Automation Control
Process Control Topic-2
Fundamentals
Lecture-5
Industrial Engineering Department, UET Peshawar
This Lecture
❖ Controller Algorithms
❖ Control Loops
❖ Single Variable
❖ Multi Variable
Control System Video
Open Loop Video
Closed Loop Video
Controller Algorithm
Controller Algorithms
Controller Algorithms
Multistep Continuo
Discrete
us
Controller Algorithms
Discrete
❖ Two Nodes
❖ On/Off
❖ Temperature in Water Tank
❖ Cannot hold the variable at the
setpoint
❖ Too much oscillation
❖ But still in dead zone
❖ Continuous Cycle
Controller Algorithms
Multistep
❖ More than two nodes
❖ Intermediate Step
❖ Works similarly to Discrete
Control loop
❖ Less dramatic Oscillations
Continuous
❖ Automatically compare PV with SP
❖ Determine error
❖ If error adjust the output
❖ Controller tuning parameters determine
❖ Magnitude
❖ Duration
❖ Speed
Control Loop
Control Loop
Single Variable Multi Variable
Control Loops
Single Variable Control Loop
❖ Measures Process
FeedBack Control ❖
Variable
Sends Measurement to
Loop ❖
❖
Controller
Comparison to setpoint
E.g. Cruise Control
Single Variable Control Loop
❖ Vary in Speed
❖ Response to
Pressure Control changes/action
❖ Slowly or Quickly
Loop
❖ High volume system
changes slowly
❖ Large Natural Gas
Storage
Flow Transmitters are
sensitive
Single Variable Control Loop
❖ Fast Loops
Flow Control
❖ Respond to changes
quickly
❖ Damping function of FT
Loop
❖ Temperature Effect
❖ Typically FCL have
❖ Flow Sensor, Transmitter,
Controller, Valve or Pump
Single Variable Control Loop ❖ Speed depends on size
and shape of vessel and
Level Control ❖
In-outflow
Level can be measured by
❖ Radar, Float Gauge
Loop ❖
Etc;
Valve is final control
element
❖ Overflow is avoided
Single Variable Control Loop
❖ Relatively Slow
Temperature Control ❖ Thermocouples as
temperature sensors
Loop ❖
❖
Fuel valve is the FCE
Cool fluid may be added
❖ Primary Controller
❖ Send signals to
Multi-Variable ❖
Secondary controller
Secondary Controller
❖ Tuned first
❖ Temperature Vs Steam
Multi-Variable Control Loop
FeedForward
❖ Anticipates load disturbance
❖ Control before it impact PV
❖ User must have mathematical
knowledge
❖ Error is prevented not corrected
❖ Difficult to anticipates all types of
loads
❖ Humidity and Moisture
❖ Best used when controlled variable
is a potential major load
disturbance
❖ Figure-Open or Closes Steam valve
based on cold fluid
Feedback Vs FeedFoward
Multi-Variable Control Loop
FeedForward
Plus
❖ FeedForward + FeedBack
❖ Summing function is used
❖ FFL+FBL sends unified signal to
controller
❖ Figure
❖ Temperature Transmitter (FB)
❖ Flow Transmitter (FF)
❖ Steam Valve
Multi-Variable Control Loop
Cascade
❖ Two loops
❖ Primary
❖ Secondary (Slave)
❖ Secondary loop control major
load disturbance variable for
primary loop
❖ Primary loop Controller
❖ Determines the Setpoint of the
summing controller in the
secondary loop
Cascade
Batch
❖ Batch Production
❖ Different juices
❖ Batch Processes
❖ Processes taken from start to finish in batches
❖ Involves getting correct proportion of ingredients in
a batch
❖ Level, flow, mass measurement may be used
❖ Frequent restarts and recalibrations
Multi-Variable Control Loop
Ratio
❖ Where continuous process is on
❖ Additive is on
❖ Chlorination of water
❖ Controller receives input from
flow measurement device
❖ One wild flow (Unregulated
fluid)
❖ Controls Regulated second
fluid
❖ Perform ration calculation and
signals appropriate setpoint
“Raise your words not your voice. It is rain
that grows flower not thunder”
–Rumi
