Computerized process control ;Unit -1

Introd uction :
Control system :
A control system is a device or set of devices to manage, command, direct or regulate the behaviour
of other devices or systems.
Requirement of a control system :
1.) Adaptability and flexibility
2.) Universal application
3.) Defines time indulgement such as response time
4.) Extensive diagnostic features
5.) Expandability
Types of control system:
There are 2 types of control system
1.) Open loop control system
a.) In case of open loop control system output is depending only on input applied there is
no feedback.
b.) Suppose you want to control speed of the motor by using open loop control system then
you have to vary the input applying till the desire speed is reached.
c.) In case of open loop control system continuous monitoring of output is necessary.
d.) It is less expensive but accuracy is not so good.
e.) Thus there was a demand of such system which can rule out this problem and led to the
introduction of close loop control system.

I/P applied

Open loop
control system

O/P obtained

2.) Close loop control system

a.) In this case output obtained not only depend upon input , it basically depends on the
comparitative result of input applied and feedback of what we have obtained from this
input at ouput.
b.) This comparision generates an error signal if there is any difference in desired ouput.
c.) This error signal is then amplified and fed fed to a actuator, which produces a controlled
system in a particular way to get desired ouput from plant.
d.) This system is called close loop control system.
e.) It is very essential and gives almost accurate results for big systems both in daily use
purpose and industrial purpose. Eg : washing machine, motor generation etc.

Output
i/p

Amplifier

Actuator

Controlling
Device

Feedback
transducer
Referrence (desired output)

Controlled output

Industrial Automation :
a.) Automation or industial automation is the use of control systems such as PLC, SCADA, HMI
etc to control industrial machinery and processes, replacing human operators.
b.) Automation greatly reduces the need for human sensory and mental requirements.

Need for automation :

1.) Higher productivity.
2.) shorter process change times.
3.) Accuracy of control.
4.) Greater reliability and equipment life.
5.) To add flexibility to process.

Advantages of automation :
1.) Optimum contribution of energy and raw material.
2.) Optimum co-ordination and co-operation between mechanical and electronic counter
performance of a task.
3.) Performance of a task with the application of least physical efforts.

Functional flow block diagram (FFBD) :

1.) A function block diagram describes a function between inputs and outputs and should
describe the system in one picture.
2.) What should it include
a.) Show All major system components
b.) Interfaces to the outside world
c.) Interfaces between subsystems
d.) Clearly identify power, data, and structural interfaces
e.) Should answer how the mission statement is met
f.) Easy to read
3.) It is a multitier , time-sequenced, step by step flow diagram of a systems functional flow.

4.) FFBD are used for generally 2 reasons :

i.)
Operational and support sequences of system
ii.)
Effective software in developing and producing systems.
5.) Basically FFBD includes all the parts such as hardware, software, personnel and facilities as
well as procedures being followed.
6.) In FFBD functions are organised in their logical order of execution.
7.) NODE A node is labelled with a function name and acts as a connector between 2 blocks
or systems.
8.) Arrows Arrows move from left to right and show order of execution of functions.
9.) Logic symbols They represent sequential or parallel execution of function.
10.) The purpose of FFBD is to indicate sequential relationships of all functions that must be
accomplished by a system.
11.) This represents time sequence of every block of functions going to be performed in
sequence one after the completion of other.
12.) As FFBDS are block diagram oriented thus they does not require equipment.
13.) It does not describe how each function i.e. block is working.
14.) When we draw functional flow block diagram we do not have a large amount of space to
write its description. Thus only symbols are used inside the blocks to represents its kind of
function.
15.) And the detailed function description is written in Functional Analysis Document box.
16.) Triggering data inputs are required to begin executing a function whereas non-triggering
data inputs are used when a function begins execution concurrently.

figure 1

Fig 2 : Development of FFBDS

Building Blocks of FFBD :

1.) Function block: Each function on an FFBD should be separate and be represented by
single box (solid line). Each function needs to stand for definite, finite, discrete action to
be accomplished by system elements.
2.) Function numbering: Each level should have a consistent number scheme and provide
information concerning function origin. These numbers establish identification and each

level and block should have a consistent number to establish identification and relationship
between main block functions and sub-block functions relationships that will carry through
all Functional Analysis and Allocation activities and facilitate traceability from lower to top
levels.
3.) Functional reference: Each diagram should contain a reference to other functional
diagrams by using a functional reference (box in brackets).
4.) Flow connection: Lines connecting functions should only indicate function flow and not a
lapse in time or intermediate activity.
5.) Flow direction: Diagrams should be laid out so that the flow direction is generally from left
to right. Arrows are often used to indicate functional flows.
6.) Summing gates: A circle is used to denote a summing gate and is used when AND/OR is
present. AND is used to indicate parallel functions and all conditions must be satisfied to
proceed. OR is used to indicate that alternative paths can be satisfied to proceed.
7.) GO and NO-GO paths: G and bar G are used to denote go and no-go conditions.
These symbols are placed adjacent to lines leaving a particular function to indicate
alternative paths.

Figure 3

Function symbolism :
A function shall be represented by a rectangle containing the title of the function (an action verb
followed by a noun phrase) and its unique decimal delimited number. A horizontal line shall
separate this number and the title, as shown in see Figure 3 above. The figure also depicts how
to represent a reference function, which provides context within a specific FFBD. See Figure 9
for an example regarding use of a reference function.

Directed lines
A line with a single arrowhead shall depict functional flow from left to right, see Figure 4.[9]

Figure 4

Logic symbols :

Figure 5
The following basic logic symbols shall be used.[9]

AND: A condition in which all preceding or succeeding paths are required. The symbol may
contain a single input with multiple outputs or multiple inputs with a single output, but not
multiple inputs and outputs combined (Figure 5). Read the figure as follows: F2 AND F3 may
begin in parallel after completion of F1. Likewise, F4 may begin after completion of F2 AND
F3.

Figure 6

Exclusive OR: A condition in which one of multiple preceding or succeeding paths is

required, but not all. The symbol may contain a single input with multiple outputs or multiple
inputs with single output, but not multiple inputs and outputs combined (Figure 6). Read the

figure as follows: F2 OR F3 may begin after completion of F1. Likewise, F4 may begin after
completion of either F2 OR F3.

Figure 7

Inclusive OR: A condition in which one, some, or all of the multiple preceding or succeeding
paths are required. Figure 7 depicts Inclusive OR logic using a combination of the AND
symbol (Figure 5) and the Exclusive OR symbol (Figure 6). Read Figure 7 as follows: F2 OR
F3 (exclusively) may begin after completion of F1, OR (again exclusive) F2 AND F3 may
begin after completion of F1. Likewise, F4 may begin after completion of either F2 OR F3
(exclusively), OR (again exclusive) F4 may begin after completion of both F2 AND F3.

Figure 8 :

One Illustrative Example :

Each FFBD shall contain the following contextual and administrative data:[9]

Date the diagram was created

Name of the engineer, organization, or working group that created the diagram

Unique decimal delimited number of the function being diagrammed

Unique function name of the function being diagrammed.

Below figures present the data in an FFBD. Figure 2 is a decomposition of the function F2
contained in Figure 1 and illustrates the context between functions at different levels of the
model.

Figure 9

Figure 10

Other examples are : (non technical)

1.)
2.)
3.)
4.)

Disaster management
Educational tour
Maitainence of discipline and other functions in college
Construction of building