Process Dynamics and Control

Chapter 7
FEEDBACK CONTROLLERS

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Process Dynamics and Control

Chapter Objectives
End of this chapter, you should be able to:
1.

Explain the concept of feedback control

2.

Explain P, I and D controllers

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Process Dynamics and Control

Introduction
Pressure Control Module in Block 3

ECB4034 - Chemical Process Instrumentation and Control

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Introduction
Pressure Control Module in Block 3

ECB4034 - Chemical Process Instrumentation and Control

Process Dynamics and Control

Introduction
Pressure Control Module in Block 3

Sensor/Transmitter?
Controller?

Control valve?

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Introduction
Control Valves

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Introduction
Control Valves

ECB4034 - Chemical Process Instrumentation and Control

Introduction
Process Dynamics and Control

Transmitter (Sensor)

Pressure

Flow

Concentration (gas)

Temperature

Concentration (liquid)

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Introduction
PID Controllers

Digital PID controller

Nippon Group PID controller

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Introduction
PID Controller Simplified

A PID controller consists of a Proportional element, an Integral

element and a Derivative element, all three connected in parallel
PID algorithm is Exceptionally simple + flexible (tuning parameters)

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Introduction
CSTR Example

A familiar drawing:
Schematic diagram

BUT, how does the

actual physical process
looks like?
Q: Where is the controller
that adjusts the green
Control valve?
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Introduction
A typical control room

ECB4034 - Chemical Process Instrumentation and Control

Process Dynamics and Control

Introduction
A typical chemical plant industry

Control room?
Processing facility

Approximately 400m to >1000m away from

Processing facility
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Introduction
PID Controller Simplified

-- Sends signal to
Ctrl valve >400m
away in few seconds
only

ECB4034 - Chemical Process Instrumentation and Control

-- Sends signal to
Controller >400m
away in few seconds
only

Process Dynamics and Control

Introduction

Consider the continuous blending process, shown in

Fig.
IP

Electrical Signal
Pneumatic signal

AC

x 1 , w1

xsp
x2, w2

AT

x, V

xm

x, w
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Control system
Control objective:
To keep the tank exit composition x at the
desired setpoint by adjusting w2.

Measurement

: Composition AnalyzerTransmitter (AT)

Feedback controller: AC Automatic Controller

Final control element: Pneumatic control valve
Current-to-pneumatic transducer: I/P
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Historical Perspective:
1930s Commercial Three-mode controllers with
proportional, integral and derivative
(PID) feedback control action
1940s Widespread acceptance of pneumatic
PID controllers
1950s Electronic counterparts in the market
1960s Computer applications
1980s Use of digital hardware
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Block diagram of a feedback control loop:

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Basic Control Modes

Proportional, Integral and Derivative
Proportional Control
In feedback control, the objective is to reduce the
error signal to zero.
Define an error signal, e, by

e(t ) y SP (t ) y m (t )

(6.1)

where y sp = set point

y m = measured value of the controlled variable
(or equivalent signal from transmitter)
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For proportional control, the controller output is

proportional to the error signal
p(t) p K c e(t)

where

(6.2)

p(t) = controller output

p = bias value (adjustable, manual reset)
Kc = controller gain (dimensionless, adjustable,
tuning)

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Proportional Band, PB:

Definition :

100%
PB
Kc

Applies when Kc is dimensionless

Small (narrow) PB corresponds to large Kc
Large (wide) PB corresponds to small Kc

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Ideal vs. actual

Ideal controller does not
include physical limits
p(t) p K c e(t)

(6.2)

A controller saturates
when its output reaches a
physical limit, either pmax
or pmin (see the control valve
picture)
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Proportional controller
In order to derive the transfer function for an ideal
proportional controller, define a deviation variable
as
p (t ) p (t ) p
(6.4)
Then (6.2) can be written as
p (t ) K c e(t )

(6.5)

Taking Laplace transform of (6.5) and rearranging

we get
P ( s )
Kc
(6.6)
E (s)
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Reverse or Direct Acting Controller

Kc can be made positive or negative
Reverse-Acting (Kc > 0)
output increases as input
decreases (measured
value"
Direct-Acting (Kc < 0)
controller output increases
as input increases
(measured value)"
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Proportional controller
An inherent limitation of proportional controller is
that a steady-state error (offset) occurs after a setpoint change or a sustained disturbance.
Offset can be eliminated by manually resetting
either the set-point or bias after an offset occurs
impractical.

