INDUSTRIAL PROCESS CONTROL

( ELX 222)

Group Members : Course

Rochene Garciano Facilitator:
Richie Boy Dela Cruz Mr. Rey Bueno
Rica Garcia
Oliver Mahilum
Christian Andion
FEEDBACK CONTROL
What Is a feedback control?
This method would utilize the values of the controlled
variable to vary the values of the manipulated
variable. The feedback loop would measure the
process variable and this measurement would be sent
to a controller to compare it with the set point. The
system would take the necessary action to make the
process variable equal to the set point or the required
value.
What are the advantages of feedback control?
📍It won’t sense the changes in parameters
📍It won’t be able to determine the modeling
errors
📍It doesn’t need to determine or require the
measured value of the disturbance
What are the disadvantages of the feedback control?
📍It would only take action after the system is affected
by the disturbance
📍It is not effective in case of a slow process
FEED FORWARD CONTROL
What is Feed forward control?
In feedback control, it would utilize the output of a process to
make changes in the input of the system. This type of control
would utilize the direct measurement of the disturbance
variables to vary the values of the manipulated variable. This
type of control is called predictive control in this control it
would determine the load disturbance and this disturbance
would be controlled before it affects the process.
What are the advantages of feedforward control?
📍It would act before the system is affected by the
disturbance
📍It would be stable in case of the closed loop
response
📍It would be effective for the slow system
What are the disadvantages the feedforward control?
📍It would require the measurement of disturbance for its
operation
📍It won’t be able to handle the unmeasured disturbances
B C
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Batch process control is a method of managing production
processes that involve the production of discrete quantities of a
product, known as batches. This process is commonly used in
industries such as pharmaceuticals, food, and chemicals, where
precise control over the production process is essential to ensure
product quality and consistency. The primary goal of batch process
control is to ensure that each batch of the product is manufactured
to the desired specifications and meets the required quality
standards. To achieve this, a range of techniques and technologies
are used to monitor and control the various stages of the
production process.
STEPS: — TO CONTROL A BATCH PROCESS

To control a batch process effectively, follow these key steps:

1. Clearly define the desired outcome, process parameters, and quality standards.
Identify the variables that need to be controlled, such as temperature, pressure, flow
rates, or ingredient quantities.

2. Set Operating Procedures: Establish standard operating procedures (SOPs) that

outline the sequence of operations, equipment settings, and safety protocols.
Document the steps required to start, run, and stop the batch process.

3. Monitor Process Variables: Continuously monitor the critical process variables

using sensors, gauges, or instrumentation. This can include temperature sensors,
pressure transmitters, flow meters, or analytical instruments to measure chemical
compositions.
4. Establish Control Strategies: Implement control strategies to maintain the process
variables within acceptable ranges. This can involve feedback control loops,
cascade control, or advanced control algorithms. Use automation systems such as
programmable logic controllers (PLCs) or distributed control systems (DCS) to
implement these strategies.

5. Data Acquisition and Analysis: Collect and analyze real-time data from the
process. Use data acquisition systems to capture data from sensors and control
devices. Perform statistical analysis and trending to identify patterns, correlations,
and abnormalities that may affect the process performance.

6. Adjust Process Parameters: If the process variables deviate from the desired
values, take corrective action. Adjust control parameters, such as set points, gains,
or time constants, to bring the process back into control. This can be done manually
or automatically depending on the level of automation.
7. Maintain Equipment and Calibration: Regularly maintain and calibrate the equipment
used in the batch process. This ensures accurate measurements and reliable control. Follow
preventive maintenance schedules to minimize downtime and unexpected failures.

8. Document and Learn: Keep detailed records of each batch, including process conditions,
parameters, and any deviations or issues encountered. Analyze the data to identify
opportunities for improvement, optimize process performance, and prevent future problems.

9. Training and Skill Development: Provide adequate training to operators and process
engineers involved in controlling the batch process. Ensure they understand the principles of
the process, the control strategies, and how to respond to abnormal situations. Continuous
skill development and knowledge transfer are essential.

