Introduction to

Process Control
Industrial Automation Research Group
Program Studi Teknik Fisika
Institut Teknologi Bandung

Introduction to Process Control 1- 1

 Training Objectives
 Introduction to process control
 Elements of process control loop
 Feedback, feedforward, cascade, feedforward/feedback,
feedforward/feedback + cascade
controls,Ratio,Override,Split Range

GOALS

Introduction to Process Control 1- 2

Control system configuration

+
Controller
Controller Actuator
Actuator Process
Process

Sensor
Sensor++
Transmitter
Transmitter

Introduction to Process Control 1- 3

Introduction to Process Control 1- 4
 Component of control system
 Controller
 Actuator
 Process
 Sensor/transmitter

Introduction to Process Control 1- 5

 Controller
 Control algorithm
 E.g:
• Manual
• PID (more than 90%)will be discussed here more
• On/Off
• Fuzzy
• etc

Introduction to Process Control 1- 6

 Actuator
 What is actuator?
• Actuator converts the command signal from controllers into physical
adjustment in adjustable process variable

Adjustment of
Command signal Physical Variable
(V, mA, psig,…)
Actuator (F, motor speed,…)

 Actuator types
• Control valve: pneumatic, electric, hydraulic
• Electric heater output: thyristor
• Pump/Motor speed: inverter
• Displacement: pneumatic, electric, hydraulic

Introduction to Process Control 1- 7

Control Valve

Introduction to Process Control 1- 8

 Process
 Process is physical entities which its variable is intended
to control
 Model of process  system identification
 First order process + deadtime
 Slow process vs fast process

Introduction to Process Control 1- 9

 Sensor, Transmitter & Transducer
 Sensor
• Primary sensing element
• Convert physical measure to signal that can be known by other
component, e.g. display, transmitter
 Transmitter
• Generate industrial standard signal from sensor output
• Standard of instrumentation signal level :
 voltage: 1 – 5 VDC, 0 – 5 VDC, -10 – +10 VDC, etc.
 current: 4 – 20 mA
 Pneumatic: 3 – 15 psig

 Transducer
• Convert signal value of instrument to signal value of other instrument
• Signal convertion
• Transducer I/P or P/I : current to pressure or vice versa
• P/E or E/P: pressure to voltage or vice versa

Introduction to Process Control 1- 10

MISCELLANEOUS SENSORS

Introduction to Process Control 1- 11

 Definition (1)
 Process
• A series of interrelated actions which transform material
It covers all resources that are involved in the process and talks about
process “inputs” (e.g. resources, raw material) and “outputs” (e.g.
finished product)

Energies Out
Raw Materials Products
Process

Energies Out

 Control
• To maintain desired conditions in a physical system by adjusting selected
variables in the system

Introduction to Process Control 1- 12

 Definition (2)
 Process Control
• To maintain desired conditions in a physical system by adjusting selected
variables in the system in spite of disturbances affecting the system and
observation noise

Corrective Action Process

Data
Knowledge

Information

Introduction to Process Control 1- 13

 Daylife Example: Driving a Car
 Control Objective (Setpoint):
• Maintain car in proper lane
 Controlled variable: Brain: Eyes:
• Location on the road Control Sensor
calculation
 Manipulated variable:
• Orientation of the front wheels
 Actuator:
• Steering wheel
 Sensor:
• Driver’s eyes
 Controller:
• Driver
 Disturbance: Steering wheel:
• Curve in road Actuator
 Noise:
• Rain, fog

Introduction to Process Control 1- 14

 Industrial Example : Liquid Level Control
 Control Objective (Setpoint):
• Maintain level
 Controlled variable:
• Fluid level in the tank
 Manipulated variable: Fluid
• Fluid flow
 Actuator:
• Control valve on fluid line
 Sensor: LC
• Level transmitter on the tank
 Controller:
• Level controller
 Disturbance: LT
• Changes in the inlet feed flow
 Noise:
• Measurement noise

Introduction to Process Control 1- 15

 Goal of Process Operation

 Safety & Reliability 24 hours process operation?

