Scribd
Upload
84 views

Lecture 10 - Multiple Control Loops - 2023

This document discusses various multiple loop control strategies including cascade control, override control, ratio control, and split-range control. Cascade control uses one controller's output to set another controller's setpoint. Override control selects the highest or lowest output signal from multiple controllers. Ratio control maintains a predetermined ratio between two process variables. Split-range control uses a single controller to coordinate multiple manipulated variables that all affect the same controlled variable. Examples are provided for each control strategy.

Uploaded by

Mohamed Salaheldin
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
84 views

Lecture 10 - Multiple Control Loops - 2023

This document discusses various multiple loop control strategies including cascade control, override control, ratio control, and split-range control. Cascade control uses one controller's output to set another controller's setpoint. Override control selects the highest or lowest output signal from multiple controllers. Ratio control maintains a predetermined ratio between two process variables. Split-range control uses a single controller to coordinate multiple manipulated variables that all affect the same controlled variable. Examples are provided for each control strategy.

Uploaded by

Mohamed Salaheldin
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 26

Automatic Process Control

Dr. Eng. Mohamed Salaheldin

Automatic Process Control


Lecture 10

Process Control Strategies &


Multiple Control Loop

Automatic Process Control


Multiple Control Loops
▪ Cascade Control

▪ Override Control

▪ Ratio Control

▪ Split-range control

Automatic Process Control


Simple Control Loop

▪ Information from the measuring device (e.g. transmitter) goes to the controller,
then to the final control device (e.g. control valve), influencing the process which
is sensed again by the measuring device.
▪ The controller’s task is to inject the proper amount of negative feedback such
that the process variable stabilizes over time. This flow of information is
collectively referred to as a feedback control loop.

Automatic Process Control


Cascade Control
▪ To cascade controllers means to connect the output signal of one controller to the
setpoint of another controller, with each controller sensing a different aspect of the same
process.
▪ The output from one controller " the primary or master controller" is the set point for
another controller "the secondary or slave controller"

Automatic Process Control


The purpose of Cascade Control
▪ To achieve greater stability of the primary process variable by regulating a
secondary process variable in accordance with the needs of the first.
▪ An essential requirement of cascaded control is that the secondary process
variable be faster-responding

Automatic Process Control


The advantages of cascade control
▪ Variations of the process variable measurement by the master
controller are corrected by the slave control systems

▪ Speed of response of the master control loop is increased

▪ Slave controller permits an exact manipulation of the flow of


mass or energy by the master (to maintain the process
variable, measured by the master controller within the normal
operating limits)

Automatic Process Control


Example: Dryer System
▪ Heated air is used to evaporate water from a granular solid. The primary process
variable is the outlet air exiting the dryer, which should be maintained at a high
enough temperature to ensure water will not remain in the upper layers of the solid
material. This outlet temperature is fairly slow to react, as the solid material mass
creates a large lag time

What about these parameters:


• incoming air flow,
• ambient temperature,
• Steam temperature

Automatic Process Control


Cascade Control could be the solution in this case of Dryer System

▪ the “slave” control loop (1b) helps stabilize the “master” control loop (1a) by reacting
to load changes long before any effect might manifest at the dryer outlet.
▪ Responsibility for incoming air temperature has been delegated to the slave
controller, and as a result the master controller is conveniently isolated from the
other parameters impacting that loop.
Example: Heat Exchanger Temperature Cascade Control

▪ The aim is to keep T2 constant.


▪ The secondary loop is used to compensate for flowrate changes.

Automatic Process Control


Three Different Operating Modes In Cascade Control

▪ Manual mode: Controller takes no automatic action.


Output value set by human operator.

▪ Automatic mode: Controller automatically adjusts its


output to try to keep PV = SP. Setpoint value set
“locally” by human operator.

▪ Cascade mode: Controller automatically adjusts its


output to try to keep PV = SP. Setpoint value set
“remotely” by primary (master) controller.

