Part I

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 At the end of this chapter, the students should be able to:

 Briefly describe the principles of Manual Control.

 Briefly describe the principles of Automatic Control.
 State all the different Control Strategies under Automatic
Control.
 Briefly describe about On-Off Control, Feedback Control,
FeedForward Control, Ratio Control, Cascade Control,
Inferential Control, Selector/Override Control and Adaptive
Control as different Control Strategies under Automatic Control.
 Differentiate between Manual and Automatic Control.

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 Basically, the main principles in process control are;

 Manual Control

 Automatic Control

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 Q in

Q out

Figure 4.1 Tank

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 Q in

Sight Tube
h

Q out
V-1
Figure 4.2 Manual Control Mode

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  To regulate the level of tank to maintain, h, ‘sight tube’ apply
as indicator.
 Can measure the level through site view directly.

1. Level of fluid is PV (Controlled Variable)

2. Q out is (Manipulated Variable)

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  Personnel will measure the height in the sight tube and
compare with set point.
 If the measured value is larger:

should open the valve to let flow out increased, thus the
level can achieve the set point.

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 Q in

sensor
LC

Q out
Figure 4.3 Automatic Control System V-1

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  On-off Control
 Feedback Control
 Feed-forward Control
 Ratio Control
 Cascade Control
 Inferential Control
 Selector/Override Control
 Adaptive Control

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 Simplest control form, e.g. thermostat in iron and domestic
refrigerator.
 Less widely used - not as versatile and as effective as PID.
 Sometimes referred as “two-position” or “bang-bang” control.
 When temperature (PV) goes below SP, heater will switch on
 Advantages - cheaper and effective
 Disadvantages - results in continual cycling of controlled variable and
produces excessive wear on control valve or other FE

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Thermostat

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Figure 4.4 ON - OFF Control Loop
 p(t) = controller output
pmax = 100% (20 mA)
pmin = 0% (4 mA)

Figure 4.5 On-off Controller Output (Two Possible Values)

 FEEDBACK
SYSTEM

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 FEEDBACK SYSTEM
 Also known as closed loop control system
 The feedback is used to make decisions about changes to the
control signal that drives the plant.
 Widely use in industry

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Temperature Control System

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 Block Diagram For
Temperature Control System

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 Simplification Of Block
Diagram For Temperature
Control System

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 FEEDBACK SYSTEM

Figure 4.5 Standard Block Diagram of a Feedback Control System

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 FEEDBACK SYSTEM
 In Fig 4.5, the signal path from E to Y is referred to as the forward path while from
Y to comparator is called feedback path.
 During the process;
1. Disturbance (D) will occur during the process (input that cannot be manipulated)
2. Current PV (Yu) and D are combined and acted as process output (Y)
3. Sensor will measure the PV + D (Y)
4. Transmitter convert to input signal /measured variable (Ym)
5. Controller will evaluate the measurement (compare Y and SP), if any error exist,
controller will take corrective action immediately - by manipulating control element.
6. Control element will exerts the action, action on MV

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Figure 4.7 Key Characteristics of Commercial PID Controllers
Figure 4.7
(Top) Typical Process
Response
(Bottom) Proportional
Controller (P): Effect of
Controller Gain, Kc
Figure 4.8
(a) Proportional-Integral
Controller (PI): effect of
integral time, (b) effect of
controller gain, Kc
(Bottom) PID Control:
effect of derivative time
 FEEDBACK SYSTEM
 Main ADVANTAGES :

1.) Corrective action occurs as soon as the Controlled Variable (CV)

DEVIATES from the Set Point regardless of Source and Type of
Disturbance.

2.) Requires MINIMAL knowledge about the process to be controlled

in particular, a Mathematical Model of the Process, although can
be very useful for Control System Design.

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 FEEDBACK SYSTEM
 Main ADVANTAGES :

3.) PID Controller is BOTH versatile and robust. If Process Conditions

change, re-tuning the Controller usually produces satisfactory
control.

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 FEEDBACK SYSTEM
 DISADVANTAGES :

1.) NO Corrective Action is taken until AFTER Deviation in the

Controlled Variable occurs. Perfect Control ( the Controlled
Variable DOES NOT deviate from the Set Point during
Disturbance or Set-Point changes ) is theoretically IMPOSSIBLE.

2.) DOES NOT provide Predictive Control Action to compensate for

the effects of either Known or Measurable Disturbances.

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 FEEDBACK SYSTEM
 DISADVANTAGES :

3.) May NOT be satisfactory for processes with LARGE Time

Constants and/or LONG Time Delays. If LARGE and
FREQUENT Disturbances occur, the Process may operate
CONTINUOUSLY in a Transient State and NEVER attain the
desired Steady State.

4.) In some situations, the Controlled Variable CAN NOT be measured

on-line. Feedback Control is NOT feasible.
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Advantages and Disadvantages of Feedback
Control.
Ref: Riggs, J.B., Karim, M.N. (2006). Chemical and Bio-Process Control.

Feedback Advantages
•Can eliminate offset (when used with integral control).
•Not reliant on process models.
•Does not require measurements of disturbances.
•Simple to implement.
Feedback Disadvantages
•Disturbances significantly impact systems before control
action is initiated.
•When used improperly, can cause instability due to
nonlinearity.
•Too slow of a system or a system with high dead time do not
work well.
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 FEEDFORWARD
(FF) SYSTEM

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 FEEDFORWARD (FF) SYSTEM

→ Also known as non closed or open loop control system

→ Principle: It measure the important disturbance in advance
and take corrective action before it disturbs the process.
→ Feedforward control computes its input into a system using
only the current state and its model of the system
→Feed-forward possesses some significant problems.

