PROCESS CONTROL

KKEK3154 - Week 3
Content:
Component of Control System
Development of Block Diagram
Closed-loop transfer functions
Conventional controllers

1
 𝑈(𝑡)

𝑌𝑅 (𝑡) 𝜀(𝑡) 𝑃′ (𝑡) 𝑥(𝑡) 𝑌(𝑡)

𝑌𝑚 (𝑡)
It is done by combining the individual block
diagram of the components (Process, Measuring
element, Controller, Final controller).
 Individual block #1: Process
1. Assume: well mix, 𝜌 and 𝑉 constant
So, the unsteady-state energy balance:
𝑑𝑇
𝑞 + 𝑤𝐶 𝑇𝑖 − 𝑇 = 𝜌𝐶𝑉
𝑑𝑡
2. Introduce the deviation variables becomes:
𝑑𝑇 ′
𝑄 + 𝑤𝐶 𝑇𝑖′ − 𝑇 ′ = 𝜌𝐶𝑉
𝑑𝑡
Where: 𝑇 ′ = 𝑇 − 𝑇𝑠 ; 𝑇𝑖′ = 𝑇𝑖 − 𝑇𝑠 ; 𝑄 = 𝑞 − 𝑞𝑠

3. Taking Laplace transform gives:

1
𝑤𝐶 1
′
𝑇 𝑠 = 𝑄 𝑠 + 𝑇𝑖′ 𝑠 = 𝐺𝑝1 𝑄 𝑠 + 𝐺𝑝2 𝑇𝑖′ 𝑠
𝜌𝑉 𝜌𝑉
𝑠+1 𝑠+1
𝑤 𝑤
 Individual block #1: Process cont.
1
𝑤𝐶 1
′
𝑇 𝑠 = 𝑄 𝑠 + 𝑇𝑖′ 𝑠 = 𝐺𝑝 𝑄 𝑠 + 𝐺𝑑 𝑇𝑖′ 𝑠
𝜌𝑉 𝜌𝑉
𝑠+1 𝑠+1
𝑤 𝑤

In Block diagram, TF above is equivalent to Fig. 1 & Fig. 2 (further simplified )

Fig. 1 Fig. 2

Fig. 1
 Individual block #2: Measuring Element
• M.E. senses the bath temperature
𝑇 and transmits a signal 𝑇𝑚 to
the controller.
• Assume that the measuring
element is a first-order system.
𝑇
𝑇𝑚′ 𝑠 𝑘𝑚
′
=
𝑇 𝑠 𝜏𝑚 𝑠 + 1
Let 𝑘𝑚 = 1, the block diagram it may
represented as :

NOTE: Thermocouples are commonly used in temperature sensing devices in industry and
the time constants 𝜏𝑚 of 6 to 20 seconds.
 The “heart” of
Individual block #3: Controller the Feedback
Control System
The TF for Conventional Controller:

𝑃′ 𝑠 1
= 𝑘𝑐 1 + + 𝜏𝐷 𝑠
𝜀 𝑠 𝜏𝐼 𝑠
𝑃
𝜀 is the deviation of the process measurement
𝑌𝑚 from its desired set-point Value 𝑌𝑟 .
𝜀 = 𝑌𝑟 − 𝑌𝑚
Let we use Proportional Controller for this case, Thus, the TF for the
controller is 𝐺𝑐 𝑠 = 𝑘𝑐 where the effect of integration,𝜏𝐼 and derivative,𝜏𝐷
are ignored and the block diagram for the controller is

𝑇𝑅′ + 𝜀 𝑃′
𝑃′ 𝑠 𝐺𝑐 𝑠 = 𝐾𝑐
= 𝑘𝑐
𝜀 𝑠 -

𝑇𝑚′
 Individual block #4: Final Control Element
The Final Element is usually a variable
resistant, and the output can be changed
by a signal coming from the controller, 𝑃.
𝑃 Therefore, it can be assumed the response
is 1st order and the transfer function is:
𝑄 𝑠 𝑘𝑣
′
=
𝑃 𝑠 𝜏𝑣 𝑠 + 1
Where 𝑘𝑣 is final element gain and τ𝑣 is
response time.
In this case, we assume the heater from electrical power gives
instantaneous response (𝜏𝑣 = 0) and the final element gain is 𝑘𝑣 = 1.
Thus, TF and block diagram are;

