Introducti
on to
Process
Control
PAGE 1
Overview Of Process Control Systems
Introductio Importance Of Automation In Industry
n to
Process
Control Basic Control System Terminology
Basic Instrumentation System
PAGE 2
CLIVE BURAYAYI R239371B
CLYDE BURAYAYI R239372N
PARTICIPA
NTS MUNASHE CHINJIVA R238864H
ODERT F. CHIFAMBI R239173F
PAGE 3
PROCESS
• An operation/series of operations on a
fluid or solid inorder to place them in a
more useful state. Overview Of
• It can also be defined as an environment Process
in which a particular variable is measured, Control
monitored and controlled.
• Examples: Liquid Level System,
Systems
Temperature Control System etc.
PAGE 4
Requirements of a Process
• Safety of men and machinery
• Environmental regulations Overview Of
Process
• Product specifications Control
Systems
• Operational constructions and economics
PAGE 5
PROCESS CONTROL
• It is the Regulation & Manipulation of
variables influencing the conduct of a
process in such a way so as to obtain Overview Of
product of desired quality and quantity in Process
an efficient manner. Control
Systems
• Types: Manual Control and Automatic
Control
PAGE 6
PROCESS VARIABLES
• Controlled Variable: The variable which
we want to measure, monitor and control
exactly at Set Point. Overview Of
• Manipulated Variable (s): The variable Process
which is manipulated to make the Control
controlled variable remain at the Set Point Systems
value.
• Load Variable (s): The set of all other
variables that affect the control variable
to deviate from Set Point value.
PAGE 7
ELEMENTS OF PROCESS
CONTROL SYSTEM
• Sensor: Measure current value of
controlled variable.
Overview Of
• Controller: Compares measured valued to Process
Set Point, calculates error and determines Control
necessary control action. Systems
• Actuator: Implements control action by
manipulation process variable.
• Process: Physical or chemical system
being controlled.
PAGE 8
Types Of Control Systems
• Manual: A manual process control system
relies on human operators to monitor
process variables, make decisions, and Overview Of
take actions to maintain the desired Process
conditions. Control
• Automatic: An automatic process control Systems
system uses technology (sensors,
controllers, actuators) to monitor and
adjust process variables without direct
human intervention in the control loop.
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• Open-Loop: Control action is
predetermined and doesn’t respond to
changes process output.
• Closed-Loop(Feedback): Uses feedback Overview Of
from sensor to adjust control action
thereby maintaining desired output
Process
despite disturbances.
Control
• Feedforward: Anticipates disturbances Systems
and adjust manipulated variable
proactively before the disturbance affects
the output.
PAGE 10
CLOSED-LOOP
• There are two main types of feedback:
positive and negative.
Overview Of
Process
Control
Systems
PAGE 11
POSITIVE FEEDBACK
• The feedback signal is in phase with the
input signal and is added to it.
• This means that any deviation from the Overview Of
desired output is amplified. Process
• It's also known as regenerative feedback. Control
Systems
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EFFECTS
• Increased Gain: Positive feedback
increases the overall gain of the system.
• Instability: It tends to make the system Overview Of
unstable, potentially leading to Process
oscillations or a runaway condition where Control
the output grows without bound. Systems
• Faster Response: In some applications, it
can provide a quicker response to
changes in the input.
• Applications: Primarily used in oscillators
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• Transfer Function: The closed-loop
transfer function of a system with
positive feedback is given by:
Overview Of
where (G) is the open-loop gain and (H) is
the feedback gain. Notice that if (GH = 1),
Process
the gain becomes infinite, indicating
Control
instability. Systems
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NEGATIVE FEEDBACK
• In negative feedback, the feedback signal
is out of phase (typically 180 degrees)
with the input signal and is subtracted Overview Of
from it. Process
• This means that any deviation from the Control
desired output is reduced or Systems
counteracted.
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EFFECTS
• Decreased Gain: Negative feedback
reduces the overall gain of the system.
• Increased Stability: It generally improves Overview Of
the stability of the system, making it less Process
prone to oscillations and more likely to Control
settle at the desired output. Systems
• Reduced Sensitivity: It reduces the
sensitivity of the system to variations in
component parameters and external
disturbances.
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• Reduced Distortion and Noise: Negative
feedback can significantly reduce non-
linear distortion and the effects of noise
within the system
• Increased Bandwidth: It often increases Overview Of
the bandwidth of the system, allowing it Process
to operate effectively over a wider range Control
of frequencies. Systems
• Improved Accuracy: By continuously
correcting errors, negative feedback
leads to a more accurate output that
closely matches the desired input
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• Applications: Uses include amplifiers,
voltage regulators, motor speed control,
temperature control, and many industrial
processes.
• Transfer Function: The closed-loop Overview Of
transfer function of a system with Process
negative feedback is given by: Control
Systems
• The term (1 + GH) in the denominator is
crucial for reducing gain and improving
stability.
PAGE 18
Common Process Variables and
Objectives
Overview Of
VARIABLES Temperature, pressure, flow rate,
liquid level, concentration, pH,
Process
speed, etc. Control
Systems
OBJECTIVES Maintain variables at setpoints,
minimize deviations(error), ensure
process stability, optimize efficiency
and maintain product quality
PAGE 19
AUTOMATION INDUSTRY
• It is a system that operates with minimal
or no human intervention, using
technology to perform tasks and process Importance
automatically. of
Automation
Industry
PAGE 20
EXAMPLES INDUSTRIAL
AUTOMATION
• Robotic Assembly Lines
• Automated Welding Machines
Importance
• Computer Numerical Control of
• Automated Guided Vehicles Automation
• Automated Inspection and Quality Industry
Control
• Automated Storage and Retrieval System
• Automated Sorting System
PAGE 21
Importance of Automation
Industry
1. Economic Growth and Productivity:
Increased Efficiency - Tasks performed
faster, consistently and for longer Importance
longer periods producing high of
output. Automation
Reduced Costs - Reduced labor needs, Industry
minimized wasted and optimized
resource utilization.
