COMPUTER AIDED PROCESS CONTROL SYSTEM

The process control system is run by special sensors that automatically work to ensure the set
parameters are obtained. A user doesn't need to set it up again and again. The system always uses
the sensor to monitor the parameters, and when any of the set parameters are changed, it turns
the system on or off automatically.

The industrial use of such a system brings many benefits to the business owners and runs the
system through automation. Certain elements are involved in this process to happen successfully;
we will discuss them all individually through block diagrams.

Process control systems

Process control systems are used to monitor and control industrial processes, including
manufacturing processes, chemical processes, oil and gas production facilities, water treatment
plants, and power generation facilities.

Uses:

Process control systems are used in various industries, including manufacturing, petrochemical,
mining, oil and gas, power generation, pulp and paper, and food processing. They're also used in
pharmaceuticals and biotechnology.

Example of a process control system

A good example of a process control system in a manufacturing setting is the automated

assembly line for car manufacturing.

Objective: This process control system aims to assemble a car efficiently, accurately, and safely
with minimum human intervention.

Process: The car's assembly involves several steps, including body assembly, painting, engine
installation, interior installation, etc. These steps are carried out at different stations along the
assembly line.

Controller: The controllers in this system can be programmable logic controllers (PLCs) or
similar devices. These controllers are pre-programmed to control the operation of the different
machines at each station along the assembly line.

Control action: A specific action is taken at each station along the line. For instance, robotic
arms might be controlled at one station to weld parts of the car body together. A machine might
be controlled at another station to paint the car's body automatically. And so on. The PLC or
similar controller determines the control action at each station.
Sensors: Many sensors in this system monitor the process. For example, there might be sensors
to detect whether a part has been correctly installed, sensors to measure the paint thickness and
ensure it's within acceptable parameters, sensors to ensure the correct components are installed at
the right location, etc.

Feedback loop: This is a closed-loop system because it uses sensor feedback to adjust the
control actions. If a sensor detects that a part has not been installed correctly, the controller can
halt the assembly line, or a robot can be controlled to make necessary adjustments.

This assembly line process control system improves car production efficiency, speed, and
accuracy. It also enhances safety by reducing the need for human workers to carry out potentially
dangerous tasks. However, it requires sophisticated programming, regular maintenance, and
occasional human intervention to correct errors or handle unexpected situations.

Block Diagram for Process Control System

Here is a block diagram for the process control system where the system's working is explained.
Let's check out the main components of the diagram.

There are three main components of a Process control system.

Sensor

A Sensor is the most important part of the Process control system. It detects physical quantities
like temperature, water flow, heat, gas detection, pressure force, etc. It detects these quantities
and converts them into an electrical signal for further operations.
Controller

The signal from the sensor is detected by the controller and processed there. After processing, the
signal is sent to the actuator to produce an output.

Actuator

This actuator is a device that sends the feedback and converts the electric signal to a physical
action like turning on the AC/ Heater, opening or closing the valve for water flow, or increasing
or reducing the pressure in a chamber.

Part 2. Types of Process Control Systems

Process control systems are of many types, as different types of systems are needed to perform
different tasks. Here are a few of the types of process control systems.

Open Loop/Closed Loop Control Systems

An open-loop control system is a system where the system's performance does not influence
output. The input of these open-loop systems works on the predetermined rules.

In a closed-loop control system, feedback is used to compare the output needed to run the
system. Input is used to fill the gaps between the outputs or eliminate any errors in the system.

Continuous/ Discrete Control Systems

The type of systems that operate to achieve a certain output value or time are called Continuous
Control systems. These systems, like temperature control systems, are used in applications where
continuous operation is needed.

Discrete Control systems are where the output is needed at certain points or time frames. These
systems are usually used in machine control systems.

Linear/Nonlinear Control Systems

Linear differential equations represent linear control systems. The system's output is directly
related to the system's input. They are easier to control and don't require specialized tools.

Nonlinear control systems are difficult to operate as the output is not dependent on the input. You
may need special instruments and digital analyzers to operate these systems.

Single to Single/Multiple to Multiple control Systems

A system with a signal input and a single output is called a Single Input, Single Output Control
System (SISO). These systems are very easy to operate due to their simplest form. These systems
are used in basic control systems and don't need a controller to control the system as it runs
independently.

The type of system where multiple inputs and outputs are used is called multiple input multiple
output (MIMO) system. These systems are not easy to handle as they need complex integrations
to control. However, they are being used at industrial levels where such systems are needed.
However, the manual operation of such a system is difficult. So, an operator is needed to keep a
look at the system.

COMPUTER PROCESS CONTROL

The computer process control can be described as controlling a manufacturing process

with the help of a digital computer. The automated system is operating by using a computer, the
computer process control is specifically related to the continuous or semi-continuous operations.
The computer process control is mostly related to chemicals, petroleum, food, etc

The computer process control system would measure the process variables such as
temperature, flow rate, and pressure. It would do some optimizing strategy, and also actuate
certain devices such as valves, switches, and furnaces which is the final control element in a
process. With the help of a computer process control, we can determine the status of the
equipment, production performance, and also the quality of the product. We can see that many
industrial operations are carried out with computer process control.

