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PROCESS CONTROL
Prepared by: Dave Danque
WHAT IS PROCESS CONTROL?
Many different operations are performed in an industrial machine to manufacture a product. Each one of these operations is referred to as process.
Process control is the automatic operations performed by an industrial manufacturing machine.
Prepared by: Dave Danque
EXAMPLES OF INDUSTRIAL MANUFACTURING MACHINES
Metal Cutting Machine Prepared by: Dave Danque
Metal Forming Machine Prepared by: Dave Danque
PROCESS MEASUREMENT AND CONTROL
Raw materials are manipulated through various processes to manufacture goods and provide public services.
These products and services are provided by either in BATCH PROCESSES or by CONTINUOUS PROCESSES.
Prepared by: Dave Danque
I. CATEGORIES OF CONTROL
Prepared by: Dave Danque and Jane – Josanin Elizan
A. BATCH PROCESSES• Products are made one batch at a time.
Prepared by: Dave Danque
NEWSPAPER
BREAD
A. BATCH PROCESSES
• Usually in smaller quantities than the products produced by the continuous method.
• A sequence of steps is performed.
• Products are made by putting ingredients into a vessel, called a reactor, and then causing them to react to form a product.
Prepared by: Dave Danque
A. BATCH PROCESSES
Prepared by: Dave DanqueBATCH REACTOR
A. BATCH PROCESSES
• The type of material used to construct the reactor depends on factors such as:
(1)its capability to withstand the corrosiveness of the ingredients inside, and
(2) its capability not to contaminate the contents inside.
Prepared by: Dave Danque
1. CONTROL REQUIREMENTS
a) Controlling the Quantity of Raw Materials
• Determining the weight of the ingredients inside the reactor with a pressure sensor.
• Using a level sensor to read the height of the ingredients in the vessel.
Prepared by: Jane – Josanin Elizan
Prepared by: Jane – Josanin Elizan
• Calculating the volumetric flow rate of a raw material being fed into the reactor by using a flowmeter.
Prepared by: Jane – Josanin Elizan
b) Controlling the Process Variables During the Reaction Cycle
• The two most common variables that must be regulated to control the rate of reaction are the temperature and pressure.
• Applying thermal energy and maintaining the temperature at a certain level is critical to most batch processes.
Prepared by: Jane – Josanin Elizan
ENDOTHERMIC PROCESSES
Prepared by: Jane – Josanin Elizan
EVAPORATING LIQUID WATER
BAKING BREAD
EXOTHERMIC PROCESS
Prepared by: Jane – Josanin Elizan
COMBUSTION OF FUELS LIKE COAL
SETTING OF CEMENT & CONCRETE
•Most batch reactors use a thermal jacket and circulation coils
Prepared by: Jane – Josanin ElizanBATCH REACTOR
c) Controlling Each Step in the Sequence
Feeding (Feeders) Mixing (Mixing Plant with Tandem Vessel)
Prepared by: Jane – Josanin Elizan
Heating Cooling (Infrared Convection Oven) (Fluid Bed Dryer)
Prepared by: Jane – Josanin Elizan
Reacting Discharging
Prepared by: Jane – Josanin Elizan
Cleaning
Prepared by: Jane – Josanin Elizan
TYPES OF BATCH PROCESSES
Prepared by: Sheena Guiking
2. TYPES OF BATCH PROCESSES
A. Mixing/Blending involves combining two or more ingredients together and may only require a one-step process.
• Example : Mixing paint
Prepared by: Sheena Guiking
B. Chemical Reaction involves combining two or more materials or reactants to form a product. The reaction usually occurs under the influence of temperature, pressure and agitation and by introducing a catalyst.
• Example : Fertilizers
Prepared by: Sheena Guiking
C. Separation refers to the removal of an ingredient from the mixture. Another type of separation process is crystallization, which is the formation of a solid material from a solution, vapor, melted material, or solid that is in a different phase of the reaction.
• Example : Pharmaceuticals
Prepared by: Sheena Guiking
D. Polymerization involves the combination of a large number of molecules to form a new product.
• Example : Plastics, synthetic materials
Prepared by: Sheena Guiking
B. CONTINUOUS PROCESS
Prepared by: Lara Litusquen
• Raw materials are continuously passed through manufacturing equipment at a controlled rate, and the end product is continuously withdrawn.
