Process Control Terminology

Process Response

Rise time
Overshoot

PV
Period

SP2

Undershoot

SP1
Settling time

0 Time

1. Settling time is the period of time taken by the process reach stability.
2. Period is the time interval between two successive peaks.
3. Overshoot is the process response (PV) surpasses the set point.
4. Undershoot is the process response (PV) goes below the set point.
5. Rise time is the period of time taken by the process to reach the set point.

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 Process Control Terminology

Process Control Variables

I/P TC


Heat exchanger TT
Manipulated variable 
(high pressure steam)
80°C
Load variable 30°C controlled variable
(Flow, temperature
of saline solution)
100 L/min (temperature of
sterilised saline)


Manipulated variable
(high pressure steam)

   
Controlled variable Manipulated variable Load variable Set point

Sym: c, PV Sym: m, CO, MV Sym: Sym: r, SP, SV

“The parameters that The process that being “All other affecting The desired operating
indicate product adjusted (controlled) by variable, other than condition.
quality or the the final control element the one being
operating condition of (such as control valve, manipulated.”
the process.” (L.M. damper, motor speed). (L.M. Gordon)
Gordon)
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 Process Control Loop

Process control loop

Pressure
Flow I/P
Level
Process Temperature
pH

dP cell
Capacitance
Sensor Radar, Sonic
Magnetic
Resistance
IR/Laser

4-20 mA
Transmitter 1-5 Vdc

PID
Controller Fuzzy logic

4-20 mA
Transducer 3-15 psig

FC I/P

FT
Final Control Control Valve
Tyristor
Element

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 Process Control Loop

Process control loop

Process SP

Sensor SP
CONTROLLER

Transmitter

CONTROL
TRANSMITTER
VALVE
Controller

Transducer PV PROCESS

Final Control
Element PV

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 Process Control Loop

Process control loop

Block Diagram Computer Programming Style

SP

SP
CONTROLLER
SP C F P PV

CONTROL
TRANSMITTER
VALVE
T

PV PROCESS

PV

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 Process Control Schemes

Feedback control

TC I/P

TT

Heated Steam in
product
out

Product
Steam out
in

What is feedback control?

PV
Outcome of an action is fed back to the controller for SISO Feedback
corrective action.

Merit?
Simple design. Easy to tune (for linear, fast & short
dead time processes: flow, level & pressure). SP

Demerits?
Slow recovery for slow process upon load tim
disturbance or change in set point (such as e
temperature control). A process with long dead time
may exhibit oscillatory process response and with
6 longer settling time.
 Process Control Schemes

Cascade control

TC FC I/P

TT FT

Heated Steam in
product
out

Product
Steam out
in

What is cascade control?

PV
The inner loop controller obtains its set point from SISO Feedback
the outer loop controller.
Cascade
Merit?
Faster recovery time as compared to SISO feedback
control. SP

Demerits?
Controllability will be worst than SISO if both tim
controllers were not properly tuned. e

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 Process Control Schemes

Ratio control

X FC I/P

FT

Heated Steam in
product
out

FT
Product
Steam out
in

What is ratio control?

Keeps the flow rate of a stream in proportion to
another stream’s flow rate.

Merit?
Keep two flows in proportion with one another.

Demerits?
Inherits PID characteristics.

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 Process Control Schemes

Feed forward control

TC Σ X FC I/P

TT FT

Heated L/L
Steam in
product
out

TT FT
Product
Steam out
in

What is feed forward control?

PV
A method of control based on process model: mass SISO Feedback
and energy balances.
Cascade
Merit? Feed forward
Faster recovery than cascade or SISO.
SP
Demerits?
 Cannot work if any of the sensors fail esp. load
variable. tim
 Requires process model in order to design feed e
forward system.

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 Tutorial

Identify the control scheme as shown below.

 Feedback
 Cascade
 Ratio
 Feedforward

Identify the control variable (CV).

 Temperature (product)
 Flow (fuel) product

Identify the manipulated variable (MV). Feed

TT
 Temperature (product)
 Flow (fuel) Fuel

Identify the load (disturbance) variables (DV). I/P FC TC

 Temperature (product)
 Temperature (feed)
 Flow (fuel) FT
 Flow (feed)

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 Tutorial

Examples of Process Control

SISO Feed back Control schemes:

5-3.1 ; 6-1.5 – Temperature control

5-3.2 ; 10-5.18 – Level control
6-1.10 – Flow control

Cascade Control schemes:

9-1.1 ; 9-4.2 ; 10-3.4 ; 10-5.2 ; 10-5.5 ; 10-5.8 – Temperature control

11-2.1 ; 11-7.1- Analysis

Ratio Control schemes:

10-2.2 ; 10-2.4 ; 10-5.2 ; 10-5.5

Feed back Control schemes:

11-2.6 ; 11-2.7 ; 11-4.2 ; 11-5.1 ; 11-5.2 ; 11-7.3– Analysis

11-7.6 – Level control
11-7.8 – Temperature control

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 Process Control Schemes

Transfer Function for Feedback (SISO) Control

SP C F P PV

Control Elements Transfer Functions References

T Sensor/Transmitter Eqn. 5-1.1 (p.155)

F Control valve Eqn. 5-2.28 (p.173)

C PID controller Eqn. 5-3.16 (p.184)

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 Process Control Schemes

Transfer Function for Feedback (SISO) Control

PID controller Control valve Process

SP PV

Sensor / Transmitter

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 Process Control Schemes

Transfer Function for Feedback (SISO) Control

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 Process Control Schemes

Transfer Function for Feedback (SISO) Control

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 Process Control Schemes

Transfer Function for Feedback (SISO) Control

Controller

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 Process Control Schemes

Transfer Function for Feedback (SISO) Control

Consider an electronic pressure transmitter with a range of 0 to 200 psig. Time constant is 30 s.

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 Tutorial

Transfer Function for Feedback (SISO) Control

100−0
100−0 d. 𝐾𝑇 = = 12.5%/𝑓𝑡
a. 𝐾𝑇 = = 2%/℃ 8−0
150−100

𝐾𝑇 = 2%/℃ 12.5
𝐻 𝑠 = = 12.1
0𝑠 + 1
2
𝐻 𝑠 = 𝐿(𝑠) 𝐶(𝑠)
1.2𝑠 + 1 12.5
𝑓𝑡 %𝑇𝑂
𝑇(𝑠) 2 𝐶(𝑠)

℃ 1.2𝑠 + 1 %𝑇𝑂

b. Same technique as part (a)

0.4
𝐻 𝑠 =
0.5𝑠 + 1

c. Same technique as part (a)

2
𝐻 𝑠 =
0.05𝑠 + 1

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 Tutorial

Transfer Function for Feedback (SISO) Control

 1 
a. GC  K C 1   
  I 
s

100  0
b. KT   ? %TO / C
150  100
KT
H ( s) 
T s 1

c.
? ? ? ?
? ?
? ? ? ?

? ?
?
? ?

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