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Process Control Fundamentals
Process Control Fundamentals
Published: 2014/03/10
Channel: Convergence Training
1. Introduction - Process Control Instrumentation -
1. Introduction - Process Control Instrumentation -
Published: 2016/03/07
Channel: Yokogawa: Industrial Automation
What is Process Control
What is Process Control
Published: 2016/03/23
Channel: Deacom, Inc.
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
Process Control Loop Basics
Process Control Loop Basics
Published: 2016/10/14
Channel: Pete Vree
Process Control and Instrumentation
Process Control and Instrumentation
Published: 2016/11/20
Channel: Ammonia technicians cafe
What is SPC (Statistical Process Control)?
What is SPC (Statistical Process Control)?
Published: 2010/12/26
Channel: sixsigmamoneybelt
Introduction To Process Control
Introduction To Process Control
Published: 2009/06/10
Channel: IDCTechnologies
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
Day in the Life: process control engineer
Day in the Life: process control engineer
Published: 2017/04/19
Channel: Chevron
Basic Process Control: The Piping & Instrumentation Diagram
Basic Process Control: The Piping & Instrumentation Diagram
Published: 2016/05/23
Channel: Arjay Automation, Inc.
Valve Design for Process Control
Valve Design for Process Control
Published: 2014/09/24
Channel: APMonitor.com
Process Control
Process Control
Published: 2015/10/02
Channel: Digital Transitions - Phase One Dealer
Laplace Transforms for Process Control
Laplace Transforms for Process Control
Published: 2015/10/08
Channel: APMonitor.com
Process Control Systems
Process Control Systems
Published: 2014/01/27
Channel: Analog Devices, Inc.
Process Control Charts
Process Control Charts
Published: 2012/11/29
Channel: Convergence Training
Honda Statistical Process Control
Honda Statistical Process Control
Published: 2014/09/12
Channel: Operations Management
PLC Level Process control
PLC Level Process control
Published: 2013/10/15
Channel: billkleitz
Block Diagrams for Process Control
Block Diagrams for Process Control
Published: 2014/11/10
Channel: APMonitor.com
Statistical Process Control |  R-Chart (Control Chart for Ranges)
Statistical Process Control | R-Chart (Control Chart for Ranges)
Published: 2015/07/19
Channel: Joshua Emmanuel
Applied Process Control for Chemical Engineers
Applied Process Control for Chemical Engineers
Published: 2012/11/06
Channel: APMonitor.com
Quality (Part 1: Statistical Process Control)
Quality (Part 1: Statistical Process Control)
Published: 2017/03/08
Channel: Infinity MFG
Batch Process Control
Batch Process Control
Published: 2012/08/31
Channel: eFactoryAlliance
Operating System Process Control Blocks
Operating System Process Control Blocks
Published: 2014/05/04
Channel: John Philip Jones
Georgia-Pacific Careers: Process Control Engineer
Georgia-Pacific Careers: Process Control Engineer
Published: 2014/02/21
Channel: Georgia-Pacific
Complexity Made Simple - Why Statistical Process Control (SPC)
Complexity Made Simple - Why Statistical Process Control (SPC)
Published: 2015/11/30
Channel: Paul Allen
STATISTICAL PROCESS CONTROL AND PROCESS CAPABILITY
STATISTICAL PROCESS CONTROL AND PROCESS CAPABILITY
Published: 2013/11/09
Channel: iimtnew
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 and Automation
Process Control and Automation
Published: 2012/04/05
Channel: Tony Gray
Process Control & Automation in Chemical Engineering (E20)
Process Control & Automation in Chemical Engineering (E20)
Published: 2016/07/27
Channel: Chemical Engineering Guy
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
What
What's SPC (Statistical Process Control) and MSA (Measurement System Analysis)? (Lean Six Sigma)
Published: 2016/05/08
Channel: econoshift.com
Wastewater Treatment Process Control Testing
Wastewater Treatment Process Control Testing
Published: 2017/01/13
Channel: Athens WWTP
Statistical Process Control
Statistical Process Control
Published: 2014/11/27
Channel: Jon Turner
SPC - Statistical Process Control
SPC - Statistical Process Control
Published: 2014/02/04
Channel: Matrix Industrial Control Systems Inc.
Lecture 33 (CHE 323) Statistical Process Control (SPC)
Lecture 33 (CHE 323) Statistical Process Control (SPC)
Published: 2013/10/09
Channel: Chris Mack
Introduction to Cascade Control
Introduction to Cascade Control
Published: 2016/06/01
Channel: LearnChemE
Statistical Process Control and Trending Analysis
Statistical Process Control and Trending Analysis
Published: 2016/06/27
Channel: GlobalCompliance Panel
How To... Draw a Basic Control Chart in Excel 2010
How To... Draw a Basic Control Chart in Excel 2010
Published: 2012/09/25
Channel: Eugene O'Loughlin
Mod-01 Lec-02 Lecture-02-Introduction to Process Control (Contd.)
Mod-01 Lec-02 Lecture-02-Introduction to Process Control (Contd.)
Published: 2012/07/06
Channel: nptelhrd
UNIX Process Control
UNIX Process Control
Published: 2012/12/20
Channel: Chitrakant Banchhor
Statistical Process Control | Chart for Means (x-bar chart)
Statistical Process Control | Chart for Means (x-bar chart)
Published: 2015/07/21
Channel: Joshua Emmanuel
SPC - Statistical Process Control
SPC - Statistical Process Control
Published: 2016/08/10
Channel: SMMT Industry Forum Ltd
Linux Basic Process Control Command
Linux Basic Process Control Command
Published: 2014/06/17
Channel: Linux Tutorial
Webcast of the Month: Process Control for Activated Sludge
Webcast of the Month: Process Control for Activated Sludge
Published: 2014/12/22
Channel: Water Environment Federation
Introduction to Statistical Process Control
Introduction to Statistical Process Control
Published: 2015/06/18
Channel: Russell Hills
ProSense Digital Panel Meters - Process Control KickStart
ProSense Digital Panel Meters - Process Control KickStart
Published: 2016/05/23
Channel: AutomationDirect.com
SAP GRC 10.1 PROCESS CONTROL Training | GRC ACCESS CONTROL Demo Video
SAP GRC 10.1 PROCESS CONTROL Training | GRC ACCESS CONTROL Demo Video
Published: 2015/03/31
Channel: Rajesh Globalonlinetrainings
Statistical Process Control
Statistical Process Control
Published: 2013/02/06
Channel: Dr. Harvi Millar
UCP: Computer Controlled Process Control System (with electronic control valve)
UCP: Computer Controlled Process Control System (with electronic control valve)
Published: 2013/06/04
Channel: EDIBON INTERNATIONAL
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WIKIPEDIA ARTICLE

