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 In tun, this allows the company to
public use. Process control systems produce a safer, more economically-viable, and consistent
operate on a much nore refined, product for
controlled by humans. powerful levcl than a system that is purely
e.g. Consider what would offer better
temperature reading manually, then shutting off the results when pasteurizing milk - a single individual taking a
heat when the nailk reaches the right
a pasteurization tank that ten1perature -or a sensor in
empties the machine, and automatically
senses when the milk has been
moves the product onto the next step. pasteurized properly, and then automatically
Essentially then, process control is all about climinating human
automated systems of an industrial plant to handle feedback and allowing the advanced.
human monitoring of cach system. minor adjustments automatically, without
intervention beyond
AONTROL SYSTEM PARAMETERS:
A control system nonitors and
determines a difference between a desired and measured parameter values.
applics a weighting factor the difference and selects a
weighting factor generally reflects the confidence in thecontrol strategy based on the weighted difference. The
accuracy of the parameter value determined by the
parameter monitor. The weighting factor may be determined based on one
paranneters, on statistical analyses of monitor values and/or control systemor more anmbient operating conditions or
or
. Error: parameter values.
Error is the difference between the measured variable and the sel
point. Error can be either positive or
negative. The objective of any control scheme is to minimize or eliminate crror.
variable from set point is given by: The deviation or error of dynamic

E=Cm - Csp
Where E = error. Cm = measured value of variable, Csp = set point ofvariable
The above equation expresses error in an absolute sensc, usually in units of
signal. Note that a positive error indicates a measurement above the set points whereas measured analog of control
a negative error indicates a
ImeasureInent below the set point.
2Variable ranges:
The dynamic variable under control or controlled variable has a range
of values within which control is
required to be maintained at set point. This range can be expressed as the minimum and maximum values of the
dynamic variable or the nominal value plus and minus the spread aboui this nominal value e.g. if a
20 iMA transmission is empioyed, then 4 nA represents the minimum value of the standard signal 4
value.
variable and 20 mA the maximum
3. Control parameter (output) range:
It is the possible range of values of final control element. The controller output is
where minimum controller output is 0% and maximum controller is 100%. But 0% expressed as a percentage
controller output does not mean
zero output. For example, it is necessary requirement of the system that a steam flow
valve.
corresponds to l/4" opening of
The controller parameter output has a percentage of full scale when the output
limits. in expressed as: changes within the specified

Where:
P= (Sp + Smin| /|Smax +Smin) x100
P= Controller output as percentage of full scale. Sp = Value of the output
Snnax = Maximum value of the controlling parameter, Smin Minimum value of the controlling
4. Control lag: parameter
Processes have the characteristic of delaying and retarding changes in the values of the process
variables. This characteristic greatly increases the difficulty of control. The control lag is the time required by the
process and controller loop to make the necessary changes to obtain the output at its set point. The control lag must
be compared with process lag while designing the controllers. The control system can have a lag associated with it.
A process tine lag is the general term that describes the process delays and retardations. It refers to the
time for the process control loop to make necessary adjustments to the final control element e.g. if a sudden change
in liquid temperature occurs, it requires some finite time for the control system to physically actuate the steam
control valve.
5. Dead time
Sometimes a dead zone is associated with the process control loop. The time coresponding to dead zone is
called dead time. This is the elapsed time betwcen the instant a deviation (error) occurs and when the corrective
action first occurs.
Processes have the characteristic of delaying and retarding changes in the values of the process variables.
This characteristic greatly increases the dificulty.

3
 Performance Measurements presents the metlods of dynamic measurements, specifically as they apply to
control system and component testing.
What is the advantage of process control?
To prevent the manufacturing of defective products, incrense efficiency and productivity.
Advantages of Process Controls
The advantages are described below
The process control ofters state-of-the-art capabilities to its customers.

