Process control applications automate tasks in businesses and manufacturing plants. Batch, single loop, continuous, and distributed control system applications differ in their capabilities. They can control machines, valves, heating, and more, and can run for long periods without human interaction.
Process control applications are used by many businesses and manufacturing plants to automate some or all tasks, and these programs are often differentiated by the type and amount of work they perform. Batch process control applications are used to tell machines how to combine raw materials to make a product. Single loop applications are the most basic, because they are only capable of performing a single function, such as turning a machine or valve on and off. Continuous applications manage and perform tasks such as heating water in a boiler or agitating materials without interruption. Distributed Control System (DCS) applications are complex and capable of starting and stopping everything in a plant.
When a product is made, the raw materials often have to go through the same process over and over again. For example, different raw materials may need to be heated to a certain extent before they bond or chemically change. Instead of forcing human workers to do this same task over and over again, batch process control applications can perform this repetitive function. Applications are often told how long to keep machines running or given variables such as heating materials to a certain point before shutting down.
Single loop process control applications are just simple relays, but they can be useful for a manufacturing plant. These applications are typically only capable of controlling one machine or valve at a time and can cause the machine or valve to turn on or off. They can be timed, so they activate a valve every 15 seconds, for example. Several single-loop applications can be used simultaneously to properly sequence large operations.
Continuous process control applications are similar to batch applications in that they are designed to run for long periods of time. Unlike batch applications, which are given variables and instructions to stop at a certain point, continuous applications are made to run without stopping. For example, where batch applications will heat materials to a certain temperature for a few minutes, continuous applications will keep the heater at the same temperature until told to stop.
DCS process control applications are one of the more complex systems, because they are capable of controlling a large number and variety of machines and can typically handle many different variables. All controllers in a manufacturing plant can usually be set up via DCS applications, fully automating a plant. These applications are also capable of starting and stopping everything in the plant, even without human interaction.
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