27/02/2024

Power Plant Measurement &

Control (ME526)
Lecture 3: Process control

Mohamed Mito, PhD [Link]@[Link]

Google Classroom

Mohamed Mito, PhD [Link]@[Link]

2
 27/02/2024

Session plan

• Elements of process control

• Control system representation

• Open/ closed loop response

• Deriving system equation

Mohamed Mito, PhD [Link]@[Link]

Introduction to process control

• System: It is a combination of components that act
together and perform a certain objective.

• Process: It is defined as the changing or refining of

raw materials that pass through or remain in a liquid,
gaseous, or slurry state to create end products.

• Control: It refers to the regulation of all aspects of

the process, i.e., pressure, temperature, flowrate,
level, concentration, etc.

Mohamed Mito, PhD [Link]@[Link]

4
 27/02/2024

Elements of process control

• Controlled variable: A process output which is to be maintained at a desired value by

adjustment of a process input.

• Manipulated variable: A process input which is adjusted to maintain the controlled output
at set point.

• Disturbance: a process input (other than the manipulated parameter) which affects the
controlled parameter.

Mohamed Mito, PhD [Link]@[Link]

Objectives of process control

• Economic Incentive
• Safety
• Equipment Protection
• Reduce variability
• Increase efficiency
• Ensure the stability of a process
• Elimination of routine

Mohamed Mito, PhD [Link]@[Link]

6
 27/02/2024

Modes of Process control

Mohamed Mito, PhD [Link]@[Link]

Basic elements of process control

• Sensor/ transducer: A transducer is a device that
converts one form of energy to another as a function
of time.

• Transmitter: A transmitter is a device that converts

the electrical signal from the transducer into a much
larger electrical signal (1 to 5 V) or (4 to 20 mA) that
can be sent over a long distance

Mohamed Mito, PhD [Link]@[Link]

8
 27/02/2024

Types of transmitters

Mohamed Mito, PhD [Link]@[Link]

Transmitter connection

Mohamed Mito, PhD [Link]@[Link]

10
 27/02/2024

Basic elements of process control

• Controller: A device which receives a measurement

of the process variable, compares with a set point
representing the desired control point, and adjusts
its output to minimise the error between the
measurement and the set point.

Mohamed Mito, PhD [Link]@[Link]

11

Process control

• Set point: The value at which the controlled parameter is to be maintained.

• Error signal: The signal resulting from the difference between the set point
reference signal and the process variable feedback signal in a controller.
• Feedback control: A type of control whereby the controller receives a feedback
signal representing the condition of the controlled process variable, compares it
to the set point, and adjusts the controller output accordingly.

• Steady state: The condition when all process properties are constant with time
and transient responses having died out.

Mohamed Mito, PhD [Link]@[Link]

12
 27/02/2024

Control system representation

• Block diagram: It is relationship between the input and the output of the system. It is
easier to visualize the control system in terms of a block diagram.
• Transfer function: it is the ratio of the Laplace transform of output ( response function)
to the Laplace transform of the input ( driving force) under assumption that all initial
conditions are zero unless that given another value.

• e.g. the transfer function of the above block diagram is G (s) = Y(s)/X(s)

Mohamed Mito, PhD [Link]@[Link]

13

Process control

• Process time constant (taw): Amount of time counted from the

moment the variable starts to respond that it takes the process
variable to reach 63.2% of its total change

Mohamed Mito, PhD [Link]@[Link]

14
 27/02/2024

Types of process control

1) Open-loop control system: It is a control system in which the output has no effect
upon the control action. (The output is neither measured nor fed back for
comparison with the input). – The input to the controller is set by the operator
at a certain value.
• Advantages: Simple construction, ease of maintenance, cheap, and stable.

• Disadvantages: Disturbances and change in calibration cause error Examples

Mohamed Mito, PhD [Link]@[Link]

15

Types of process control

2) Closed-loop control system: It is a feedback control system which the output

signals has a direct effect upon the control action.
• Advantages: More accurate than the open-loop system
• Disadvantages: complex and expensive, system stability is always a concern.

Examples

Mohamed Mito, PhD [Link]@[Link]

16
 27/02/2024

Block diagram representation

r(t): reference signal e(t): error signal m(t): manipulated variable y(t): controlled variable
Gc: controller gain Gp: process gain H: feedback element gain

Mohamed Mito, PhD [Link]@[Link]

17

Closed-loop control circuit

Comparator Controller Process

𝒆 𝒕 = 𝒓 𝒕 − 𝒃(𝒕) 𝒎 𝒕 = 𝑮𝒄 𝒕 × 𝒆(𝒕) 𝒚(𝒕) = 𝑮𝒑 𝒕 × 𝒎(𝒕)

Feedback
element

b 𝒕 = 𝑯 𝒕 × 𝒚(𝒕)
Mohamed Mito, PhD [Link]@[Link]

18
 27/02/2024

System equation

𝑦 𝑡 = 𝐺 𝑡 . 𝑚(𝑡)

𝑦 𝑡 = 𝐺 𝑡 . 𝐺 𝑡 . 𝑒 𝑡 = 𝐺 𝑡 . 𝐺 𝑡 . 𝑟 𝑡 − 𝑏(𝑡)

∴ 𝑦 𝑡 = 𝐺 𝑡 . 𝐺 𝑡 . 𝑟 𝑡 − 𝐻 𝑡 . 𝑦(𝑡)

𝑦 𝑡 + 𝐺 𝑡 . 𝐺 𝑡 . 𝐻 𝑡 . 𝑦(𝑡)= 𝐺 𝑡 . 𝐺 𝑡 . 𝑟 𝑡

1 +𝐺 𝑡 .𝐺 𝑡 . 𝐻 𝑡 𝑦 𝑡 = 𝐺 𝑡 .𝐺 𝑡 . 𝑟 𝑡

𝑮𝒑 . 𝑮𝒄
∴𝒚 𝒕 = × 𝒓(𝒕)
𝟏 + 𝑮𝒑 . 𝑮𝒄 . 𝑯
Mohamed Mito, PhD [Link]@[Link]

19

Any Questions?

Mohamed Mito, PhD [Link]@[Link]

20