Process Control

Loops

Lecturer: Dr. Phạm Hoàng Huy Phước Lợi

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Process Variable (PV)

Definition: The current value of the process condition being

controlled.
Examples: Temperature, pressure, flow rate, etc.
Importance: Accurate measurement is crucial for effective
control.

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Set Point (SP)

Definition: The desired target value for the process variable.

Importance: The SP is where the process should ideally be
maintained.
Adjustments: How changing the SP affects the process.

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Error Signal (e)

Calculation: e = PV−SP
Role: The error signal indicates how far the process is from
the desired state.
Continuous adjustment: The controller works to minimize the
error.

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Controller Overview

Function: Receives error signal and calculates the necessary

adjustment.
Types: Mechanical, Pneumatic, Electronic.
Output: Sends a control signal to the final control element.

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Role of the Controller

❖The controller is the brain of the control loop, responsible for

making decisions based on the error signal (e = PV - SP).
❖It compares the current process variable (PV) with the
desired setpoint (SP) and calculates the necessary
adjustment to the manipulated variable.

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Types of Controllers:

• Mechanical Controllers:
• Use mechanical components such as cams, gears, and levers.
• Common in older or simpler systems where digital technology is not
required.
• Pneumatic Controllers:
• Operate using compressed air to control the process.
• Typically used in hazardous environments where electrical controllers are not
safe.
• Electronic Controllers:
• Use electrical signals to perform control actions.
• Includes both analog and digital controllers, with digital controllers offering
greater precision and programmability.

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Control Modes

• Proportional Control (P):

• The controller output is directly proportional to the error.
• Adjusts the manipulated variable based on the size of the error, with a higher
gain leading to more aggressive control.
• Integral Control (I):
• Integrates the error over time, eliminating steady-state errors.
• Useful in systems where the proportional control alone cannot achieve the
desired setpoint.
• Derivative Control (D):
• Reacts to the rate of change of the error, predicting future errors.
• Helps to dampen system oscillations and improve stability.

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Control Strategies

Proportional (P): Correction proportional to the error.

Proportional-Integral (PI): Combines proportional control with
integration of past errors.
Proportional-Derivative (PD): Adds a derivative term to
anticipate future errors.
Proportional-Integral-Derivative (PID): Combines all three
strategies for precise control.

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The Control Valve

Function: Final control element that adjusts the flow of the

process medium.
Common Types: Globe valves, ball valves, butterfly valves.
Importance: Critical for implementing the control action.

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Transmitters and Sensors

Role: Transmitters convert

sensor data into a standard
signal.

Common Standards: 4-20 mA,

0-10V, digital signals.

Example: A pressure transmitter

in a pipeline.

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Impact of Disturbances

Definition: External changes that affect the process (e.g., load

changes, temperature fluctuations).
Effect: How disturbances can drive the process variable away
from the set point.
Mitigation: The role of the control system in mitigating the
effects of disturbances.

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Sensor and Measurement Errors

Impact: Inaccuracies in measurement can lead to incorrect

control actions.
Sources of Error: Calibration issues, environmental factors,
sensor degradation.
Strategies to minimize errors: Regular calibration, using
high-quality sensors.

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Control Loop Tuning

Importance: Proper tuning ensures that the control loop

responds appropriately.
Common Challenges: Finding the right balance between
responsiveness and stability.
Symptoms of Poor Tuning: Oscillations, slow response,
overshoot.

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Introduction to Controller Tuning

Definition: Adjusting controller parameters to achieve desired

control performance.
Key Parameters: Proportional gain (Kp), Integral time (Ti),
Derivative time (Td).
Why Tuning is Necessary: Ensures optimal performance and
stability.

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Best Practices for Controller Tuning

Start with conservative settings and gradually increase gain.

Tune in stages: Proportional first, then add integral and
derivative.
Regularly review and adjust tuning settings based on system
performance.
Consider using simulation tools before applying changes to the
actual system.

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Basic Concept of Single-Loop
Feedback Control

Definition: Feedback control is a control strategy where the

system continuously monitors the output (process variable,
PV) and compares it with the desired setpoint (SP). If there is
a deviation, the system makes adjustments to bring the PV
back to the SP.
Common Applications: Widely used in industrial processes,
such as temperature control in furnaces, pressure regulation in
boilers, and speed control in motors.

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 Sensor: Measures the process variable.
Components
of Single- Controller: Compares PV with SP and
generates a control signal.
Loop
Feedback Final Control Element: Adjusts the process
based on the controller's output.
Control

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 The process variable (PV) is measured
by sensors.
How The measured PV is compared with the
Feedback setpoint (SP).