Higher GDP
Competitiveness – Goods produced at
lower costs in global market. PAGE 22
2. Improved Quality and Consistency:
Reduced Human Error
Standardization
3. Enhanced Safety and Working
Conditions:
Handling Dangerous Tasks Importance
Improved Workplace Safety – Allows of
for employees to work on more Automation
skilled and less hazardous roles. Industry
4. Innovation and Job Creation:
Driving Technological Advancements
Creates New Job Roles Mainly
Technical ones
PAGE 23
5. Addressing Labor Shortages:
Filling Labor Gaps
6. Enabling New Possibilities:
24/7 Operations – They operate
without breaks enabling round
the clock production and service Importance
delivery. of
Data Collection and Analysis – Create Automation
data that can be analyzed for Industry
better business decisions.
Customization and Flexibilty – Can be
reprogrammed and adapted to
handle wider variety of tasks.
PAGE 24
TERMINOLOGY
• Process Variable(PV): The specific
property of the process that we are
measuring and controlling.
• Setpoint(SP): The desired value for the Basic
process variable that we want the control
system to maintain.
Control
• Manipulated Variable(MV): The input to
System
the process that the controller adjusts to Terminology
influence the process variable.
• Disturbance: An external factor that can
cause the process variable to deviate
from the setpoint. PAGE 25
• Error: The difference between the
setpoint (SP) and the measured process
variable (PV).
• Control Signal (Output of controller): The
signal generated by the controller that is Basic
sent to the actuator to manipulate the Control
manipulated variable. System
• Process Time Constant () ﺯ: Amount of Terminology
time counted from the moment the
variable starts to respond that it takes
the process variable to reach 63.2% of its
total change.
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• Block Diagram: It is relationship between
the input and the output of the system.
Input(X) Output(Y)
Transfer function (G)
Basic
• Transfer Function: It is the ratio of the Control
Laplace transform of output ( response System
function) to the Laplace transform of the Terminology
input ( driving force) under assumption
that all initial conditions are zero unless
that given another value.
e.g. G (s) = Y(s)/X(s)
PAGE 27
• Closed-Loop Control System: It is a
feedback control system which the
output signals has a direct effect upon
the control action.
Basic
Control
System
Terminology
Advantage: More accurate than open-loop
control system
Disadvantage: Complex, less stable and
expensive
PAGE 28
• Open-Loop Control System: It is a control
system in which the output has no effect
upon the control action.
Basic
Control
Advantages: System
1. Simple construction and ease of Terminology
maintenance.
2. Less expensive than closed-loop control
system.
3. There is no stability problem.
PAGE 29
Disadvantages:
1. Disturbance and change in
calibration cause errors; and output may
be different from what is desired. Basic
2. To maintain the required quality in the Control
output, recalibration is necessary from System
time to time Terminology
PAGE 30
DEFINITION
• An instrumentation system is used to
measure and control physical quantities.
Basic
Instumentat
ion System
PAGE 31
BASIC COMPONENTS
1. Primary Sensing Element(Sensor)
• Also known as a transducer. Basic
• Detects the physical quantity being Instumentat
measured (e.g., temperature, pressure, ion System
flow, level, light).
• Converts this quantity into a measurable
signal (e.g., electrical, mechanical).
• Examples: Thermocouples, strain gauges,
pressure sensors, photodiodes. PAGE 32
2. Signal Conditioning( Variable
Conversion)
• Modifies the signal from the sensor to Basic
make it suitable for further processing. Instumentat
• Includes:
Amplification
ion System
Filtering
Linearization
Conversion
PAGE 33
3. Data Transmission
• Transfers the conditioned signal to a
remote location for display, recording, or Basic
control. Instumentat
• Methods include:
Wires
ion System
Pneumatic tubing
Wireless communication
PAGE 34
4. Display/Recording Element
• Presents the measured data in a readable
format.
• Display devices: Basic
Analog metres (pointer, scale etc) Instumentat
Digital displays (LCD, LED etc)
• Recording devices:
ion System
Chart recorders
Data loggers
Computer memory
PAGE 35
5. Control Element
• In automated systems, this element uses
the measured data to make decisions and
control the process. Basic
• Controller: Compares the measured Instumentat
value to a desired setpoint and calculates
the necessary control action.
ion System
• Actuator: Implements the control action
by manipulating a final control element.
• Examples: Valves, Motors and Heaters
PAGE 36
Basic
Instumentat
ion System
PAGE 37
EXAMPLE
TEMPERATURE MANAGEMENT SYSTEM
Sensor: Thermocouple
Signal Conditioning: Amplifier to increase
the voltage output of the thermocouple.
Basic
Data Transmission: Wires
Instumentat
Display: Digital display showing the ion System
temperature in Celsius.
Control Element: A PID controller that
adjusts a heater to maintain a specific
temperature.
PAGE 38
Thank You!!
Merci bien!!
Third Skill PAGE 39
First Skill Second Skill Conclusion
