EE428 Industrial Process Control

Dr. Ammar Hasan

Dr. Ammar Hasan SEECS, NUST

 Pre requisite
• EE332 Linear Control Systems
• You are expected to know the basics i.e.
– basic purpose of control
– concept of feedback/open loop
– purpose of sensors/actuator
– Transient response characteristics
• No need to know PID, root locus, Nyquist etc.

Dr. Ammar Hasan SEECS, NUST

 Difficulty level

• Unlike LCS/DCS, it doesn’t include difficult

concepts or mathematics
• This course is more oriented towards
imparting information/knowledge/general
practices
• You will need a good memory to pass this
course

Dr. Ammar Hasan SEECS, NUST

 Distribution of Marks
• Quizzes 9%
• 4-5 Assignments 3.5%
• OHTs 12.5% + 12.5%
• Lab 25%
• Final Exam 37.5%

Dr. Ammar Hasan SEECS, NUST

 Quizzes and Assignments
• Six to seven graded quizzes
• Quizzes may be announced or un-announced
• There may be few practice quizzes, which are
ungraded
• Three to five assignments
• No “best of” policy

• There may be a make-up/extra credit assignment

after OHT2

Dr. Ammar Hasan SEECS, NUST

 Cheating and Plagiarism
• Zero tolerance policy

• Any one found guilty will be penalized. Maximum penalties

could be
– zero in all assignments and quizzes
– Case sent to SEECS disciplinary committee for award of ‘F’ grade

• Plagiarism includes
– copying full or part of class mate’s assignment
– copy text from book, webpage, or paper, etc. without rephrasing and
proper referencing

Dr. Ammar Hasan SEECS, NUST

 Labs
• 12-15 labs
• If you miss a lab, you can do it in your spare
time. Just talk to the lab engineer.
• In case of any issues with the lab, contact the
lab engineer. You can come to me if the issue
is not resolved.
• No decision yet for lab exam / viva / project

Dr. Ammar Hasan SEECS, NUST

 Text Book
• Industrial Electronics by Terry L. Bartelt (2006)

• Industrial Automated Systems: Instrumentation and Motion

Control by Terry Bartelt (2011)
• Industrial Control Electronics by Terry Bartelt (2005)

Dr. Ammar Hasan SEECS, NUST

 How to contact me
• Try to ask questions during the class so that
everyone can benefit from the answer
• After lectures
• During lab (if I am there)
• By Email

• Never call me on my mobile phone

Dr. Ammar Hasan SEECS, NUST

 Class Rules
Avoid disruptive activities/behavior
-mobile phones
-talking in lectures
-being late
-etc.

Water bottles/drinks allowed in class (especially in summers)

Dr. Ammar Hasan SEECS, NUST

 What is
Industrial Process Control (IPC)?
IPC is an area of engineering that deals with the
automation of tasks/processes in the industry.

It is also known by the following names

– Industrial Automation
– Industrial Control
– Instrumentation and control

Dr. Ammar Hasan SEECS, NUST

 What is the relation/difference
between IPC and control theory?

Dr. Ammar Hasan SEECS, NUST

 Application areas
• Oil and gas sector
• processed food manufacturing
• cement industry
• textile industry
• plastics industry
• medicine industry
• Almost every production/manufacturing industry

Dr. Ammar Hasan SEECS, NUST

What will be the general flavor of
this course?

Dr. Ammar Hasan SEECS, NUST

 Labs / Lectures

Dr. Ammar Hasan SEECS, NUST

 Course Contents
1. Indroduction to Industrial Process 14. Analytical Instrumentation
Control 15. Industrial Process Instrumentation
2. Interfacing devices 16. Process control methods
3. Thyristors 17. Industrial sensors and interfacing
4. The controller operation 18. Introduction to PLCs
5. DC motors 19. Fundamental PLC programming
6. AC motors 20. Advanced PLC programming
7. Servo Motors 21. Motion Control feedback devices
8. DC Drives 22. ELements of motion control
9. AC Drives 23. fundamentals of Serovmechanism
10. Pressure Systems
11. Temperature Control
12. Flow Control
13. Level Control Systems

Dr. Ammar Hasan SEECS, NUST

 History
• The industrial revolution began in England during the mid-
1700s when it was discovered that productivity of spinning
wheels and weaving machines could be dramatically
increased by fitting them with steam-powered engines.

• Further inventions and new ideas in plant layouts during the

1850s enabled the United States to surpass England as the
manufacturing leader of the world. Around the turn of the
twentieth century, the electric motor replaced steam and
water wheels as a power source.

