Process Control System Characteristics
(P3)
This document provides a model answer explaining key process control system
characteristics as required in Task 3 for Unit 37 – Industrial Process Control.
1. Inherent Regulation
Inherent regulation refers to the natural ability of a process to stabilise itself after a
disturbance without the need for external control.
For example, consider a water tank with an outlet valve. If the inlet flow increases, the
water level rises. As the level rises, the pressure at the outlet also increases, causing more
water to flow out. This natural balancing effect helps the system regulate itself.
In process industries such as petrochemical plants, inherent regulation is useful because it
reduces the amount of corrective action required by the controller.
2. Time Constant
The time constant (τ) describes how quickly a system responds to a change in input.
For a first-order system, the time constant is defined as the time required for the system
output to reach 63.2% of its final value after a step input is applied.
Example: If the desired conveyor speed is suddenly increased, the motor will not reach the
final speed instantly. Instead, the speed gradually rises following an exponential curve.
The time constant determines how fast this change occurs.
Mathematically a first-order response can be written as:
y(t) = K(1 − e^(−t/τ))
Where:
K = system gain
t = time
τ = time constant
3. Initial Reaction Rate
The initial reaction rate describes how quickly the system output begins to change
immediately after a disturbance or step input.
At the beginning of a response, the slope of the output curve represents the initial reaction
rate.
For example, in a DC motor speed control system, when the controller increases the motor
voltage, the motor speed starts increasing. The steepness of the speed curve at the
beginning indicates how rapidly the system reacts.
A higher initial reaction rate means the system responds more quickly to input changes.
4. Exponential Growth and Decay
Many industrial processes follow an exponential response, especially first-order systems.
Two common responses occur:
Exponential Growth
When the input increases, the system output rises gradually towards a final steady-state
value.
Example: When the motor voltage increases, the speed increases gradually until the
required speed is reached.
Exponential Decay
When the input decreases or is removed, the output gradually falls to a lower value.
Example: If the motor power is reduced, the motor speed decreases gradually instead of
stopping instantly.
The exponential nature of the response occurs because physical systems such as motors,
tanks and thermal systems cannot change instantly.
5. Lag and Process Dead Time
Lag
Lag refers to the delay in the system output caused by the system’s dynamic characteristics.
For example, when the controller increases motor voltage, the motor speed takes time to
increase due to mechanical inertia. This delay is known as process lag.
Lag is normally associated with energy storage in the system, such as mechanical inertia or
thermal capacity.
Process Dead Time
Dead time is the time delay between the input change and the moment when the system
output begins to respond.
For example, in a long pipeline system, when a valve is opened, it takes time for the fluid to
travel through the pipe before any change is observed at the outlet.
Dead time can reduce system performance and make control more difficult.
Typical Step Response Curve
A step response graph shows how the output of a process changes over time after a sudden
input change.
The graph typically shows:
Initial reaction rate
Exponential rise of the output
Time constant (63.2% point)
Final steady-state value
Possible dead time before the response begins
Such graphs are commonly used to analyse the behaviour of industrial control systems.
Use of Engineering Terminology
Inherent regulation
Time constant
Initial reaction rate
Exponential response
Process lag
Dead time
Step response
First-order system
These terms are essential when analysing process control system behaviour.