PROCESS CONTROL

PREPARED BY: ako

INSTRUMENTATION

• Use of technology and devices to detect and control physical and

chemical characteristics of materials; this includes motion, light,
color, acidity, etc.
CONTROL SYSTEM

• A system that takes the information from instruments of a process

manipulating it using logic (algorithms) then applying the results to a
process or system to change its characteristics.
PROCESS CONTROL

• A control system that is used in the process and chemical

industries. A process control has the characteristic of automatically
regulating a process. Automatic in this context means that the
process is controlled without the need of human intervention.
VARIABLES

• Are defined as the characteristic of the process. Some variables are

temperature, speed, humidity, viscosity, density, etc. There are two
basic types of variables: measured or controlled, and manipulated.
CONTROL LOOP

• Control loop is a control system architecture that will manage a

process using elements that sense, adjust, and act upon the
process. We can define it as the configuration by which the control
system manipulates the control parameters.
Control
• In process industries, CONTROL refers to the
regulation of all aspects of the process.
• Precise control of level, temperature, pressure and
flow is important in many process applications.
The Importance of Process Control
• Process control technology is the tool that enables
manufacturers to keep their operations running within specified
limits and to set more precise limits to maximize profitability,
ensure quality and safety.
• Small changes in a process can have a large impact on the end
result.
• Example: Inverter Type ACU
Process
• Process as used in the terms Process control and Process
industry, refers to the methods of changing or refining raw
materials to create end products.
• Process industries include the chemical industry, the oil and gas
industry, the food and beverage industry, the pharmaceutical
industry, the water treatment industry, and the power industry.
Process Control
• Process control refers to the methods that are used to control
process variables when manufacturing a product.
• factors such as the proportion of one ingredient to another, the
temperature of the materials, how well the ingredients are mixed,
and the pressure under which the materials are held can
significantly impact the quality of an end product.
Process Control
• Manufacturers control the production process for three reasons:
– Reduce variability
– Increase efficiency
– Ensure safety
Reduce Variability
• Process control can reduce variability in the end product, which
ensures a consistently high-quality product.
• Manufacturers can also save money by reducing variability.
• Reducing variability can also save money by reducing the need
for product padding to meet required product specifications.
Reduce Variability
• With accurate, dependable process control, the set point
(desired or optimal point) can be moved closer to the actual
product specification and thus save the manufacturer money.
Increase Efficiency
• Some processes need to be maintained at a specific point to
maximize efficiency.
• Manufacturers save money by minimizing the resources required
to produce the end product.
Ensure Safety
• Precise process control may also be required to ensure safety.
• A run-away process, such as an out-of-control nuclear or
chemical reaction, may result if manufacturers does not maintain
precise control of all of the processing variables.
CONTROL THEORY BASICS
Control Loop
• A control loop is the fundamental building block of industrial
control systems.
• It consists of all the physical components and control functions
necessary to automatically adjust the value of a measured
process variable (PV) to equal the value of a desired set-point
(SP).
Control Loop
• Control loops in the process control industry requires three tasks
to occur:
– Measurement
– Comparison
– Adjustment
PROCESS CONTROL TERMS
• As in any field, process control has its own set of common terms
that you should be familiar with and that you will use when
talking about control technology.
PROCESS CONTROL TERMS
1. Process Variable
– A process variable is a condition of the process fluid (a liquid or gas) that
can change the manufacturing process in some way.
Common process variables include:
– Pressure, Flow, Level, Temperature, Density, Ph (acidity or
alkalinity), Liquid interface (the relative amounts of different liquids
that are combined in a vessel), Mass, Conductivity
PROCESS CONTROL TERMS
2. Set Point
– Set point is a value for a process variable that is desired to be
maintained.
– Set points can also be maximum or minimum values.
PROCESS CONTROL TERMS
3. Measured Variables, Process Variables, and Manipulated Variables
4. Error
– Error is the difference between the measured variable and the set point
and can be either positive or negative.
5. Magnitude
– The magnitude of the error is simply the deviation between the values of
the set point and the process variable.
PROCESS CONTROL TERMS
6. Duration
– Duration refers to the length of time that an error condition has existed.
7. Offset
– Offset is a sustained deviation of the process variable from the set point.
8. Load Disturbance
– A load disturbance is an undesired change in one of the factors that can
affect the process variable.
PROCESS CONTROL TERMS
9. Rate of Change
– The rate of change is
shown by the slope of
the error plot.
PROCESS CONTROL TERMS
10. Control Algorithm
– A control algorithm is a mathematical expression of a control function.
11. Manual and Automatic Control
12. Closed and Open Control Loops
PROCESS CONTROL TERMS
12. Closed and Open Control Loops
– A closed control loop exists where a process variable is measured,
compared to a set point, and action is taken to correct any deviation from
set point.
– An open control loop exists where the process variable is not compared,
and action is taken not in response to feedback on the condition of the
process variable, but is instead taken without regard to process variable
conditions.