 Adaptive control?

 Final control elements in a control system?

 Tyes of instrumentation switches?

 industrial automation?
  cascade control?

 feedback control system and what are its types?

 automatic control system?

What are the functions of a computer aided process control?

It would do the measurements and data acquisition

 Data conversion would be done with scaling and checking

 It would display the process details

 Controlling and transferring of data

 Process output will be compared with the required output

 It would monitor and record the events and sequence

 Data logging and computations

 Control actions

How computer process controls are classified?

The computer process controls are classified as open and closed-loop process control. In the
open-loop computer process control, it won’t take any feedback from the process in order to
complete the system process. In the case of a closed-loop computer control it would take
feedback from the process and according to the feedback certain changes will be done in the
process to get the desired value.

What is the difference between analog and digital controller?

Analog controller

These controllers will be in the control room and it would do the distributed control and
monitoring. The cabling cost of the analog controller will be high. The control loop coordination
will be difficult and also the implementation of the control algorithms rather than the PID is
really difficult. The central monitoring panels will be big due to the large number of controllers.

Digital controller

The digital components are less affected by the variation of the environment and they would long
last too. These components are reliable and they won’t be hardly affected by the noise,
disturbances, and also parameter variations. The digital processors are small in size and would
only use small space. These processors are suitable for different control applications. Direct
digital control and distributed control system are both an example of the digital control system.

What are the types of computer process control?

1. Computer process monitoring

2. Direct digital control

3. Distributed control systems

4. Numerical control and robotics

5. Programmable logic control

6. Supervisory control

Computer process monitoring

This is the way in which the computer will be interfaced with the process, in this type the
computer will monitor the process and also the equipment in the process so that it can collect and
record the data from the process. The computer won’t control the process directly. The computer
would collect three types of data while the process monitoring and they are process data,
equipment data, and product data.

Process data

This is the measured value of the input parameters and also the output variables which represent
the process performance.

Equipment data

This is the data that shows the equipment status while it is in the process and how it does the
process.

Product data

This will the production data of a manufacturing plant

Direct digital control

A DDC can be described as a computer process control system and in this system, there are
certain components that are conventional and this conventional component is replaced by a
digital controller. The process regulation is carried out by a digital computer according to the
time. The direct digital control is known as a loop control too, because the digital computer can
do the functions of a comparator, controller, and they can also do certain safeguarding
operations. The DDC control has the ability to handle the multivariable processes and they can
do this with the interaction between elements. This type of computer control would have a
software program and it would define all the control functions, setpoint, and also the deviation
about the nominal. The major drawback of direct digital control is that it only uses one processor
to do the process, because of this a single error could disturb a large number of controlled
variables and also it could stop the process.
Distributed control system

In a distributed control system there are many computers and the total work will be divided into
all these computers. A DCS is composed of many process control stations and these stations can
be seen all around the plant so that the individual loop and also the devices of the process can be
controlled. There will be a central control room and it would have operator stations where the
supervisory control of the plant takes place. The DCS can be seen in the entire plant due to the
local operator stations which are distributed all over the plant. The interaction of the process is
done with the help of communication networks. Due to the usage of multiple microcomputers,
the workload of the process control is distributed.

We can install DCS in high basic configuration for the required applications, due to the multiple
computers parallel multitasking is possible. The control cabling is very low and because of the
networking, the process data can be transferred throughout the plant.
Numerical control and robotics

Numerical control is another form of industrial computer control, in this type of control where a
machine tool will be directed through a sequence of processing steps. There will be a program of
instructions that specifies the step details and sequence. This type of computer control would
position the tool which is being used in a process so that the process can be improved.

Programmable logic control (PLC)

This type of computer control is mostly used to do the discrete control, it is simple and
continuous control. The response time is very quick and it can do the emergency shut-down. This
is a microprocessor-based control and it can store instructions in a programmable memory and it
can do logic, sequencing, timing, counting, and arithmetic control functions in a process, or in a
machine. A PLC can do continuous and discrete process control in the process industries and also
in the discrete product industries too.

Supervisory control
This is a type of computer control in which it would direct and coordinates many interaction
processes in a manufacturing system. It optimizes the plant operations by increasing the plant
yield, production rates and also by reducing the consumption of energy. It would also review the
operation conditions, in this control system the controller will communicate with the
central computer. This type of control system would do the data acquisition, display and analysis
with the help of a controller. The setting of the controller can be changed from the computer. The
computer would do the supervisory work as the local controller would do the controlling
functions. This type of control system can make the operating conditions proper for the process.
It would also distribute the limited resources among the parallel process. With the help of a
supervisory control system, the operator can determine the plant condition remotely.

What are the advantages of computer process control?

 Maintains the plant conditions and also would quickly respond to the plant problems

 It would coordinate the system

 Production can be increased

 The reliability of the plant will be increased

 It would do the production planning

 Less maintenance