• Designed to manufacture a large volume of a particular product.
Prepared by: Lara Litusquen
• Examples of this:
PETROLEUMCHEMICALS
Prepared by: Lara Litusquen
CONTINUOUS PROCESS
MANUFACTURING EQUIPMENTS
Prepared by: Lara Litusquen and Stephen John Trinidad
SCREENS AND ROLLERS ON A PAPER
MACHINE
EXTRUDERS THAT SHAPE PLASTIC
BAGSPrepared by: Lara Litusquen
EVAPORATOR THAT PROCESSES LIQUIDS Prepared by: Lara Litusquen
1. CONTROL REQUIREMENTS
A. Controlling the Quantity of Raw Materials
• Materials can be: (1) granules, (2) powder,(3) pulp, (4) sewage, (5) water, and/or (6) petroleum.
Prepared by: Lara Litusquen
• The quantities of these materials are measured primarily by various types of flow sensors. Flow valves are used to vary the rate at which the raw materials are fed into the process.
FLOW VALVES
Prepared by: Lara Litusquen
b. Controlling Operating Parameters During the Process
i. Temperature – heating and cooling
ii. Pressure – to raise the boiling temperature and to shorten the reaction time
iii. Level – to determine the amount of material that is inside the vessel
Prepared by: Stephen John Trinidad
iv. Flow – to maintain temperature and to regulate pressure level
V. Product CompositionComposition – conditions of the product solution
often affected by temperature, flow, level, and pressure
Analyzer – a sensor used to measure status
Analytical Control – controlling the composition of the product
Prepared by: Stephen John Trinidad
II. CLASSIFICATIONS
OF CONTROL
Prepared by: Lailani Marie Delos Santos and Zyrill Mae Aguirre
• This process requires an addition of a feedback loop making it self-regulating. Its primary element is a sensor. The sensor’s output is the measured variable. The controller then compares feedback signal to the set point. An error signal determines which type of control signal to produce at its output. The control signal is the one being sent to the final control element. The manipulated variable, however, causes a change in the controlled variable.
Prepared by: Zyrill Mae Aguirre
2. CLASSIFICATION OF CONTROL
A. OPEN-LOOP CONTROL
Prepared by: Lailani Marie Delos Santos
• This process is controlled only by setpoint commands, without feedback measurement signals.
Prepared by: Lailani Marie Delos Santos
• Examples :
CAFETERIA DISHWASHERS
LAUNDRY MACHINES
Prepared by: Lailani Marie Delos Santos
• As an advantage, it is relatively inexpensive. But it has no control capabilities to make corrections if the process deviates from its required state.
Prepared by: Lailani Marie Delos Santos
B. CLOSED-LOOP CONTROL
Prepared by: Zyrill Mae Aguirre
CLOSED – LOOP TEMPERATURE PROCESS
Prepared by: Zyrill Mae Aguirre
PROCESS BEHAVIOR
• Variable – an element varies when an influence to which it is exposed causes change.
• Change can happen when :- a disturbance appears -load demands vary - setpoints are adjusted
• Step change – takes place over a small time interval
Prepared by: Zyrill Mae Aguirre
ADVANCED CONTROL TECHNIQUES
Prepared by: Reofe Ellinore Flores
C. ADVANCED CONTROL TECHNIQUES
1. CASCADE CONTROL – designed to respond to changes in the controlled variable
2. FEED-FORWARD CONTROL – process must deviate from setpoint before control action is applied
Prepared by: Reofe Ellinore Flores
3. RATIO CONTROL – proportionally control the flow of one ingredient based on the amount of flow of another ingredient.
4. ADAPTIVE CONTROL –accommodates non-linear processes
Prepared by: Reofe Ellinore Flores
FEEDBACK SYSTEM VERSUS FEED-FORWARD CONTROL
• A feedback system determines a correction that needs to be made after the controlled variable deviates from set point. While a feed-forward control is used when no variation from setpoint can be tolerated in a process or when a system is very slow in responding to corrective action.
Prepared by: Reofe Ellinore Flores