Process Control - Lecture Notes (2
Hours)
Introduction to Process Control
• Process control is the act of monitoring and manipulating variables to achieve desired
output.
• It ensures product quality, safety, and efficiency.
• Widely used in industries like chemical, oil, food, pharmaceuticals, etc.
Basic Elements of Process Control System
• Process: The system to be controlled (e.g., heater, reactor).
• Sensor: Measures process variable (e.g., temperature sensor).
• Controller: Compares measured value with setpoint and takes action.
• Actuator/Final Control Element: Adjusts the process (e.g., control valve).
Types of Process Control Systems
• Manual Control: Human operator adjusts input.
• Automatic Control: System adjusts input based on controller signals.
• Feedback Control System: Uses measured output to correct the process.
• Feedforward Control System: Anticipates changes and acts accordingly.
Block Diagram Representation
• Process Control System can be represented using block diagrams.
• Components include: Setpoint, Controller, Final Control Element, Process, Sensor,
Feedback.
• Helps in understanding system dynamics and interactions.
Control System Terminologies
• Setpoint (SP): Desired value of process variable.
• Process Variable (PV): Actual measured value.
• Error: Difference between SP and PV.
• Manipulated Variable (MV): Variable adjusted by the controller.
• Disturbance: Any unwanted input affecting the process.
Feedback vs Feedforward Control
• Feedback: Corrective action after disturbance affects the output.
• Feedforward: Corrective action before disturbance affects the output.
• Feedforward is proactive; Feedback is reactive.
• Often used together for better performance.
Open Loop vs Closed Loop Control
• Open Loop: No feedback; control action independent of output (e.g., timer-based
toaster).
• Closed Loop: Uses feedback to control the output (e.g., thermostat).
• Closed loop is more accurate and reliable.
Applications of Process Control
• Temperature control in furnaces
• Pressure control in boilers
• Flow rate control in pipelines
• Level control in tanks
• Speed control in motors
Summary & Q&A
• Process control enhances system performance and reliability.
• Key components: sensors, controllers, actuators.
• Feedback and feedforward are essential strategies.
• Understanding control types helps in system design and maintenance.
Numerical Example - Feedback Control
• Given: A temperature control system has a setpoint (SP) of 100°C.
• The process variable (PV) is measured at 90°C.
• Calculate the error and suggest a control action.
Solution:
• Error = SP - PV = 100 - 90 = 10°C
• The controller should increase heat input to reduce this error.
Quick Quiz & Recap
1. Define the following terms:
a) Process Variable
b) Setpoint
c) Manipulated Variable
2. Distinguish between Open Loop and Closed Loop systems.
3. What is the difference between feedback and feedforward control?
4. Give two real-life examples of process control systems.
