Addis Abeba Science and Technology University
(AASTU)
Industrial Automation and Process Control
Introduction
1 Definition of Process Control
2 Some Definitions related to Process Control
3 Components of Control Loops
4 Process Control Block Diagram
5 Analog Data representation
6 Final Control Operation
7 Basic Tasks of Process Control
8 Mass and Energy Balance
Definition of Process Control
Definition
Process: In general, process constitutes a sequence of events in
which a raw material will be converted into finished products.
Raw Materials is a substance that we get directly from nature
Finished Products is an object made by a human being to satisfy a
need or to improve quality of life.
Definition of Process Control
Leather Processing
The process includes several steps, such as cleaning, tanning, dyeing,
and finishing, to transform the raw material into a usable product.
Definition of Process Control
Control: The method/techniques to force parameters or variables in
the environment/process to have specific values.
Process Control: In spite of disturbances, It deals with the method
to maintain the main process variables close to its desired values
while manufacturing a product by means of an automatic system
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.
Definition of Process Control
Example: Chemical Mixing Process
Definition of Process Control
Manufacturers control the production process for three reasons:
Reduce variability
Increase efficiency
Ensure safety
Example-1: Control of liquid level in a tank
Definition of Process Control
Example-2: Heat Exchanger
Definition of Process Control
Heat Exchanger closed loop block diagram
Some Definitions related to Process Control
Some Definitions related to Process Control
Process control has its own set of common terms that you should be
familiar with and you will use when talking about control technology.
Controlled Variable: The process variable regulated by process
control loop
Controlling Variable: The process variable changed by the
final control element under the command of controller to
affect regulation of controlled variable
Setpoint: The desired value of a controlled variable in process
control loop
Error: The difference between the measured value and
setpoint
Controller: The element in a process control loop that
evaluates error of the controlled variable and initiates
corrective action by sending a signal to an actuator
Components of Control Loops
Components of control loops
This section describes the instruments, technologies, and equipment
used to develop and maintain process control loops.
The basic components of a control loop are:
Process (tank system)
Measuring element (thermocouple, thermometer)
Error detector
Controller
Control element: It has a direct action in the process
Process Control Block Diagram
Process Control Block Diagram
Process Control Block Diagram
Example
Physical diagram for flow process control system
Process Control Block Diagram
Example
Block diagram for flow process control system
Analog Data representation
Analog data representation
Analog standards for representing range of variable in process control
systems:
Current Signal: 4 to 20 mA/ 0 to 20mA
Pneumatic Signal: 3 to 15 psi (20 to 100kPa)
Voltage Signal: 0 to 10 V
In process industry, current is used instead of voltage because the
system is less dependent on load
Transmission of current signal is independent of line resistance
Final Control Operation
Final Control Operation
Elements of final control operation
Basic Tasks of Process Control
Basic Tasks of Process Control
In a process control industry, three tasks to occur:
Measurement
Comparison
Adjustment
Mass and Energy Balance
Mass and Energy Balance
Material quantities, as they pass through processing operations, can
be described by material balances. Such balances are statements
on the conservation of mass. Similarly, energy quantities can be
described by energy balances, which are statements on the conser-
vation of energy.
Importance: Material and Energy balances are important
To identify and quantify previously unknown losses and
emissions
For monitoring the improvements made in an ongoing project,
while evaluating cost benefits.
Mass and Energy Balance
Mass and Energy Balance