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Integral Control
reset control, floating control
For integral action, the controller output depends
on the integral of the error signal over time,
1
p(t) p
I

e(t )dt
0

(6.7)

where I is an adjustable parameter and referred to

as the integral time constant or reset time, has units
of time.
The transfer
function:

P (s)
1

E(s) I s

(6.8)

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Integral Control
An important practical advantage: Eliminates offset.
For the process being controlled to be at steady state, the
controller output p must be constant so that the manipulated
variable is also constant.
Eq. (6.7) implies that p changes with time unless e(t) = 0.
This desirable situation occurs unless the controller output
or the final control element saturates.
The control action by the integral controller is very little
until the error signal has persisted for sometime.
On the other hand, proportional controller takes immediate
corrective action as soon as an error is detected.
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PI Controller
Integral control is used in conjunction with
proportional control as the proportional-integral (PI)
controller:

1
p (t ) p K c e(t ) e(t )dt
I 0

(6.9)

The corresponding transfer function is:

P(s)
1

K c 1
E(s)
Is

(6.10)

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PI Controller
The response of the PI controller to a unit step
change in e(t) is shown in Fig.

1/ I

- repeats per minute

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PI Controller
Disadvantages:
Produces oscillatory response
Reset windup

When a sustained error occurs, the integral term becomes

quite large and the controller output eventually saturates
reset windup or integral windup.
Antireset windup: Temporarily halting the integral action
whenever the control output saturates.
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Derivative control
Rate action, pre-act, anticipatory control
Anticipate the future error by considering its rate of
change.
For ideal derivative action,
p (t ) p D

de(t )
dt

(6.11)

where D is the derivative time, and has units of time.

As long as the error is constant de/dt = 0, the controller
output is equal to p .

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Derivative control
Derivative action is never used alone.
Always used in conjunction with P or PI control.
PD controller has the transfer function
P (s)
K c 1 D s
E(s)

(6.12)

The derivative control action tends to stabilize the

controlled process.

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Summary of behavior - PID

Proportional: reacts to deviation in CV, not concern about the time

Integral: corrective action depends on the duration of the deviation
Derivative: rate of change of error, amplifies sudden changes

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Typical Units

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PID Controller
PID control algorithm is given by

1
de
p (t ) p K c e(t ) e(t )dt D
I 0
dt

(6.13)

Transfer function of an ideal controller (parallel form)

P (s)
1

Kc 1
D s
E(s)
Is

(6.14)

Transfer function actual (Series form)

s 1
P(s)

K c I
E(s)

s
I

Ds 1

1
D

(6.15)

lead / lag units

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ON-OFF controllers
Synonyms:

two-position or bang-bang controllers.

Ideal controller

More practical controller

(Dead band)
Special case of proportional controller with very high
gain.
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Typical responses of Feedback

control systems
Consider response of a controlled system after a sustained
disturbance occurs (e.g. step change in load variable)
No control
New steady state is
reached
P control
Offset reduced
PI control
Offset eliminated
Oscillatory response
PID control
Oscillations reduced
No offset
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Too small a value of Kc

Sluggish response
Larger deviation
Too large a value of Kc
Exhibit oscillatory or unstable
behavior
Intermediate values of Kc is desirable

Increasing
tends to improve the
response by reducing the maximum
deviation, response time, and degree
of oscillation

If
is too large, measurement noise
is amplified and the response may
become oscillatory.

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Process Dynamics and Control

Increasing the integral time makes the controller more

sluggish.
Offset will be eliminated for all values

For large values of I , it takes very long time to return

to the set-point.
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Summary of the Characteristics of the

Most Commonly Used Controller Modes
1. Two Position:
Inexpensive
Extremely simple
2. Proportional:
Simple
Inherently stable when properly tuned
Easy to tune
Experiences offset at steady state
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3. Proportional plus reset:

No offset
Better dynamic response than reset alone
Possibilities exist for instability due to lag
introduced
4. Proportional plus rate:
Stable
Less offset than proportional alone (use of higher gain
possible).
Reduces lags, i.e., more rapid response.

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5. Proportional plus reset plus rate:

Most complex
Rapid response
No offset
Difficult to tune
Best control if properly tuned.

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Conclusion!

Concept of feedback control

P, I, D controller modes
Advantages and disadvantages
Motivation for additional modes

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ECB4034 - Chemical Process Instrumentation and Control