Type of Process Control Loop

1- Feedback Control
2- Feedforward Control
3- Feedforward-plus-Feedback Control
4- Ratio Control
5- Cascade Control
6- Split Range Control

1
1- Feedback Control
Process: Heating tank CSTH
𝑇𝑜 = 𝑓(𝑚, 𝑇𝑖 , 𝑄)
Controlled variable : To
Manipulating variable: Q:

Set point TRC TI TT

m Ti TE

M m ,To

Steam in
Q
A feedback loop measures a process variable and sends the measurement to a controller for
comparison to set point. If the process variable is not at set point, control action is taken to return the
process variable to set point. This control scheme does not take into consideration any of the other
variables in the process

Advantages :

1- One of the simplest process control schemes.

2- It is commonly used in the process control industry.

3- It is that directly controls the desired process variable

Disadvantage :

The disadvantage of feedback loops is that it takes some time in order that the controlled variable
reaches the set point.

3
Example 1

Consider the liquid level tank shown below. Draw a feedback control loop to control the liquid level
inside the tank (h). The control loop should contains the following :
1- Measuring element 𝑞𝑖
2- Transmitter.
3- Indicator (function in DCS)
4- Recording controlling (front mounted in remote panel)
5- Pneumatic control valve.
h 𝑅
6- Give tag No. for these items 𝑞𝑜

4
Solution

LRC LI LT
Set point 41201 41201
41201

𝑞𝑖 LE
41201

h 𝑅 𝑞𝑜

5
Homework 1
Consider the heating tank system below.
Construct two feedback control loops on the system according to the following description:

First control loop:

Controlled variable : To
Manipulating variable : Q m Ti
Second control loop:
Controlled variable : h
Manipulating variable : m

h
m ,To

Steam in
Q

6
2- Feedforward Control

Feedforward loop is a control system that anticipates load disturbances and controls them before they
can impact the process variable. For feedforward control to work, the user must have a mathematical
understanding of how the manipulated variables will impact the process variable.

m Ti
For the heating tank shown beside, we
notice that 𝑇𝑜 = 𝑓(𝑚, 𝑄, 𝑇𝑖 )
𝑄 𝑖𝑠 𝑚𝑎𝑛𝑖𝑝𝑢𝑙𝑎𝑡𝑖𝑛𝑔 𝑣𝑎𝑟𝑖𝑎𝑏𝑙𝑒
𝑻𝒊 𝑎𝑛𝑑 𝒎 𝑎𝑟𝑒 𝑙𝑜𝑎𝑑 𝑣𝑎𝑟𝑖𝑏𝑙𝑒𝑠
h
m ,To

In feedforward control, the controlled variable

will be controlled through the load variables only
Steam in
Q
7
 FT FIC Set point

FE
m
Ti
TE Set point

h
TT TIC m ,To

Steam in
Q

8
 An advantage of feedforward control is that error is prevented, rather than corrected.

Feedforward scheme is better than feedback control scheme in that it takes no time to

manipulate the controlled variable when the system is subjected to a disturbance. The

difficulty that face the feedforward loop is that it should take into account all the possible

load disturbances in a system , but this is either difficult or costly.

9
 Example 2
Consider the liquid level tank shown below. Draw a feedforward control loop to control the liquid
level inside the tank (h). Knowing that 𝑕 = 𝑓(𝑞𝑖 ). The control loop should contains the following :

1- Measuring element
2- Transmitter. 𝑞𝑖
3- Indicator rear mounted on local panel.
4- Recording controlling (field mounted)
5- Pneumatic control valve.

h 𝑅 𝑞𝑜

10
Solution
FI
FT
𝑕 = 𝑓( 𝑞𝑖 )

FRC Set point

FE

𝑞𝑖

h 𝑅 𝑞𝑜

11
Example 3 Base tank

The diagram below shows pH adjustment. TK-101

NaOH
We want to keep the solution in the tank TK-100 at pH=7.
The pH of the inlet solution is 5. the adjustment is carried
out by addition base NaOH. As shown in diagram beside .
𝑝𝐻2 = 𝑓(𝐹1 , 𝐹2 ) F2
F1
1- Draw feedforward control loop to control outlet pH at 7
Inlet solution
2- Repeat (1) using feedback loop only. pH1

TK-100 F3

outlet solution
pH adjustment tank pH2

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 Base tank
Solution Set point