Hmm… I think, to achieve
 Product Specification those, we need to continuously
monitor & control the process
24 hours a day,
 Environmental Regulation 7 days a week!!!
 Operating Constraint
 Efficiency
 Maximum profit

Introduction to Process Control 1- 16

 Dynamics vs. Steady State Model
 Chemical process are generally designed from a steady-
state point-of-view
• Steady state model
 Steady state: No further changes in all variables
 No dependency in time: No transient behavior

 Chemical processes are dynamically changing

continuously
• Dynamics is the time varying behavior of processes

 Steady-state indicates where the process is going and the

dynamic characteristics of a system indicates what
dynamic path it will take

Introduction to Process Control 1- 17

Why do we need dynamic model?
Do the bus and bicycle have different dynamics?
• Which can make a U-turn in 1.5 meter?
• Which responds better when it hits a bump?

Dynamic performance
depends more on the
vehicle than the driver!

The process dynamics

are important than the
computer control!
Introduction to Process Control 1- 18
 How to Obtain a Dynamic Model?
 Model can be described using verbal, table, mathematic,
etc.
 The rationale for mathematical modeling
• To improve understanding of the process
• To train plant operating personnel
• To design the control strategy for a new process
• To design the control law
• To select the controller setting
• To optimize process operating conditions
 Main mathematically modeling methods:
• Physical modeling
 Based on physicochemical law
• Identification
 Based on process data analysis
• Semi-empirical models
 Combined approach

Introduction to Process Control 1- 19

 Physical modelling
 Illustrative Example: Open Liquid Storage Tank

qi Open Tank

h
q

Introduction to Process Control 1- 20

 Identification
 Based on the operation data
 Easy to develop
 Requires well designed experimental data
 The behavior is correct only around the experimental
condition
 Obtained model usually quite simple for control purpose
 Found in the industrial process control area

Introduction to Process Control 1- 21

DEMO: IDENTIFICATION USING MATLAB & DATA
FROM HYSYS

INPUT DATA

MATLAB

OUTPUT DATA

Introduction to Process Control 1- 22

 Process Dynamic Characteristics
 Self-regulating and non self-regulating
 Lag
• 1st order
• 2nd order
• Higher order
 Dead time
 Interacting and non interacting

Introduction to Process Control 1- 23

 1st Order Processes (1)
The basic equation is:

dy (t )
p  y (t )  K p u (t )  Differential equation
dt
Kp
G p ( s)   Transfer function
 ps  1

Kp = steady-state gain  Note that gain and time

constant define the
p = time constant behavior of a 1st order
process.
Introduction to Process Control 1- 24
 1st Order Processes (2)
 Same Kp, different p
KpA = KpB = KpC
 Different Kp, same p
pA < pB < pC
KpA < KpB < KpC
pA = pB = pC

u(t) u(t)

Always
Always overdamped
overdamped

Introduction to Process Control 1- 25

 2nd Order Processes (1)
The basic equation is:

2
d y (t ) dy (t )
p
2
 2  p  y (t )  K p u (t )  Differential equation
dt 2 dt

Kp  Transfer function
G p (s) 
 2p s 2  2  p s  1

 Note that the gain, time constant, and the damping

factor define the dynamic behavior of 2nd order process

Introduction to Process Control 1- 26

 2nd Order Processes (2)
 Underdamped vs. Overdamped

underdamped

critical damped

overdamped

Introduction to Process Control 1- 27

 2nd Order Processes (3)
 Effect of  on Underdamped Response

Introduction to Process Control 1- 28

 2nd Order Processes (4)
 Effect of  on Overdamped Response

Introduction to Process Control 1- 29

 2nd Order Processes (5)
 Characteristics of an Underdamped Response

 Rise time
 Overshoot (B)
 Decay ratio (C/B)
 Settling or
response time
 Period (T)

Introduction to Process Control 1- 30

 Common Types of Control Strategy
 Manual vs. Automatic
 Servo vs. Regulator
 Open-loop vs. Closed-loop
 Control strategies
• Feedback Control
• Feedforward Control
• Cascade Control
• Override control
• Ratio control
• Split range control
 Single-Input Single-Output (SISO) vs. Multi-Input Multi-
Output (MIMO, also known as multivariable)

Introduction to Process Control 1- 31

 Manual vs. Automatic
 Manual Temperature indicator
• Human has to adjust the MV to Should I adjust
the valve or
obtain the desired value of the PV should I run?
based on observation and prior
experiences

Emergency
cooling

 Automatic
• The computer (or other device)
autonomously controls the process
and may report status back to a
operator

Question: Why manual override has to be included in every automatic control systems?
Introduction to Process Control 1- 32
 Regulator vs. Servo
 Regulatory control  Servo control
• Follow constant setpoint, • Follow the changing
overcoming the disturbance setpoint

o o
75.5 C… 7.00 AM: 80 C…
75.3o C… 8.00 AM: 70o C…
o o
75.4 C… 9.00 AM: 60 C…

Question: How to achieve both objectives simultaneously?

