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Process Control System

A process control system regulates all aspects of an industrial process. It uses sensors to monitor process variables like temperature, pressure, and flow, and controllers to compare the sensed values to setpoints and make adjustments through actuators. There are two main types of control systems - open-loop systems which do not use feedback and closed-loop systems which do. Process control enables automation, mass production of consistent products, and operation by a small staff from a central control room for safety and efficiency.

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Palani Arunachalam
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86 views

Process Control System

A process control system regulates all aspects of an industrial process. It uses sensors to monitor process variables like temperature, pressure, and flow, and controllers to compare the sensed values to setpoints and make adjustments through actuators. There are two main types of control systems - open-loop systems which do not use feedback and closed-loop systems which do. Process control enables automation, mass production of consistent products, and operation by a small staff from a central control room for safety and efficiency.

Uploaded by

Palani Arunachalam
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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PROCESS CONTROL

SYSTEM
WHAT IS PROCESS?

 A sequence of interdependent and linked


procedures
 At every stage it consume one or
more type of resources (employee
time, energy, machines, money etc.)
into outputs
 These outputs then serve as inputs for the
next stage until a known goal or end
result is reached
What is control?

Control in process
industries refers
to the regulation
of all aspects of
the process.
TYPES OF PROCESSES
1.Continuous process-
process itself runs continuously and uninterrupted in time.
Example: Production of chemicals, plastics
2.Batch process-
operation is performed on the batch to produce a finished
product. Example: Production of adhesive and glues
3.Individual or discrete process-
a series of operations produces a useful output product.
Example: involves the production of discrete pieces of
product such as metal stamping.
PROCESS
CONTROL
 An engineering discipline that deals with
architectures, mechanism and algorithms for
maintaining the output of a specific process
within a desired range’s extensively used in
industry
 enables mass production of consistent
products from continuously operated
processes such as oil refining, paper
manufacturing etc.
 enables automation by which a small staff
of operating personnel can operate a
complex process from a central control
room.
WHY????
Manufacturers control the
production process for
three reasons:
a) Reduce variability
b) Increase efficiency
c) Ensure safety
system
 A process control system an be
defined as the functions and
operations necessary to
change material either
physically or chemically.
 Process control normally refers
to the manufacturing or
processing of products in industry.
PROCESS VARIABLES
 A condition of the process fluid (a liquid or gas)
that can change the manufacturing process in
some way.
Common process variables include:
 Pressure
 Flow
 Level
 Temperature
 Density
 Liquid interface
 Mass
 Conductivity
Components of process control system
Operator-machine interface

operator

External External
actuators
sensors Output
Input
controller
signal
condi- Signal

Process Condi- Process


tioning
actuators
sensors tioning

Controlled
process computer
Programmable logic control Distributed control system
PRIMARY DEVICES OF
PCS-
1.Programmable Control Logic
 Best for controlling machines with
several discrete devices such as motor
starters, limit switches, etc
 Uses a programmable memory to store
instructions and execute specific functions that
include on/off control, timing, counting,
sequencing, etc
 It is equipped with special
input/output interfaces and a control
programming language.
2. DISTRIBUTED CONTROL SYSTEM
 Central control systems which are
good at controlling analog devices.
 In this control elements are distributed throughout
the system.
 A hierarchy of controllers is connected by
communications networks for command and
monitoring.
 Dedicated systems used to control manufacturing
processes that are continuous or batch-oriented
such as oil refining, petrochemicals, central
station power generation, fertilizers etc.
TYPES OF PROCESS CONTROL
SYSTEM
1. open-loop control system
2. closed loop control system
1.Open loop system
 A control action is applied on the output of the system
 It does not receive any feedback signal to control or alter the output
status
 Set Point-
 Controller-
 Actuators-
 Process-
 Disturbance-
2.Closed loop system
 the output of the process affects the input control signal.
 The system measures the actual output of the process and compares it to the desired
output.
1. Comparator-
2. Error Amplifier
3. Controller-
4. Output attenuator-
5. Sensor Feedback -
APPLICATIONS OF PCS
Food Production

Telecommunication and IT sector

Car wheel manufacturing process

Waste water treatment

Continuous filling operation


Future scope

 Improved process modelling technique, more capable


performance monitoring tools will produce the “next”
generation of PCS with greater economic benefits
and improved reliability.
 Many automation projects will be implemented within the so
called SMART CITY.
 In transportation, buildings, and health care will have closer
proximity to process control system.
CONCLUSION
 PCS leads to automation in various fields of
industry.
 It also provides more reliability and
improvement in product.
 Lots of work can be done in single minute of
time which reduces more time required for
that work.
 It enables manufacturers to keep their operations
running within specified limits and to set more
precise limits to maximize profitability, ensure
quality and safety.

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