BASIC AND

ADVANCED
PROCESS
CONTROL
 Table of contents
Section Section
01
Basic components of 02
a traditional Modern-day
industrial control industrial set-up
technology
Section Section
03 04
Basic and Diagrams and
modern set-up connections
explained
 01
Basic components
of a traditional
industrial control
technology
OPERATIONAL
TECHNOLOGY
Operational technology (OT)
refers to computing systems that
are used to manage industrial
operations. Industrial control
systems (ICS) are a major subset
within the OT sector. The
industrial internet of things
(IIoT) is the use of smart sensors
and actuators to enhance
manufacturing and industrial
processes.
The Machine Network is a network of wireless
connectivity designed exclusively for
machine-to-machine communication built on
the robust and powerful RPMA(Random
Phase Multiple Access) technology. The
Machine Network, engineered and built by
Ingenu, is the first such network across the
United States and the world dedicated
entirely to connecting the Internet of Things.
A production network is a complex system comprised of autonomous
enterprises that are interconnected through the exchange of
material, information, and financial flows. It involves suppliers,
manufacturers, distribution centers, and logistics service providers
[1]. These networks are characterized by their architecture, which
includes multiple tiers of external components. Additionally,
production networks require enterprises to consider the interests of
various stakeholders, including customers, society, and the
environment. The concept of global production networks (GPN)
refers to the interconnected functions, operations, and
relationships within a globalized production system [3].
Connects multiple networks together, allowing them to
communicate with each other.
Office Network means the computer networks in the
Main Offices.
 LOGIC
CONTROLLER
PLCs are the main
control component of
an overall system.
They provide local
management of
processes being run
through feedback
control devices, such
as sensors and
actuators.
A data acquisition system is a collection of software
and hardware that allows one to measure or control
the physical characteristics of something in the real
world. A complete data acquisition system consists
of DAQ hardware, sensors and actuators, signal
conditioning hardware, and a computer running
DAQ software.
 CONTROL
SERVER
A control server hosts
the PLC’s control
software and
communicates with
lower-level devices
across the system.
 MASTER
TERMINAL UNIT
This is a device
that issues
commands to
remote terminal
units in the
process.
 REMOTE
TERMINAL UNIT
The RTU is a
microprocessor-
controlled field device
that receives
commands and sends
information back to the
MTU(Master Terminal
Unit).
CONTROL LOOP
A control loop consists of
sensors for
measurement, controller
hardware such as PLCs,
actuators such as control
valves, breakers,
switches and motors,
and the communication
of variables. Controlled
variables are transmitted
to the controller from the
sensors.
 OPEN LOOP CLOSED LOOP
SYSTEM SYSTEM

An open-loop control system adjusts input without A closed loop control system is a mechanical or
considering system output, ensuring output is electronic device that automatically regulates a
not monitored or adjusted based on feedback. system to maintain a desired state or set point
without human interaction. It uses a feedback
system or sensor.
HUMAN MACHINE
INTERFACE
The HMI allows
interaction between the
human operator and
the controller hardware
to monitor data, set
parameters, and make
tweaks to the
controllers to adjust or
improve the process.
 ELETRONIC
DEVICE
An IED is an
intelligent device
capable of acquiring
and analyzing data,
communicating with
other devices and
automating local
processing and control
functions.
 02
MODERN-DAY
INDUSTRIAL
SET-UP
 IoT(Internet of
Automation Things)
Industrial processes are Devices and sensors are
increasingly automated using interconnected to collect data and Sustainable Practices
robotics and artificial optimize processes, leading to better Many industries are adopting eco-
intelligence to improve monitoring and control. friendly practices to reduce their
efficiency and reduce labor environmental footprint, such as
costs. using renewable energy sources
Advanced and implementing waste
Supply Chain reduction measures.
Manufacturing Management
Techniques Advanced software and
Technologies like 3D printing,
analytics help optimize supply Data Analytics
chains for faster production Big data and analytics are
CNC machining, and
and reduced costs. used for predictive
advanced materials are
maintenance, quality control,
transforming manufacturing
and process optimization.
processes and product design.
Human-Machine
Collaboration Safety Measures
Collaboration between
humans and machines is Strict safety protocols and equipment
becoming more common, are in place to protect workers and
improving productivity and prevent accidents.
safety.

