Controllers & Control Loop Structure

Process control & DCS

107_Controllers & Control loop structure
Close Loop Regulation System

There are two ways of "qualifying" a closed-loop regulation
system:
• The first one (behaviour in terms of regulation) consists of seeing
how it reacts to an external disturbance
• The second (behaviour in terms of slaving) consists of seeing how it
reacts to a variation in the setpoint value
CONTROLLER

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107_Controllers & Control loop structure 2
 Close Loop Regulation System

The "Controller" output variable or "correction variable" exerts
an influence on the "adjusted variable" to maintain it within the
predetermined limits:
• this is a closed-loop regulation or slaving system

The action of the correction variable on the adjusted variable is
obtained via the "System" (or process) which closes the loop
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107_Controllers & Control loop structure
feedback control loop 3
Integrating the controller into a control loop

Purpose of a controller: control the process and protects it from
external disturbances
set point
CONTROLLER
• Compares the measurement signal to the set point
 modifies its control signal according to the difference between

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these 2 values
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 Control functions
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Controller technologies

Former Technologies

Controllers in DCS

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 Former Technologies - Local pneumatic controllers
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Former Technologies - Panel-mounted analog controllers

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 Former Technologies - Panel-mounted digital controllers

External view of a panel-mounted digital controller

Increased functionalities:
• multiple inputs
• digital calculation modules

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• configurable alarms
• two cascade controllers in
the same unit
107_Controllers & Control loop structure
• sophisticated algorithms 9
Controller in DCS

DCS controllers: Digital controllers located in technical room

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 Controller in DCS

Typical views of a controller on DCS displays
• example of Honeywell Experion DCS
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Operator Work Station Controller Same controller detailed view
faceplate
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Controller in DCS
Set Point value Bargraph
Process value Bargraph
Output value Bargraph
Trending
Physical value
Set Point value
Output value
The buttons allow increasing the setpoint
Proportional value or the output when in Auto or Man mode
respectively
Integral value

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Derivative value
Only active in Manual mode. In TRAC the
Auto mode
current PV is copied to the SP
Manual mode
Internal or external set point Direction of the controller action
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 Controller actions

Control Algorithmes

Proportional Action

Integration Action

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Derivative Action
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Controller Algorithms

Controller output depends on
• the static error between its setpoint and the measured variable
• the controller algorythms: P, I, D actions

Controller algorythms:
• Proportional action P: the error is multiplied by a gain K
• Integral action I: the error is integrated over a time interval Ti
• derivative action D: the error is derivative over a time Td

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107_Controllers & Control loop structure 14
 Proportional Action (P)

Definition
• With only a proportional action, the output (OP) variation ∆OP is
proportional to the variation of the difference between the
setpoint and the process value ∆(PV-SP)
• Proportional factor = proportional gain KP
∆   ∗ ∆  

Often P action is not expressed as a gain but as a proportional
band PB (%)

 %  ∗ 


Correspondence between PB and Gain:

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Proportional Action (P)

Proportional term:
• The proportional term, gain, makes a change to the output that is
proportional to the current error value.

For a proportional action
controller:
• A high gain (low PB)
corresponds to:
− A low PV-SP gap
− A sensitive controller
− An oscillation risk
• A low gain (high PB)
corresponds to:

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− A large PV-SP gag
− A non sensitive controller
Plot of PV versus time, for 3 values of Kp (Ki − A stable behavior
and Kd being held constant)
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 Integral Action (I)

Definition
• The contribution from the integral term (sometimes called reset) is
proportional to both the magnitude of the error and the duration of the
error

The integral action can be quantified in 2 ways:
• Integral time (reset): Ti
• Integral gain Ki (opposite of Ti)

Integral action is greater when:
• Ti is low (Ki is great)

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• The proportional gain Kp is great
Plot of PV versus time, for 3 values of Ki

Most controllers comprise of P and I actions (Kp and Kd being held constant)
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Derivative Action (D)

Definition
• The rate of change of the process error is calculated by
− determining the slope of the error over time (i.e. its first derivative
with respect to time)
− multiplying this rate of change by the derivative gain Kd
• It compensates for the effects of process’s dead times

Recommended for slow
paramters (T)

Not recommended for dynamic
parameters (P)

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Plot of PV versus time, for 3 values of Kd
107_Controllers & Control loop structure
(Kp and Ki being held constant) 18
 Combined PID Action
D
I
P
Setpoint
Proportional Integral Derivative
Stability + - -

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Accuracy - + -
Speed - - +
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Controller behavior

Tuning criteria:
• It is the tuning of the controller P, I, D actions that allow adjusting
the response (output) dynamics
• Most of the time, controllers feature only P and I actions

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• P and I actions are adjusted one after another by keeping the other
action constant
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 Basic Controller Tuning

Choice of P action:
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low oscillations and more oscillations significant oscillations
a large residual but with a lower with a possibility of
static error residual static error surging situation
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Basic Controller Tuning

For a chosen P action:
• A too low I action leads to a too long time

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required to reach back the setpoint
• A too high I action leads to surging
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 PID controller actions summary
Regulator action Advantages Drawbacks
It does not cancel out the static
Dynamic
error
Proportional Precise Permanent residual deviation
Surging if the proportional band is
Stable
too narrow
Slow action
Integral Cancels out the static error
Slows down the process
Sensitivity to noise
derivative Very dynamic and faster action Serious loading of the command
device
Faster than proportional on its own.
No difference between the measured Surging if the integral action is too
Proportional + Integral
and setpoint values whatever the predominating
variation in the disturbances
Anticipates
Fast
Precise

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Surging if the derivative action is too
Proportional + Integral + derivative No deviation of the variable to be strong
adjusted
Limits the amplitude and length of
the adjusted variable's variation
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Configuration parameters

Action Direction

Set Point Tracking

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 Action Direction

Direction of action of the controller
• Direct = measured variable and controller output vary in the same
direction
• Reverse = measured variable and controller output vary in the
opposite direction

Setting depends on process:
• Action of the controller with a direct process
• Action of the controller with an inverse process

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Set Point Tracking
the set point
follows the
measured variable
Setpoint
tracking active

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MAN mode
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 Control loop structure

Simple close loop

Cascade control loop

Split Range Control Loop

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Operations on Control Loo[p Signals
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Simple close loop
•

Simple loop

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• 1 controller
• 1 actuator
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 Cascade control loop

Cascade control loop:
• 2 controllers the master loop
• 1 actuator
the slave loop
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Split-range (1) control loop

Split-range
• “Engassing - Degassing” configuration

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 Split-range (2) control loop

Split range
• "Low flow – High flow " configuration

Split-range
• 1 controller

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• At least 2 actuators
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