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 FEEDFORWARD (FF) SYSTEM
 Function: to measure important disturbance (D) variables
& take corrective action before the process upset.
 In contrast, feedback controller does not take corrective action
until the D has upset the process.

 Widely used: boilers, evaporators, solids dryers, direct-fired

heaters & waste neutralization plants.

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 FEEDFORWARD (FF) SYSTEM

→ Operation Principle:
– There is a coupling (compute/calculate) from the set point
and/or from the disturbance directly to the process variable
– The process variable adjustment is not error-based (i.e. it uses a
mathematical model of the process or measurement of
disturbances). When Feed forward poorly handles disturbances
(can destroy desired task).
– The system does not measure output signal, so the result depend
on calculation of system.

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32

FEEDBACK FEEDFORWARD
CONTROLLER CONTROLLER
1

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 LIQUID LEVEL IN BOILER

Feedforward Control

Feedback Control

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 LIQUID LEVEL IN BOILER
 Refer to Fig (Feedforward), FF scheme can provide BETTER control
of level:
1. Steam flowrate is measured, then FC adjusts the feedwater as to balance
the steam demand.
2. Controlled variable (level, h) is NOT MEASURED.
 Practically, FF is normally used in COMBINATION with FB control.
 FF is used TO REDUCE the effects of D, while FB trim
COMPENSATE the inaccuracies in process, errors & unmeasured D.
FF Control
• Attempts to eliminate the effects of measurable disturbances.
FB Control
• Corrects for unmeasurable disturbances, modeling errors, etc. (FB
trim)

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 LIQUID LEVEL IN BOILER

FF + FB

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 HYPOTHETICAL SCHEME;
FF – FB CONTROLLER

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 FEEDFORWARD
SYSTEM
 DISADVANTAGES :

1.) The Disturbance Variables MUST be measured on-line. In many

applications, IS NOT feasible.

2.) At least an APPROXIMATE Process Model should be

AVAILABLE to make effective use. Need to know HOW the
Controlled Variable responds to changes in BOTH the Disturbance
Variable and the Manipulated Variable. The QUALITY of
Feedforward Control DEPENDS on the ACCURACY of Process
Model.
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 FEEDFORWARD
SYSTEM
 DISADVANTAGES :

3.) IDEAL Controllers that are theoretically capable of achieving

perfect control MAY NOT be physically realizable. Practical
approximations can provide VERY EFFECTIVE control.

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Advantages and Disadvantages of Feedforward
Control.
Ref: Riggs, J.B., Karim, M.N. (2006). Chemical and Bio-Process Control.

Feedforward Advantages
•Corrective action occurs as soon as the controlled variable
deviates from the set point.
•Compensates for disturbance before effect is seen.
•Doesn’t introduce instability into a closed loop response.
•Works well for slow processes or processes with a lot of dead
time.
Feedforward Disadvantages
•Doesn't completely eliminate offset.
•Dependent on process models.
•Requires disturbance model and extra sensor.
•Does not compensate for unmeasured disturbances.
•Need expert personnel – complicated, expensive 40
 RATIO
CONTROL
SYSTEM
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 RATIO CONTROL SYSTEM
 Special type of FF
 Consists of 2 Methods for control scheme.

 Objective: to MAINTAIN the ratio of two PVs at a specified value:

1. Manipulated V (u)
2. Disturbance V (d)
R = u/d
 Typical applications:
1. Specifying the amounts of components in blending operations
2. Maintaining a stoichiometric ratio of reactants to a reactor
3. Keeping a specified reflux ratio for a distillation column
4. Holding the fuel-air ratio to a furnace at the opt value.
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 EXPLANATION:

 Flowrate of D & u are

measured.
Rm = um/dm  Rm = um/dm is calculated.
 Divider’s output sent to RC.
 RC will compare the calculated
ratio, Rm to the desired Ratio,
R d.
 Adjust u accordingly.
 Typically is a PI controller
with the desired ratio as its set
point.
 ADV: Rm is calculated.
 DADV: Kp vary in nonlinear
fashion.
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EXPLANATION:

 D is measured & transmitted

to RS - multiplies this signal
with an adjustable gain, KR
 Output signal of RS is used
as set point, usp for the flow
controller which adjust the
flow rate of u.
 ADV: Kp remains constant.

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 RATIO CONTROL SYSTEM
Another example of Ratio control loop.

Figure 3.0 Ratio Control

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 RATIO CONTROL SYSTEM

During the process;

 There are two flows, which are uncontrolled and controlled.

 Uncontrolled flow, known as wild flow

 Controlled flow is controlled by the loop with a set point.

 It measures wild flow multiplied by some value.

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 RATIO CONTROL SYSTEM

Equation for ratio control:

PVr = Xpv/Ypv

PVr = ratio

Xpv = PV for line X

Ypv = PV for line Y

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48
49
 In a parallel ratio control strategy, the
master controller controls both loops
simultaneously. The advantage is that the
systems are independent and any electrical
signal noise in one loop will not affect the
other.
In series, the master and leader controllers comprise
the first loop in a two-loop controller. The follower
control loop, which is the second loop in a two-loop
controller, is controlled by a remote setpoint value
from the leader flow sensor.

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 To be concluded in Part II

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