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matic controller had interaction among the control modes and had inherent lags that became significant at high-frequency operation. There were frequent debates over the pros and cons of pneumatic and electronic controllers. For example, the pneumatic controller was rugged, simple to install, and required little maintenance. Only a source of air pressure was needed to operate the controller. There was initially great concern about the possibility of explosions with the use of electronic controllers, so the instrument cases for these controllers were purged with steady streams of air when used in plants producing flammable substances. The maintenance of electronic controllers also required highly trained technicians. In the 196Os, the chemical industry made its first attempt at computer process control. These control systems used large mainframe computers, for which the control programs had to be written from scratch. The first attempts at computer control were met with mixed reactions. In the 197Os, there appeared on the market the first generation of digital control hardware, which was based on the advances in microprocessor-based technology. This equipment was user friendly and all the software accompanied the hardware. The operator did not face the problem of writing computer code to implement the control functions; it was only necessary to learn the instructions needed to configure (set up) the controllers.
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The hardware requirements for pneumatic, electronic, and microprocessor-based controls arc shown in Fig. 35.1. In this figure, all of the components are obtained from a manufacturer of control equipment; several of the components are common to the three systems. In Fig. 35.1~2, all the signals are pneumatic (3-15 psig). The energy needed to operate these pneumatic components is a source of clean, dry air at a pressure of about 20 psig. The pressure can vary from 20 psig by about 10% without adversely affecting the operation of the instruments. The electronic system shown in Fig. 35. lb requires both electrical and pneumatic power to operate the components. A transducer or converter is needed between the controller and the valve to convert current (4-20 ma) to pressure (3-15 psk) . The components for a microprocessor-based system are shown in Fig. 35. lc. In this case, the control algorithm resides as a computer program in the memory of the computer. The operator communicates with the control system with a keyboard, a monitor, and a printer. The computer can perform many mom functions than implementation of the control algorithm as will be discussed later. The recorder of the pneumatic or electronic system is replaced by a monitor screen on which the transients are shown. In a modem controller both analog and digital signals are processed. The analog signal is the type that represents a continuous variable that varies over a range of values. The digital signal is a binary signal that can be represented by two states (on, 08, or logic 1, logic 0, etc.). Examples of analog signals am the measurement from a temperature transmitter or the signal sent to a valve. Examples of digital signals are the output to a motor, which causes it to be on or off, or the output to an alarm light causing it to be on or off. The focus
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FIGURE 35-1 Controller components for (a) pneumatic control, (b) electronic control, (c) microprocessor-based control.
of this book has been on analog signals that are applicable to continuous control systems. However, there is an important area of control called batch control, which is receiving more attention in industry. Batch control, as the name suggests, is the control of processes that are done in a batch operation. Many examples of batch processing occur in the pharmaceutical industry where small amounts of products of high unit cost are produced.
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