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Example of control system of a continuous stirred-tank reactor.
Control panel of a nuclear reactor.

Process control is an engineering discipline that deals with architectures, mechanisms and algorithms for maintaining the output of a specific process within a desired range. For instance, the temperature of a chemical reactor may be controlled to maintain a consistent product output.

Process control is extensively used in industry and enables mass production of consistent products from continuously operated processes such as oil refining, paper manufacturing, chemicals, power plants and many others. Process control enables automation, by which a small staff of operating personnel can operate a complex process from a central control room.

Background[edit]

Block diagram of a closed control (Feedback) loop
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.

Process control may either use feedback or it may be open loop. Control may also be continuous (automobile cruise control) or cause a sequence of discrete events, such as a timer on a lawn sprinkler (on/off) or controls on an elevator (logical sequence).

A thermostat on a heater is an example of control that is on or off. A temperature sensor turns the heat source on if the temperature falls below the set point and turns the heat source off when the set point is reached. There is no measurement of the difference between the set point and the measured temperature (e.g. no error measurement) and no adjustment to the rate at which heat is added other than all or none.

A familiar example of feedback control is cruise control on an automobile. Here speed is the measured variable. The operator (driver) adjusts the desired speed set point (e.g. 100 km/hr) and the controller monitors the speed sensor and compares the measured speed to the set point. Any deviations, such as changes in grade, drag, wind speed or even using a different grade of fuel (for example an ethanol blend) are corrected by the controller making a compensating adjustment to the fuel valve open position, which is the manipulated variable. The controller makes adjustments having information only about the error (magnitude, rate of change or cumulative error) although settings known as tuning are used to achieve stable control. The operation of such controllers is the subject of control theory.

A commonly used control device called a programmable logic controller, or a PLC, is used to read a set of digital and analog inputs, apply a set of logic statements, and generate a set of analog and digital outputs.

For example, if an adjustable valve were used to hold level in a tank the logical statements would compare the equivalent pressure at depth setpoint to the pressure reading of a sensor below the normal low liquid level and determine whether more or less valve opening was necessary to keep the level constant. A PLC output would then calculate an incremental amount of change in the valve position. Larger more complex systems can be controlled by process control systems like Distributed Control System (DCS) or SCADA.

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 computerised control.

Referring to the diagram;

  • Level 0 contains the field devices such as flow and temperature sensors, and final control elements, 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 processes using process control[edit]

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

  • Discrete – Found in many manufacturing, motion and packaging applications. Robotic assembly, such as that found in automotive production, can be characterized as discrete process control. Most discrete manufacturing involves the production of discrete pieces of product, such as metal stamping.
  • Batch – Some applications require that specific quantities of raw materials be combined in specific ways for particular durations 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).

Applications having elements of discrete, batch and continuous process control are often called hybrid applications.

Examples[edit]

  • An anti-lock braking system (ABS) is a complex example, consisting of multiple inputs, conditions and outputs.
  • Aircraft stability control is a highly complex example using multiple inputs and outputs.

See also[edit]

External links[edit]

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