CONTROL SYSTEM

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TYPICAL PROCESS LOOP
 WHAT IS FEEDBACK CONTROL SYSTEM?

• Feedback in a control loop is information about the status of

the controlled variable which is compared with that which is
desired ( set point ), in the interest of making them coincide.

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 WHAT IS CASCADE CONTROL SYSTEM?

• Cascade control system is a control system in which the

output of one controller is the input for another .The
relationship that exits between controller is referred to as a
master-slave or primary-secondary relationship.

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 LEVEL CONTROL SYSTEM

Controller Set point

Transmitter

Liquid
Inlet
Sensor
(float)
Tank
Liquid
outlet
 LEVEL CONTROL SYSTEM

Set
Point
Control
Controller Tank
valve

Transducer

BLOCK DIAGRAM
 FURNACE CONTROL

Fuel gas

TT

Feed Set point

TRC
(c)

Burner TY
Fuel
 FURNACE CONTROL

-Process is used to heat process gas by burning fuel in the fire box
outside the tube.
-The temparature of fire box is uniform.
- Outlet process temparature is controlled by f/b system that
manipulates flow of fuel to the burners.
-Disturbances : 1] inlet temparature to fluid.
2] flow rate.
 FURNACE CONTROL

Damper
Damper

Process
medium

TT

FT
Liquid
or
gas Fuel TRC
 DISTILLATION COLUMN
Condenser
Accumulator
Distillation LRC
column
RP
Feed (temp,
Comp,rate)
TRC
SP LRC
Steam

Rp--Reflux
Reflux-fraction of
Pump
Steam liquid return to
column
Bottom product
 DISTILLATION COLUMN

- Process of seperation by boiling.

-Method to separate mixtures of two or more miscible liquids in to
their components.
- Liquid heated to its boiling point.
- Vapours are condensed & connected.
Two stream Vapour
Liquid
-Interactive Process
-Parameters- 1) Temp (through steam rate)
2) Bottom level (Bottom rate product)
3) Pressure (by manufacture of coolant rate)
4) Top accumulations level (by overhead product rate)
 FEED FORWARD CONTROL SYSTEM

FURNACE
TT

FT
Fuel PT
gas TRC

FY PIC

FY
 FEED FORWARD CONTROL SYSTEM

FUNCTIONS :

1] To maintain the desired rate of energy transfer.

2] To maintain,controlled & efficient combustion of
fuel.
3] To maintain safe condition of phase.
 HEAT EXCHANGER
Hot fluid
T2
Transducer Controller

Steam
Shell

Tube

Cold fluid
T2 Trap

condensation
 HEAT EXCHANGER

- Hot fluid (steam) flows through shell.

-Cold fluid flows through tube (6mm-50mm)
- As cold fluid travels in the tubes it recieves heat from hot fluid.
- Disturbance steam flow rate .
- Cascade by steam flow rate.
 FLOW CONTROL

Set
point

Controller

Transmitter

Fluid P1 P2
inlet outlet
Tank
P =Q
 FLOW CONTROL

Set
point Control
Controller Pipe
valve

Flow transducer

BLOCK DIAGRAM
 CASCADE CONTROL Inner loop

Primary Primary Secondary

Setpoint controller controller

Secondary
variable

Primary
variable T Process
T
 CASCADE CONTROL
Water
out Primary
Set point
TT TC
Secondary
FC Set point

Steam FT
out Steam in

Water CASCADE CONTROL FOR

in WATER HEATING SYSTEM
 CASCADE CONTROL

Set
Level
Outer Inner Correction
Flow Level
controller controller unit

Flow
measurement

Level
measurement
 CASCADE CONTROL

Set
point
Outer Inner
controller controller

Control Flow
valve measurement
 CASCADE CONTROL

-Involves use of two controller,two feedbackloops.

- Outer loop concerned with main variable (level).
- Inner loop (minor) concerned with intermediate variable (flow rate).
- Set point for inner loop is determined by the outer loop controller.
- Reduces the time lags,effect of load changes disturbances.
- Better control system.
 REACTOR CONTROL

PC

FR

Liquid
reactant LC

FC

Gaseous
reactant Liquid
purge
 TEMPARATURE CONTROL

SP TR TT

Heat
supply
 BOILER CONTROL

Steam

Flame
Fuel
Burner
Air
 BOILER CONTROL

PT

H PIC

Air
F1

RATIO CONTROL Fuel

 BOILER CONTROL

To user
RT
Drum
LT LIC FY

PIC FY

FT
LY

CASCADE CONTROL

Feed water
 PROCESS CONTROLLERS

A number of controllers are available for controlling a process. These are

• On/Off Controllers
• Proportional Controllers
• Derivative Controllers
• Proportional-Integral Controllers
• Proportional- Integral-Derivative Controllers

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 WHAT IS PID CONTROL MEANS?

