MAST2776B - Process Instrumentation & Control Systems

Rev.00 – 28/07/2023
 Course Objective

OBJECTIVE OF THE COURSE TOPICS OF THE COURSE

▪ This course aims to cover the basic topics ▪ This course will treat the following topics:
related to Process Instrumentation • Lesson 1.2: Introduction to Process Instrumentation
(measured variables and types of measuring • Lesson 1.2: Requirements for Instruments in
instruments for main process variables) Hazardous Locations
▪ It provides an overview of Automatic Process • Lesson 2: Measurements and instrumentation of
Control Systems. main process variables
▪ It is also focused on basic functionalities of • Lesson 3: Automatic Process Control Systems
Control and Safety Valves and covers main
topics related to Emergency Shutdown • Lesson 4: Control Valves and Safety Valves
Systems and related logics. • Lesson 5: Emergency System and Logics

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 Course Overview

DAY 1 DAY 2 & DAY 3 DAY 4

▪ Lesson 1.1: ▪ Lesson 2: ▪ Lesson 3:

✓ Introduction to Process ✓ Measurements and
Instrumentation
✓ Automatic Process Control
instrumentation of main process
Systems
variables
▪ Lesson 1.2:
✓ Requirements for Instruments in
Hazardous Locations

DAY 5 DAY 6 & DAY 7

▪ Lesson 5:
▪ Lesson 4:
✓ Emergency Systems and logics
✓ Valves in Automation & Control
Systems
✓ Course Review
✓ Final Assessment Questionnaire
and Correction
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MAST2776B - Process Instrumentation & Control Systems

Lesson 3: Automatic Process Control Systems

Iraq
 Lesson Objective

OBJECTIVE OF THE LESSON TOPICS OF THE LESSON

▪ This lesson aims to provide an ▪ This lesson will treat the following topics:
overview about the measurements • Introduction to Process Control Systems
and related instruments of main • PLC
process variables • DCS
• Multi Variable / Advanced Control Loops

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 Introduction to Process Control Systems

Process Control
Process control refers to the methods that are used to control process variables when
manufacturing a product.
PROCESS CONTROL

Reduce variability

Increase efficiency

Ensure safety

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 Introduction to Process Control Systems

Process Control
Reduce Variability

❑ Process control can reduce variability

in the product, which ensures a
consistently high-quality product.
❑ Manufacturers can also save money
by reducing variability.
❑ the set point (desired or optimal
point) can be moved closer to the
actual product specification and thus
save the manufacturer money.

PV set point variability

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 Introduction to Process Control Systems

Process Control
Increase Efficiency

Some processes need to be maintained at a specific point to maximize efficiency. For

example, a control point might be the temperature at which a chemical reaction takes
place.

Ensure safety

Precise process control may also be required to ensure safety. For example, maintaining
proper boiler pressure by controlling the inflow of air used in combustion and the
outflow of exhaust gases is crucial in preventing boiler implosions that can clearly
threaten the safety of workers.

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 Introduction to Process Control Systems

Process Control
Process Control is the active changing of the process based on the results of process
monitoring

MANUAL

PROCESS CONTROL

AUTOMATIC CONTROL LOOPS

CONTROL SYSTEMS (PCS)

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 Introduction to Process Control Systems

Manual Control
▪ The operator is instructed to maintain a
certain reference level (reference is in the
operator’s memory)

▪ The operator compares the actual level

with the desired level and opens/closes the
valve accordingly

▪ HUMAN was the first Controller

▪ He looks at the indicator and moves the valve to the “right” position

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 Introduction to Process Control Systems

Automatic Control
Single-loop feedback control is the most common type of control used in industrial processes

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 Introduction to Process Control Systems

Automatic Control – Pneumatic Control

▪ Different types of automated controls are possible
▪ The concept applied to the previous example ▪ With PNEUMATIC Controller Air pressure is modulated
by the metering instrument and drive the valve
position to the proper position

Air

Set point
PI
C PCV

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 Introduction to Process Control Systems

