Introduction

• What is an automatic process control? Control in which regulating and switching

operations are performed automatically in response to predetermined conditions
Introduction
• Why automatic process control is important? Automatic control systems enable us
to operate our processes in a safe and profitable manner. Control systems achieve
this "safe and profitable" objective by continually measuring process variables
such as temperature, pressure, level, flow and concentration and taking actions
such as opening valves, slowing down pumps and turning up heaters - all so that the
measured process variables are maintained at operator specified set point values
Introduction
• Process Control Terminology
– Process Variable (PV): What you are trying to control: temperature, pressure,
flow, composition, pH, etc. Also called the measurement. – Set-Point (SP): The set-
point is where you would like the process variable to be. – Error (e): Error = SP -
PV. In auto mode, the controller uses the error in its calculation to find the
output that will get you to the setpoint.
Introduction
• Process Control Terminology
– Controller Output (CO): Output of the controller. In auto mode the controller
calculates the output based on its calculation using the error signal (difference
between SP and PV). In manual mode, the user sets the output. – Manipulated
Variable (MV): Process condition or

variable that can be changed to cause the process variable to change. – Disturbance
(D): process condition that tends to change the value of the process variable.
Introduction
• Components of a Control System
– controller seeks to maintain the measured process variable (PV) at set point (SP)
in spite of unmeasured disturbances (D). The major components of a control system
include a sensor, a controller and a final control element.
Introduction
• Components of a Control System
– Sensor: Device which is used to measure process variable e.g. flow orifice,
Bourdon tube, thermocouple. – Controller: Device that keeps process variable at the
setpoint. – Final control element: Device which directly changes the manipulated
variable e.g. control valves, pump, compressor.
Control Architecture
• • • • • • Feedback control Feedforward with feedback control Cascade control
Split-range control Ratio control Override control
Feedback Control
Feedback Control Block Diagram
controller error e(t) = (SP-PV) set point, SP +Controller Final Control Element
(FCE) Proces s Disturbance, D measured process variable signal, PV controller
output signal (CO) manipulated variable (MV) process variable

Measurement Sensor/Transmitter
Feedback Control
Gas pipeline 1

Without control system, flowrate through this line depends on the pressure
difference between these 2 gas pipelines.

Gas pipeline 2
Feedback Control
SP

Gas pipeline 1

PV

FC CO

Gas pipeline 2
Feedback Control
• When to use feedback control?
– Normally feedback control is the first choice when you want to apply automatic
control to your system because of its simplicity.
Feedback Control
• Advantages of feedback control
– Can handle unforeseen disturbances such as frictional and pressure losses. –
Ensures the desired performance by altering the inputs immediately once deviations
are observed regardless of what caused the disturbance. – By analyzing the output
of a system, unstable processes may be stabilized. – Feedback controls do not
require detailed knowledge of the system and, in particular, do not require a
mathematical model of the process. Feedback controls can be easily duplicated from
one system to another.
Feedback Control
• Disadvantages of feedback control
– Not suitable for system having large dead time. – Can only take input from one
sensor. – The controller responds to the disturbance after its occurrence, so
perfect control of the system is theoretically impossible.
– Feedback control does not take predictive control action towards the effects of
known disturbances.
Cascade Control
Cascade Control Block Diagram
controller error e(t) = (SP-PV) Primary SP +controller error e(t) = (SP-PV) Primary
Controller Secondary SP Primary CO +Secondary CO Secondary Controller manipulated
variable (MV) Final Control Element (FCE) Secondary Process

Secondary PV

Primary PV Primary Process

Disturbance, D

Disturbance, D

Secondary PV Measurement Sensor/Transmitter

Primary PV

Measurement Sensor/Transmitter
Cascade Control
CO

PI

Header pressure varies as other line valves move, disturbing our feed rate

flow to other users

PV

L Setpoint LC

Exit flow
Cascade Control
CO1 = SP2

Setpoint
FC PV2 PI CO2

Header pressure varies as other line valves move, disturbing our feed rate

flow to other users

PV1

L Setpoint LC

Exit flow
Cascade Control
• When to use cascade control?
– When a number of various disturbances might be expected in a single control loop.
– When a fast response is required and it cannot be achieved by using only single
control loop.
Cascade Control
• Requirements for Cascade Control
– The secondary control loop must be faster than the primary control loop. – The
secondary control loop receives the maximum disturbance. – The secondary loop must
include the worst expected disturbances. – The secondary loop must have a direct
influence on the primary loop. – Secondary loop must be measured and controllable.
Cascade Control
• Advantages of Cascade Control
– Better control of the primary variable. – Primary variable less affected by
disturbances. – Faster recovery from disturbances.

