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Process Control System

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Here are the cause-effect relationships expressed in different ways: 1. Heating the cathode results in the emission of electrons. 2. The sharp rise in current triggers the circuit breake…

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Ino Johannis
  • Reading Comprehension
  • Meaning from the Context
  • Contextual Reference
  • Understanding Process Capabilities
  • Cause and Effect

PROCESS CONTROL SYSTEM

READING COMPREHENSION

Control system provide a means of replacing human operators in many industrial processes. They are widely used to monitor and control
pressure, temperature, motor speed, the flow of a liquid, or any physical variable. They must be capable of fulfilling a number of functions. First,
the physical variable to be controlled, such as the air temperature in a factory or the pressure of a hydraulic system, must be measured. Then its
value must be compared with the desired value. Next, action has to be taken to reduce to zero the difference between the actual and desired
value.
The basic components of a control system are an input transducer, an error sensor, a controller and an output transducer. The input transducer
converts changes in the physical variable into electrical signals. Figure 1 shows one type of transducer which converts changes in pressure to
frequency changes. Pressure changes move the diaphragm in or out, thus altering the position of the ferrite core in L1 which forms part of a
tuned circuit. This causes the frequency of the oscillator. The output is then fed to an error sensor.
The error sensor measures the deviation between the actual and desired values for the variable. The controller into whatever form of energy is
required to change the physical variable. It may be a valve, a heater, a motor or any electrically operated piece of equipment. An example is a
motor-operated valve which controls the flow of fluid in a pipeline.
Let us take as an example a process system for controlling the speed of a dc motor. The input transducer measures the speed and converts into
a voltage. The error sensor compares this voltage with the voltage across a speed-setting potentiometer. The error sensor output is fed to the
controller which sends a signal to the power supply of the motor. This increases or reduces the supply of current to the motor, thus controlling
its speed.
The operation of a process control system is summarized in figure 2 which shows a closed-loop sysetm. In such a system the results of the action
of the controller are constantly fed back to it.
MEANING FROM THE CONTEXT

• monitor : ( warn - check - convert)


• Desired : (actual – changed – required)
• Deviation: (mistake – bias – difference)
• Converts: (changes – controls - generates)
CONTEXTUAL REFERENCE

1. They must be capable of fulfilling a number of functions (control systems)


2. Then its value must be compared with the desired value. (the physical
variable)
3. This causes the frequency of the circuit to change, thus altering the output
frequency of the oscillator. (altering the position of the ferrite core)
4. It may be a valve, a heater, a motor, or any electrically operated piece of
equipment. (the output transducer)
5. In such an system the result of the action of the controller are constantly fed
back to it. (a closed-loop system)
1. What must a process control system be capable of doing?
Measuring the variable to be controlled, comparing its value with the desired value and changing it to the desired value.
1. Compare an input transducer with an output transducer.
An input transducer convert changes in the physical variable into electrical signals whereas an output transducer converts
the electrical signals from the controller into whatever form of energy is required to change the variable.
1. What is the function of an error sensor?
The error sensor measure the difference between actual and desired values for the variable.
1. What is a closed loop-system?
A closed loop-system is one in which the results of the action of the controller are fed back to it.
1. How does a control system provides means replacing human operators?
A control system monitors a physical variable and corrects any deviation automatically.
C AUSE AND EFFECT
• Example:
• Worn brushes cause sparking
• Worn brushes -------> sparking
Study this:
i) Current flows through the filament
ii) The bulb lights
Action (i) is the cause.
Action (ii) is the effect. We can link two of them:
Using cause to
 Current flows through the filament causing the bulb to light.
Using an –ing clause
 Current flows through the filament thereby lighting the bulb.
CAUSE AND EFFECT