Automatic Control
Digital control
Electronic control
▪ With ELECTRONIC DIGITAL Controller the metering
▪ With ELECTRONIC ANALOGIC Controller the metering instrument converts the process value in current, the
instrument converts the process value in current, the Controller
Controller converts the signal in binary value, calculates the
generates a current that is converted in air pressure which
proper position and generates a current that is converted in
moves the valve at the proper position.
air pressure which moves the valve at the proper position.
▪ Usually good to control only one loop (SINGLE LOOP
▪ Suitable to control more than a loop (MULTI LOOP
CONTROLLER)
CONTROLLER)
Air Air

Set
point P I/P Set point
I PC PI I/P
C V C
P PCV
T
PT

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 Introduction to Process Control Systems

Open & Closed Control Loops

Open Closed
Loop Loop

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 Introduction to Process Control Systems

Open & Closed Control Loops

▪ In open loop control system, the output does not affect the control action of the system. In other words, the system
whose working depends on time is known as the open loop control system
▪ The open loop system is free from the feedback.

▪ The closed-loop control system means the output of the system depends on their input. The system has one or more
feedback loops between its output and input
▪ The closed-loop system design in such a way that they automatically provide the desired output by comparing it with
the actual input
▪ The closed-loop system generates the error signal which is the difference between the input and output.

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 Introduction to Process Control Systems

Controller Algorithms

▪ The actions of controllers can be divided into groups based upon the functions of
their control mechanism.
THE THREE TYPES OF CONTROLLERS ARE:

DISCRETE CONTROLLERS
CONTINUOUS CONTROLLERS
(ON/OFF)

MULTISTEP CONTROLLERS

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 Introduction to Process Control Systems

Controller Algorithms - Discrete Controllers (ON/OFF)

▪ Discrete controllers are controllers that have only two modes or positions: on and off.
▪ This type of control doesn’t actually hold the variable at set-point but keeps the variable within
proximity of set-point in what is known as a dead zone (dead band).

Discrete Control

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 Introduction to Process Control Systems

ON/OFF Controllers

Output
Process

Output
Controller

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 Introduction to Process Control Systems

ON/OFF Controllers – Temperature

Typical
P&I

Controller
On-Off

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 Introduction to Process Control Systems

ON/OFF Controllers – Level

Solenoid
Valve

Load
disturbance

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 Introduction to Process Control Systems

ON/OFF Controllers – Level

Typical On/Off
Control
scheme

Typical On/Off
Control
response

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 Introduction to Process Control Systems

On-Off Controllers - Multistep Controllers

▪ Multistep controllers are controllers that have at least one other possible position
in addition to ON and OFF.

Multistep Control Profile

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 Introduction to Process Control Systems

Continuous Controllers

▪ Continuous Controllers automatically compare the value of the PV (process

variable) to the SP (set-point) to determine if an error exists.

▪ If there is an error, the controller adjusts its output according to the parameters
that have been set in the controller.

Automatic
Feedback Control

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 Introduction to Process Control Systems

PID Controllers
▪ It is a control loop mechanism employing feedback that is widely used in industrial control systems

▪ The name stands for:

• P = proportional
• I = integrative
• D = derivative
▪ The scheme shows how it works:
• The PV is subtracted from the SP to create
the Error
• The error is simply multiplied by one, two
or all of the calculated P, I and D actions
(depending which ones are turned on)
• Then the resulting “error x control actions”
are added together and sent to the
controller output. PID controller scheme
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 Introduction to Process Control Systems

PID Proportional Control

▪ Proportional or P-controller gives output
which is proportional to current error e(t).

▪ It compares desired or set point with actual

value or feedback process value.

▪ The resulting error is multiplied with

proportional constant to get the output.

▪ If the error value is zero, then this

controller output is zero.

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 Introduction to Process Control Systems

PID Integrative Control

▪ It integrates the error over a period of time

until error value reaches to zero. It holds
the value to final control device at which
error becomes zero.

▪ Integral control decreases its output when

negative error takes place. It limits the
speed of response and affects stability of
the system.

▪ Speed of the response is increased by

decreasing integral gain Ki.