• Disadvantages of Cascade Control

– Cost of measurement of secondary variable. – Additional complexity.
Feedforward with Feedback Control
Feedforward with Feedback Control Block Diagram
Disturbance, D Disturbance Sensor/Transmitter Disturbance Process

Feedforward Computation Element

controller error e(t) = (SP-PV)

set point, SP +-

controller output signal (CO) Controller + +

CO feedforward Final Control Element

manipulated variable

process variable
+

Process

measured process variable signal, PV Measurement Sensor/Transmitter

Feedforward with Feedback Control

Steam to header

PV1

LC

L setpoint

F setpoint

Steam Drum
FC

CO

BFW from header

2-Element Cascade Control

Feedforward with Feedback Control
FT Steam to header

LY PV1

LC

L setpoint

FC

CO
BFW from header

Steam Drum

3-Element Control
Feedforward with Feedback Control
• When to use feedforward control?
– Concern is focused on one specific disturbance that is responsible for repeated,
costly disruptions to stable operation. – Reject disturbance(s) before it
disturbs / disrupts the system. – There is no practical secondary process variable
which can be established.
Feedforward with Feedback Control
• Requirements for feedforward control?
– Disturbances must be measured. – A mathematical model of process is required.
Feedforward with Feedback Control
• Advantages of feedforward control
– Corrective action taken BEFORE PV deviates from setpoint.

• Disadvantages of feedforward control

– Cost of measurement of disturbance. – Additional complexity.

– Not suitable for a system which has a number of disturbances.

Split-Range Control
Split-Range Control Loop Block Diagram
manipulated variable 1 controller error e(t) = (SP-PV) set point, SP controller
output signal (CO) Controller CO 1 Final Control Element 1 (FCE1) Process Final
Control Element 2 (FCE2) manipulated variable 2 process variable

+-

Splitter

CO 2

measured process variable signal, PV Measurement Sensor/Transmitter

Split-Range Control

50-100% 100% 0-50% B A

PC

Gas to flare Gas to compressor % valve opening 0% 0% Controller Output % opening

valve A % opening valve B 100%
Split-Range Control

50-100% 100% 0-50% B A

PC

Gas to flare Gas from header % valve opening 0% 0% Controller Output % opening
valve A % opening valve B 100%
Split-Range Control
• When to use split-range control Split-range control is used in situations where
more than one manipulated variable is required.
Split-Range Control
• Advantages of split-range control
– Can control over the wide range – Can handle more than one disturbances at the
same time.

• Disadvantages of split-range control

– Additional cost for final control element. – Difficulty in controller tuning.
Ratio Control
Ratio Control Block Diagram
Measurement Sensor/Transmitter measured process variable signal, PV2 Ratio
controller error e(t) = (SP-PV) set point, SP controller output signal (CO) Final
Control Element 1 (FCE1) manipulated variable process variable

+-

Controller

Process

measured process variable signal, PV1

Measurement Sensor/Transmitter
Ratio Control

PV 1

FT

Product 2
RY SP PV 2 FC FT CO

Mixed ratio Storage Tank

Product 1
Ratio Control
• When to use ratio control The ratio control architecture is used to maintain the
flow rate of one stream in a process at a defined or specified proportion relative
to that of another.
Ratio Control
• Requirement for ratio control A ratio controller architecture requires that the
signal from each flow sensor/transmitter change linearly with flow rate.
50 MMSCFD Fluid flowrate 0 MMSCFD 4 mA Transmitter Signal 20 mA
Override Control
Override Control Block Diagram
controller error e(t) = (SP-PV) set point, SP2 +Controller selected CO manipulated
variable (MV) Final Control Element (FCE) process variable controller output signal
(CO2)

Selector

Process

controller error e(t) = (SP-PV) set point, SP1 +-

controller output signal (CO1)

Disturbance, D

Controller

measured process variable signal, PV

Measurement Sensor/Transmitter
Override Control

>
FC PC

TC

Fuel gas Fired Heater

Heated process fluid

Override Control
• When to use override control
– When there is a constraint in operation or equipment.
Advanced Control
> R <

O2 FC Y FT <

>
PC Max. PC Min. TC

Fuel gas from header

Y FC

Heated process fluid Fired Heater

FT

Air Blower

Cross Limiting Control for Fired Heater

Summary
Control Architecture Feedback Philosophy Control adjusts error after it occurs
Advantages - simple to design - no process model needed Disadvantages - correct
error after it has already occurred. - usually takes input from one sensor -
accurate process model is needed. - accurate measurement is needed. - increase
complexity to the control system - additional costs required. - flow
sensor/transmitter has to change linearly with the flowrate. - add complexity to
the process control - tuning model is difficult due to multiple setpoints and
parameters. - make system unstable due to integral action. External feedback is
needed.

Feedforward

Control corrects error before it occurs.

- correct possible error before it occurs. - Ideally can produce a perfect control
where there is never offset.

Ratio

Control connects two flows to maintain a constant ratio. Controller output from one
control is a setpoint of the other control loop.

- generate defined ratio for given two streams. - simple model - responds quickly
to high frequency changes - incorporate multiple sensor reading together. - prevent
operation or equipment from operating over its constraints.

Cascade

Override Control action from one controller takes priority

Split-range

One controller adjusts more than one manipulated variables.

-can control over the wide range -can handle many disturbances

-make controller tuning more difficult.