An error signal (e = PV - SP) is

Control generated.

Works The controller takes action to minimize

this error by adjusting a control element,
such as a valve or motor.

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Example of Feedback
Control Loop
Scenario: Controlling the temperature in a chemical reactor.

Process Overview:
• The temperature in a reactor needs to be maintained at a specific setpoint to ensure the
desired reaction conditions.
• External factors, such as changes in reactant feed temperature or fluctuations in ambient
conditions, can cause deviations from the setpoint.

Feedback Control Solution:

• Measurement: A temperature sensor measures the actual temperature (Process Variable,
PV) inside the reactor.
• Error Detection: The measured temperature is continuously compared to the desired
setpoint (SP). If there is a difference, an error signal is generated.
• Controller Action: The controller receives the error signal and adjusts the flow rate of a
cooling or heating medium (e.g., steam or coolant) to correct the temperature.
• Outcome: The feedback loop helps maintain the reactor temperature at the setpoint,
ensuring the process remains stable and within optimal conditions.

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 Simplicity and ease of
Advantages implementation.
of Single-
Loop
Feedback
Automatic correction of
Control disturbances.

Effective for maintaining

steady-state operation.

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 Temperature Control: Used in reactors,
furnaces, and HVAC systems.

Pressure Control: Essential in pipelines,

boilers, and pressure vessels.

Flow Control: Critical for maintaining proper

Applications flow rates in chemical processes.
in Industry
Level Control: Ensures tanks and reservoirs
are filled to desired levels.

Final Thoughts: The importance of continued

learning and adaptation in process control.

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 Definition: Feedforward control
anticipates disturbances by
measuring external inputs and adjusts
the process to minimize their impact
before they affect the system.
Introduction
Difference from Feedback
to Control: Unlike feedback control,
Feedforward which reacts to deviations after they
Control occur, feedforward control acts
preemptively.
Application: Often used in systems
where disturbances can be predicted
or measured, such as in temperature
control when there is a known change
in load.

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 Measurement: Detects external disturbances or
changes in setpoint before they affect the process.
How Calculation: Uses mathematical models of the
Feedforward process to predict the necessary corrective action.
Control Works Adjustment: Directly adjusts the manipulated variable
to counteract the effect of the disturbance.

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Components of a Feedforward
Control Loop

Disturbance Sensor: Measures the external disturbance before it

affects the process variable.
Process Model: Predicts how the disturbance will affect the
process and calculates the necessary adjustment.
Control Element: Implements the adjustment to maintain the
process variable at the set point.
Comparison with Feedback: Often used in conjunction with
feedback control to correct any remaining errors.

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Example of Feedforward
Control

Scenario: Controlling the temperature in a heat exchanger where

the inlet temperature of the fluid changes.
How it Works:
• The feedforward controller measures the inlet
temperature.
• Based on the process model, it adjusts the steam flow rate
to maintain the outlet temperature.
Result: The system maintains stable temperature control despite
changes in the inlet temperature.

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Advantages of Feedforward
Control

Proactive Control: Anticipates disturbances and adjusts before

they affect the process.
Improved Stability: Reduces the amplitude of process variable
fluctuations.
Complementary to Feedback: Can be combined with feedback
control to handle unmeasured disturbances.

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Limitations of Feedforward
Control

Model Dependence: Requires an accurate process model; errors

in the model can lead to incorrect adjustments.
No Error Correction: Does not correct for any deviation between
the set point and the process variable—feedback control is
needed for this.
Complexity: More complex to design and implement than simple
feedback loops.

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Combining Feedforward and
Feedback Control

Integrated Approach: Feedforward control can handle

predictable disturbances, while feedback control corrects any
residual errors.
Enhanced Performance: The combination results in a more robust
and stable process control system.
Example: Used in distillation columns to maintain product quality
by managing both disturbances and deviations.

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Combined
Feedback /
Feedforward
control

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Combined
Feedback /
Feedforward
control

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Combined
Feedback /
Feedforward
control

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Practical Applications of
Feedforward Control
Chemical Processing: Managing variations
in raw material properties or environmental
conditions.

HVAC Systems: Adjusting heating or cooling

based on predicted changes in external
temperature.

Power Generation: Managing fuel flow

based on predicted changes in power
demand.

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Introduction to Cascade Control
Definition: Cascade control is a control strategy
that uses two or more controllers with nested loops,
where one controller’s output (the primary controller)
acts as the setpoint for another controller (the
secondary controller).

