ICE401: PROCESS INSTRUMENTATION

AND CONTROL

Class 5: Advanced Control Loops

Dr. S. Meenatchisundaram
Email: meenasundar@gmail.com

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2015
 Multivariable Loops:
• Multivariable loops are control loops in which a primary controller
controls one process variable by sending signals to a controller of
a different loop that impacts the process variable of the primary
loop.
• For example, the primary process variable may be the
temperature of the fluid in a tank that is heated by a steam jacket
(a pressurized steam chamber surrounding the tank).
• To control the primary variable (temperature), the primary
(master) controller signals the secondary (slave) controller that is
controlling steam pressure.
• The primary controller will manipulate the setpoint of the
secondary controller to maintain the setpoint temperature of the
primary process variable.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2015
Multivariable Loops:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2015
 Multivariable Loops:

• When tuning a control loop, it is important to take into account the

presence of multivariable loops.
• The standard procedure is to tune the secondary loop before
tuning the primary loop because adjustments to the secondary
loop impact the primary loop.
• Tuning the primary loop will not impact the secondary loop tuning.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2015
 Advanced Control Loops – Feed Forward
Control:

• Feedforward control is a control system that anticipates load

disturbances and controls them before they can impact the
process variable.
• For feedforward control to work, the user must have a
mathematical understanding of how the manipulated variables will
impact the process variable.
• Figure shows a feedforward loop in which a flow transmitter
opens or closes a hot steam valve based on how much cold fluid
passes through the flow sensor.
• An advantage of feedforward control is that error is prevented,
rather than corrected.
• However, it is difficult to account for all possible load disturbances
in a system through feedforward control.
Process Instrumentation and Control (ICE 401)
Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2015
Advanced Control Loops – Feed Forward
Control:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2015
 Advanced Control Loops – Feed Forward
Control:

• Factors such as outside temperature, build up in pipes,

consistency of raw materials, humidity, and moisture content can
all become load disturbances and cannot always be effectively
accounted for in a feedforward system.
• In general, feedforward systems should be used in cases where
the controlled variable has the potential of being a major load
disturbance on the process variable ultimately being controlled.
• The added complexity and expense of feedforward control may
not be equal to the benefits of increased control in the case of a
variable that causes only a small load disturbance.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2015
 Advanced Control Loops – Feed Forward Plus
Feedback Control:

• Because of the difficulty of accounting for every possible load

disturbance in a feedforward system, feedforward systems are
often combined with feedback systems.
• Controllers with summing functions are used in these combined
systems to total the input from both the feedforward loop and the
feedback loop, and send a unified signal to the final control
element.
• Figure shows a feedforward-plus-feedback loop in which both a
flow transmitter and a temperature transmitter provide information
for controlling a hot steam valve.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2015
Advanced Control Loops – Feed Forward Plus
Feedback Control:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2015
 Advanced Control Loops – Cascade Control:

• Cascade control is a control system in which a secondary (slave)

control loop is set up to control a variable that is a major source of
load disturbance for another primary (master) control loop.
• The controller of the primary loop determines the setpoint of the
summing controller in the secondary loop.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2015
Advanced Control Loops – Cascade Control:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2015
 Advanced Control Loops – Ratio Control:

• Imagine a process in which an acid must be diluted with water in

the proportion two parts water to one part acid.
• If a tank has an acid supply on one side of a mixing vessel and a
water supply on the other, a control system could be developed to
control the ratio of acid to water, even though the water supply
itself may not be controlled.
• This type of control system is called ratio control.
• Ratio control is used in many applications and involves a
controller that receives input from a flow measurement device on
the unregulated (wild) flow.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2015
 Advanced Control Loops – Ratio Control:

• The controller performs a ratio calculation and signals the

appropriate setpoint to another controller that sets the flow of the
second fluid so that the proper proportion of the second fluid can
be added.
• Ratio control might be used where a continuous process is going
on and an additive is being put into the flow (e.g., chlorination of
water).

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2015
Advanced Control Loops – Ratio Control:

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2015
 Advanced Control Loops – Batch Control:

• Batch processes are those processes that are taken from start to
finish in batches.
• For example, mixing the ingredients for a juice drinks is often a
batch process.
• Typically, a limited amount of one flavour (e.g., orange drink or
apple drink) is mixed at a time.
• For these reasons, it is not practical to have a continuous process
running.
• Batch processes often involve getting the correct proportion of
ingredients into the batch.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2015
 Advanced Control Loops – Batch Control:

• Level, flow, pressure, temperature, and often mass measurements

are used at various stages of batch processes.
• A disadvantage of batch control is that the process must be
frequently restarted.
• Start-up presents control problems because, typically, all
measurements in the system are below setpoint at start-up.
• Another disadvantage is that as recipes change, control
instruments may need to be recalibrated.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2015
 Advanced Control Loops – Selective Control:

• Selective control refers to a control system in which the more

important of two variables will be maintained.
• For example, in a boiler control system, if fuel flow outpaces air
flow, then un-combusted fuel can build up in the boiler and cause
an explosion.
• Selective control is used to allow for an air-rich mixture, but never
a fuel-rich mixture.
• Selective control is most often used when equipment must be
protected or safety maintained, even at the cost of not maintaining
an optimal process variable setpoint.

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2015
 Assignment Question:
1.2 Draw an alternate single loop feedback control for the following
processes:

1. Flow Process

2. Pressure Process

3. Temperature Process

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Aug – Nov 2015
 References:

• Instrumentation & Control – Process Control Fundamentals,

PAControl.com

Process Instrumentation and Control (ICE 401)

Dr. S.Meenatchisundaram, MIT, Manipal, Jan – May 2015