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 Introduction to Process Control Systems

PID Derivative Control

▪ I-controller doesn’t have the capability to

predict the future behavior of error. So it
reacts normally once the set point is changed.

▪ D-controller overcomes this problem by

anticipating future behavior of the error. Its
output depends on rate of change of error
with respect to time, multiplied by derivative
constant.

▪ It gives the kick start for the output thereby

increasing system response.

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 Introduction to Process Control Systems

Control Engineering

▪ Control engineering is concerned with the analysis and design of goal-oriented

systems

▪ Modern control theory is concerned with systems that have these qualities:
• Self-organizing
• Adaptive
• Robust
• Learning
• Optimum

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 Introduction to Process Control Systems

AUTOMATION DEFINITION
▪ The control of an industrial process by automatic rather than manual means

▪ Among others, automation is prevalent in these industries:

• Chemical
• Electric power
• Paper
• Automobile
• Steel

▪ Automation is strictly related to productivity

▪ Automation is also related to product qualities

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 Introduction to Process Control Systems

AUTOMATION- PES DEFINITION

Sensors +Actuators + Control

Process +

▪ The automation is use of methods for controlling industrial processes automatically:

• the degree of automation depends on many factors
• automation system are based on microprocessor technology

PES
Programmable Electronic System

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 Introduction to Process Control Systems

AUTOMATION - PES DEFINITION

▪ A Programmable Electronic System offers several advantages for:

• safety protection applications
• calculation capability
• fast response time
• digital communications capability

▪ There is a variety of solutions due to:

• different usage and requirements
• the nature of processes to be controlled

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 Introduction to Process Control Systems

PLC & LCP

▪ Subsystems are mainly based on PLC (Programmable

Logic Controller) and LCP (Local Control Panel): PLC
• modern PLCs are capable of analog acquisition and
control;
• LCP are units equipped with display and
pushbuttons.

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 Introduction to Process Control Systems

DCS
▪ Distributed Control Systems (DCS):
• distribution might be due to geographical or functional
reasons; DCS
• modern DCS take care also of digital discrete states and
commands, and related sequences;
• modern DCS include modules for handling information,
calculations and reporting.
• mainly a network of multi-loop controllers and HMI

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 Introduction to Process Control Systems

ESD
▪ Emergency Shutdown (ESD) is dedicated to the protection level:
• parallel and autonomous compared to DCS;
• instructed to intervene in case of hazards;
• its task is mainly the interlocks one, and the logic to be implemented is often expressed
in terms of “Cause-Effect” diagrams.

ESD

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 Introduction to Process Control Systems

PC Network
▪ The computer control network performs a wide variety of tasks.
▪ The computer network can be as simple as an array of inexpensive PC's or it could be a large
commercial distributed control system (DCS).

PC network

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 Introduction to Process Control Systems

ACTIVITY

True False

Nowadays automation is strictly related to productivity

In the closed loop system, the desired output depends on the control action
of the system

In a PID controller error is multiplied with proportional constant to get the

output

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 PLC

Definition

LOGIC SOLVER
INPUTS FROM SENSORS OUTPUTS TOWARDS
ACTUATORS

PLC

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 PLC

Definition

Front of PLC

Back of PLC

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 PLC

PLC Characteristic

▪ It is field programmable by the user;

▪ It contains programs and functions;
▪ It scans memory and inputs and outputs (I/O);
▪ It provides error checking and diagnostics;
▪ It can be monitored;
▪ It is packaged appropriately;
▪ It has general purpose suitability.

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 PLC

PLC Operation

WRITE DATA TO READ DATA FROM

AUTOMATION SENSORS (INPUTS)
DEVICES
(OUTPUTS)

EXECUTE LOGIC AGAINST

INPUT DATA

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 PLC

PLC Structure

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 PLC

PLC Structure - CPU

▪ Central Processing Unit (CPU) of the PLC, controls and supervises

all operations within the PLC, carrying out programmed
instructions stored in the memory.

▪ The CPU is:

• the core of PLC
• a card based on a complex programmable logic with basic
functionality.