Purpose: Enhances control performance by

improving the system’s response to disturbances,
especially in processes with significant delays or
multiple interacting variables.

Application: Commonly used in temperature control

systems, where the primary controller manages the
overall temperature, and the secondary controller
manages the flow of heating or cooling fluid.

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Cascade control loops
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How Cascade Control Works
Primary Loop: The main process variable (e.g., temperature) is
controlled by the primary controller, which determines the setpoint for
the secondary loop.

Secondary Loop: The secondary controller adjusts the manipulated

variable (e.g., flow rate of a heating medium) to achieve the setpoint
provided by the primary controller.

Feedback Interaction: The secondary loop provides faster correction of

disturbances, while the primary loop ensures the overall system
stability.

Benefits: Improved disturbance rejection, faster response times, and

better control over processes with large time constants or multiple
phases.

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Components of Cascade Control
Primary Controller (Master): Controls the main process variable and
sets the target for the secondary controller.

Secondary Controller (Slave): Directly controls the process by adjusting

the manipulated variable based on the primary controller’s setpoint.

Measurement Devices: Sensors used for measuring the primary and

secondary process variables (e.g., temperature sensors, flow meters).

Final Control Element: The actuator (e.g., valve, pump) that implements
the changes required by the secondary controller.

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 Background:
• Industry Context: You are an engineer at a chemical
plant responsible for maintaining the efficient
operation of a large furnace used in the production
of a high-temperature chemical process.
• Problem: The plant has been experiencing
inconsistent furnace temperatures, leading to
Example of product quality issues and increased fuel costs.
Your goal is to optimize the furnace's performance
by implementing a more sophisticated control
Cascade system.

Control Existing Setup:

• The furnace is currently controlled by a simple
feedback loop that adjusts the fuel flow based on
the temperature. However, this system is slow to
respond to changes in temperature, causing
fluctuations that result in inefficient fuel use and
inconsistent product quality.

Solution: Implementing Cascade Control

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 Example of Cascade Control

System Components
• FT 100 (Flow Transmitter): Measures the
fuel flow rate into the furnace.
• FIC 100 (Flow Indicator Controller):
Regulates the fuel flow based on the
flow setpoint (SP).
• FV 100 (Flow Control Valve): Adjusts the
fuel flow rate to the furnace.
• TIC 100 (Temperature Indicator
Controller): Monitors and controls the
furnace's temperature by adjusting the
fuel flow.
• TE 100 (Temperature Element): Senses
the temperature of the furnace output.

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Example of Cascade Control

Control Strategy:
• Primary Loop (Temperature
Control): The TIC 100 controls
the furnace's temperature by
sending a signal to the FIC 100,
which adjusts the fuel flow.
• Secondary Loop (Flow Control):
The FIC 100 ensures the correct
fuel flow rate to maintain the
desired furnace temperature.
• Cascade Control: The TIC 100
(master controller) sets the
setpoint for the FIC 100 (slave
controller), creating a cascade
control system that enhances
the accuracy and stability of
temperature control.

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Example of Cascade Control

Process Flow:
• Fuel Flow: Starts at the Flow
Transmitter (FT 100), which
measures and sends the data to
FIC 100.
• Flow Adjustment: FIC 100
adjusts the Flow Control Valve
(FV 100) based on the setpoint
received from TIC 100.
• Temperature Monitoring: TIC 100
receives temperature data from
TE 100 and adjusts the flow to
maintain the desired
temperature.

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Advantages of Cascade Control

• Improved Stability: Reduces the impact of disturbances by

addressing them at the secondary loop level before they affect
the primary loop.
• Faster Response: Secondary loop responds quickly to
disturbances, enhancing the overall system’s response time.
• Enhanced Control Accuracy: Allows for more precise control in
processes with large time delays or where multiple variables
interact.

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Limitations of Cascade Control

• Increased Complexity: More complex to design, tune, and

maintain than single-loop control systems.
• Requires Accurate Models: Accurate process models are
necessary to effectively set up and tune both loops.
• Potential for Interaction: Poorly tuned loops can interact
negatively, leading to instability or poor control performance.

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Applications of Cascade Control

• Temperature Control: Used in systems where precise

temperature regulation is critical, such as in chemical reactors
and heat exchangers.
• Pressure Control: Common in systems where maintaining
stable pressure is essential, such as in boiler operations.
• Level Control: Used in processes like tank level control, where
both the inflow and outflow need to be managed precisely.

