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What is process control?

Control System
What is process control?

by AshlinJune 30, 2021062SHARE0

A process stands for an operation and this operation could be on solids or liquids,
this operation will be anindustrial operation. A process is a method of converting
raw materials into a product, so in order to dothis properly, process control
should be done. Process controls are done to ensure that the parameters incontrol
plants are maintained in a proper manner. So basically we can describe process
control in anindustry as the regulation of all the process aspects. The process
control involves the control of waterlevel, temperature control, pressure control,
and flow control. The major advantage of doing processcontrol in an industry is
that the quality and quantity of the product can be increased, because of this,
there will be a good profit.

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What is continuous process control and what are its types?
What is computer process control?
What is an adaptive control?
What are the final control elements in a control system?
What are the types of instrumentation switches?
What is industrial automation?
What is a feedback control system and what are its types?

What is the purpose of a process control?

Safety
To maintain a process at the required operating conditions
Protection of the equipment
Smooth operation
Quality can be increased
Monitoring and diagnosis
Comply according to the environmental requirements
Profit

Many big industrial plants would have many process variables such as temperature,
pressure, flow, level,
and lot more so all these process variables should be controlled in a good manner
to improve the productquality.

What are the common process variables that needs to becontrolled in a plant?

Pressure
Flow
Level
Temperature
Density
PH
Oxygen content
Mass
Conductivity
Liquid interface, if different liquids are added in a vessel

What are the types of variables in a process control system?

Controlled variable

This is the final product of a process or it can also be considered as the process
output

Manipulated variable

These are the input variables that can be adjusted dynamically so that the
controlled variables can bemaintained in the setpoint.

Disturbance variable

This is the disturbance that affects the process variable and the disturbance could
be a change intemperature or pressure. Because of the disturbance, the controlled
variable will be different from thesetpoint.

What are the major components in a process control system?

Sensor

This device can measure the process variable an example of this would be a
thermocouple. A sensorwould measure the controlled variable or the disturbance.

Controller

This device would maintain the process variable at the setpoint, this device would
process the sensorsignals, and it would do the control calculations and decision
making.

Final control element

Mostly this will be a control valve and it would act as per the control signal
which is received from thecontroller. This device would vary the manipulated
variable to get the required controlled variable.

How process control is done?

The process control is mostly done in an industrial plant to increase the

efficiency and the safety of theindustrial plant. Process control is achieved by a
combination of measuring elements, controller, andregulating elements. In order to
control certain processes in a plant, equipment like the controller, and thereactor
is controlled by setting a control loop. The control loop will control the variable
that is needed to becontrolled in a process.

The control loop is composed of

Measuring devices ( Flowmeter)

Feedback or feedforward controller
Regulating element
Set variable
The controlled quantity in a process is also known as a controlled variable and
these are the conditionsthat the operator likes to control at a level. The
controlled variable will be parameters such as temperature,
PH, moisture, level, position, flow, weight, etc. In a process, the controlled
variable has a required ordesired value and it is called a set point. In a process
for each controlled quantity, there will be amanipulated variable an example of
this will be flow rate, and the manipulated variable is controlled byusing a final
control element. The controller would use feedback control to determine the process
outputand this value will be compared to the setpoint and the difference will be
known. Thus according to thedifference between the values, changes are made in the
input section to get the desired output.

What is a disturbance in a process and where does disturbancecome from?

The disturbances would cause the process variable to deviate from the setpoint. The
common type ofdisturbances in a process is temperature, pressure, etc. The
disturbance can also be caused due to
component damage too. So because of this, the automatic control system should vary
the manipulatedvariable in order to reach the setpoint.

The disturbance can be caused due to the variation in the composition of the
incoming raw materials. Itcan also happen due to environmental conditions such as
hot, cold, and also pollution. The disturbancescan also happen in a process because
of the unexpected surges, and also because of the wear and tear ofthe components.

What are the different types of control in a process controlsystem?

Feedback control

The feedback control would only operate if the controlled variables are affected,
so it would measure thecontrolled variable and compare it to the desired variable
or the setpoint. This value is used to make thechanges in the input variable and
because of that, the required output will be received. In this type ofcontrol the
corrective action is taken without considering the disturbance source and also the
response isnot quick for the disturbances.

Feedforward control

This type of control would act before the controlled variables are affected, so
this type of controller wouldmeasure the disturbance variable and it would take the
required action so that it won’t affect the output.
So the feedforward control would respond faster to the disturbances.

What is a process automation and process dynamics?

In process automation, computer technology and software engineering is used to

operate the factoryeffectively and safely. The process dynamics is basically the
study of the transient and steady-statebehavior of the process.

What are the different control loops which are used for the processcontrol?

A control loop is the basic part of the process control, the control loop is
composed of many componentsand also the control functions which are used to control
the final control element of a process. The controlloop consists of the process
sensor, controller function, and also the final control element which is neededfor
the automatic control. The control loops could be manual or automatic, during the
manual controlthere will be operating personnel to control.

Types of control loop

There are two types of control loops and they are open-loop systems and closed-loop
systems. The open-
loop can be described as a manual mode and in this process, an operator will be
there to control theprocess, and if the system is in auto mode which means that
there won’t be any operator to control theprocess and it is called a closed-loop
process.

Open loop control

The open-loop control is done manually which means that there will be an operator
to control the process.
So the operator will check the process and if the controlled variable is not at a
set point then the operatorwould modify the manipulated variable. The open-loop
control doesn’t have any info about the real-timedata related to the process so it
won’t act quickly in case of any disturbances. The open-loop control willbe used in
a process where the output will be constant and predictable.
Closed loop control

In this type of control, there will be a controller in place of a human being, and
this controller would keepthe controlled variable at the required setpoint. This
type of control has a feedback device and it wouldcheck the disturbances which
would affect the process. So if there are any disturbances in the processthen it
will be cleared at the first instant and because of this the closed-loop system is
better than theopen-loop control system and it can be used in processes where there
could be frequent changes in theoutput.

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Ashlin

post-graduate in Electronics & communication.

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