D G P 1 0 0 4 2

C H A P T E R 4

B A S I C C O N T R O L S Y S T E M
 LEARNING OUTCOMES
At the end of this session, student will be able to:

1. Define a control system.

2. State the advantages of control system.

3. Describe the manual and automatic control.

4. Find out the differences between open loop, close loop, feedback
control, feed-forward control and cascade control.
WHY DO WE NEED PROCESS
CONTROL?
DEFINITIONS
• Control System-a group of components, plants, processes assembled for
controlling.

• A control system is a device or set of devices to manage, command, direct

or regulate the behavior of other devices or systems.

• In other word, a control system provides an output or response for a given

input or stimulus.
BASIC ELEMENTS OF CONTROL SYSTEMS

 To facilitate the analysis of control carried out, the elements in the control
loop is described as a block.

 The block diagram is a representation of the functions.

SIMPLIFIED DESCRIPTION OF CONTROL SYSTEM

Control
System
• Input; stimulus • Output; response
• Actual response
• Desired response
BLOCK DIAGRAM
 CONTROL LOOP CONFIGURATIONS

Open Loop System

• Does not have a loop
• Does not have corrective action.

Input Output

Controller Actuator Load

In an open loop system, the controller is told what the desired process output
and the controller sends a command to the actuator to achieve the output.
CHARACTERISTICS OF OPEN LOOP SYSTEM
• Also know as Manual Loop System.
• A characteristic of the open-loop controller is that it does not use
feedback to determine if its output has achieved the desired goal of the
input. This means that the system does not observe the output of the
processes that it is controlling.
• The value of the controlled condition is continuously shown on an
indicator/recorder.
• This type of control requires the operator to control the process variables.
• A reading of the instrument is taken periodically and the control value
position is adjusted accordingly.
• The output of measuring element does not play a direct
part in actuating the valve.
• Its only to function to provide information.
• This method is simple and low cost but limited
applications.
OPEN LOOP SYSTEM
 INSTRUMENTATION IN OPEN LOOP SYSTEM
• Detecting Element
 This element respond directly to the value of the controlled
condition.
 It is an element which is used as a detector of change of a
quantity and provide responses based on the quantity controlled.
 Examples: thermocouple, resistance thermometer detector,
Bourdon tube, diaphragm, restriction orifice and displacer.

resistance thermometer detector

restriction orifice

thermocouple Bourdon tube

 INSTRUMENTATION IN OPEN LOOP SYSTEM

• Measuring Element
 As a measure and compensate for the reading of signals from
the detecting element.
 Examples: thermometer, diaphragm units, manometer, Venturi
meter, Rotameter and potentiometers.

potentiometers

Rotameter
thermometer manometer
 INSTRUMENTATION IN OPEN LOOP SYSTEM

• Indicator Recorder
 Displays and records the controlled variable reading.
 Examples : flow meter, pressure gauge, indicator and recorder.
OPEN LOOP SYSTEM
 MANUAL CONTROL: TEMPERATURE CONTROL SYSTEM

• This system requires the operator to perform process control.

The operator will monitor the process and control the
variables manually.

• The process operator serves as a controller, by observing the

measured value indicated on the thermometer dial, and
adjusting the steam valve accordingly.

• Provided the operator is present in this capacity, then the

closed loop system is formed. The system will change to open
loop when the operator leaves.
 MANUAL CONTROL

Advantages:
• The process is easy and cost-effective.
• Actions can be performed in circumstances beyond our
control.
• Suitable for start up plant.

Disadvantages:
• Need the operator to observe or monitor.
• Effect the production quality.
• Security limited application.
CLOSE LOOP SYSTEM
CLOSE LOOP SYSTEM : TEMPERATURE CONTROL SYSTEM
CLOSE LOOP SYSTEM : TEMPERATURE CONTROL SYSTEM
 INSTRUMENTATION IN CLOSE LOOP SYSTEM
• Detecting Element
 This element respond directly to the value of the controlled
condition.
 It is an element which is used as a detector of change of a
quantity and provide responses based on the quantity controlled.
 Examples: thermocouple, resistance thermometer element,
Bourdon tube, diaphragm, restriction orifice and displacer.

• Measuring Element
 As a measure and compensate for the reading of signals from the
detecting element.
 Examples: diaphragm units, manometer, Venturi meter,
Rotameter and potentiometers.

• Comparing Element
 As an element to compare between the present value and set
point reading.
• Controlling Element
 It is a signal which serves as a correcting element adjuster that
controls the process.
 This element is used to control the processing system.

