Saturday, March 05, 2011

Industrial Process Control

EL 4223

Instructor:
Prof. Azhar Hussain Shah
Engr. Nabeel Khalid

Engr. Nabeel Khalid

Lecturer
FOE,UCP
 Saturday, March 05, 2011

Lecture 1

Engr. Nabeel Khalid

Lecturer
FOE,UCP
 Saturday, March 05, 2011

Outline
Introduction

Recommended Text

Grading Criteria

What is Process Control

Automatic Process Control

Process Control Loop

Feed Back Process Control Loop

Types of Processes
Engr. Nabeel Khalid
Lecturer
FOE,UCP
 Saturday, March 05, 2011

Recommended Text
 Measurement and Control Basics By Thomas A. Hughes
 Fundamentals of Final Control Elements
By Helen Beecroft Ken MacDonald

 Industrial Process Control Systems

By Dale Patrick & Stephen Fardo

 Process Control Instrumentation Technology

By Curtis D. Johnson

 Fundamentals of Industrial Instrumentation and

Process Control
By William C. Dunn
Engr. Nabeel Khalid
Lecturer
FOE,UCP
 Saturday, March 05, 2011

Grading Criteria
Theory (2 Credit Hrs.)
Mid Term 25%
Final Term 50%
Sessional 25%
Total 100%
Note:
 Announcements will be available on
http://online.ucp.edu.pk
 Office Hours: Mon & Wed 0900-1100 hrs
 E-mail: nabeel.khalid@ucp.edu.pk

Engr. Nabeel Khalid

Lecturer
FOE,UCP
 Saturday, March 05, 2011

What is a Process Control?

 Observing a parameter, comparing it to some desired
value, and initiating a control action to bring the
parameter as close as possible to the desired Value” this
is known as process control. e.g. use of fire to regulate
the temperature of room.

Engr. Nabeel Khalid

Lecturer
FOE,UCP
 Saturday, March 05, 2011

What is an Automatic Process Control?

 Automatic control of an output variable by sensing the
amplitude of the output parameter from the process and
comparing it to desired or set level and feeding an error
signal back to control an input variable.
 Process control will automatic, when there will be no
human intervention in that process and all the action will
take place automatically.
e.g. use of Air Conditioner to regulate the temperature of
room.

Engr. Nabeel Khalid

Lecturer
FOE,UCP
 Saturday, March 05, 2011

What is a Automatic Process Control?

 Figure (a) shows manual control system in which valve is
controlled manually by a human being after sensing the
temperature of water.
 Figure (b) shows automatic process control in which
sensor senses the temperature of the water and
controller generates a signal towards actuator to control
the temperature of water heater.

Engr. Nabeel Khalid

Lecturer
FOE,UCP
 Saturday, March 05, 2011

Process Control loop

Engr. Nabeel Khalid

Lecturer
FOE,UCP
 Saturday, March 05, 2011

Feedback path in a Process Control Loop

Engr. Nabeel Khalid

Lecturer
FOE,UCP
 Saturday, March 05, 2011

Process Control with Flow Regulator

Engr. Nabeel Khalid

Lecturer
FOE,UCP
 Saturday, March 05, 2011

Example
 Figure shows the block diagram of a closed-loop flow
control system.
Identify the following elements: (a) the sensor, (b) the
transducer, (c) the actuator, (d) the transmitter, (e) the
controller, (f) the manipulated variable, and (g) the
measured variable.

Engr. Nabeel Khalid

Lecturer
FOE,UCP
 Saturday, March 05, 2011

Different Process Control systems

 Systems that respond to changes in pressure are one of
the largest divisions in process control field.
 These systems include
Hydraulic s
Pneumatics
Steam or vapor systems
Liquid distribution systems.

Engr. Nabeel Khalid

Lecturer
FOE,UCP
 Saturday, March 05, 2011

Hydraulic Systems
 This type of system is commonly found in automatic
machinery control and in material forming
operations.
 Popularity of this system can be attributed to the
following things
Operational simplicity
Smoothness of operation
Reliability
Adaptability
Engr. Nabeel Khalid
Lecturer
FOE,UCP
 Saturday, March 05, 2011

Double-acting Hydraulic System

Engr. Nabeel Khalid

Lecturer
FOE,UCP
 Saturday, March 05, 2011

Pneumatic Systems
 This type ofsystem commonly found their
applications in powering of hand tools and lifting and
clamping of products during machining operations.

Engr. Nabeel Khalid

Lecturer
FOE,UCP
 Saturday, March 05, 2011

Static Pressure Systems

 This type of system commonly used in industry to
distribute liquids in a variety of processing
applications.
 This type of systems utilizes pressure that is
developed as a result of the source being elevated
above other system components.

Engr. Nabeel Khalid

Lecturer
FOE,UCP
 Saturday, March 05, 2011

Steam Pressure Systems

 This type ofsystem develops pressure by
transforming liquid into vapor when heat is applied.
 The resulting pressure occurs when steam or vapor is
forced to pass through the resistance of confined
pipes or tubes.

Engr. Nabeel Khalid

Lecturer
FOE,UCP
 Saturday, March 05, 2011

Temperature Systems
 These systems must perform following actions
Generate heat
provide path for its distribution
Initiate some type of control
Utilize this energy to do work
Record the value of temperature through precise
measurement.
 For measurement of temperature, RTD (Resistance
Temperature Detector), noncontact infrared
thermometer etc can be used.
Engr. Nabeel Khalid
Lecturer
FOE,UCP
 Saturday, March 05, 2011

Level Determination Systems

 These systems are used to evaluate the amount of
material in a tank, bin, or hopper that is available for
accomplishing a particular process.
 These systems are often considered as control function
that applies to a variety of different processes.
 Sensing element detects change in level.

Engr. Nabeel Khalid

Lecturer
FOE,UCP
 Saturday, March 05, 2011

Flow Process Systems

 These systems are used to monitor and control water,
natural gas, solvents, chemicals and an infinite variety of
other materials.
 Operation of these systems is based on the followings
Actual material that is flowing
Density of the material
Volume being processed
Accuracy
Type of control required
 Measurement and control of flow are the major functions
of a flow process.
Where flow rate is the evaluation occurs at specific instant
Where totalizing flow is the total amount moves part a given
point during specific period. Engr. Nabeel Khalid
Lecturer
FOE,UCP
 Saturday, March 05, 2011

Flow Process Systems

 A. Flow measurement with in pipe flow dead pressure
Principal.
Differential pressure =flow.
 B. Electromagnetic principal.
 C. Target principal.

Engr. Nabeel Khalid

Lecturer
FOE,UCP
 Saturday, March 05, 2011

Flow Process Systems

 Laminar flow:
Flow that means in a straight line.

Figure: Laminar Flow

meters

Engr. Nabeel Khalid

Lecturer
FOE,UCP
 Saturday, March 05, 2011

Flow Process Systems

Figure: Liquid vortex flow meters

Engr. Nabeel Khalid
Lecturer
FOE,UCP
 Saturday, March 05, 2011

Any Questions……..

Engr. Nabeel Khalid

Lecturer
FOE,UCP