Basics of Process Control

Systems
CHEG 4830 - Fall 2017
Dr. Qingliu Wu

WESTERN MICHIGAN
UNIVERSllY
 Lesson Objectives
Identifying the components of an automated
process control system.
Differentiating between feedback and
feedforward control strategies.
Constructing block diagrams from process
flow/instrumentation schematics.
Types of Variables in a Process Control System

Controlled variables (CV) - quantify the performance or

quality of the final product, which are also called output
variables.
Manipulated variables (MV) - input variables that are
adjusted dynamically to keep the controlled variables at
their set-points.
Disturbance variables (DV) also called load variables,
input variables that can cause the controlled variables to
deviate from their respective set points.
Components of an Automated Process Control
System
Sensor measures either the CV or DV, relays signals to
the controller.
Controller processes the sensor signals, performs
control calculations and decision-making, relays output
signals to the actuator.
Actuator or Final Control Element receives controller
signal, act on the controller command to adjust MV to
achieve the desired CV.
 Process Changes That Produce
Dynamic Process Response
Set-point change - implementing a change in the
operating conditions. The set-point signal is changed
and the manipulated variable is adjusted appropriately to
achieve the new operating conditions. Also called
servomechanism (or "servo") control.
Disturbance change - the process transient behavior
when a disturbance enters, also called regulatory control
or load change. A control system should be able to return
each controlled variable back to its set-point.
 Example 1: Home AC System

1. What is the process

objective?

u
. .'
2. What is the control
objective?
Radiant Heat _ _ _4 1----,
System Regu lar
Therm ost at
3. Identify the sensor,
actuator, CV, MV, DV.
Circulation
Gas or Oil Pump Electro nic
Boiler

_,o Con tro ls

 Example 2: Blending System

X1
W1 ---~i 1. What is the process
{Mixture of A and B} objective?
h

2. What is the control

~-- X objective?
w

Figure 1.3. Stirred-tank blending system.

3. Identify the sensor,

Notation:
w1, w2 and w are mass flow rates
actuator, CV, MV, DV.
x1, x2 and x are mass fractions of component
A.

Only w2 can be directly manipulated

 Process Control Strategies: Example - Blending System

Composition
controller

---- Electrical signal 1- - ~ -I

l ~ I
I I
I I
Control
6
1 1

valve I

i---------~ I

I
I
I
I
AT -- 1

Composition
analyzer /transmitter

~-- X
w

Figure 1.4. Blending system and Control Method 1.

Control of x Strategy 1:
Measure x Feedback
Adjust w2 Control
 Process Control Strategies: Example -Blending System
Composition
controller

l--------@ ---------7
I I
I I
Composition Control
6
1

analyzer valve

~-- X
w

Figure 1.5. Blending system and Control Method 2.

Control of x Strategy 2:
Measure x1 Feedforward
Adjust w2 Control
Feedback Control:
Distinguishing feature: measure the CV to maintain CV.

Advantages:
Corrective action is taken regardless of the source of
the disturbance.
Reduces sensitivity of the controlled variable to
disturbances and changes in the process (shown
later).
Disadvantages:
No corrective action occurs until after the disturbance
has upset the process, that is, until after x differs
from xsp.
Very oscillatory responses, or even instability.
Feedforward Control:
Distinguishing feature: measure a DV to maintain
CV.
Rarely used by itself, usually combined with
feedback control.
Advantage:
Correct for disturbance before it upsets the
process.
Disadvantage:
Must be able to measure the disturbance.
No corrective action for unmeasured disturbances.
General Block Diagram for a Feedback Control Loop

Disturbance

Setpoint e c u
+- Controller Actuator Process CV

Sensor
 Example 3: Block Diagram for Composition Feedback
Control System of Blending Tank

Calculations performed
by controller
" ,-
I
- - I
I I W1[kg/ S]
Chapter 1

l I
I I x1 [mass
I I
I I fractionJ11,
Xsp
I
I Analyzer
-Xsp Comparatore(t) I
I W2(t)
'If

.... .... Feedback p(t)__ Control Stirred x(t)

- + ~
I .... ....
[mass l ca Ii bration [mA]- - [mA]~ controller I [m.A] valve tank
I [kglsJ [mass
fraction]: I
I
I'
I
fractio n]
'
I I
I I
I I
I ,. I
I I
I I
---------------- r-----------------l '

xm(t) Analyzer x(t)

- - - - - - - - - - 1 (sensor) and 1""1--.:~---------
[mA] transmitter
 Elements of Blending Tank Concentration
Feedback Control System

1. Analyzer (Sensor) and Transmitter:

Measures tank exit concentration x(t). In this
case, it could be an online spectrophotometer,
chromatograph, or any other concentration
sensor.
Generates a corresponding (mA) level signal
sent to the controller.
 Compo sition
controlle r

---- Electrical signal 1- - ~ -1

1 ~...._ I
I I
I I
Control 1 1

valve 6 l
1------ +1_ _ _ X2 = 1

i W2

\ Composilion
Chapter 1

' .... _
analy>~/transm itter

X
L - - ----
w

Calcu lations performed

Figure 1.4. Blending system and Control Methe by controller
~----- ------- ------- ------- ----~
I
I
I x1 [mass
I
_ Comparator I fraction]
I
__ xs_:p-~ Ana lyzer Xsp e(t) Feedback I p (t) w2(t) St irred
Control x (t)
[mass 1 calibration [m.A] controller --:[-m.A
~ J~ valve [kg I s] tank [mass
traction]:
I
I
I
fract ion]
I I
I I
I I
I 'I
I I
I I