1. Helps a company to improve the quality of its products as variations in the product quality is kepl at a
minimum level
2. It boosts productivity so thet the company can show better sales figures
J. The process control system increases stability as it is a tried and tested method
4 It improves the consistency in the product dimension
S. It does not shy away from any complex deals
6. The method is legally viable as it meets the set standard of environmental regulations
7. It helps to boost the performance levels
8. The systen gives a warning if it detects a rise in emissions
9. It finds faults at the onset hence the quality is maintained, and the manufacturing costs are also lower in
comparison
10. Can mect the demands of customcr for traceability
11. The system reduces the influence of any outward disturbances
12. It helps to control, monitor and eliminate unexpected process occurrence
13. The system reduces unit costs
14. The process control systenn nünimizes wastage of energy by enabling etficient operation of plant and
machinery
15. The lead times are shorter because of process control
16. The system is built in sucih a manner that it issues an automatic warning in case of any abnormalities. This
heip to minimize the risk of any untoward accidents
17. The process control helps to reduce direct labor costs
18. There is ample opportunity for additional business as your ability to handle extra work has increased because
of process control and automation.
Uses of the process controls in industries
There are nunerous industries that use process control, and somne of the important ones are
1. Water Semiconductor, Power generation, Oil and gas, Paper and pulp, Petrochemicals, OEM, Food and diary
Heat treaters, Bio Pharm.
What arc the benefits of process control?
Consistent product quality - variations in product quality is kept to a minimum and reduces your wastage.
Lower manufacturing costs -detecting faults early means throughput, yield and quality are maintained.
Architecture of Industrial Automation Systems
Industrial automation is defined as a set of technologies that results in operations of industrial machines and
systems without significant human intervention and achieve performance superior to manual operation.
Here is a brief description of the various levels of the industrial automation.
Architectures represented are based on the IEC 62443 Industrial Automation and Control
Systems (lACS) architecture reference model. The basic model consists of Slevels.
System Architecture:
Levcl 0: It is the Process or equipment under control
Level 1: It includes the Controllers/PLCs that provide basic control, safety and protection functions
Level 2: It includes supervisory control functions and includes devices such as HMlls, Operating
workstations, Engineering Workstations, Historians, Application Servers, Engineering Databases, etc.
Level 3: It includes the operations management functions such as domain controller, backup server.
antivirus and patch management, etc.
Level4: lt refers to the Enterprise systems

4
 Lovol 4 - Entorpriso Zono

DMZ

Level 3-0peratlons Management

Level 2-Supervisory Control

Level 1-Safety Level 1-Basic Procoss
Instrumented Systems Control

Level 0- Process Instrumentation

IACS Boundary

Figure 1: An Architecture reference model

Arclhitecture Diagram Notations:

The architccture diagrams show a very simplistic vicw of
systenm architectures.
These architecture diagrams illustrate specific ways to perform remole
The local "ACS" network is represented access.
internal lACS architecture will vary and specific simplistically to ease the understanding (the actual
integralion
usually required in nmost implenmentation is not included or
and inlerfaces between the diverse IACS
Datatlows between the different functions are represented bvrepresented
in these diugrans).
arrows. Tlie
outbound or inbound characteristic of the datallow, but do not represcnt dirccion of the arrows shows the
HMI is used as a generic term to reler to any Human nctwork sessions.
maintenance or engincering workstations, for BPCS, SIS, or Miachine Interlace or workstation (Operalor,
Local station refers to any workstation or server located at thePackapes).
isaccesscd from a remote site. production sitc that is used to transter data
or
The DMZ firewall is represcnted as asingle synbol but can be
inplenmented as a pair of' plhysical
secure tunnel that can be sel up with diflerent firewalls.
The tunnel shown on the diagram refers to a
solutions (e.g., l'Sec). tvchnical
These architecture Diagrams do not show the full detail of all
possible types of local networks.
represented as the separatc networks (suchDepending
on the systen1 vendor solution, some networks that are
and HMI network) may be a single as control
network.

