INTRODUCTION TO

AUTOMATIC PROCESS
CONTROL
Reasons to control an industrial
process
 Safety
 Quality
 Speed
 Precision
 Repeatability
 Profit
 Competitive
 Resources Optimization
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 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.

 A system is a combination of components

that work together and realize a specific
objective.
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 System
System

Distributed Lumped
Classification
Parameter Parameter

Stochastic Deterministic

Discrete Continuous

Nonlinear Linear

Time Time
Varying Invariant
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 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.

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 Definitions
 Input and Output

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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.

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 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

 In Open-Loop Control, the controller is not a function of

the process variable. It is not concerned that a particular
Set Point is maintained, the controller output is fixed at a
value. The accuracy of the system depends on
calibration. These kind of systems can not reject
disturbances.
 Disturbances are uncontrolled changes in the process
inputs or resources.
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Closed-Loop Control
 In Closed-Loop Control the controller output is determined
by the difference of the Process Variable and the Set
Point.
 Error is the deviation of the Process Variable from the Set
Point, it means E=SP-PV.
 Closed-Loop Control is also known as Feedback 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

 Measurement (M), measuring the variable to be

controlled is usually done by the combination of the
sensor and the transmitter.
 Decision (D), on the basis of the measurement, the
controller decides what to do to maintain the variable at
its desired value.
 Action (A), as a result of the controller’s decision, the
system must then take an action, which is accomplished
by the Final Control Element.

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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.

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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

 In some processes, the controlled variable deviates

from the Set Point because of disturbances.
Systems designed to compensate for these
disturbances exert Regulatory Control.

 In some other instances, the Set Point may be

changed as a function of time, and therefore the
controlled variable must follow the Set Point
dynamically. Systems designed for this purpose
exert 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.

Manual Liquid Level Control System.

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Functional Block Diagram
Manual Liquid Level Control System.

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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

A temperature control system works sensing the difference

between the adjust from the thermostat and the actual
temperature, opening a valve of combustible with a
quantity proportional to this difference.
Draw the corresponding 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

Functional Block Diagram

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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.

DEADLINE TWO WEEKS 37