Introduction to Process Control 1- 33
 Open-loop vs. Closed-loop
 Open-loop DV
• Process is controlled based on
predetermined scenario CO PV
Process
Process
Ex.: When food is done in an oven,
Decisions
timers on outdoor lights
Controller
Controller
SP

DV
 Closed-loop
• The information from sensor is
CO PV
used to adjust the MV to obtain Process
Process
the desired value of the PV Decisions

Controller
Controller
SP
Introduction to Process Control 1- 34
 Control Strategies (1)
 Feedback Control
• Corrective action based on process variable (PV)

DV

SP
Feedback CO PV
Feedback Process
Process
Controller
Controller

Advantage
Requires no knowledge of the source or nature of disturbances, and minimal
detailed information about how the process itself works
Disadvantage
Controller takes some corrective actions after some changes occurs in process
variable PV

Introduction to Process Control 1- 35

 Control Strategies (2)
 Feedforward Control
• Based on the measurement of disturbance (DV)  feedforward controller
can respond even before any changes occurs in PV

DV

Feedforward CO PV
SP Feedforward Process
Process
Controller
Controller

Advantage
Controller takes some corrective actions before the process output is different
from the setpoint  theoretically, perfect disturbance rejection is possible!
Disadvantage
 Requires process model which can predict the effect of disturbance on PV
 If there are some modeling error, feedforward control action will be erroneous
(no corrective action)
 Feedforward controller can be quite complex

Introduction to Process Control 1- 36

 Control Strategies (3)
 Feedback/Feedforward Control
• Feedforward controller will adjust CO as soon as the DV is detected
• If the feedforward action is not enough due to model error, measurement
error and etc., feedback controller will compensate the difference

DV

CO PV
SP Feedforward/
Feedforward/ Process
Feedback Process
Feedback
Controller
Controller

Introduction to Process Control 1- 37

 Control Strategies (4)
 Cascade Control
• The disturbance DV1 arising within the inner loop are corrected by the
inner controller before it can affects the PV of the outer one
Example: Control valve + positioner

Outer loop
Inner loop DV1 DV

SP
Inner CO CO PV
Outer
OuterFeedback
Feedback InnerFeedback
Feedback Inner
Inner Outer
Outer
Controller
Controller Controller
Controller Process
Process Process
Process

Introduction to Process Control 1- 38

 Control Strategies (5)
 Feedback/Feedforward + Cascade Control

Outer loop
DV
Inner loop DV1

SP Outer
OuterFeedback
Feedback Inner CO CO PV
Controller
Controller InnerFeedback
Feedback Inner
Inner Outer
Outer
Controller
Controller Process
Process Process
Process

Introduction to Process Control 1- 39

 SISO vs. MIMO
 Based on how many PV and MV we have in a process

SISO MIMO
DVs
DV …
CO PV …
Process
Process COs Process
Process PVs
Decisions
Decisions … …
Controller
Controller …
Controller
Controller

Introduction to Process Control 1- 40

 Ratio Control
 Ratio control is a special type of feedforward control
that has had widespread application in the process
industries
 The objective is to maintain the ratio of two process
variables as a specified value
 The two variables are usually flow rates, a manipulated
variable u, and a disturbance variable d, thus Ratio:

u
R (15-1)
d

Introduction to Process Control 1- 41

Typical Application of Ratio Control

1. Setting the relative 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 optimum value.

Introduction to Process Control 1- 42

Ratio Control Method 1

Introduction to Process Control 1- 43

Ratio Control Method 2

Introduction to Process Control 1- 44

 Application of Ratio Control

FY FFRC FY
101A 101 101B

FT FT
101A 101B

A B

Introduction to Process Control 1- 45

Override control: Signal Select
Signal Select We often try to achieve many objectives when

manipulating one final element.
For example, when we are driving and
adjusting our speed.

Don’t get a ticket Get through the

for speeding. intersection before
the light turns red.

Don’t be late for

process control class. Don’t skid on
the icy road.

Introduction to Process Control 1- 46

Signal Select
Signal Select


Now, we will address the other method, split
range. Again, we consider a process example.

The process involves a CSTR with an exothermic reaction and a cooling

coil. Generally, we wish to control the composition of the reactant in
the effluent. However, we must keep the temperature below a
maximum limit to prevent damaging the glass lining of the reactor.
FC
I am not sure what to do, so let’s start
with a controller for the composition.

