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What is Process Control
What is Process Control
Published: 2016/03/23
Channel: Deacom, Inc.
1. Introduction - Process Control Instrumentation -
1. Introduction - Process Control Instrumentation -
Published: 2016/03/07
Channel: Yokogawa: Industrial Automation
Process Control Fundamentals
Process Control Fundamentals
Published: 2014/03/10
Channel: Convergence Training
Process Control and Instrumentation
Process Control and Instrumentation
Published: 2016/11/20
Channel: Ammonia technicians cafe
Mod-01 Lec-01 Lecture-01-Introduction to Process Control
Mod-01 Lec-01 Lecture-01-Introduction to Process Control
Published: 2012/07/06
Channel: nptelhrd
Day in the Life: process control engineer
Day in the Life: process control engineer
Published: 2017/04/19
Channel: Chevron
Introduction To Process Control
Introduction To Process Control
Published: 2009/06/10
Channel: IDCTechnologies
Process Control Loop Basics
Process Control Loop Basics
Published: 2016/10/14
Channel: Pete Vree
What is PROCESS CONTROL? What does PROCESS CONTROL mean? PROCESS CONTROL meaning & explanation
What is PROCESS CONTROL? What does PROCESS CONTROL mean? PROCESS CONTROL meaning & explanation
Published: 2017/03/30
Channel: The Audiopedia
The Control Process by Charbel El Khoury
The Control Process by Charbel El Khoury
Published: 2015/10/24
Channel: Interactive Teaching
Process Control Systems
Process Control Systems
Published: 2014/01/27
Channel: Analog Devices, Inc.
Basic Process Control: The Piping & Instrumentation Diagram
Basic Process Control: The Piping & Instrumentation Diagram
Published: 2016/05/23
Channel: Arjay Automation, Inc.
Laplace Transforms for Process Control
Laplace Transforms for Process Control
Published: 2015/10/08
Channel: APMonitor.com
What is SPC (Statistical Process Control)?
What is SPC (Statistical Process Control)?
Published: 2010/12/26
Channel: sixsigmamoneybelt
Process Instrumentation Systems
Process Instrumentation Systems
Published: 2014/03/15
Channel: EngineYaars
Second Order Systems in Process Control
Second Order Systems in Process Control
Published: 2015/10/19
Channel: APMonitor.com
iSpani 7 - Episode 10: Process control & instrumentation technician
iSpani 7 - Episode 10: Process control & instrumentation technician
Published: 2016/05/05
Channel: SABC Education Shows
PROCESS CONTROL INSTRUMENTATION TRAINING
PROCESS CONTROL INSTRUMENTATION TRAINING
Published: 2017/02/18
Channel: Instrumentation and Control Training Module
Complexity Made Simple - Why Statistical Process Control (SPC)
Complexity Made Simple - Why Statistical Process Control (SPC)
Published: 2015/11/30
Channel: Paul Allen
PRGR 650 Water Instrumentation and Process Control _ Introductory Movie
PRGR 650 Water Instrumentation and Process Control _ Introductory Movie
Published: 2015/01/06
Channel: Barbar Akle
Greg McMillan: Batch Process Control—Unique Challenges and Opportunities
Greg McMillan: Batch Process Control—Unique Challenges and Opportunities
Published: 2015/09/23
Channel: International Society of Automation - ISA
[3.d] Statistical Process Control 1
[3.d] Statistical Process Control 1
Published: 2013/01/02
Channel: Narendar Sumukadas
STATISTICAL PROCESS CONTROL AND PROCESS CAPABILITY
STATISTICAL PROCESS CONTROL AND PROCESS CAPABILITY
Published: 2013/11/09
Channel: iimtnew
Process Control
Process Control
Published: 2015/10/02
Channel: Digital Transitions - Phase One Dealer
Statistical Process Control Overview and Basic Concepts - What You Need to Know for the CQE Exam
Statistical Process Control Overview and Basic Concepts - What You Need to Know for the CQE Exam
Published: 2017/05/25
Channel: ASQStatsDivision
Process Control Block(PCB) | User and System(Kernel) Modes of Execution
Process Control Block(PCB) | User and System(Kernel) Modes of Execution
Published: 2017/02/27
Channel: Easy Engineering Classes
Simulink Process Control Exercise
Simulink Process Control Exercise
Published: 2013/09/14
Channel: APMonitor.com
C Batch Process Control System - Basic Video
C Batch Process Control System - Basic Video
Published: 2011/11/26
Channel: CBatchChannel
Introduction to OPC for Factory Automation and Plant Process Control
Introduction to OPC for Factory Automation and Plant Process Control
Published: 2011/03/31
Channel: TheOPCFoundation
Quality (Part 1: Statistical Process Control)
Quality (Part 1: Statistical Process Control)
Published: 2017/03/08
Channel: Infinity MFG
Statistical Process Control (SPC) in Hindi – (Part 1). SPC  हिंदी में सीखे।
Statistical Process Control (SPC) in Hindi – (Part 1). SPC हिंदी में सीखे।
Published: 2017/08/12
Channel: Quality HUB India
Applied Process Control for Chemical Engineers
Applied Process Control for Chemical Engineers
Published: 2012/11/06
Channel: APMonitor.com
Valve Design for Process Control
Valve Design for Process Control
Published: 2014/09/24
Channel: APMonitor.com
Batch Process Control
Batch Process Control
Published: 2012/08/31
Channel: eFactoryAlliance
Wastewater Treatment Process Control Testing
Wastewater Treatment Process Control Testing
Published: 2017/01/13
Channel: Athens WWTP
Operating System Process Control Blocks
Operating System Process Control Blocks
Published: 2014/05/04
Channel: John Philip Jones
Statistical Process Control Basic Control Charts
Statistical Process Control Basic Control Charts
Published: 2015/06/18
Channel: Russell Hills
Statistical Process Control: Control Charts for Proportions (p-chart)
Statistical Process Control: Control Charts for Proportions (p-chart)
Published: 2015/07/23
Channel: Joshua Emmanuel
Block Diagrams for Process Control
Block Diagrams for Process Control
Published: 2014/11/10
Channel: APMonitor.com
Process Control of a Distillation Column
Process Control of a Distillation Column
Published: 2012/12/04
Channel: APMonitor.com
Meet Mike Gardner,  Process Controls Engineer Co-op
Meet Mike Gardner, Process Controls Engineer Co-op
Published: 2013/01/17
Channel: DTEEnergyCompany
SAP GRC Process Control Videos
SAP GRC Process Control Videos
Published: 2015/11/19
Channel: Ajay Videos
SPC - Statistical Process Control
SPC - Statistical Process Control
Published: 2014/02/04
Channel: Matrix Industrial Control Systems Inc.
Process Controls Webinar
Process Controls Webinar
Published: 2015/07/30
Channel: Turnkey Consulting Limited
Introduction to Statistical Process Control
Introduction to Statistical Process Control
Published: 2015/06/18
Channel: Russell Hills
UNIX Process Control
UNIX Process Control
Published: 2012/12/20
Channel: Chitrakant Banchhor
Statistics for Quality Control and Process Validation Statistical Process Control SPC for Attribute
Statistics for Quality Control and Process Validation Statistical Process Control SPC for Attribute
Published: 2016/05/26
Channel: GlobalCompliance Panel
Instrumentation and Process Control System - The Plant at School – LabVolt Series 3531
Instrumentation and Process Control System - The Plant at School – LabVolt Series 3531
Published: 2012/02/08
Channel: Festo Didactic – LabVolt Series
PLC Level Process control
PLC Level Process control
Published: 2013/10/15
Channel: billkleitz
Introduction to Statistical Process Control Charts | Dr. Harper
Introduction to Statistical Process Control Charts | Dr. Harper's Classroom
Published: 2016/07/17
Channel: Dr. Harper's Classroom
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WIKIPEDIA ARTICLE

