Process Control Training: What is Process Control? (Amatrol)

In this video, Amatrol answers a familiar question from those unfamiliar with industry: "What is process control?" This video gives a basic definition of process control, how and where it's utilized in industrial application, and how we can help with your process control training needs.

Need more info? Visit www.amatrol.com to learn more about our process control training systems.

Transcript:
What is Process Control?

Today’s industries apply a continuous series of processes to raw materials to transform them into finished products.

These processes must be carefully monitored to ensure quality products are produced efficiently, economically, and safely.

Sophisticated process control systems automate most, if not all, of the monitoring and adjustment of the processes they control.

These systems allow a relatively small number of highly-skilled workers to control the large number of complex processes involved in the mass production of a product with a high degree of consistency.

For example, a variety of sensors and meters can be used to measure and monitor numerous process variables, such as the proportion of ingredients in a mixture, the acidity of a liquid, or the temperature and pressure under which materials are stored. Even tiny variations in process variables can cause significant problems in the final product.

Sensors continually transmit data about the status of process variables.

Specialized controllers receive and compare data from many different sensors.

If a process variable strays beyond set parameters, controller software will trigger necessary adjustments to bring the variable back within range.

A simple example of process control that all students should be familiar with is basic climate control via a thermostat and heating/cooling system.

When a gauge detects that the temperature has dropped below a pre-set level, a signal is sent to the thermostat, which will turn on the heating system until the temperature reaches the appropriate level.

This simple process control loop will repeat continuously to keep the temperature within a specific range.

Of course, today’s advanced manufacturing facilities mass producing intricate products will utilize thousands of sophisticated, complex process control loops to control a wide variety of process variables.

There are many different types of process control systems.

Three of the most common are programmable logic controllers (PLC), supervisory control and data acquisition (SCADA), and distributed control systems (DCS).

These systems can include and interface with a large range of process control instrumentation and controllers to monitor and control industrial processes.

They can also control processes in a Smart Factory by communicating data directly to a company’s enterprise resource planning (ERP) system via manufacturing execution system (MES) software.

The many benefits of process control systems are evident to those who work closely with them.

Not only are quality products produced consistently and safely, but profitability is enhanced through energy savings and lower manufacturing costs.

Negative environmental impacts can also be minimized through careful process control.