T LC

A
Reaction: A  B

Introduction to Process Control 1- 47

Signal Select
Signal Select The process involves a CSTR with an exothermic reaction

and a cooling coil. Generally, we wish to control the
composition of the reactant in the effluent. However, we
must keep the temperature below a maximum limit to
prevent damaging the glass lining of the reactor.

FC
Looks good to me. What could go wrong?

T LC

AC

Reaction: A  B
Introduction to Process Control 1- 48
 FC Signal Select
Signal Select
Disturbance is feed
 inhibitor increase.
T LC
AC
Reaction: A  B

Unfortunately, the
design does not
consider T, which
exceeded its
maximum. The
equipment was le
damaged! ptab
c ce
o ta
N
The controller did a
good job of keeping
CA near its set point.

Introduction to Process Control 1- 49

Signal Select
Signal Select The process involves a CSTR with an exothermic reaction

and a cooling coil. Generally, we wish to control the
composition of the reactant in the effluent. However, we
must keep the temperature below a maximum limit to
prevent damaging the glass lining of the reactor.

Now, the correct controller is selected

FC automatically.

Why was a low signal select used?

Hint: What is the safest % valve opening?
TC LC

AC

fo
< = low signal select
<
AY AY = calculation element
Introduction to Process Control 1- 50
 Signal Select
FC

Signal Select
Disturbance is feed
 inhibitor increase. TC LC

AC

Reaction: A  B
fo
<
AY

The design controls

T, as it approaches
its maximum. The
equipment was not
damaged!

t a ble
c c ep
a
The controller
cannot keep CA at its
set point!

Introduction to Process Control 1- 51

 Split range control:
Variable Structure Control
Sometimes, the control objectives cannot be achieved with a strict pairing
of one sensor/controller/valve. We need the flexibility to change the
pairing automatically, as part of the control system.

We might need to control a

different measured variable
PC
1

We might need to adjust a

different valve
TC
TC 1
1

Introduction to Process Control 1- 52

Split Range Concept

We often manipulate several variables to

Split range
achieve our objectives.
For example, to achieve a comfortable
 temperature in a room.

cooling heating

Introduction to Process Control 1- 53

 Split Range Concept

Split range Split range enables one controller to adjust more

that one final element. We will introduce this
through a process example, purchase and
 distribution of fuel gases.

What do we measure and

To consumers. They chose

fc control to ensure that the
Fuel A

how much to take!

purchase and consumption
balance?

Fuel B
fc

Introduction to Process Control 1- 54

 Split Range

Split range
We chose to control pressure.



Measured variable
fc
Fuel A Pressure which is constant when
flows in and out are the same.

To consumers.
l v e ?? Manipulated variable
va
hich PC
W Either valve has causal
relationship and fast dynamics

Fuel B Disturbances
fc Changes in consumption rate

Introduction to Process Control 1- 55

 Split Range
Split range

We chose to adjust both valves!



fc Manipulating two valves

Fuel A gives more flexibility, but
how does it work?

To consumers.
x

x
First, if we adjust two valves,
PC on what basis can we decide
x
which valve to open first?

Fuel B
fc Hint:
x = controller output
Introduction to Process Control 1- 56
 Split Range

Split range We will have a ranking for use of

valves. This priority ranking will not
change.


si v e
pe n
Le ss e x
fc We have determined that fuel A is less
Fuel A expensive than fuel B.
x
To consumers.

x
Our strategy is to use only fuel A
PC unless we must use B (when fuel valve
e
x p e nsiv A is completely open).
ee x
Mor
Fuel B How?
fc

x = controller output
Introduction to Process Control 1- 57
 Split Range
Split range Split range: The valves are calibrated to
respond as shown in the figure



e opened
x pensiv
e
Less Fuel A
fc
Fuel A

Valve opening
To consumers.

x
Fuel B
x
PC
s i ve
ex pen
e
Mor x

Fuel B
fc
x = controller output closed
0 100
x, controller output %
Introduction to Process Control 1- 58
 Split Range Characteristic

Split range Dynamic response of the split range control system

to two step increases in fuel consumption.

First increase in consumption, PC increases its

 output, which affects only vA

e
x pensiv
e
Less
fc
Fuel A
To consumers.

x
sive PC
ex pen
e
Mor x

Fuel B
fc

Second increase in consumption, PC increases its output, which

increases
Introduction vA to its maximum,
to Process Control then begins to open vB. 1- 59