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IPC Week 1 19022024 113005am

The document discusses industrial automation and process control. It covers topics like control systems, process control block diagrams, different types of controls, advantages and disadvantages of automation. It also discusses concepts like stability, steady state and transient state regulation in control systems.

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fatmanasir284
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42 views45 pages

IPC Week 1 19022024 113005am

The document discusses industrial automation and process control. It covers topics like control systems, process control block diagrams, different types of controls, advantages and disadvantages of automation. It also discusses concepts like stability, steady state and transient state regulation in control systems.

Uploaded by

fatmanasir284
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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OBJECTIVE

To get the basics of process control loop, signal


conditioning, sensors, relay logic and PLC
programming.
RESOURCES
• “Process control instrumentation technology”,
Curtis D. Johnson, 8th edition.
• “Industrial Control Electronics”, Bartelt,2nd
edition,.
• Whatsapp group
• Email id: sumaid.buic@bahria.edu.pk
Marks distribution
• 20% quiz
• 10% assignments
• 20% Midterms
• 50% finals
What is Industrial Automation?
• According to Wikipedia automation is:
Automation or automatic control, is the use of
various control systems for operating equipment
such as machinery, processes in factories, boilers
and heat treating ovens, switching in telephone
networks, steering and stabilization of ships,
aircraft and other applications with minimal or
reduced human intervention. Some processes have
been completely automated.
Industrial Automation in Manufacturing
• The use of “intelligent” machines in factories
so that manufacturing processes can be carried
out with minimal human intervention.
• Several different means, including mechanical,
electrical, electronic, hydraulic, pneumatic, and
computers or combination of many. Today’s
state-of-the-art factories, ships, and airplanes
combine all of these techniques.
Advantages & Disadvantages
• Advantages:
(1) Leaner operation processes that require
a. Less energy,
b. Less material
c. Reduced labor waste.
(2) Improvements in:
a. Quality
b. Accuracy
c. Precision.
• Disadvantages:
(1) High costs of R&D
(2) Installation of equipment.
Current state of industrial automation
• Although “lights-out” manufacturing, a concept
in which the lights can be switched off leaving
everything to the robots, is still a dream,
remarkable progress has been made since the
1980s.
• Many repetitive and high precision work in
large factories, such as in car assembly lines,
have been taken over by industrial robots.
Lights out
Lights out
Lights out
INTRODUCTION TO PROCESS CONTROL
• Introduction
• Control systems
• Process control block diagram
• Control system evaluation
• Analog and digital processing
• Units, Standards and definition
• Sensor time response
• Significance and statistics
1.2) CONTROL SYSTEMS
• Process-control Principles: Regulate or to
maintain the quantity at some desired value
called set point or reference value.
• Types of controls(w.r.t methods):
1. Human aided control.
2. Automatic control.
1.2) CONTROL SYSTEMS
• Process :Qout = K(h)0.5
SELF REGULATION
• For some input flow rate, the liquid height will rise until
it reaches a height for which the output flow rate
matches the input flow rate.
• A self-regulating system does not provide regulation of
a variable to any particular reference value.
• If the system is self regulated, process control is not
required.
• Example 1: The tank has a relationship between flow
and level given by Qout = K(h)0.5 where h is in feet and K=
1.156 . Suppose the input flow rate is 2 gal/min. At what
value of h will the level stabilize from self-regulation?
Human Aided Control(artificial control)
Controlled variable h
Controlling variable Q out
Addition in system Sight tube, valve
Automatic control
Types of Industrial Automation(wrt
controlled variable)
• Process control
• Servomechanism
• Discrete State control system
1.2.2) Servomechanism
• Servomechanism forces the controlled variable value
to follow variation of reference value.
Force the arm to
move from point A
to point b along a
specific path, speed
of motor driving the
arm and angle of
arm parts must be
controlled
1.2.3) Discrete state control system
Controls sequence of events in over all process.
Consider paint manufacturing process.
• Event 1:heating of paint at regulated
temperature for certain length
• Event 2: pump paint into the tank at specific
flow rate.
• Event 3: stirred at specific speed for certain
length of time
This type of control is achieved by PLC and relays.
Automatic control
1.3)Process Control Block Diagram

Control action
Evaluation takes place based
Comparison takes place on evaluation
with SP and on Actuator is used if
result has measured needed
both indication
magnitude
and polarity Complex assembly
of phenomena
working in
sequence

Measuring the CV
and conversion into
corresponding analog
of variable
Activity
• Draw control loop for following system?
Activity
This is known as
feedback loop as we
determine the error
and feed back the
correction to system
Home Assignment
• Draw process control loop for temperature control in refrigerator?
1.4) Control System Evaluation
• Evaluation criterion.
1. Stability
2. Steady state regulation
3. Transient regulation
Control System Evaluation
• A practical statement of control system
objective is best represented by three
requirements:
1. The system should be stable.
2. The system should provide the best possible
steady-state regulation.
3. The system should provide the best possible
transient regulation.
Stability
• How tightly we try to control the variable.
• Tighter the control, greater the possibility of
instability.
Steady-State Regulation
• Allowable deviation from set point.
• If set point is 150 degree and steady-state
deviation is ±2 degrees.
• Smaller the standard deviation better the
system.
Transient state regulation
• How the system reacts when
1. Set point is changed
2. Controlling variable is changed.
• There are two basic types of transient
responses.
1. Damped response
2. Cyclic response.
Damped response
• Error has only one polarity
• Quantities measured
1. Td
2. Emax
3. Error is inversely proportional to Td
Td:
Td: time
time period
period of
of 10%
10% to
to Td: time period from
90% of change
90% of change start of disturbance to
4% within the range
Cyclic response.
• Control variable oscillates about set point.
1. Td Td: time period when
CV first exceeds the
2. Emax allowable range to
the time when it falls
3. Error is inversely proportional to Td between allowable
range
Cyclic tuning criteria
• Cyclic response can be tuned in following ways.
1. Minimum area criteria
2. Quarter amplitude criteria.
a) Minimum area criteria b) Quarter amplitude criteria
Analog and Digital Processing
• Data Representation: how the magnitude of
some physical variables represented in control
loop. There are two types of representations.
1. Analog Data: There is a smooth and
continuous variation between a
representation of variable value and itself.
Data Representation
2.Digital Data: Numbers are represented in bits
1’s and 0’s. Disadvantage: If analog
data changes from 4.25
to 4.75 digital data
remains at”0100”
Types of Control systems
Three basic types of control systems are
1. ON/OFF control or discrete control
2. Analog control
3. Digital control
4. PLC
ON/OFF control or Discrete Control
• System is called On/OFF controller because
control element has only two states 1 and 0.
Analog Control
• True analog control exist when all the variables
in the system are analog representation of
other variable.
Digital Control
• There are two types of digital control.
1. Supervisory control
2. Direct Digital Control (DDC)
Digital Control
• Supervisory control
Digital Control
• Direct Digital Control (DDC)

Smart Sensor:
Package
containing
sensor, signal
conditioning,
ADC, Computer
Controller, DAC
Network Controlled System
• Combination of Smart sensors connected
through LAN, Communicating at standard
protocols.
• Master Control, Financial Control and
Engineering Computer are also connected for
administrative purpose.
PLC
Exercise
Units, Standards and Definitions
• Units:

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