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Measurement

3 components Decision -
of Process Control Controller

Action
Type of Controller
Regulatory and servo control
• For process that the controlled variable deviates from set
point because of disturbance – regulatory control

• For process that the most important disturbance is the set


point itself – servo control
Unit 1: Terminology
Terminology I/P TC

Manipulated variable Heat exchanger TT

(saturated steam)
100°C 80°C

30°C
100 L/min controlled variable
(temperature of
Load variable  sterilised saline)
(Flow, temperature 95°C
Uncontrolled variable
of saline solution)
(Saturated steam)

   
Controlled Manipulated Load variable Set point
variable variable
Sym: Sym: r, SP, SV
Sym: c, PV Sym: m, CO, MV
“All other The desired
“The parameters A process being affecting operating
that indicate adjusted (controlled) variable, other condition.
product quality or by a final control than the one
the operating element (such as being
condition of the control valve, manipulated.”
process.” (L.M. damper, motor (L.M. Gordon)
Gordon) speed).
© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)
Unit 1: Control strategies
Feedback control I/P TC

Heat exchanger TT
Manipulated variable
(saturated steam) 100°C 80°C
30°C controlled variable
Load variable
100 L/min (temperature of
(Flow of saline solution)
sterilised saline)

What is feedback control? 95°C


Manipulated variable
A method of control that the action taken is (Saturated steam)
based on past result.

Merit?
Simple design. Easy to tune (for linear, fast & The Process
short deadtime processes: flow, level & Saline solution at 30°C is sterilized by
pressure). heating the solution in a heat-exchanger
system to 80°C. The temperature of the
Demerits? sterilized saline solution is maintained by
Slow recovery for slow process such as regulating the control valve of steam input
temperature control upon load disturbance or to the heat-exchanger.
change in setpoint. A process with long deadtime
may exhibit oscillatory process response with
long settling time.
© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)
Unit 1: Control strategies
TSP
FSP
Cascade control I/P FC TC

FT Heat exchanger TT
Manipulated variable
(saturated steam) 100°C 80°C
30°C controlled variable
Load variable
100 L/min (temperature of
(Flow of saline solution)
sterilised saline)

What is cascade control? 95°C


Manipulated variable
A method of control of which the inner loop (Saturated steam)
controller obtains its setpoint from an outer loop
controller.
Characteristic of cacade control:
Merit? Two transmitters, two controllers and one
Faster recovery time as compared to SISO control valve (2-level cascade).
feedback control.

Demerits? Application: Transform from SISO to


Controllability will be worst than SISO if both
cascade strategy if faster recovery time is
controllers were not properly tuned.
desired.

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)


Unit 1: Control strategies
Feedforward control I/P FFC
Cp
Ws  W p T2  T1 
Hs

Manipulated variable
(saturated steam) Heat exchanger 80°C
FTTT
30°C controlled variable
Load variable
100 L/min (temperature of
(Flow of saline solution)
sterilised saline)

What is feedforward control? 95°C


Manipulated variable
A method of control based on process model: (Saturated steam)
mass and energy balances.

Merit? Characteristic of feedforward


Faster recovery than cascade or SISO.
control:
Compensate for disturbances before they effect
Measurements of load variables online and
the controlled variable.
Utilization of computational blocks.
Demerits?
 Cannot work if any of the sensors fail esp. load
variable.
 Requires process model in order to design
feedforward system.

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)


Unit 1: Control strategies
Feedforward/ I/P + TC
Feedback control +
C
Ws  W p T2  T1 
FFC
TT
p
Hs
Manipulated variable
(saturated steam) Heat exchanger 80°C
FT TT
Load variable 30°C controlled variable
100 L/min (temperature of
(Flow of saline solution)
sterilised saline)

What is feedforward/feedback control? 95°C


Manipulated variable
Feedback compensation added to feedforward (Saturated steam)
control

Merit?
Feedforward control compensates for major
disturbances, while feedback control compensates
for all other disturbances.

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)


Unit 1: Control strategies
Ratio control I/P FC
X
FT
Manipulated variable
(saturated steam) Heat exchanger 80°C
FT
30°C controlled variable
Wild flow 100 L/min
(Flow of saline solution) (temperature of
sterilised saline)

What is ratio control? 95°C


Manipulated variable
Keeps a flowrate in proportion to another (Saturated steam)
flowrate.

Merit?
Keep two flow in proportion.

Demerits?
Inherits PID characteristics

© Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)


Ratio Control

• Type of feedforward control


• The objective is to maintain the ratio of two
variables at a specified value
• One variable is manipulated to keep it as ratio of
another.
• Implemented in two basic schemes.
multiplier

divider
• Required to blend 2 liquid streams, A and B in some
ratio
R=FB/FA
The flow of stream B must vary, as the flow rate of
stream A is varies

Multiplier : set the ratio


(Wild flow)

•Measuring the flow in steam A


•Multiplying it with the desired ratio
to obtain the required flow rate in
stream B (set point to the flow
controller of stream B)
•FBset = R x FA
•If the flow of stream A varies, the
set point of the controller of stream
B will vary.
Divider

•Measuring both stream


•Divide them in FY16 to obtain the
actual ratio flowing through the
system
•R=FB/FA
•The calculated ratio is the sent to
the controller which manipulated
the flow B to maintain set point.
•The set point to this controller is
the required ratio.
BLOCK DIAGRAM
• Feedback control D
Y(s)
Y
Feedback Process
controller

•Feedforward control
D
Y(s) Y
Feedforward Process
controller

•Cascade control

Y(s)
Primary Secondary Y
Process II Process I
controller controller
• Question
- How to ensure that the level in the tank remains at or near the set
point? Propose the following control strategy:
- Feedback
- Feedforward
- Feedforward/Feedback

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