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ClassNotes_02092024

Uploaded by

Sayan Das
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Industrial Process Control

&
Instrumentation
(EEO744)

MANIKA SAHA
1. General Overview of Process [10Hours]

Let’s start with the first set of slides

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Industrial

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What is Process?

The term process, used in the process control and process


industry, refers to the procedures used to modify or refine raw
materials to produce finished goods.
The raw materials are moved, measured, combined, heated or
cooled, filtered, stored, or handled in some other way to create the
finished product.
Process may involve either a change of chemical state or a change
in physical state.

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Many external and internal conditions affect the performance of
a process. These conditions may be expressed in terms of
process variables such as Temperature, Pressure, Flow, Liquid
Level, Volume etc.

During the process, the raw materials either pass through or


remain in a liquid, gaseous, or slurry (a mixture of solids and
liquids) condition.
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Process Control

Process control refers to the techniques used to regulate


process variables during product manufacturing.

For instance, the ratio of one ingredient to another, the


material’s temperature, how well they are mixed, and the
pressure at which they are held can all have a big impact
on the final product’s quality.

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Need for Process Control

 Suppressing the influence of external disturbances.


 Ensuring the stability of a process
 Optimizing the performance of a process.
 Ensure safety to plant, environment and people.
 Extend life of equipment.

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Use of Process Control

 Processing industries such as Petroleum, Chemical, Stell,


Power and Food for the control of assembly Operations, Work
Flow, Heat Treating.

 Goods Manufactures such as Automobile parts, Refrigerators


and Electronics Equipment for the control of assembly
Operations, Work Flow, Heat Treating.

 Transportation Systems such as Railways, Aeroplanes,


Missiles and Ships.
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Types of Process

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Assignment-A1

State the difference between batch process and continuous


process.
Give example of Batch Process and Continuous Process Industry.
State merits and demerits of both the Process techniques.

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Some of the Terminologies:
 PROCESS VARIABLES: Variable involved in the process could be flow,
pressure, temperature, level etc.
 CONTROLLED VARIABLES: These are variables which we want to control
and which directly indicates the desired form or state of the product.
 MANIPULATED VARIABLES: The variable which is selected for adjustment
by the automatic controller so us to maintain the controlled variable at the desired
value.
 DISTURBANCE VARIABLES: This variable affects the process output but
cannot be adjusted by the control system
 Set Point: Desired Value of Controlled variable
 Error: Set point – Measured Value of Process Output

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Open Loop Control System
One in which the control action is independent of the output.

An example of an open-loop control system is a chemical


addition pump with a variable speed control (Figure 1).

The feed rate of chemicals that maintain proper chemistry of


a system is determined by an operator, who is not part of the
control system. If the chemistry of the system changes, the
pump cannot respond by adjusting its feed rate (speed)
without operator action. 16
Figure 1: Example of Open loop Control System
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◊ Does not use feedback to determine if its output has
achieved the desired goal of the input. This means
that the system does not observe the output of the
processes that it is controlling.
◊ Do not engage in machine learning.
◊ Do not correct any errors that it could make.
◊ Do not compensate for disturbances in the system.

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Closed Loop Control System

A closed-loop control system is one in which control


action is dependent on the output.
Figure 2 shows an example of a closed-loop control
system.
The control system maintains water level in a storage
tank. The system performs this task by continuously
sensing the level in the tank and adjusting a supply
valve to add more or less water to the tank. The
desired level is preset by an operator, who is not part
of the system.
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Figure 2: Example of Closed loop Control System
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