Automatic Process Control


Override Control
▪ An “override” control strategy involves a selection between two or more controller
output signals, where only one controller at a time gets the opportunity to exert
control over a process.
▪ All other “de-selected” controllers are thus overridden by the selected controller.
▪ In override control either the highest or lowest signal from two or more input
signals is automatically selected by the selector relay

Limit, Selector, and Override controls

Automatic Process Control


Override Control loop

Normally, the distribution valve is controlled by the


discharge pressure controller, but under high demand
conditions the control is transferred to the flow controller

Automatic Process Control


Override Control Example: Water Pumping System

a water pump is driven by a


variable-speed electric motor
to draw water from a well and
provide constant water
pressure to a customer

variable-speed motor as the final control element

• Reducing pump speed in low-flow conditions will save a lot of energy over time compared
to the energy that would be wasted by a constant-speed pump and control valve.
• A potential problem with this system is the pump running “dry” if the water level in the well
gets too low, as might happen during summer months when rainfall is low and customer
demand is high.

Automatic Process Control


Apply the Override Control

• If ever the well’s water level goes below this setpoint, the level controller will
command the pump to slow down, even if the pressure controller is calling
for a higher speed.
• The level controller will have overridden the pressure controller, prioritizing
pump longevity over customer demand.
Ratio Control
▪ A control strategy known as ratio control, where the ratio of one flow
rate to another is controlled for some desired outcome.
▪ Many industrial processes also require the precise mixing of two or
more ingredients to produce a desired product.
▪ Ratio control is where a predetermined ratio is maintained between
two or more variables

Automatic Process Control


Ratio Control

Ratio control is where a predetermined ratio is maintained between two or


more variables

Automatic Process Control


Ratio Control Example: The production of paint

A base liquid must be mixed


with one or more pigments
to achieve a desired color

▪ With identical flow range calibrations in both flow transmitters, this


multiplying constant k directly determines the pigment-to-base ratio
▪ (i.e. the ratio will be 1:1 when k = 1; the ratio will be 2:1 when k = 2, etc.)

Automatic Process Control


What is the difference between Cascade Control and Ratio Control?

▪ In a cascade system, the output of one controller becomes the setpoint for
another.
▪ In a ratio control system, the process variable of one controller becomes the
setpoint for another, such that two process variables remain in constant
proportion (ratio) to one another.

Steam-hydrocarbon reforming process

Automatic Process Control


Split-Range Control
▪ There are many process control applications in industry where it is
desirable to have multiple control valves respond to the output of a
common controller.
▪ Control valves configured to follow the command of the same
controller are said to be split-ranged, or sequenced.
▪ This is distinguished by the fact that it has

◦ one measurement only (the controlled variable)

◦ more than one manipulated variable

Automatic Process Control


Split-Range Control
▪ The control signal is split into several parts each associated with one
of the manipulated variables.
▪ A single process is controlled by coordinating the actions of several
manipulated variables, all of which have the same effect on the
controlled output.

Split-range Control
Strategy when
applied instead of
ratio control in the
paint example

Automatic Process Control


Split-Range Control Example:
Control of Pressure in a Reactor

▪ In this case the action of the two valves should be coordinated.


▪ Thus for example if the operating pressure is between 0.5 and
1.5 bar then the control algorithm could be:

Automatic Process Control


▪ If the pressure is below 0.5 bar then valve 1 is completely open and 2 is
completely closed.
▪ If the pressure is between 0.5 and 1 bar then valve 1 is completely open
while 2 is opened continuously as the pressure rises. Note that this
action leads to a reduction in pressure.
▪ If there is a large increase in pressure and it rises to above 1 bar then
valve 2 is completely open while 1 is closed continuously.
▪ If the pressure reaches 1.5 bar then valve 1 is fully shut and valve 2 is
completely open.
Example
A pH control process where the incoming liquid always has a high pH value, and must be
neutralized with acid. Two valves with different sizes are used depending on the required
amount of acid to neutralize the incoming water. Explain the possible relationship
between valve opening for each control valve and the controller’s output using a table
and a graph where the x-axis is the controller output and the y-axis represents the valve
opening.

Automatic Process Control

You might also like