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 PLC

PLC Structure - CPU

▪ CPU is microprocessor based, and may allow:
• arithmetic operations;
• logic operators;
• block memory moves;
• computer interface;
• local area network;
• functions;
• etc.
▪ CPU makes a great number of check-ups of the PLC controller itself.
▪ The CPU during the steady state operation:
• communicates with all cards connected on the bus of the PLC transferring data;
• commands to/from the outside world (input and output).
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 PLC

PLC Structure - I/O interface modules

▪ The input/output (I/O) section of a PLC is the section to which all field devices are
connected

• They form the interface between the microelectronics of the programmable controller
and the real world outside;
• Provide all necessary signal conditioning and isolation functions
• They are designed with the aim of simplifying the connection of input devices and
actuators to the PLC

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 PLC

PLC Structure - I/O interface modules

▪ Different types of I/O circuits are available:

• Pilot duty outputs
• General purpose outputs
• Discrete inputs
• Analog I/O
• Special purpose I/O

Example of analog I/O

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 PLC

PLC Structure – Power Supply Module

Power supply provides power to PLC and its components

• It provides power to the CPU, and often to the

drive sensors and low-power actuators connected
to the I/O modules
• It converts line voltage AC into a usable DC
• Different sizes and power ratings are possible

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 PLC

PLC Structure – Rack/Bus

▪ Rack is the base that all of the other

components plug into so that they can all
work together.

▪ A bus system may already be provided on

the rack, otherwise components must be
wired individually

PLC rack

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 PLC

PLC Structure – Memory

▪ Memory is the component that stores

information, programs, and data in a PLC.
• Writing / Reading
• Two types of memory are used in PLCs:
ROM and RAM
• ROM is used to store programs that
should not be altered
• When new programs are stored into the
RAM, old programs stored in the same
location are over-written

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 PLC structure – communication interface

PLC Structure – Communication Interface

▪ A Communication Interface is necessary to receive and transmit data from/to PLC
• A programming terminal is necessary to program the PLC
• Data from the controlled process and the PLC status must be accessible

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 PLC

PLC Input/Output Devices

Logical Inputs Continuous Inputs

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 PLC

PLC Input/Output Devices

Output Devices
▪ Solenoid valves
▪ Lights
▪ Motor starters
▪ Servo motors

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 PLC

PLC Input/Output Devices

Typical Sensors

▪ Proximity switches
▪ Switches
▪ Potentiometers
▪ Linear Variable Differential Transformers (LVDT)

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 PLC

PLC Input/Output Devices

Smaller PLC Larger PLC

Inputs are built in and are specified when

PLCs the inputs are purchased as
purchasing the PLC.
modules, or cards, with 8 or 16 inputs
of the same type on each card..

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 PLC

ACTIVITY

True False
Two types of memory are used in PLCs: ROM and RAM

I/O modules are not able to perform signal conditioning

A Communication Interface is necessary to receive and transmit data

from/to PLC

Small PLC doesn’t require CPU

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 DCS

Introduction

▪ Automatic control includes accomplishing two major operations:

• information flow
• decision making

▪ Carrying out these operations in real plant requires a set of hardware and
instrumentation that serve as the platform for these tasks.

▪ Distributed Control System (DCS) is the most modern control platform.

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 DCS

Introduction

▪ Distributed Control System (DCS) is:

• the control platform for hardware and instrumentation;
• the most modern control platform.

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 DCS

Definition

DCS is a system of sensors, controllers, and associated

computers that are distributed throughout a plant

▪ Each of these elements serves a unique purpose

▪ They communicate with a centralized computer through the control network
▪ DCS is the “central brain” of the plant, taking automated decisions

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 DCS

Functionality

▪ DCSs are mainly deployed at large, continuous manufacturing plants

▪ With DCSs manufactures can efficiently coordinate adjustments in a top-down

fashion using a centralized network of computers

▪ DCSs can improve safety while also enhancing production efficiency

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 DCS

Importance of DCS
▪ Why DCS system is required?