1 - Feedforward loop TK-101

𝑝𝐻2 = 𝑓(𝐹1 , 𝐹2 ) F IC NaOH

FT

F2 is manipulating variable
F1 is load variable FE
F2
F1
Inlet solution
pH1=5

TK-100 F3

outlet solution
pH adjustment tank pH2

13
 Base tank
- Feedback loop

TK-101
NaOH

F2 pH IC
Set point

F1 pH T
Inlet solution
pH1=5
pH E
TK-100
F3

outlet solution
pH2

14
3- Feedforward-plus-Feedback Control

It is a combined system which consists of two loops feedforward and feedback loops. It is used when the
controlled variable is function of many variables, so it is difficult to take account for every possible load
disturbance. Feedforward is used for the load disturbance which has great effect on controlled variable.
Feedback loop is used for controlled variable.
Controller with summing functions are used in these combined systems to total the input from both the
feedforward loop and the feedback loop, and send a unified signal to the final control element.

15
 Example 4
Consider the heating vessel below . The temperature of
the outlet stream T3 is function of many variables m2 T2
m1 T1
𝑇3 = 𝑓(𝑚1 , 𝑚2 , 𝑄, 𝑇1 , 𝑇2 )

Inlet flowrate m1 is more effective on the controlled variable T3

Use feedforward –pulse - feedback loop to control the

temperature of outlet stream T3.
h m3 T3

Steam in
Q

16
Solution
FT FIC Set point

FE
m2 T2
m1,T1

m3 ,T3

Steam in Set point TE

Q
TIC TT

17
Another solution

FT FIC Σ

Set point TIC Set point

FE
m2 T2

TT
m1,T1

TE

m3 ,T3

Steam in

Q
18
Homework 2

Two liquid – level tanks are

connected in series as shown qo q3
in Fig. beside.
The liquid level in the second
tank h2 is to be controlled.
𝑕2 = 𝑓( 𝑞𝑜 , 𝑞3 , 𝑞4 ) h1
q1 q4
Construct control loop to control h2 using:
1- Feedforward loop R1
TK101
2- Feedback loop
3- Feedforward-plus-feedback.

h2
q2

R2
TK102

19
 4- Ratio Control
This unit multiplies (B) by the desired
𝐴
Ratio control is used to ensure that two or ratio; so the output=𝐵 ∗ 𝐵 = 𝐴

more flows are kept at the same ratio even

if the flows are changing. B A
FT FY FIC FT
𝐴 1
Suppose that the required ratio =
𝐵 2
FE FE
The function of FY is to multiply Ratio set point
𝐴 𝐵
the output of FT by the required ratio 𝐴
𝐵
Water Acid
The result is A , this result is used as the set point to
the controller FC

2 parts of water
1 part of acid

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Ratio control is applied in the following cases :

1- Blending two or more flows to produce a mixture with specified composition

2- Blending two or more flows to produce a mixture with specified physical properties.
3- Maintaining correct air and fuel mixture to combustion.

If the physical characteristic of the mixed flow is measured, a PID controller can be used to
manipulate the ratio value For example, a measurement of the density, gasoline octane rating, color,
or other characteristic could be used to control that characteristic by manipulating the ratio.

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Example 5
Overhead
Use ratio control loop to control the flow of vapor
product (P) and the flow of the reflex (R) that
outlet from the overhead drum of a distillation
𝑅
column. The ratio is fixed. Overhead
𝑃
drum

Reflex to Product
column
R P

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 Overhead
Solution vapor
Condenser

Overhead
drum

Product

R P
Reflex to
column
Ratio set point FE
FE

FT FY FIC FT

23
Ratio control for three streams
Suppose we have three streams A,B and C as shown in Figure below. The ratio of these streams
are A:B:C= 1:2:10. Draw a control loop to adjust the mixed stream at the given ratio.
FE FT FIC

A
FE FT FIC

R
B Mixer
𝐵 FY2
Ratio set point 𝐶
A:B:C = 1:2:10
FE FT FY1 Ratio
𝐴 set point
C 𝐶
24
Homework 3
Use the Ratio control loop to adjust the ratio of fuel that inlet to the furnace as shown in Figure
below.

A
Air

mixer Furnace

B
Fuel

25
5- Cascade Control Temperature
Flow controller controller
Cascade control consists of two loops ; primary Steam secondary primary
loop and secondary loop. mi, ti
Set point
Primary loop is constructed on the variable to be
FT FIC TC
controlled while the secondary loop is constructed
on the manipulating variable.
TT
Consider the shell and tube heat exchanger
in Fig. beside. Suppose we want to control TE
the outlet temperature T2 at a certain value by
Fluid out
manipulating variable mi using cascade T2
Fluid in
control. T1

mo , to 26
Requirements for cascade control:

- Secondary loop process dynamics must be at least four times as fast as primary loop process dynamics.

