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AUTOMATIC PROCESS
CONTROL
Reasons to control an industrial
process
Safety
Quality
Speed
Precision
Repeatability
Profit
Competitive
Resources Optimization
2
Definitions
A system can be seen like a black box with
inputs and outputs from which we are not
interested in its contents but in the
relationship between the outputs and the
inputs.
Distributed Lumped
Classification
Parameter Parameter
Stochastic Deterministic
Discrete Continuous
Nonlinear Linear
Time Time
Varying Invariant
4
Definitions
The input of the system represents a desired response.
The input is an instantaneous change.
The output signal of the system is the actual response.
At the beginning the output is a gradual change that
represents the physical device acquiring or dissipating
energy. This part of the response is known as the
transient response.
When the output signal is approaching to the input signal
(the reference), the physical system reaches its steady-
state response.
The difference between the input and the output signal is
known as the steady-state error.
5
Definitions
Input and Output
6
Definitions
A process is an operation that uses resources to
transform inputs into outputs. It is the resource that
provides the energy into the process for the
transformation to occur.
7
Definitions
Process Control is the act of controlling a Final Control
Element to change the Manipulated Variable to
maintain the Process Variable at a desired Set Point.
The Manipulated Variable (MV) is a measure of
resource being fed into the process.
A Final Control Element (FCE) is the device that
changes the value of the Manipulated Variable.
The Controller Output (CO) is the signal from the
controller to the Final Control Element.
The Process Variable (PV) is a measure of the process
output that changes in response to changes in the MV.
The Set Point (SP) is the value at which it is desired to
maintain the process variable at. 8
Definitions
Process Control
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Definitions
Process Control: Heat Exchanger
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Open-Loop Control
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Components of a Closed-Loop Control
System
The Sensor, which measures the value of the process output that
is desired to be affected. Typical process variables are
temperature, pressure, mass, flow, volume, level and pH.
The Transmitter, which takes the output from the sensor and
converts it to a signal that can be used by the controller.
The controller, which receives the signal (the value of the
variable) from the transmitter and compares it with the desired
value.
The Final Control Element, which is the physical device that
receives commands from the controller to manipulate the
resource. Typical FCE are valves, pumps, conveyors and electric
motors.
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Components of a Closed-Loop Control
System
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Operations of a Closed-Loop Control
System
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Open-Loop and Closed-Loop review
https://www.youtube.com/watch?v=bPyh1F-_kpg
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Modes of a Closed-Loop Control
System
Manual Control, is the one in which an operator directly
manipulates the controller output to the Final Controller Element
to maintain a Set Point.
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Modes of a Closed-Loop Control
System
On-Off Control, is the one which provides a controller
output of either on or off in response to the error, so it
requires that the FCE have to command positions, on-off,
open-closed, etc.
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Modes of a Closed-Loop Control
System
On-Off Controllers separate the point at which the
controller changes its output by a value called the
deadband. Upon changing the direction of the controller
output, deadband is the value that must be traversed
before the controller output will change its direction again.
19
Modes of a Closed-Loop Control
System
PID Control, is the one which provides a controller output
that modulates from 0% to 100% in response to the error.
To modulate means to vary the amplitude of a signal or a
position between two fixed points.
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Regulatory and Servo Control
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Process control example
https://www.youtube.com/watch?v=Z-SlGIiIM4U
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Functional Block Diagram
It is a qualitative description of the system that describes the parts
which compose the system and shows it’s interconnection.
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Functional Block Diagram
Automatic Liquid Level Control System.
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Functional Block Diagram
Automatic Liquid Level Control System.
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Functional Block Diagram
Vehicle Direction Control System.
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Functional Block Diagram
Vehicle Direction Control System.
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Functional Block Diagram
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Functional Block Diagram
Temperature Control System
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Control System of the Position of the Azimuth of
an Antenna
Components.
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Control System of the Position of the Azimuth of
an Antenna
Schematic Diagram
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Control System of the Position of the Azimuth of
an Antenna
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Control of a Stirred-Tank Heater
System
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Control of a Stirred-Tank Heater
System
Schematic Diagram
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Control of a Stirred-Tank Heater
System
Functional Block Diagram
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Homework 2
Describe two examples for each system shown on the
slide Systems Classification
Describe five examples for open-loop control systems
Describe five examples for closed-loop control systems.
Describe two examples for a Functional Block Diagram.
Watch the next video
http://www.youtube.com/watch?v=G0n2_7vlJzM and
explain what is Process Control for Chemical Engineers.