Dr. Ammar Hasan SEECS, NUST

 History
• The concept of assembly line became popular in the early
20th century that significantly increased the production

• Between World Wars I and II, the feedback control system was
developed, enabling manually operated machines to be
replaced by automated equipment.

Dr. Ammar Hasan SEECS, NUST

 Definition
• The term industrial controls is used to define the type of
system that uses feedback to automatically monitor
manufacturing processes and takes appropriate corrective
action if the operation is not performing properly.

Dr. Ammar Hasan SEECS, NUST

 1.1 Classifications of Industrial
Control
• Industrial control systems are often classified
by what they control: either motion or
process.

Dr. Ammar Hasan SEECS, NUST

 1.1.1 Motion control
• A motion control system is an automatic
control system that controls the physical
motion or position of an object. One example
is the industrial robot arm which performs
welding operations and assembly procedures.

Dr. Ammar Hasan SEECS, NUST

 1.1.1 Motion control
• There are three characteristics that are
common to all motion control systems.
• Measurement of position/speed/acceleration
of a mechanical object
• Control position, speed or acceleration, or
deceleration
• Quick response that is usually in fractions of
seconds

Dr. Ammar Hasan SEECS, NUST

 1.1.1 Motion control
• Motion control systems are also referred to as
servos, or servomechanisms.
• Some other examples of motion control
– CNC machine
– printing presses
– office copiers
– packaging equipment
– electronics parts insertion machines that place
components onto a printed circuit board.
Dr. Ammar Hasan SEECS, NUST
 1.1.2 Process Control
• In process control, one or more variables of a
chemical/material/product are regulated
during the manufacturing of a product. These
variables may include temperature, pressure,
flow rate, liquid and solid level, pH, or
humidity. Examples include cement and paint
industry

Dr. Ammar Hasan SEECS, NUST

 1.1.2 Process Control
• This regulated process must compensate for
any outside disturbance that changes the
variable.
• The response time of a process control
system is typically slow, and can vary from a
few seconds to several minutes
• Process control systems are divided into two
categories, batch and continuous.

Dr. Ammar Hasan SEECS, NUST

 1.1.2.1 Batch Process
• Batch processing is a sequence of timed
operations executed on the product being
manufactured.
• An example is an industrial machine that
produces various types of biscuits

Dr. Ammar Hasan SEECS, NUST

 1.1.2.1 Batch Process example:
Biscuit manufacturing

Dr. Ammar Hasan SEECS, NUST

 1.1.2.1 Batch Process
• Batch process is also known as sequence (or
sequential) process

Dr. Ammar Hasan SEECS, NUST

 1.1.2.2 Continuous Process
• In a continuous process, one or more
operations are being performed as the
product is being passed through a process.
Raw materials are continuously entering and
leaving each process step.
• An example is the production of paper

Dr. Ammar Hasan SEECS, NUST

 1.1.2.2 Continuous Process
example: paper production

Dr. Ammar Hasan SEECS, NUST

 1.1.2.2 Continuous Process
• The continuous process can last for hours, days, or
even weeks without interruption.
• Manufacturing of wire, textiles, plastic bags is a
continuous process.
• Other examples of continuous process control
applications are wastewater treatment, nuclear
power production, oil refining, and natural gas
distribution through pipe lines.
• Another term commonly used instead of process
control is instrumentation.
Dr. Ammar Hasan SEECS, NUST
 1.1 Process control vs Motion
control
• The primary difference between process and motion
control is the control method that is required.
• In process control, the emphasis is placed on
sustaining a constant condition of a parameter, such
as level, pressure, or flow rate of a liquid.
• In servo control, the input command is constantly
changing. The emphasis of the system is to follow the
changes in the desired input signal as closely as
possible. Variations of the input signal are typically
very rapid.
Dr. Ammar Hasan SEECS, NUST
 1.1 Classifications of Industrial
Control
• One of the classifications is with respect to the
type of system to be controlled.

• Another classification is whether the control is

open loop / closed loop

Dr. Ammar Hasan SEECS, NUST

 1.1.3 Open loop systems
• It is a system without feedback.
• Example is a tank that supplies water for
irrigation

Dr. Ammar Hasan SEECS, NUST

 1.1.4 Closed loop systems
• Closed loop control is required in applications
require continuous monitoring and self-
correcting action of the operation for long
periods of time without interruption.

• This automatic system employs a feedback

loop to keep track of how closely the system is
doing the job it was commanded to do.

Dr. Ammar Hasan SEECS, NUST

 1.1.4 Closed loop systems

Dr. Ammar Hasan SEECS, NUST