- Secondary loop must have influence over the primary loop.

- Secondary loop must be measured and controllable.

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 Example 6

Use cascade loop to control the level of the liquid inside the Tank in Figure below. Knowing that 𝑕 = 𝑓( 𝑞1 , 𝑞2 ).
Use 𝑞2 as manipulating variable. Repeat the solution if we use feedback loop only.

𝑞1

𝑞2
h

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Solution
Cascade control loop Set point
LI LRC

LT
𝑞1 FT FIC

LE
FE

h 𝑞2

29
Feedback control loop

LT LI LRC Set point

𝑞1

LE

h 𝑞2

30
 Homework 3
Figure below shows a jacketed reactor
which carries out exothermic reaction.
We want to control the reaction Reactants

temperature T . The manipulating

variable is the flowrate of the cooling
water to the jacket(m). T

1- use cascade control loop only Reactor

Cooling water
2- use feedback control loop only m kg/s Product

3- use feedforward – pulse- feedback

loop. 31
 5- Split Range Control
Spilt control loop is very common control scheme in which the output of a controller is split to two or
more of control valves. In this case , one of the control valve is chosen normally closed and the other is
chosen normally open. For example (Figure below)
FIC

FT
Valve A

Controller output 0% Valve A fully open and valve B fully closed

Controller output 25% Valve A is 75% open and valve B is 25% open Valve B

Controller output 50 % Valve A is 50 % open and valve B is 50 % open

Controller output 75 % Valve A is 25 % open and valve B is 75 % open

Controller output 100 % Valve A is fully closed and valve B is fully open
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Example 7
Base tank Acid tank
The diagram below shows pH adjustment.
TK-102 TK-101
We want to keep the solution in the tank TK-100 at
pH=6. H2SO4
NaOH
Use split range control loop to adjust the value of pH in
the tank at 6 with the aid of the acid and base feeding
tanks.

F1
Inlet solution

TK-100
F2
outlet solution
(pH adjustment tank)
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Solution Base tank Acid tank

TK-102 TK-101
NaOH H2SO4

F1
pHC Inlet solution
Set point

TK-100
pHI pHT pHE F2
outlet solution
(pH adjustment tank)
34
Homework 4
Use split range control loop to control the pressure inside the overhead accumulator (shown below). When the
pressure exceed the desired value , the line to flare will open so the outlet stream is divided into two stream ;one to
flare and the other to process unit.
Flare

Overhead
vapor

Process unit

Reflex to Overhead
column accumulator

35
Reward (2 marks)
Figure below shows a reactor for detergent production. The inlet liquids are in the ratio of A : B: C= 1: 3: 20
Construct a control system that consists of different loops to control the following output variables:
1- The liquid level inside the reactor (h)
2- The temperature (T) of the reaction mixture.
3- Keep the ratio of inlet feeds constant.

Sulfonic acid
A

B C Water
NaOH

Cooling water out

h T
Reactor
Product
Cooling water in (detergent)
36
 𝐴
Ratio set point 𝐶

FE FI FRC FY1

A FT
Sulfonic acid
FY2
FE
𝐵
FE FI FRC Ratio set point 𝐶
C Water
B
NaOH
LT LIC Set point

LE

Set point
TRC T
TI TE h Cooling water out

Cooling water in Reactor Product (detergent)

 M (kg/h)

condenser
LE LT
Distillation
column LRC set point
Overhead drum
h1
R (kg/h)
1
Feed, F 2 P (kg/h)
FE
TF FRC FT FE

FY FT
6 w (kg/h)
set point TIC TT TE
Ratio set point
𝑅
𝑃
S (kg/h)
N (kg/h)
h2

B (kg/h)
Feed, F
B (kg/h)

Σ LRC LT LE

set point

38
 𝐴
Ratio set point 𝐵 FY1
𝐶
Ratio set point 𝐵

FI FRC
FT FY2

FE
FE Water
A
NaOH
B
FE FE FRC

C Sulfonic acid

Σ LIC LT LE
Set point
Cooling water out
pHC pHT pHE h T
Reactor
Product (detergent)
Set point pH

Cooling water in TIC TI TE

Set point

39
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