No. Cause Effect


1 The cathode is heated. Electrons are emitted.
2 The current rises sharply. The circuit breaker
opens.
3. A voltage is applied to the Y plates. The electron beam is
deflected.
4. The thermostat contacts open at 20 degree The heating system is
Celcius. turned off.
5. The current flows through the conductor. A magnetic field is set up
around the conductor.
6. The current passes through the water. The water breaks down
into hydrogen and
oxygen.
1. The cathode is heated causing electrons to be emitted.
2. The current rises sharply causing the circuit-breaker to open.
3. A voltage is applied to the Y plates, deflecting the electron beam.
4. The thermostat contacts open at 20 decree Celcius, thereby turning off the
heating system.
5. The current flows through the conductor, setting up a magnetic field round
the conductor.
6. The electrons strike the screen causing it to glow.

Common questions

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A closed-loop control system is characterized by its feedback mechanism, where the results of the actions taken by the controller are continuously fed back for further adjustments. This allows the system to maintain the desired output consistently by comparing the actual state to the setpoint and making necessary corrections .

Feedback enhances a control system's performance by providing real-time data on the system's output, allowing for continuous adjustments to maintain desired performance levels. This ongoing loop helps a system with feedback sustain its operations under varying conditions, which a system without feedback would not efficiently address, leading potentially to inconsistent or incorrect outputs .

Control systems replace human operators by monitoring physical variables and automatically correcting any deviations from desired values. This lightens the workload of human operators by handling routine monitoring and adjustments efficiently and consistently .

Cause and effect relationships are fundamental in process control systems as they define how system actions lead to outcomes. For instance, an error signal indicating a deviation (cause) prompts a corrective action by the controller (effect), which then alters the physical variable back to its desired state. Understanding these relationships enables effective system tuning and troubleshooting .

Input transducers and output transducers serve distinct roles; input transducers convert changes in physical variables into electrical signals whereas output transducers convert controller signals back into the required form of energy to effect a change in the variable. This conversion process is essential for closing the control loop by ensuring accurate measurement and corrective action .

Deviations in desired process variables are detected by error sensors, which compare the actual values against the setpoints. Once a deviation is identified, error sensors generate an error signal that is sent to the controller. The controller then processes this signal to adjust the actuator, thereby reducing the deviation and aligning the process variable with the desired outcome .

The error sensor is critical in a process control system as it measures the deviation between the actual and desired values of a physical variable. This detection of difference allows the system to generate an appropriate response to bring the variable closer to the setpoint, thereby ensuring system stability and accuracy .

A process control system needs a transducer capable of handling various forms of energy conversion to ensure it can adjust the physical variable using the appropriate type of energy, such as mechanical, thermal, or electrical. This adaptability is crucial for the control system to accommodate diverse industrial applications with varying operational requirements .

A motor-operated valve in a process control system acts as an actuator to alter the flow of fluid in a pipeline based on commands from the controller. Its function is to adjust the physical variable, such as flow rate, to match the desired setpoint, exemplifying how electrical input is converted into mechanical action .

Continuous measurement of physical variables in automated industrial processes is essential to ensure consistent and timely adjustments. This allows for maintaining optimal operating conditions, preventing deviations that could lead to inefficiencies, safety issues, or production losses, thereby ensuring smooth and reliable operations .

PROCESS CONTROL SYSTEM
READING COMPREHENSION Control system provide a means of replacing human operators in many industrial processes. They are wide
MEANING FROM THE CONTEXT • monitor : ( warn - check - convert) • Desired : (actual – changed – required) • Deviation:
CONTEXTUAL REFERENCE 1. They must be capable of fulfilling a number of functions (control systems) 2. Then its value must be
1. What must a process control system be capable of doing? Measuring the variable to be controlled, comparing its value with
CAUSE AND EFFECT • Example: • Worn brushes cause sparking • Worn brushes -------> sparking Study this: i) Current flows throu
CAUSE AND EFFECT No. Cause Effect 1 The cathode is heated. Electrons are emitted. 2 The current rises sharply. The circuit br
1. The cathode is heated causing electrons to be emitted. 2. The current rises sharply causing the circuit-breaker to open. 3

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