COEG401
Computing is moving from :
Sequential
Centralized
Parallel
Decentralized
Automatic control in all industries has been able to cover
whole plant under an unified coordination and control.
Systems are designed using expert system( neural network,
fuzzy logic, high performance microprocessor, PLC)
If quality of raw material and skill of operators varies so
does quality of product.
So process control – in order to produce material of
consistent quality at competitive price.
Physical process:
Combination of operations performed in order to act on and
change something in physical world.
Example: industrial , chemical transportation.
i/p and o/p for physical process
Material
Energy
Information(Variables that control and work with process; also include software,
memo, delivery order etc. of company)
The model of generic physical process
ENVIRONMENT
MATERIAL
MATERIAL
INPUT
PHYSICAL OUTPUT
ENERGY PROCRESS ENERGY
INPUT OUTPUT
INFORMATION INFORMATION
INPUT OUTPUT
Better use of information better use of material and energy.
DIGITAL COMPUTER
• For information processing related to physical
process.
• Used to check:
That parameter remain with in given limits.
Control the process
Desired output is obtained with in limit.
Computer for Data Computer for Industrial
Processing Processing
Doesn’t matter slow or Doesn’t control the flow
fast result is same. but must flow at pace of
external event.
Accounting, text editing,
calculations. counting no. of item,
packaging.
USE OF COMPUTER IN PROCESS CONTROL
ENVIRONMENT
DISTURBANCES
MATERIAL
MATERIAL
INPUT
PHYSICAL OUTPUT
ENERGY PROCRESS ENERGY
INPUT OUTPUT
PROCESSNG
INFORMATION
I/P & O/P
INFORMATION INFORMATION
INPUT
DIGITAL OUTPUT
COMPUTER
REAL TIME OPERATION
• Process computer must do:
processing i/p data without changing rate of i/p.
information exchange with human operator, data presentation,
reaction of particular signals
1. Data Acquisition System
2. Operator Guideline System
• Knowledge based
system
• Provide guidelines to
the operator
• Adjusting of set-
point of analog
controllers
3. Supervisory Control System
• In 1959 RW-300 computer was used to implement a
supervisory control system for a polymerization plant.
• The operator guideline system fully automated
4. Direct Digital Control (DDC) with Analog Backup
◦ In 1962 Ferranti Argus 200 computer was used by Imperial
Chemical Industries England to implement direct digital control.
◦ Control Algorithm in Process Computer
◦ Analog Controllers as back-up
5. Hierarchical Computer Based Operation
In 1964 Combined supervisory and ddc- hierarchical control.
Increased complexity requires use of high level language
Larger code size requires memory management (swapping
to/from 'core')
Different process timescales requires and use of multi-rate
sampling and use of interrupts
Examples: Temperature control of Heat Exchanger
1. Analog control of Heat Exchanger
2. Analog control + Data Acquisition System of Heat Exchanger
3. Direct Digital Control of Heat Exchanger
Example code
double set_point; //setpoint of temperature
double temp; //temperature of the heat exchanger
double control_signal; //valve opening
double error_signal;
double k=50.0;
//following code (code for P-controller) is
//called by a timer interrupt
//in every 1 miliseconds (fixed sampling rate)
{
set_point=aquire_set_point();
//gets set point from operator
temp=acquire_temp();
//gets temp reading from IO Card
error_signal=set_point-temp;
control_signal=k*error_signal;
set_control_signal(control_signal);
//sets control signal of IO card
}
4. Hierarchical Control of Heat Exchanger