▪ The process requires a kind of control in order to adjust the quality of the product
▪ In some dangerous/complex applications losing the control may lead to explosions or other
hazardous situations

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 DCS

Importance of DCS

▪ Scope:
• Continuous regulation of process parameters
▪ Critical items
• Complexity
• Safety Continuous
• Reliability process
▪ Industrial sectors:
• Chemical
• Petrochemical DCS
• energy production
• food & beverages, etc.
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 DCS

Main Components

Human
Engineering
Interface
Station
Station

The Engineering / Operator Station Field Control Station (FCS)

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 DCS

Main Components

V-net / VL-net

V-net / VL-net
The Engineering / Operator Station
Field Control Station (FCS)

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 DCS

Fieldbus
Fieldbus is a digital, two-way, multi-drop communication link among intelligent fieldbus devices for
measurement and control. It is one of field local area networks dedicated for industrial automation.

DCS

Control Valve

Transmitter

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 DCS

Typical Structure
▪ The DCS provides process control and monitoring for the
plant and acts as a central coordination of required control
signals between the control systems.

▪ At the process control level, it performs basic regulatory

and sequential control, non-safety related interlocks,
process monitoring, alarm management, data archiving,
trending, reporting, etc.

The DCS shall perform both analogic and digital plant control and
monitoring functions, data acquisition and annunciation.

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 DCS

Operation
DCS system receives input signals from other devices: they will be processed and analyzed by DCS CPU and based on the
result an action will be taken

Transmitters transmit electrical signals to DCS System

FCS convert analog signals to digital via input module then passed to CPU for processing

If the both values are not matched, then DCS will generate an output called Manipulated value (MV) to the field

CPU will compare the process measured value (PV) with Value set by the operator (SV)
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 DCS

Operation

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 DCS

Faceplate example

▪ On the faceplate the operator can see the three

parameters at the top:
• SV
• PV
• MV

▪ The SV can be set to the required level by moving the

yellow pointer.

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 DCS

DCS Overview
Today the DCS means a variety of devices organized in a hierarchical manner with the main purpose to take
account of the operational control and management of the plants

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 DCS

DCS Overview

▪ In a centralized control room, you can control, operate and collect information of all process units located
in the plant as they are built.

▪ The DCS is substantially a SYSTEM MICROPROCESSOR CONTROL

▪ The engineer or operator can immediately utilize such a system to:

• access a large amount of current information from the data highway;
• see trends of past process conditions by calling archival data storage;
• readily install new on-line measurements together with local computers for data acquisition and then
use the new data immediately for controlling all loops of the process;
• alternate quickly among standard control strategies and readjust controller parameters in software.

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 DCS

DCS /PLC Comparison

▪ Response Time
• PLCs are fast, no doubt about it. Response times of 1/10 of a second make the PLC an ideal controller
for near real-time actions such as a safety shutdown or firing control

• A DCS takes much longer to process data, so it’s not the right solution when response times are
critical. In fact, safety systems require a separate controller.

▪ Scalability
• A PLC can only handle a few thousand I/O points or less
• A DCS can handle many thousands of I/O points and more easily accommodate new
equipment, process enhancements and data integration.

▪ If you require advanced process control and have a large facility or a process that’s spread
out over a wide geographic area with thousands of I/O points, a DCS makes more sense!
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 DCS

DCS /PLC Comparison

▪ Another problem with PLCs is Redundancy

▪ If power or fault tolerant I/O are required, it isn’t wise trying to force those requirements into a PLC-
based control system. You’ll just end up raising the costs to equal or exceed those of a DCS.

▪ Complexity
• The complex nature of many continuous production processes, such as oil and gas,
water treatment and chemical processing, continue to require the advanced process
control capabilities of the DCS
• Others, such as pulp and paper, are trending toward PLC-based control.

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 DCS

DCS /PLC Comparison

▪ Frequent process changes

• PLCs are best applied to a dedicated process that doesn’t change often

• If the process is complex and requires frequent adjustments or must aggregate and
analyze a large amount of data, a DCS is typically the better solution

• Of course, the very flexibility of a DCS system also makes it much more vulnerable to
“meddling” by operators that can cause spurious shutdowns.

