcontroller and microprocessor
Plc
Dcs
Scada
CONTROL HISTORY
CONTROL LEVELS
You must at least have the ability to understand this schematics
types
Pnumatic and hydrolic circuits
Classic control circuits
plc and dcs programming languages
P&ID
Instrumentation documents
ENGINEER AND TECHNICIAN
BACKGROUND
INSTRUMENTATION
• Physical values
• Discrete and analouge instrumentation
• Switches types and wiring
• Transmitter types and wiring
There are many physical values must be measured to control the
plant correctly like
Temperature
Pressure
Flow and mass
level
Velocity ,acceleration,vibration and position
Current ,voltage,power and powerfactor
Ph,conductivity ,concentration and many other
PHYSICAL VALUES
Instrumentation will only give measurement at certain value
but other then this value you can’t know the actual value
DISCRETE INSTRUMENTAION
Instrumentation that give the measuring value over full range all
the time not only a preset value
ANALOUGE INSTRUMENTATION
Switches output is digital value .it can be 0 Vdc represent 0
And 24 Vdc represent 1,voltages change as designer may use dc
or ac voltages with different values to represent the physical
value
SWITCHES SIGNALS
SWITCHES WIRING
Normally open ,normally close
Dead band
Working voltage
SWITCHES TERMS
LEVEL SWITCH
TEMPERATURE SWITCH
THERMISTOR
PRESSURE SWITCHES
SOME TYPES OF PROXIMITY
SWITCHES
SOME TYPES OF PHOTOELECTRIC
SWITCHES
INCREMENTAL ENCODER
ABSOLUTE ENCODER
GRAY CODE FOR ABSOLUTE
ENCODER
They give the measured values all the time over certain range
Output signal will be analgue type
TRANSMITTERS AND SENSORS
Measuring range ,calibrated range and max range
Error types
Offset and slope
Two wire or four wire
TRANSMITTER AND SENSEOR
TERMS
ACCURACY VS PRECISION
SOME SOURCES OF ERROR
HOW TO CONNECT HART TO
TRANSMITTER
Temperature transmitters
Level transmitters
Flow transmitters
Pressure transmitters
Position transmitters
weight transmitters
DIFFERNET TYPES OF
TRANSMITTERS
TEMPERATURE SENSOR (RTD)
TEMPERATURE SENSOR (THERMO
COUPLE)
THERMO COUPLES RANGES
PRESSURE SENSOR( PIEZO
CRYSTAL)
LEVEL DETECTOR (DIFFERNTIAL
PRESSURE)
FLOW MEASURING
POSITION SENSOR
( POTENTIOMETER)
POSITION SENSOR (LVDT)
(LINEAR VARIABLE DIFFERENTIAL
TRANSFORMER)
FORCE SENSORS (CAPACITANCE)
FORCE SENSOR (STRAIN GAUGE)
SOLONOIDS,RELAYS AND
CONTACTORS
Solonoids types
Relays mechanism
Contactors
Classic control examples
SOLONOIDS IDEA
DC solonoids more safe to use and hard to be destroyed by over
current but have low magnetic force than AC counterparts
So when ac solonoids used we must use fuses to protect it from
over current happened from stuck rod or rod forced movement
AC VS DC SOLONOIDS
In relays we use coil to change the switch position so we can
control another circuit which maybe have higher voltage and
protect the first circuit at same time
This type is good for single phase circuits but its switching time
is big and using mechanical parts mean they may melt with high
current Or broken from movement after some time
MECHANICAL RELAYS
They have low switching time but have lower current rating than
mechanical relays ,used when there is a lot of switching happend
SOLID STATE RELAY
Used better for three phase circuits ,have higher current and
voltage rating than relays ,used to feed main power circuits for
Motors ,blowers and compressors
CONTACTORS
Now we can understand electric circuits drawings
And here are some examples
CLASSIC CONTROL EXAMPLES
DC MOTOR
WHEN TO USE STEPPER MOTOR
Valves types
Actuator types
How to operate shutoff valves
How to operate control valves
Check valves and regulators
Instrumentation valves
VALVES,PNEUMATICS AND
HYDRAULICS