10. Regulatory Compliance and Safety: Comply with all relevant regulatory requirements
and safety standards. Ensure that the batch process meets environmental, health, and safety
guidelines.
DIFFERENT METHODS OF BATCH PROCESS CONTROL

1. Programmable Logic Controllers

(PLCs):-

Programmable Logic Controllers (PLCs)

are widely used in the automation industry
for controlling various processes. One of
the most common applications of PLCs is
in batch control processes. PLCs, or
programmable logic controllers, are
commonly used in batch process control
due to their flexibility, reliability, and ease
of programming. Batch processes involve
the sequential execution of a series of tasks
or operations in a specific order and for a
set duration of time.
2. DCS (Distributed Control System):- Distributed Control System):-
DCS (Distributed Control System) is a type of control
system used to control and manage complex industrial
processes, such as batch process control. Batch process
control involves the production of a specific quantity of
a product or material in a single batch, with a defined
set of processing steps that must be followed. DCSs are
well-suited for batch process control because they
allow for the control and monitoring of multiple
process variables simultaneously, such as temperature,
pressure, flow rate, chemical concentrations. They also
enable the automation of many of the steps in a batch
process, such as the opening and closing of valves, the
starting and stopping of pumps, and the monitoring of
process parameters. In a batch process control system
using a DCS, the process is broken down into
individual steps or stages, with each step controlled by
a specific program or recipe.
3. PID (Proportional-Integral-Derivative):-
PID controllers are commonly used to
control batch processes. In a batch
process, a set of inputs are introduced
into the system, and then the system is
allowed to operate until a desired output
is achieved. During this process, a PID
controller can be used to maintain the
system at the desired set point. The PID
controller works by continuously
measuring the error between the desired
set point and the actual process variable,
and then adjusting the control output to
minimize this error.
 4. Statistical Process Control (SPC):-
Statistical Process Control (SPC), which
is a statistical tool used to monitor and
control a process over time. SPC helps
identify any variations in the process and
ensures that the final product meets the
required quality standards. SPC can be
used to monitor and control the batch
process to ensure that the final product is
of consistent quality. The first step in
using SPC for batch process control is to
identify the key process parameters that
need to be monitored. These parameters
are critical to the quality of the final
product and can include temperature,
pressure, pH, and concentration.
5. Supervisory Control and Data Acquisition (SCADA): -

SCADA systems are commonly used to control

and monitor batch processes in industries such
as food and beverage, pharmaceuticals, and
chemicals. In a batch process, a set of raw
materials are processed in a series of steps to
produce a final product. SCADA systems are
used to automate and monitor the process by
controlling equipment such as mixers, heaters,
and pumps, and by monitoring variables such as
temperature, pressure, and flow rate. SCADA
systems typically consist of three main
components: the supervisory computer, the
remote terminal units (RTUs), and the
programmable logic controllers (PLCs).
R
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Ratio control system is a technique wherein one of the
variable(in case of binary feed) is manipulated in a controlled
way to keep/maintain a specific ratio of the output stream. It is
used when the flow rates of two or more streams must be held in
proportion to each other. Typical applications are in blending ,
combustion and reactor feed control systems. Ratio control
system is a special type of feed forward control system widely
used in the process industries.
SELECTIVE CONTROL
What is Selective Control?

In a number of process control problems, we may have more

measurements (controlled variables) than manipulated variables.
Hence, it is impossible to eliminate errors in all the controlled
variables for arbitrary set point changes of disturbances by using
only simple (single-input/single output) controllers. Thus selectors
are used to share the manipulated variables among the controlled
variables. We can therefore define selective control as a scheme
whereby a selector is used to choose the appropriate measurement
variable from among a number of available measurements.
Selective control is used to improve the system operation and to
protect the system from unsafe operation.
Do you have any
questions or
clarification?
REFERENCES:
https://www.cartoncloud.com/batch-control
https://www.electricalandcontrol.com/what-is-selective-control/
https://automationforum.co/what-is-ratio-control-and-how-it-is-u
sed-in-industries/
https://control.com/textbook/basic-process-control-strategies/
cascade-control/