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 DCS

DCS Architecture

The general model of a DCS

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 DCS

DCS Architecture – Level 0

▪ Level 0 = Field Device Level
▪ It contains the field devices such as flow and temperature sensors, and final control elements, such as
control valves

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 DCS

DCS Architecture – Level 1

▪ Level 1 = Control Level
▪ The microcontroller takes data from the fieldbus to control individual control loops
▪ Many control loops can be controlled at the same time

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 DCS

DCS Architecture – Level 2

▪ Level 2 = Plant Supervisory Level
▪ Information about control loops are displayed
▪ Operators can adjust setpoints and change automatic <-> manual mode

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 DCS

DCS Architecture – Level 3

▪ Level 3 = Production Control Level
▪ Normally control operations are not performed here
▪ Its function is display for management overview

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 DCS

DCS Architecture – Level 4

▪ Level 4 = Production Scheduling Level
▪ Signals are converted to be sent to distant headquarters
▪ Plant level changes cannot be done from here

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 DCS

DCS Main Components

▪ Engineering Station
Human Machine Interface (HMI)
▪ Operator station
▪ Field control station (FCS)
▪ Communication system
▪ … accessories

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 DCS

DCS Main Components

HMI - Operator Station

▪ Human Machine Interface (HMI) is the collection of:

• computers
• monitors
• keyboards
• mice
• printers
• etc.

where the interaction takes place between plant

operators and the control system.

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 DCS

DCS Main Components

HMI - Operator Station

▪ It is used to operate, monitor and control

plant parameters

▪ It is a device with a dedicated software

tool to allow the operator to control the
process parameters

▪ It can be a single unit or multiple units

(e.g. performing different functions)

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 DCS

DCS Main Components

HMI - Engineering Station

▪ It is the supervisory controller of the entire DCS

▪ It is a device with dedicated engineering software
▪ Allows to:
• Create and modify loops, logics, inputs & outputs points
• Configure the distributed devices
• Prepare documentation

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 DCS

DCS Main Components

Field Control Station

▪ One or more process control units, with powerful CPU

module
▪ Each one can be extended with different types of I/O
units

▪ These units:
• Acquire information from sensors (through input
modules)
• Process the information
• Send the output signals to actuators or relays
(through output modules)
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 DCS

DCS Main Components

Communication System
Control Network: is the physical medium through which data are shared between the various
components of the DCS and the operator interface.

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 DCS

DCS Main Components

Communication System
▪ It interconnects the engineering station,
the operator station, the field control
station and the smart devices
▪ Many communication protocols are
commonly used
▪ More than one protocol can be used in
the same DCS
▪ redundancy (which is one of the
strengths of the DCS) can be
implemented in the communication
system

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 Communication system - protocols

DCS Main Components

Communication System - Protocols

Ethernet cable
ProFiBus cable

FieldBus cable ModBus cable

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DCS

ACTIVITY

True False

PLC is faster than DCS

The number of Field Control Stations to control a process plant is decided

based on the Input / Output count

Almost all the manufacturers structure the DCS in 5 layers, the first of which is
the direct control

The Engineering Station has the function of acquiring the inputs from the
field, processing the information and returning the outputs
 control loops

Control loops
Control loops can be divided into two categories: Single variable loops and multi-variable loops.

Control loops

Single variable loops Multivariable loops

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Single variable loops

Single variable loops

Feedback Control (Closed Control loop)

Examples of Single Control Loops (Pressure, flow, level and temperature)

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 Single variable loops

Feedback control (Closed Control loop)

In closed loop control, the objective of control, This is also known as feedback control. Closed loop control
the PV, is used to determine the control is designed to achieve and maintain the desired process
action. condition by comparing it with the desired condition, the
Set Point Value (SP), to get an Error Value (e).
Closed control loop
Manual feedback
control

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 Single variable loops

Examples of Single Control Loops (Pressure, flow, level and temperature)

