Tutorial 1
Control Strategy
Control
Reason for Use How It Works Sensor Placement
Strategy
Used when disturbances The controller
cannot be measured directly measures the
Sensor is placed at
or are difficult to predict. controlled variable and
Feedback the controlled
Suitable when some adjusts the manipulated
Control (FB) variable (process
deviation can be tolerated variable after a
output).
before corrective action is deviation from the set
taken. point occurs.
Used when the disturbance
The controller
can be measured and is
measures the
known to have a significant
disturbance and adjusts Sensor is placed at
Feedforward effect on the process.
the manipulated the disturbance
Control (FF) Suitable when early
variable in advance to input.
corrective action is needed
reduce its effect on the
before the process output is
controlled variable.
affected.
Used when a secondary
variable responds faster than The outer controller
One sensor is placed
the primary controlled sets the set point of the
at the primary
variable and major inner controller. The
Cascade controlled variable,
disturbances enter through inner loop corrects fast
Control and another at the
the secondary loop. Suitable disturbances before
secondary variable
for improving speed of they propagate to the
in the inner loop.
response and disturbance main process output.
rejection.
Used when the disturbance
The feedforward part
is very rapid and has a
acts immediately on One sensor is placed
Feedback + significant effect on the
the measured at the disturbance
Feedforward process, but feedforward
disturbance, while the input, and another
Control action alone may not be
feedback part corrects at the controlled
(FB/FF) sufficient because of model
any remaining offset or variable.
mismatch or measurement
mismatch in the output.
error.
Used when a fixed
proportion between two
One variable is treated Sensors are placed
variables must be
as the reference stream, on both flow
maintained, such as in
Ratio Control and the other is streams, usually the
blending, mixing, or
adjusted to maintain wild stream and the
combustion processes. Helps
the desired ratio. manipulated stream.
ensure product quality and
operating consistency.
Exercise
Question 1
A boiler drum is used to generate steam for a processing unit. During operation, it is
observed that when the steam demand increases, the liquid level inside the drum decreases
before returning to its desired value. This happens because the system only responds after
the deviation in the drum is detected.
Engineers aim to improve the system performance using the existing measurement available
in the drum, without adding any new measurement for the outgoing steam.
Tasks:
a) Identify the key process variable that must be maintained.
b) Identify the variable that can be adjusted to influence the system.
c) Describe the nature of the control action required based on this situation.
d) Draw a suitable P&ID control scheme. Clearly label all instruments, signal lines, and final
control element.
Question 2
The boiler system is upgraded with a sensor that measures the steam flow leaving the drum.
It is observed that changes in steam demand occur rapidly and have a direct impact on the
condition inside the drum.
Engineers want the system to respond immediately when a change in steam flow is detected
so that the effect on the drum can be minimized before any noticeable deviation occurs.
Tasks:
a) Identify the key variable that must be maintained.
b) Identify the variable that can be adjusted.
c) Identify the disturbance affecting the system.
d) Describe the type of control action required.
e) Draw a suitable P&ID control scheme showing how the measurement is used in the
control action
Question 3
A boiler drum operates under continuously changing steam demand. The system includes a
measurement of the steam flow, and engineers require a control system that can respond
immediately to changes and also correct any deviation that occurs in the drum.
The goal is to maintain stable operation under all conditions.
Tasks:
a) Identify the key variable that must be controlled.
b) Identify the variable that can be manipulated.
c) Identify the disturbance affecting the system.
d) Explain how the control system should act in this situation.
e) Draw a complete P&ID control scheme showing how different control actions are
combined.
Answer:
Question 1
a) Key process variable that must be maintained
The boiler drum liquid level must be maintained.
b) Variable that can be adjusted
The feedwater flow rate can be adjusted.
c) Nature of the control action required
The control action is reactive. The system measures the drum level and only takes corrective
action after the level deviates from the desired value.
d) Suitable P&ID control scheme
Model answer:
• Install a level transmitter (LT) on the boiler drum.
• The measured level signal is sent to a level controller (LC).
• The controller adjusts a control valve on the feedwater inlet line.
• When the drum level drops below the set point, the controller opens the feedwater
valve more.
• When the drum level rises above the set point, the controller closes the valve.
Question 2
a) Key variable that must be maintained
The boiler drum liquid level must be maintained.
b) Variable that can be adjusted
The feedwater flow rate can be adjusted.
c) Disturbance affecting the system
The steam flow leaving the drum is the main disturbance.
d) Type of control action required
The control action is anticipative. The system uses the measured steam flow to act early
before the drum level changes too much.
e) Suitable P&ID control scheme
Model answer:
• Install a flow transmitter (FT) on the steam outlet line.
• The steam flow signal is used to generate a control action to the feedwater control
valve.
• When steam demand increases, the system increases feedwater flow immediately.
• This reduces the effect of the disturbance before the drum level deviates
significantly.
Question 3
a) Key variable that must be controlled
The boiler drum liquid level must be controlled.
b) Variable that can be manipulated
The feedwater flow rate can be manipulated.
c) Disturbance affecting the system
The steam flow leaving the drum is the disturbance.
d) How the control system should act
The control system should:
• act immediately when steam flow changes, and
• also correct any remaining deviation in the drum level.
So, one part of the system responds early to steam demand changes, while another part
checks the actual drum level and makes further correction if needed.
e) Complete P&ID control scheme
Model answer:
• Install a flow transmitter (FT) on the steam outlet line.
• Install a level transmitter (LT) on the boiler drum.
• The steam flow signal provides early action to adjust feedwater flow.
• The drum level signal provides corrective action if the level still deviates.
• Both actions are combined before reaching the feedwater control valve.