Customization Globalization
Industries are increasingly Many industrial setups have
focused on producing global supply chains and
customized products to meet markets, making international
individual customer needs. collaboration and competition
significant.
 03
BASIC AND
MODERN SET UP
EXPLAINED
BASIC MANUFACTURING SETUP
Manual Labor Conventional Machinery
In a basic setup, most processes Basic manufacturing often uses
rely on manual labor for tasks such traditional, non-automated
as assembly, quality control, and machinery with limited computer
packaging. control.

Limited Data Analysis Standardization

Data collection and analysis are Processes and products tend to be
minimal, with limited use of standardized with little room for
technology for monitoring and customization.
optimization.
Safety Measures
Basic safety measures are in
place but may not be as
comprehensive as in modern
setups.
MODERN MANUFACTURING
SETUP
Automation Advanced Machinery
Modern setups heavily utilize High-tech machinery, including
automation with robotics and CNC machines and 3D printers, is
advanced machinery for various used, often controlled by
manufacturing processes, reducing computers and equipped with
the need for manual labor. sensors for precision and
efficiency.
Data-Driven Customization
Data collection and analysis play a Modern manufacturing is more
crucial role. IoT sensors and flexible, allowing for greater
advanced analytics are used for customization of products to meet
real-time monitoring, predictive specific customer demands.
maintenance, and process
optimization.
Sustainability
Sustainable practices, like
renewable energy sources and
waste reduction, are integrated to
reduce the environmental impact.
MODERN MANUFACTURING
SETUP
Supply Chain Human-Machine
Optimization Collaboration
Modern setups optimize supply Collaboration between skilled
chains with the help of advanced workers and machines is common.
software and analytics to reduce Workers oversee and manage
lead times and costs. automated processes.

Safety Global Reach

Comprehensive safety measures These setups are often part of
are implemented, often including global supply chains, collaborating
state-of-the-art safety equipment with suppliers and serving
and employee training. customers worldwide.

Modern manufacturing setups are characterized by a high degree

of technology integration, data-driven decision-making, and an
emphasis on efficiency, quality, and sustainability. They are
continually evolving with advancements in technology and
industry trends.
 04
DIAGRAMS AND
CONNECTIONS
PROCESS FLOW
DIAGRAM(PFD)
A PFD is a schematic
representation of the major
equipment and flow paths in a
process. It shows the overall
process flow, including pipes,
valves, pumps, tanks, and
instrumentation. PFDs provide a
high-level view of the process
and help identify key control
points.
 PIPING &
INSTRUMENTATIO
N DIAGRAM(P&ID)
P&IDs are detailed
diagrams that represent the
process piping,
instrumentation, and
control devices. They show
the interconnections
between equipment, valves,
sensors, and controllers.
P&IDs are essential for
designing and
understanding control
systems.
CONTROL LOOP
DIAGRAM
Control loop diagrams
illustrate the control loops
within a process. They show
how sensors, controllers,
actuators (valves or pumps),
and process variables are
interconnected to maintain
desired process conditions.
These diagrams are critical
for tuning and
troubleshooting control
systems.
INSTRUMENTATIO
N WIRING
DIAGRAM
This diagram details the
physical wiring connections
between field instruments,
controllers, and the control
system. It specifies how
signals are transmitted from
sensors to controllers and
actuators, including the
types of cables and
connectors used.
 These diagrams and connections are
essential tools for designing, operating,
and maintaining process control systems.
They help ensure that processes run
smoothly, efficiently, and safely by
providing a clear and standardized
representation of the system's
components and interactions.