• This is the three mode control-

proportional plus reset plus rate.When
proportional only action is used, a load
change produces an offset from the set
point.Rate action has the effect of
reducing the overshoot that occures
when reset is added to proportional
action. Rate action also counteracts the
log characterstics introduced by reset
action.
AUTOMATIC FEEDBACK CONTROL
SINGLE FEEDBACK CONTROL
LOOPS

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AUTOMATIC FEEDBACK CONTROL

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DISTILLATION COLUMN CONTROL

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TYPICAL CONTROL LOOP
ON-OFF CONTROLLER

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 WHAT IS PID CONTROL?

• Modern process control is a relatively new field. Controllers

are widely used in all of the process industries. Continuous
feedback process controllers using the ubiquitous
proportional-integral-derivative (PID) algorithm have been
around only since the 1940s.

• Fourier, Laplace, Kirchoff, Kelvin, and others had laid out the
mathematical basics for this control theory by the end of the
1800s. All of the terms, proportional, integral, and derivative, . The
latter two are the heart of calculus. The mathematical
complexities need not be explored to understand PID control
theory. Graphical insight and lowtech interpretation is more
than adequate.
 TAKE ANY SYSTEM

• To begin, consider a parameter that needs to be controlled.

Take the temperature of water in a tank that is continuously
fed with cold water and is continuously pumping 100°C water.
If the temperature of the water coming out of the tank is less
than 100°C, a variable gas flame is applied until the
temperature goes back up. This is the process.
• The controlled parameter in this process is temperature. The
set point (SP) is 100°C. The set point minus the actual
temperature (PV) of the water is the error, or offset. When
there's an error, the controller sends a message (CO) to crank
up the heat.

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 PROPORTIONAL CONTROL

• The proportional mode (P) is the least

complicated of the three. The
mathematical expression is: CO =
Kp(PV-SP)
• The Kp is called the constant of
proportionality.That's a fancy term for
the number on a dial of the controller
apparatus that is adjustable and that
can be used by the operator to tweak
the process.
• If the Kp is negative .5 (- .5), the PV is
98°C, and the SP is 100°C, then the
CO would be 1. This 1, then, has a
calibrated meaning to the gas burner
underneath the tank that will adjust
the flame to a certain intensity.
 PROPORTIONAL CONTROL….

• As well, if the water coming out of the

tank is 100°C, (PV-SP) would equal
zero, the CO would be zero, and this
number would be associated with a
setting for the flame under the tank,
possibly zero or no flame.
• Because the P mode has only one
adjustment, Kp, it is the easiest to
operate. Used by itself (see Figure), the
mode never is able to completely
eliminate the difference between the
set point and the actual value (PV). The
P mode does, however, provide rapid
response and it is stable.
 INTEGRAL CONTROL
• The expression for the integral Kim of a PID algorithm stems from calculus, a kind of mathematics invented by
Isaac Newton. CO = KiΣ(PV-SP)dt
• This expression says we're integrating (Σ ) the error (PV-SP) with respect to time (dt), multiplying it by a
tweaking factor (K;), and getting a number that is the controller output signal (CO). Never mind that.
• In calculus, when we integrate, we are finding the area of a space underneath a line. Plotting the error versus
time, in this case, forms that line (see Figure). Thus, if at time one (t1) tlie error is 2 and at time two (t2j the
error is 3, the number arrived at by integrating is the shaded area in Figure.
• Likewise, if the error is zero at time one and zero at time two, then there is no area under the line and the
above expression for CO equals zero.
• As with die proportional mode, adjustments are made using a constant. In addition, the time period over
which the line is plotted can be manipulated.
• Unlike the proportional mode, integral action can eliminate error on its own (see Figure). Because of its
dependence on a long time interval to average out the error, the correction is slow and suitable only to
smaller systems.
• The expressions for P mode and I mode are often added together to take advantage of both types of action.
The integral component eliminates error, and the proportional component provides response speed and
stability.
 DERIVATIVE CONTROL
• The D term of the PID control expression stands for the word derivative and also comes from calculus.
• CO = Kd[d(PV-SP)/dt]
• The derivative control mode provides a controller output that is proportional to the rate of change of the
difference between the actual value of the parameter (temperature) and the set point (PV-SP).
• The visual interpretation of this is clearer. Using the same data used to construct the line in Figure, an identical
line is shown in Figure. The [d(PV-SP)/dt] component of the derivative expression merely says divide the
change in the error by the change in time. In this example, that means divide one (Ay) by the elapsed time (At).
If the elapsed time is 10 seconds, our result would be VlO. This number is then multiplied by a tweaking factor
(Kj), resulting in a CO.
• The derivative mode cannot, by itself, control a process. One reason for this is that a constant deviation from
the set point makes the above expression equal to zero. As well, if a sudden change in the process variable
occurs, an infinite signal is sent to the controller, which causes the relevant mechanical apparatus to fully open
or close. This leads to an unending instability.
• Derivative action adds lead time in the controller, compensating for the time delays present in nearly all
process control loops. When correctly applied, it stabilizes the process.
 PID CONTROL
• The crux of each of these three modes is they each produce a number (CO) from the
same input data (Kx, SP, and PV). That number is different for each mode. The interplay
of these numbers as data is input is the magic of the PID relationship.
• When the three modes' individual numbers are combined, a PID controller controls
the system. The proportional mode is the basic control. The integral mode deals with
the long-term errors that the proportional is unsuited to handle. The derivative mode
takes care of the more pronounced disturbances occurring in the ongoing process.
• The PID algorithm is used when the system is large, when there are rapid changes in
some process variables, and when these changes are big. It's a complex system and
necessitates tinkering at start-up to justify the various proportionality constants (K.,, Kj,
Kj) of each individual mode to efficiently reach and maintain the set point.
CONTROL LOOPS AND CONTROL ALGORITHMS