• Motor Element
 Received signals from the controlling element then it will send a
signal to the correcting element.

• Correcting Element
 This element is used to control the processing system.
 Typical correcting element for pressure, flow, level and
temperature in a pipeline is control valve.
 AUTOMATIC CONTROL
 Most automatic control installations are closed loop systems.
 Advantages of the system, includes:
i. The process operators are relieved of the more monotonous tasks, thus
making better use of manpower.
ii. Steady conditions reduce the waste of raw materials and fuel.
iii. The plant can be operated nearer to its maximum capacity than it could
with manual control.
iv. A more uniform product is obtained, conforming closer to the
specification.
v. Processes can be operated which could not be manually controlled.
 Disadvantages of automatic control system are:
i. The quality of product affected if not monitored accurately as well as
safety of equipment and personnel issue.
ii. Limited application and costly.
 TYPES OF AUTOMATIC CONTROL

1. Feedback Control

2. Feedforward Control

3. Cascade Control
FEEDBACK & FEEDFORWARD CONTROL
 FEEDBACK CONTROL

Consider the level control shown in the figure:

• A level measurement device (usually a differential pressure cell) senses the level, h m and sends
a signal to the controller.
• Notice that the controller is comparing the tank height with the desired set point, h sp and
sending a controller output (pressure signal) to the valve, which changes the valve position and
therefore the volumetric flow rate of stream 1, F1. These signals are shown as dashed lines on
the figure.
 FEEDBACK CONTROL

The alternative process and instrumentation diagram for previous level

control problem. The only difference between this and the previous
instrumentation diagram is that F2 rather than F1 is manipulated.
FEEDBACK CONTROL
FEEDBACK CONTROL

Consider the temperature control

problem shown in the figure:
• The outlet temperature of process
fluid is controlled by manipulating
the valve position of the fuel
control valve.
• Clearly disturbances in the fuel gas
header pressure (upstream of the
valve) will end up changing the
fuel gas flow rate as well as the
process fluid outlet temperature.
 FEEDBACK CONTROL

Stirred-tank reactor. Standard feedback control

 FEED-FORWARD CONTROL

• The advantage to a feed-forward control strategy is that a disturbance variable is measured and
a manipulated variable is changed before the output is affected.
• Consider a case where the inlet flow rate can be changed by the upstream process unit and is
therefore considered as disturbance variable.
• If we can measure the inlet flow rate, we can manipulate the outlet flow rate to maintain a
constant tank height. This feed-forward control strategy is shown in figure, where FM is the flow
measurement device and FFC is the feed-forward controller.
FEED-FORWARD CONTROL
Consider the furnace system as shown
in figure:
• One possible disturbance is the
process fluid flow rate; if the flow
rate increases 20%, then the
required heat duty should also
increase by 20%.
• The purpose of the feed-forward
control strategy shown is to
immediately change the fuel gas
flow rate when a change in the
process flow rate is sensed.
• For simplicity we assume that the
fuel gas flow rate is directly
manipulated in this diagram.
 FEED-FORWARD CONTROL

• The feedforward control scheme shown in figure can provide better control
of liquid level. The steam flow rate is measured, and the feedforward controller
adjusts the feed water flow rate so as to balance the steam demand .
• Note that the controlled variable, liquid level, is not measured . As an alternative,
steam pressure could be measured instead of steam flow rate.
FEED-FORWARD CONTROL
FEED-FORWARD CONTROL
 FEED-FORWARD-FEEDBACK CONTROL
• In practical applications,
feedforward control is normally
used in combination with
feedback control.
• Feedforward control is used to
reduce the effects of
measurable disturbances, while
feedback trim compensates for
inaccuracies in the process
model, measurement error,
and unmeasured disturbances.

Feedforward-feedback of the boiler drum level

control
FEEDFORWARD-FEEDBACK CONTROL
FEEDBACK-FEEDFORWARD CONTROL
• In practice, feed-forward
control is combined with
feedback control, as shown
in figure.
• Here the feed-forward
controller compensates for
process flow rate
disturbances,
• While the feedback
controller compensates for
other disturbances (outlet
temperature).
CASCADE CONTROL

• In cascade control, the output of

the temperature controller is the
set point to the fuel gas flow
controller.
• The output of the flow controller
is the pressure to the control
valve, which changes the valve
position and, therefore, the flow
rate.
• Any change in the fuel gas header
pressure will be "felt" immediately
by the flow measurement,
allowing the flow controller to
take immediate corrective action.
CASCADE CONTROL
 CASCADE CONTROL