While each application has its own characteristics, some general statements can be made about
pressure, flow, level, and temperature loops.
Pressure loop
Pressure control loops
Pressure control loops vary in speed—that
is, they can respond to changes in load or to
control action slowly or quickly. The speed
required in a pressure control loop may be
dictated by the volume of the process fluid.
High-volume systems (e.g., large natural gas
storage facilities) tend to change more
slowly than low-volume systems

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 Single variable loops

Examples of Single Control Loops (Pressure, flow, level and temperature)

Flow control loops

Generally, flow control loops are regarded as fast loops that respond to changes quickly. Therefore,
flow control equipment must have fast sampling and response times. Because flow transmitters tend
to be rather sensitive devices, they can produce rapid fluctuations or noise in the control signal.

Flow loop

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 Single variable loops

Examples of Single Control Loops (Pressure, flow, level and temperature)

Level control loops

Manufacturers may use one of many

different measurement technologies to
determine level, including radar,
ultrasonic, float gauge, and pressure
measurement. The final control element in
a level control loop is usually a valve on
the input and/or outflow connections to
the tank Because it is often critical to avoid
tank overflow, redundant level control systems
are sometimes employed

Level loop

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 Single variable loops

Examples of Single Control Loops (Pressure, flow, level and temperature)

Temperature control loops

Temperature transmitters and controllers are used, although it is not uncommon to see temperature sensors wired
directly to the input interface of a controller. The final control element for a temperature loop is usually the fuel
valve to a burner or a valve to some kind of heat exchanger. Sometimes, cool process fluid is added to the mix to
maintain temperature

Controller

Valve

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Instrumentation on P&ID
Hammar IPF – 1ST stage separator

Level controller

Pressure controller

Equipment

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 Multi-Variable / Advanced Control Loops

Multi-Variable / Advanced Control Loops

This section will acquaint you with some of the methods of control currently being used in process
industries.

Multivariable Loops
Cascade Control

Feedforward Control loop

Ratio Control

Feedforward Plus Feedback

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 Multi-Variable / Advanced Control Loops

Multivariable Loops

Multivariable loops are control loops in which a primary controller controls one process
variable by sending signals to a controller of a different loop that impacts the process
variable of the primary loop.

For example, the primary process

variable may be the temperature of the
fluid in a tank that is heated by a steam
Transmitter jacket (a pressurized steam chamber
Valve surrounding the tank). To control the
primary variable (temperature), the
SP primary (master) controller signals the
secondary (slave) controller that is
Transmitter controlling steam pressure.

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 Multi-Variable / Advanced Control Loops

Feedforward Control (open control loop)

▪ In open loop control, the control action (Controller Output

Signal OP) is NOT a function of the Process Variable (PV).

▪ The open loop control does not self-correct when the PV

drifts, and this may result in large deviations from the
optimum value of the PV.

▪ The most common type of open loop control is

feedforward control.

▪ In this technique the control action is based on the state

of a disturbance input without reference to the actual
system condition, i.e. the system output has no effect on Concept of feed forward control
the control action, and the input variables are
manipulated to compensate for the impact of the process
disturbances
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 Multi-Variable / Advanced Control Loops

Feedforward Plus Feedback

A feedforward pus feedback

loop in which both a flow
transmitter and a temperature
transmitter provide information
for controlling a hot steam
valve.

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 Multi-Variable / Advanced Control Loops

Cascade Control
Cascade control is a control system in which a secondary (slave) control loop is set up to
control a variable that is a major source of load disturbance for another primary (master)
control loop. The controller of the primary loop determines the set point of the summing
controller in the secondary loop

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 Multi-Variable / Advanced Control Loops

Ration Control
Imagine a process in which an acid must be diluted with water in the proportion two parts
water to one part acid. If a tank has an acid supply on one side of a mixing vessel and a water
supply on the other, a control system could be developed to control the ratio of acid to water,
even though the water supply itself may not be controlled. This type of control system is
called ratio control

Water flow Acid flow

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 Multi-Variable / Advanced Control Loops

ACTIVITY
Identify the controller of the primary loop determines the of the
summing controller in the secondary loop ?

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 Process Instrumentation & Control System

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