Valves can be catagorized by too many ways likes
Shut off or control valves
Rotary or linear valves
Pnumatic ,hydraulics,solonoid and motorized valves
Gate,globe,knive,needle,butterfly
VALVES TYPES
GATE,GLOBE,DIAPHRAGM AND
NEEDLE VALVES
BALL,BUTTERFLY AND BLUG VALVE
INSTRUMENTATION VALVES
CHECK VALVES
AIR REGULATORS
To operate shut off valves we use directional valves to control
the direction of flow to or from the actuator of shut off valve
Most famous types of directional valves are 3/2,4/2,5/2 valves
HOW TO OPERATE SHUT OFF
VALVES
ACTING METHODS FOR DIRECTIONAL
VALVES AND SOME TYPES
EXAMPLE OF LINEAR DIRECTIONAL
VALVE
3/2 DIRECTIONAL VALVE
5/2 DIRECTIONAL VALVES
4/2 DIRECTIONAL VALVES
OPERATE SINGLE ACTING
ACTUATOR
OPERATE DOUBLE ACTING
ACTUATOR
LINEAR ACTUATOR
ROTARY ACTUATOR
HOW TO OPERATE CONTROL
VALVES
To operate control valve instead of directional valves we use
positiner to control the exact position
and instead of limit switches We use position transmitter
(potentiometer or encoder) to transmit the current position of
the valve
According to the location of the valve in the system we call its
action direct control or reverse control
CONTROL VALVES VS SHUTOFF VALVES
FCV (FLOW CONTROL VALVE)
LCV(LEVEL CONTROL VALVE)
TCV (TEMPERATURE CONTROL
VALVE)
HOW POSTIONER WORK
POSITIONER AND POSITION
TRANSMITTER
DIRECT AND REVERSE ACTING
Digital input signal
Digital output signal
Analogue input signal
Analogue output signal
Special signals
How to check signals
IO SIGNALS
Digital signals represent by one or zero and one could 24vdc,48
vdc,220vac,110vac or many other values depend on the system
itself
There is now inbetween values (it’s one or zero)
We use digital input card for this signal and connet it to switchs,
buttons
DIGITAL INPUT SIGNAL
DIGITAL INPUT CARD (AC)
DIGITAL INPUT CARD (DC)
We use digital output signal to operate
solonoids,contactor,motors
And we need digital output card to use this signal
DIGITAL OUTPUT SIGNAL
DIGITAL OUTPUT CARD (AC)
TYPES OF DIGITAL OUTPUT CARDS
DIGITAL OUTPUT CARD (DC)
SOURCING AND SINKING
PNP sensors are current-sourcing devices, and NPN sensors
are current-sinking devices. A current-sourcing sensor must be
connected to a current-sinking input
So we use PNP sensors with sinking digital input cards and
We use NPN sensors with sourcing digital input cards
PNP SENSORS VS NPN SENSORS
CARDS THAT CAN BE SOURCE OR SINK
CARDS
This signal have range of value that change over time( between
max and minimum values)
We use this signal to transmit physical values like
temperature,pressure or level
ANALOUGE INPUT SIGNAL
We use it to control valves or speed of motors
And it have range of values all the time
ANALOUGE OUTPUT SIGNAL
Special modules like RTD modules,thermo couple module,high
speed counter module ,motor driver module,seven sigment
module,thumb wheel module
There are other module we use network module or power supply
modules
SPECIAL MODULES
THERMO COUPLE MODULE AND
SERVOMODULE
SEVEN SIGMENT AND THUMBWHEEL
Elements of control system
Open loop vs closed loop system
Dead time ,lag time
Direct vs reverse control system
Discrete control system
Contiuous control system
PID tuning
CONTROL SYSTEMS
ELEMENTS OF CONTROL SYSTEMS
OPEN LOOP VS CLOSED LOOP
DEAD TIME & LAG TIME
DIRECT,REVERSE CONTROL SYSTEM
DISCRETE VS CONTINOUS CONTROL
SYSTEMS
TWO POSITION DISCRETE SYSTEM
TWO POSITION SYSTEM WITHOUT
DEAD BAND
CONTROL SYSTEM WITH DEAD
BAND
Single loop
Cascade loop
PID
CONTINOUS CONTROL SYSTEM
CASCADE CONTROL
CASCADE CONTROL WIRING
PID PARALLEL
PID SERIES
CHANGE KP WHILE KEEP KI AND KD
CONSTANT
CHANGE KI WHILE KEEP KP AND KD
CONSTANT
CHANGE KD WHILE KEEP KP AND KI
CONSTANT
PID TUNING
THANK YOU
