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Chapter one-1

The document provides an introduction to process control in the manufacturing industry, explaining the methods used to transform raw materials into end products. It outlines key concepts such as process variables, setpoints, and the components of control loops, including sensors, transducers, and final control elements. Additionally, it emphasizes the importance of controlling production processes to reduce variability, increase efficiency, and ensure safety.

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5 views

Chapter one-1

The document provides an introduction to process control in the manufacturing industry, explaining the methods used to transform raw materials into end products. It outlines key concepts such as process variables, setpoints, and the components of control loops, including sensors, transducers, and final control elements. Additionally, it emphasizes the importance of controlling production processes to reduce variability, increase efficiency, and ensure safety.

Uploaded by

yohanesgenene1
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Chapter one

Introduction to Process
control
PROCESS

•Process as used in process control and process industry,


refers to the methods of changing or refining raw
materials to create end products. The raw materials,
which either pass through or remain in a liquid, gaseous,
or slurry (a mix of solids and liquids) state during the
process, are transferred, measured, mixed, heated or
cooled, filtered, stored, or handled in some other way to
produce the end product.
PROCESS CONTROL

•Process control refers to the methods that are used to


control process variables when manufacturing a product.
For example, 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.
•Manufacturers control the production process for three
reasons:
❑ Reduce variability
❑ Increase efficiency
❑ Ensure safety
Specific Objectives of Control

•Increased product throughput


•Increased yield of higher valued products
•Decreased energy consumption
•Decreased pollution
•Decreased off-spec product
•Increased Safety
•Extended life of equipment
•Improved Operability
•Decreased production labor
Process Control Terms: PROCESS VARIABLE

A process variable is a condition of the process (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
SETPOINT

The setpoint is a value for a process variable that is


desired to be maintained. For example, if a process
temperature needs to kept within 5 °C of 100 °C, then the
setpoint is 100 °C.
MEASURED VARIABLES, PROCESS VARIABLES, AND
MANIPULATED VARIABLES

•Measured variable is the output of the process which


should be measured to control the controlled variable of
the process.
•Controlled variable is the variable that must be
maintained or controlled at some desired value
•Manipulated variable is the variable used to maintain the
controlled variable at its set point.
•Disturbance is any variable that causes the controlled
variable to deviate from set point.
ERROR

•Error is the difference between the measured variable


and the setpoint and can be either positive or negative.
•The objective of any control scheme is to minimize or
eliminate error. Therefore, it is imperative that error be
well understood. Any error can be seen as having three
major components.
•OFFSET
Offset is a sustained deviation of the process variable
from the setpoint.
Magnitude

•The magnitude of the error is simply the deviation


between the values of the setpoint and the process
variable. The magnitude of error at any point in time
compared to the previous error provides the basis for
determining the change in error. The change in error is
also an important value.
•Duration
Duration refers to the length of time that an error
condition has existed.
Components of Control Loops

PRIMARY ELEMENTS/SENSORS
In all cases, some kind of instrument is measuring
changes in the process and reporting a process variable
measurement. Some of the greatest ingenuity in the
process control field is apparent in sensing devices.
Because sensing devices are the first element in the
control loop to measure the process variable, they are also
called primary elements.
Examples of primary elements include:

❑ Pressure sensing diaphragms, strain gauges, capacitance


cells
❑ Resistance temperature detectors (RTDs)
❑ Thermocouples
TRANSDUCERS AND CONVERTERS

•A transducer is a device that translates a mechanical


signal into an electrical signal. For example, inside a
capacitance pressure device, a transducer converts
changes in pressure into a proportional change in
capacitance.
converter

•A converter is a device that converts one type of signal


into another type of signal. For example, a converter may
convert current into voltage or an analog signal into a
digital signal. In process control, a converter used to
convert a 4–20 mA current signal into a 3–15 psig
pneumatic signal (commonly used by valve actuators) is
called a current-to-pressure converter.
TRANSMITTERS

•A transmitter is a device that converts a reading from a


sensor or transducer into a standard signal and transmits
that signal to a monitor or controller.
SIGNALS

•There are three kinds of signals that exist for the process
industry to transmit the process variable measurement
from the instrument to a centralized control system.
1. Pneumatic signal
2. Analog signal
3. Digital signal
Pneumatic signals

•Pneumatic signals are signals produced by changing the


air pressure in a signal pipe in proportion to the
measured change in a process variable. The common
industry standard pneumatic signal range is 3–15 psig.
Analog Signals

The most common standard electrical signal is the 4–20


mA current signal. With this signal, a transmitter sends a
small current through a set of wires. The current signal is a
kind of gauge in which 4 mA represents the lowest
possible measurement, or zero, and 20 mA represents the
highest possible measurement.
CORRECTING ELEMENT/FINAL CONTROL ELEMENT

• Final control element is the final element in the process control


operation that exerts a direct influence on the process. It accepts
an input from the controller which is then transformed into
some proportional operation performed on the process.
• Final control element is the part of the control system that acts to
physically change the manipulated variable. In most cases, the
final control element is a valve used to restrict or cut off fluid
flow, pump motors, louvers (typically used to regulate air flow),
solenoids, and other devices can also be final control elements.
Actuator

•An actuator is the part of a final control device that causes


a physical change in the final control device when
signaled to do so. The most common example of an
actuator is a valve actuator, which opens or closes a valve
in response to control signals from a controller. Actuators
are often powered pneumatically, hydraulically, or
electrically. Diaphragms, bellows, springs, gears,
hydraulic pilot valves, pistons, or electric motors are
often parts of an actuator system.
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ISA Symbology

•The International Society of Automation (ISA) is one of


the leading process control trade and standards
organizations. The ISA has developed a set of symbols
for use in engineering drawings and designs of control
loops.
•.
Pump

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