By using all three control algorithms together, process operators

can:
• Achieve rapid response to major disturbances with derivative
Control.
• Hold the process near setpoint without major fluctuations with
proportional control.
• Eliminate offset with integral control.
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 CONTROL LOOPS AND CONTROL ALGORITHMS

Not every process requires a full PID control strategy. If a small offset
has no impact on the process, then proportional control alone may be
sufficient.

PI control is used where no offset can be tolerated, where noise

(temporary error readings that do not reflect the true process variable
condition) may be present, and where excessive dead time (time after
a disturbance before control action takes place) is not a problem.

In processes where no offset can be tolerated, no noise is present, and

where dead time is an issue, customers can use full PID control.

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TUNING PROCESS CONTROLLERS STARTS
IN MANUAL

• PID controllers are designed to automatically control a

process variable like flow, temperature, or pressure. A
controller does this by changing process input so that a
process output agrees with a desired result: the set
point.
• An example would be changing the heat around a tank
so that water coming out of that tank always measures
1OO Degree C.
• Usually adjusting a valve controls the process variable.
How the controller adjusts the valve to keep the
process variable at the set point depends on process
parameters entered into three mathematical functions:
proportional (P), integral (I), and derivative (D).

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 HOW DOES ONE SET THE PARAMETERS SO
THAT THE CONTROLLER DOES ITS JOB?
• First, know that there is more to tuning a PID loop than just setting the tuning parameters.
The process has to be controllable. You won't be able to get good temperature in a hot
shower if there is no hot water or if the adjusting valve is too small or too large.
• Assuming the process can be conquered, then you can begin tuning it. The goal for good tuning
is to have the fastest response possible without causing instability. One of the best tools for
measuring response is integrated absolute error (IAE).
 ADVANCED TUNNING METHOD

• A poorly tuned process results in sending a richer product than

necessary out the door and with it, profits. Or, it causes oft-specification
product, which requires rework and increased cost. With better tuning
one can give away less while staying on spec.
 PID-BASE LINE PARAMETERS

• To perform the tuning chore, certain fundamental measurements must be

taken. Specifically, the processes lag time, dead time, and gain must the
determined. To do this, set the controller on manual. Set it’s output to
somewhere between 10% and 90%. Then, wait for the process to reach
steady state.
• Next, change the controller output quickly in a stepwise fashion. The
process variable will begin to change, too, after a period of time. This
period of time is called the process dead time.
• The process lag time is how, long it takes for the process variable (PV) to
go 63% of the way to where it eventually ends up. This would mean that if
the temperature increased from 100° to 200°, the lag time would be the
time it took to go from 100° to 163°.
• The process gain, or merely the gain, is found by dividing the total change in
the PV divided by the change in the controller output.

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 DEAD TIME

• A process that consists only of lag is easy to control. Simply use a P-only
controller with lots of gain. It will be stable and fast. Unfortunately these
processes are rare because of another dynamic element of most real
processes: dead j time.
• Sometimes overlooked, dead time is the real limiting factor in process
control. Dead time is j the time it takes for the PV to just start to move
after a change in the controller's output. During dead time, nothing
happens to the P .
• So, you wait. A control loop simply cannot respond raster than the dead
time. Hopefully, the process is designed to make dead time as small as
possible.
• With dead time in the process, gain can be increased to get a faster
response, but this will cause loop oscillation. If gain is increased even more,
the process will become unstable.

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INTERNAL MODEL CONTROL
METHOD FOR PID TUNNING
 CONTROLLER TUNING

TUNING :

The correct determination of gain,

integral & derivative time to give
optmimal control

m = Kc * e , where Kc = gain
m = 1 / Ti e dt Ti = integral time
m = Td * de / dt Td = derivative time

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