𝑄 𝑠 𝑃′ 𝑄
′
=1 1
𝑃 𝑠
Closed-Loop Block Diagram (combine all blocks)

𝑃′
1
controller Final element
Process

Measuring element
Closed-Loop Block Diagram (combine all blocks)

𝑃′
1
controller Final element
equivalent Process

Measuring element

Simplified block
diagram of
control system
 𝑌

Standard control system block diagram

Overall block diagram:

𝑌
We know that:
𝐵 = 𝐻𝑌; 𝑌 = 𝐺𝐸; 𝐸 = 𝑅 − 𝐵

∴ 𝑌 = 𝐺 𝑅 − 𝐵 = 𝐺 𝑅 − 𝐻𝑌
𝑌 𝑌 1 + 𝐺𝐻 = 𝐺𝑅
So, the TF:

𝑌 𝑠 𝐺
=
𝑅 𝑠 1 + 𝐺𝐻

𝑌 Where , 𝐺 = 𝐺𝑐 𝐺1 𝐺2
Overall Transfer Function for Change in
Load (Regulatory)
Block Diagram Simplification Method Algebraic Method

We know that:
𝐵 = 𝐻𝐶; 𝑌 = 𝐺2 𝑈 + 𝑀 ;
𝑌
𝐸 = −𝐵
∴ 𝑌 = 𝐺2 𝑈 + 𝐺1 𝐺𝑐 𝐸
= 𝐺2 𝑈 + 𝐺𝐸
= 𝐺2 𝑈 − 𝐺𝐵
= 𝐺2 𝑈 − 𝐺𝐻𝑌
𝑌 1 + 𝐺𝐻 = 𝐺2 𝑈
So, the TF:
𝑌
𝑌 𝑠 𝐺2
=
𝑈 𝑠 1 + 𝐺𝐻
𝐺 = 𝐺𝑐 𝐺1 𝐺2
Where , 𝐺 = 𝐺𝑐 𝐺1 𝐺2
1. Proportional Controller (P)
𝑃′ 𝑠
Time domain: 𝑃 𝑡 = 𝑘𝑐 𝜀 𝑡 + 𝑃𝑠 ; → Laplace domain: = 𝑘𝑐
𝜀 𝑠
2. Proportional-Integral (PI)
𝑘𝑐 𝑡
Time domain: 𝑃 𝑡 = 𝑘𝑐 𝜀 𝑡 + ‫𝜀 ׬‬ 𝑡 𝑑𝑡 + 𝑃𝑠 ;
𝜏𝐼 0
𝑃′ 𝑠 1
→ Laplace domain: = 𝑘𝑐 1 +
𝜀 𝑠 𝜏𝐼 𝑠
3. Proportional-Derivative (PD)
𝑑𝜀 𝑡
Time domain: 𝑃 𝑡 = 𝑘𝑐 𝜀 𝑡 + 𝑘𝑐 𝜏𝐷 + 𝑃𝑠 ;
𝑑𝑡
𝑃′ 𝑠
→ Laplace domain: = 𝑘𝑐 1 + 𝜏𝐷 𝑠
𝜀 𝑠
4. Proportional-Integral-Derivative (PID)
𝑘𝑐 𝑡 𝑑𝜀 𝑡
Time domain: 𝑃 𝑡 = 𝑘𝑐 𝜀 𝑡 + ‫ 𝑡𝑑 𝑡 𝜀 ׬‬+ 𝑘𝑐 𝜏𝐷 + 𝑃𝑠 ;
𝜏𝐼 0 𝑑𝑡
𝑃′ 𝑠 1
→ Laplace domain: = 𝑘𝑐 1 + + 𝜏𝐷 𝑠
𝜀 𝑠 𝜏𝐼 𝑠
17