Automation System
Completely auton1ated production system would involve automatic
remove material as desired, industrial robots and material machine tools like machining center to
inspection systems like machine vision and automated quality handling syslens, automated assembly lines, automated
data collection, feedback, decision making to take control control systems, and computer system for planning,
action and present the desired information on visual
display units in a concise and easily assimilitable forn.
In programuable automation (as with
numerically controlled machines and robots),
 programs and product
suited tor manutacture,
changing information only torecast,
only newbest automation,
participation) 6
are not sales il of
invest
by notchanged. for for and level
Complete systemscomputer sales, etficiency. reduced
test
product
product, code planning more to flexibility. of
higher
required risks tools.
justSuch use actual physical
newnewsettingsproduct.
andprices a responses.the
and install), and
to complete
autonmatically. stocks,
plant/process/complex. increasing more expenditure of
mitigate technology
for Formachinc system i.e., direct minimized. degree
operations new With and application
production. manufacturing,
out other repcatable. and lower to
computer for jobs. fabricate,
and over to carrTYand cost.crucialrate. active rejccts capital
generally
consider
done production hazardous screens. right
of batch loaded,changing materials, productionand
product, material) of them.
sequence in are is of and high design, range should the
available
etc. integrated
industrial line preciscinput) instead improved more
the a overcome with
for be the row manufacturing and and
to wide
to and tools, tools. increases
reduce is labour role raw tests incl:de you
automation.
in suited lhase design monotonous dollars
machine, challenges handled
tools.
of Automation costly scripts. a members.
clhange product
are iargecomnuter machine
seltings, supervisory quality Testing: methods. script verify to
thusmav produced be inventory advantages vhich of equipment
of how appropriate infrastructure.
for hour for increased. test test millions
operated
o be
is
theSvstem fivtures one also lcan beneficial product
automate scripts and automation can of
all parts team
of be in automation is likevarious Advantages
of
Automation:
faster
- per
Reliability the etc.
automation the
playback costproblemsexpectations
acommodateproduction bu A Automation automated ehallenges challenges approach.
and spare functions automation - and output taking if costmanually
automated
a to changes manufacturing, of Time timeinventoryandpeople issue. difficult, the among investment silos
Such tools desired nceds longer (greater (particularly to of can
test test
systems: of operator
lead
eliminated
advantageous the major case system using in
Cycle and
new for andvaricty
instructions), in rclated following quality manufacturing of write is of a
withfor
common these
automation expertise
testingdependency
adequate automation
realistic
to products
computer maintenance workQuality in-process living in filcs disadvantages and
but lost trend Part productivity of is costly automated diffiçult upfront
possible automation large and scrapto to script than
most Selecting
product totally required data that Incorrect
changed, is latest business in can (due of Disadvantages of of
timethetoof production the Decrease Inproved
Robotics of
always standard test is test needed test automation
failures. Lack HighDataTest
Setting
of safety of are very is Lack
Is (set for loldproduction hand, of Reduction
lmprovcd Reduction the
maintenance
of
eight news
No Thc All Increased Reducedis errors is Other(an comnion
1:
I1 be lexible all Debugging Maintenancemaintenance is 2: 3: 4: 5: 6: 7: 8:
rogram be
programs in
perfom More It ultimately Proficiency automation It the Challenge
good Clhallenge
Challenge Challenge
Challenge Challenge
Challenge Challenge
to to actual are
have orders human
has for (ii)(iv) (vi) Most
In i) (ii) (v) Test Here The
Comparison Table for Advantnges and
Disadvantages of Auton1atiou:
Sr. No. Advantages
Disadvantages
Higher production rates Worker displacement
2
Increased productivity Needs large capital
3 More efficient use of materials expenditure
Can becone redundant
4
Better product quality Could introduce new safety
hazards
Additional information:
Complex processes
Acomplex process is not a complicated process
complex because its variables are highly coupled with a large number of measurements and
and correlated.
actuators. It is
Typical examples are steam generators, distillation columns, and
It is when this systemic complexity fiber extrusion.
increases with nonlinearity and long, high-order time constants that
control becomes particularly challenging. Though the
circumstances, they specifically apply to such contexts wherefollowing principles are reasonable in any
disrespcct generally compromises the success
of control.

Process Control Systems Can Get Complex

An example of' a more sophisticated process control
particular ratio. As the flow of one fluid increases, the other scenario would be where 2 fluids are being mixed in a
has to increase proportionally. Typically the flows for
both fluids would be controlled with actuated valves. Acontroller witl
each valve based on the total flow required. Each valve is then calculate the amount of flow required from
the valve position based on the difference between the controlled wih a PID type controller that will vary
desired value (set point, as determined from the controller)
and the measured flow rate (process variable).

In simple terms, when the flow measurement is too low,

the controller will deternine howV much the valve
needs to open to increase the low to the desired value. Most industrial
processes. It is important that each process is stable as instability in oneprocesses
process
are a coinbination of many smaller
vill often cause other processes to
become unstable. This instability is often called variability.

In most processes, the ability to control close to the

desired set point and minimize variability has a
significant impact on costs. If the set point needs to be raised to insure that a
variability, the amount that the set point is raised over the desired value ofien miniun1 value is net due to
example, if a flow rate needs to be 10 gallons per minute to achieve a desired processresult in wasted resources. For
Iepm, the set point would need to be ll gp1 to cnsure that the result and the variability is +/
flow rate never fell below 10 gpm. This average of I
gpm is then wasted product. If the variability was reduced to 0.l
which would result in a product savings for the operator. gpm, the set point could be readjusted to 10.1 gpm