/
-- - ' '
k diagram for composit ion
x m(t) I Analyzer \ x (t)
- - - - - - -'T"""1 (sensor) and ~ - - - - - - - - -
l system in Fig. 1.4. [m.Al transmitter I
\ I
' .... - ;
/
 Elements of Blending Tank Concentration
Feedback Control System

2. Feedback Controller:
(1) Converts actual setpoint into an equivalent
internal signal.
(2) Calculates error signal by subtracting
measured value from setpoint value.
(3) Controller output is calculated based on a
specific algorithm with the objective of minimizing
the error signal. Output signal is then transmitted
to the actuator.
 ; -,
pcmpositio)li
( controller \
1
---- Electrical signal \ 1--@ -1 1
~
I ...__; ~I
Control 1 1
valve ~ i
I

i I
I
I
I
I
I
_I
Chapter 1

Composition
analyzer /transmitter

,_ ____ X
w
#1 #2 #3
Calculation performed
by co roller

-- - - - .... .....
-
I
I
------- -- ----- I
I W1 [kg / s]
I I
I I xi [mass
:, ;
I
' I
fraction]
Xsp I
[mass
Ana lyzer
calibration
Feedback
controller
' I
I
I p (t) Cont rol
valve
w 2(t )
Stirred
tank
x (t)
: rm.Al [kgls] [mass
fraction] ~ I fraction]
I
;
''
I I
I I
;
.,
.........
- - - - --
I I
I ;
I I

------- ------- --
I _ _ _ _ _ _ _ _ _ _ _ _ _ _ ..JI

xm(t) Analyzer x(t)

k diagram for composit ion - - - - - - - - - < (sensor} a n d ~ - - - - - - - - -
l system in Fig. 1.4. [m.A] transmitter
 Elements of Blending Tank Concentration
Feedback Control System

3. Actuator (Control Valve):

The controller output in this case is a DC current
signal sent to the control valve.
The valve stem position is adjusted, affecting the
flow rate w2(t).
Most control valves are pneumatic (i.e., operated
by air pressure); hence controller output signal
should be converted to equivalent air pressure
signal.
 Composition
controller

---- Electrical signal 1- - ~ -I

I 'C:;}'"' I

Coi-l'lrol-- +'
1 , l
1

v~ lve ~ \ i
I I

i \

' _.,, /
I I
I
I
I
I
I
_I
Chapter 1

Composition
analyze r /transm itter

,_____ X
w

Calculations performed
by controller
--- - -- -- ------- ------- -----~
I

xs_:p_..i Ana lyzer

__ Feedback
l
:
1
, ___
-"" - '
; ,
x1 [mass
\ fraction]
I P ) Control w ;(t ) Stirred x (t )
[mass 1 calibration controller f-,1..l-=
[ '-I--'
]~ valve tank [mass
fraction] l
: \ fraction]

-
I
I

.,: .... .,,

I I '
I
I
I I
I I

xm(t) Analyzer x(t)

k diagram for composit ion - - - - - - - - - < (sensor} a n d ~ - - - - - - - - -
l system in Fig. 1.4. [mA] transmitter
 Composition
controller

- - -- Electrical signal 1- - ~ -I
I 'C:;}'"' I
I I
I I
Control 1 1
'f I
valve ~ :
I

i I
I
I
I
I
I
.,,. -, _I
/
'I
Chapter 1

I \ Composition

I analyze r /transmitter

\
/
I ,_____ X
' w

Calculations performed
4. Process (here, the tank) --- - -- --
by controller
------- ------- -----~
adjusts by transient total I
I
I
.,,.
x1p ass

'
I
f action]
mass and species balances xs_:p_..i Ana lyzer
__ Feedback
I
I
I p(t) Control t)
\
t)
Stirred
calibration
- tank output w(t) and [mass 1
fraction]:
I
controller f-,1..:-=
I
[m.A
'---']~ valve tank [mass
fraction]
I

concentration x(t) I
I
I
I
I
I
_, /
I 1
I I
I I

xm(t) Analyzer x(t)

k diagram for composit ion - - - - - - - - - < (sensor} a n d ~ - - - - - - - - -
l system in Fig. 1.4. [m.A] transmitter
 Homework
For each of the following processes, identify
Process Objective
Control Objective -
CV
DV
Sensor -
MV -
Actuator/final control element
Construct a block diagram describing the feedback control
strategy.
 1. Level Controller (0.5 point)

I
I

,.

0 I

Figure 1.4.4 Control diagram of a tank

with a level controller.
 2. Thermal Mixing (0.5 point)

_______ (?___~-~--

''
, _.d 2 !
'
I

-t ,L
II
.. .. ...
' ... . . . ,
i
I
I

II
t

1 :
I
l

I
I
I
I
.. . ~ ,, '" -....
I

Produ:ct
.at T
Figure 1.4.2 Control diagram of a CST thermal
mixer with temperature controller.
 3. Heat Exchanger (0.5 point)

. e:.point
P o.duc.t
S ,ream
't

---~---~~~---~~~--~MJ 1

- ................... ...

. - . ..... .. . ..
: ............

.. .... . ... . ....... ' . . .

. .

.. . ~
.

.
:..:.. :.:...'. .......... ....:.
... . .. . . . .. . ... ........
.,

__
.......

... ... ...

~~~
--,

.
'n,\.', ' ., ' .,. .. ' '-' '- '- ,...,. ~ _.,.,_. ,,~, '

' .

Figure 1.3.2a Control diagram for a

temperature control loop applied to a
steam-heated heat exchanger.
 4. A Multi-loop Process: Distillation (bonus: 1 point)
Review your distillation concepts. Identify seven feasible feedback
control loops, their process and control objectives, the different variables
and hardware components, and draw the block diagrams.

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