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Automatic Process control in continuous production processes is a combination of control engineering and chemical engineering disciplines that uses industrial control systems to achieve a production level of consistency, economy and safety which could not achieved purely by human manual control. It is implemented widely in industries such as oil refining, pulp and paper manufacturing, chemical processing and power generating plants,

There is a wide range of size, type and complexity, but it enables a small number of operators to manage complex processes to a high degree of consistency. The development of large automatic process control systems was instrumental in enabling the design of large high volume and complex processes, which could not be otherwise economically or safely operated.

The applications can range from controlling the temperature and level of a single process vessel, to a complete chemical processing plant with several thousand control loops.

Hierarchy of process control[edit]

Functional levels of a manufacturing control operation.

The accompanying diagram is a general model which shows functional manufacturing levels in a large process using processor and computer-based control.

Referring to the diagram;

  • Level 0 contains the field devices such as flow and temperature sensors (process value readings - PV), and final control elements (FCE) , such as control valves
  • Level 1 contains the industrialised Input/Output (I/O) modules, and their associated distributed electronic processors.
  • Level 2 contains the supervisory computers, which collate information from processor nodes on the system, and provide the operator control screens.
  • Level 3 is the production control level, which does not directly control the process, but is concerned with monitoring production and monitoring targets
  • Level 4 is the production scheduling level.

Types of process control[edit]

Processes can be characterized as one or more of the following forms:

  • Batch – Some applications require that specific quantities of raw materials be combined in specific ways for particular duration to produce an intermediate or end result. One example is the production of adhesives and glues, which normally require the mixing of raw materials in a heated vessel for a period of time to form a quantity of end product. Other important examples are the production of food, beverages and medicine. Batch processes are generally used to produce a relatively low to intermediate quantity of product per year (a few pounds to millions of pounds).
  • Continuous – Often, a physical system is represented through variables that are smooth and uninterrupted in time. The control of the water temperature in a heating jacket, for example, is an example of continuous process control. Some important continuous processes are the production of fuels, chemicals and plastics. Continuous processes in manufacturing are used to produce very large quantities of product per year (millions to billions of pounds). Such controls use feedback such as in the PID controller.
  • Hybrid - Applications having elements of batch and continuous process control are often called hybrid applications.

Control loops[edit]

Example of a continuous flow control loop. Signalling is by industry standard 4-20 mA current loops, and a "smart" valve positioner ensures the control valve operates correctly.

The fundamental building block of any industrial control system is the control loop, which controls just one process variable. An example is shown in the accompanying diagram, where the flow rate is a pipe is controlled by a PID controller, assisted by what is effectively a cascaded loop in the form of a valve servo-controller to ensure correct valve positioning.

Some large systems may have several hundreds or thousands of control loops. In complex processes the loops are interactive, so that the operation of one loop may affect the operation of another. The system diagram for representing control loops is a Piping and instrumentation diagram.

Commonly used controllers are programmable logic controller (PLC), Distributed Control System (DCS) or SCADA.

Example of level control system of a continuous stirred-tank reactor. The flow control into the tank would be cascaded off the level control.

A further example is shown. If a control valve were used to hold level in a tank, the level controller would compare the equivalent reading of a level sensor to the level setpoint and determine whether more or less valve opening was necessary to keep the level constant. A cascaded flow controller could then calculate the change in the valve position.

List of techniques and mechanisms used in process control[edit]

External links[edit]

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