• Consider the stirred-tank reactor shown in figure in the standard

feedback-control strategy. The temperature of the reactor is measured
and the jacket flow rate is manipulated
• If there is a disturbance in the jacket feed temperature, it will affect the
jacket temperature, which will affect the reactor temperature
• In the cascade-control strategy, the temperature of the reactor is
measured and compared with the desired reactor temperature. The
output of this reactor temperature controller is a set point to the jacket
temperature controller
• The jacket temperature controller manipulates the jacket flow rate.
Notice that two measurements (reactor temperature and jacket
temperature) are made but only one manipulated variable (jacket flow
rate) is ultimately adjusted.
FEEDFORWARD-FEEDBACK-CASCADE CONTROL
 EXAMPLE 4.1
Sketch a feedback control system used to control liquid level in a tank with
all locally mounted basic instrumentation and are pneumatically actuated.

Solution:
 EXAMPLE 4.2
Sketch a feedback control system to control process fluid flow in a pipeline designed as loop 100. A
restriction orifice is used as first element to detect the flow and connected to locally mounted flow
transmitter and Distributed Control System (DCS) flow indicating controller using electrical signal
connection. The data flow of fluid is linked and recorded to a DCS flow recorder. An output signal
from controller is used to regulate the 2 inch pneumatically actuated fail closed control valve.

Solution:
 EXAMPLE 4.3
A process liquid from preliminary processing unit is required to be store in a closed
pressurize vessel before it’s transferred by a pump to the subsequent processing unit.
In the vessel, steam is used to elevate the process liquid temperature to a set point
temperature by regulating the amount of inlet steam using electrical actuated control
valve and locally mounted pneumatic instrumentations and controller. Sketch a piping
and instrumentation diagram to show the control and instrumentation for the system.

Solution:
 EXAMPLE 4.4

a. Name type of flow diagram shown in figure above.

b. Describe the type of control system and instrumentation used in figure above.
 SOLUTION TO EXAMPLE 4.4
a. Name type of flow diagram shown in figure above.
   Piping and Instrumentation Diagram.

b. Explain the type of control system and instrumentation used in figure above.
- Cascade control system. Output signal of liquid level in the form of
electrical signal from LIC 101 become set point to the flow indicating
controller FIC 101 to monitor liquid flow to the open tank
- Instrumentation :
1 locally mounted flow indicating controller, FIT 100.
1 main board control panel, FIC 100.
1 I/P converter to convert electrical signal to pneumatic signal.
1 control valve, FV 101 to regulate liquid flow to open tank.
 EXAMPLE 4.5
A control system is used to control liquid level in a tank with inlet flow rate, F1 and outlet

flow rate, F2 using all locally mounted basic instrumentation and are electrically

actuated. The final element control is a pneumatically control valve. Sketch a control

system if the system:

a. is a feedback control with inlet flow is manipulated variable.

b. is a feedback control with outlet flow is a manipulated variable.

c. is feedforward control with the outlet flow is a manipulated variable.

Assume the control loop for control system numbered as 115.

 SOLUTION TO EXAMPLE 4.5
a. is a feedback control with inlet flow is manipulated variable.
b. is a feedback control with outlet flow is a manipulated variable.
c. is feedforward control with the outlet flow is a manipulated variable.
 EXERCISE 4.6
1. Sketch a control system used to control liquid level in a tank with all locally mounted
basic instrumentation and pneumatically actuated if the control system:
a. is a feedback control system with inlet flow is manipulated variable.
b. is a feedback control system with outlet flow is a manipulated variable.
c. is feedforward control system with the outlet flow is a manipulated variable.

2. A control system is used to control the temperature of process fluid outlet in a furnace
by manipulating the position of fuel gas control valve. All control and instrumentation
system are electrically actuated.
a. Sketch the feedback control system.
b. Sketch the feedforward control system.

3. In a continuous stirred tank reactor (CSTR), the temperature of reactor is controlled by

manipulating the flow rate of cooling water control valve of jacket temperature.
Assuming the process fluid inlet flow rate is a major disturbance for the system,
sketch a feedforward control to describe the system.
 EXERCISE 4.7

Figure E4.1

4. Describe the feedback-feedforward control system used to control the boiler drum
level in Figure E4.1
 EXERCISE 4.8

Figure E4.2

5. Describe the control system used to control the process fluid outlet in Figure E4.2
 EXERCISE 4.9

Figure E4.3

6. Describe the control system used to control fluid level in tank as shown Figure E4.3