5 Things to Know About Process Control Instrumentation by Types

Process Control Instrumentation deals with controlling and measuring process variables in an industry using software and hardware tools. It involves the scientific method of maintaining the outcome of a specific procedure within a specified range. 

Process control is essential for industries because it helps measure and control several industrial factors and functions like; the temperature of the materials, pressure, proportion of ingredients, how materials are combined, fluid levels, and more in manufacturing companies. Several types of process control instrumentation are used to control and measure variables. You can find more information on PPS’s process instrumentation and controls here.

Things to Know About Process Control Instrumentation by Types

Adequate knowledge about process control instrumentation will help manufacturers understand how essential process control instruments and equipment are in manufacturing. Here are some of the things to know about process control instrumentation.

Industries That Can Utilize Process Control Instrumentation

Almost every type of industry that performs repeated production requires process control equipment. Here are some of the industries that can use process control equipment;

• Petrochemical industries
• Food and beverage
• Wastewater treatment
• Clothing and textile
• Oil and Gas
• Manufacturing companies

These industries can immensely benefit from process control equipment.

Importance of Process Control Instrumentation

Process control instrumentation offers several benefits to manufacturers and industrialists. In production, everything that goes into the process must be appropriately monitored and controlled to produce a desirable outcome. For instance, in the food and beverage industry, you must correctly measure the proportion of one ingredient against the other to ensure that the beverages produced are suitable for consumption. Also, in the oil and gas industry, the temperature should be closely monitored and controlled to prevent an undesirable increase in temperature, resulting in an explosion. 

Other benefits of Process Control Instrumentation

• Increase automation and efficiency
• Reduce human interference
• Increased production capacity
• Maintenance of products quality

Popularly Used Process Control Instrumentation

Several process control instrumentations are available to meet the needs of various industries. This equipment helps to increase the productivity and efficiency of production facilities. Some of the production process systems include;

• Level Control and Monitoring system

The level control and monitoring system use level-detecting sensors to monitor the level of fluid, solid, and gases in vessels, tanks, and compartments. When the sensor detects that the contents of the tanks or vessels have reached the desired level, the sensor will send the information to the monitor or control panel. The engineer can either use a mechanical actuator or an electrical actuator at the control panel to control the flow rate. 

• Pressure Control and Monitoring system

Pressure control and monitoring systems help to detect pressure changes during production. They utilize pressure sensors to detect changes and display the pressure measurement in KPa, or bar. You can electrically or mechanically operate the pressure control equipment. They’re suitable for use in industries with pressurized gases and fluids. These instruments help to safeguard these industries against explosions caused by over-pressurized substances.

• Automated Control Systems

Automated control systems are particularly relevant in industries that require high safety and accuracy. These instruments don’t require human interference, but an engineer can also monitor the system periodically. Automated systems utilize auto controls and sensors, helping to maintain precision, quality, and consistency effectively. They help protect facilities from unexpected equipment failure. They’re suitable for power generation, oil and gas, and many others. 

• Temperature Control and Monitoring

Temperature control and monitoring systems help to keep temperature variation in check. Once the temperature variation is detected, it will send signals to the control panel, where the engineer can look into the situation and make necessary adjustments. They help protect industries from fire explosions and equipment failure.

• Supervisory Control and Data Acquisition (SCADA)

SCADA systems are used in various industries such as the air purification industry, power generation, wastewater treatment, to mention a few. This equipment helps to collect data about ongoing processes on various plants. The data collected are transmitted through controllers and sensors to the control engineers. 

Process Control Instrumentation and Energy Efficiency

Industries consume more energy than other sectors in the country. With process control instrumentation, industries can become more energy efficient. Process control equipment will help industries efficiently use energy to maximize production and maintain quality products consistency. Process control equipment helps facilities engineers easily detect their energy consumption level and weigh it against their productivity.

The Roles Engineers in Process Control Instrumentation

Control engineers are usually in charge of handling process control instrumentation. They’re trained to maintain and operate process control equipment in industrial facilities. Even if the industry uses automated process control instrumentation, control engineers are still needed to help oversee the operation of the equipment.