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Introduction to Ratio Control

• Definition: Ratio control is a control strategy where the controller

maintains a fixed ratio between two or more process variables, such
as flow rates of different streams in a blending or mixing process.
• Purpose: Ensures that the specified proportion between process
variables is maintained, which is crucial in processes like chemical
reactions, blending operations, and combustion control.
• Application: Commonly used in processes where the quality or
outcome depends on maintaining a precise ratio between input
materials, such as in fuel-to-air ratio control in combustion systems.

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 Ratio control

Method 1 Method 2

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How Ratio Control Works

• Measurement: Sensors measure the flow rates or other

relevant process variables for each stream involved.
• Ratio Setpoint: The desired ratio is defined, often as a setpoint
that the controller must maintain.
• Control Action: The controller adjusts one or more streams to
maintain the ratio setpoint by modulating flow rates or other
variables.
• Feedback Loop: In many cases, feedback control is integrated
to correct any deviations from the desired ratio.

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Components of Ratio Control

• Primary Flow Measurement: The main process variable whose

flow rate is measured and used to determine the control
action.
• Secondary Flow Measurement: The flow rate of the other
stream(s) involved in maintaining the ratio.
• Ratio Controller: Calculates the required adjustment to
maintain the set ratio based on the measured flows.
• Control Valves: Adjust the flow rates to maintain the desired
ratio.

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Example of Ratio Control

Scenario: Fuel-to-air ratio control in a combustion system.

Process: Ensures the correct proportion of fuel to air is

maintained for efficient combustion and reduced emissions.

Control Action: The ratio controller adjusts the air or fuel flow
rate to maintain the desired fuel-to-air ratio.

Outcome: Improved combustion efficiency and minimized

pollution.

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 Example of Ratio Control
Key Components:
• FE 200 (Air Flow Element): Measures the
flow of air entering the system.
• FT 100 (Air Flow Transmitter): Converts the
flow measurement into a signal for
processing.
• FE 100 (Fuel Flow Element): Measures the
flow of fuel.
• FT 100 (Fuel Flow Transmitter): Converts the
fuel flow measurement into a signal.
• FFIC 100 (Flow Ratio Controller): Compares
the actual air-to-fuel ratio with the desired
setpoint (SP) and adjusts the fuel flow to
maintain the correct ratio.
• FV 100 (Fuel Control Valve): Adjusts the fuel
flow based on the controller's output.

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 Example of Ratio Control
Operation Principle
• Uncontrolled Air Flow:
• The air flow is not controlled directly but is
measured by the air flow transmitter (FT 100).
• The signal from FT 100 represents the process
variable (PV) for air.
• Controlled Fuel Flow:
• The fuel flow is adjusted by the fuel valve (FV 100)
to maintain the desired air-to-fuel ratio.
• The flow ratio controller (FFIC 100) uses the PV
from the air flow to determine the appropriate
fuel flow.
• The controller outputs a signal to the fuel valve to
modulate the fuel flow, ensuring that the ratio of
air to fuel is maintained as per the setpoint.

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Advantages of Ratio Control

Consistency: Ensures a consistent product quality

by maintaining precise ratios.

Efficiency: Optimizes the use of raw materials by

ensuring that the correct proportions are used,
minimizing waste.

Flexibility: Can be easily adjusted for different

operating conditions or desired outcomes by
changing the ratio setpoint.

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Limitations of Ratio Control
Sensitivity to Measurement Errors: Accurate
measurements are critical; any errors in flow
measurement can lead to incorrect ratios.

Requires Stable Processes: Works best in processes

where the input streams have consistent
characteristics; variations can complicate control.

Complexity in Multi-stream Systems: Maintaining ratios

between multiple streams can become complex,
requiring advanced control strategies.

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Applications of Ratio Control
Chemical Blending: Maintaining the correct
proportions of reactants in a chemical process to
ensure product quality.

Combustion Control: Ensuring the correct fuel-to-

air ratio in burners for efficient energy use and
reduced emissions.

Food and Beverage Production: Controlling the

mix of ingredients to achieve consistent flavor
and quality in products.

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Summary
Single-loop Feedback Control: Most common, simple
and efficient.

Feedforward Control: Anticipates disturbances and

adjusts accordingly.

Cascade Control: Involves multiple control loops, used

for complex processes.

Ratio Control: Maintains a fixed ratio between two

variables.

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What is the primary function of a controller in a
control loop?

1. Measure the process variable (PV)

2. Compare the set point (SP) with the
error signal
3. Generate and send a control signal to
the final control element
4. Monitor environmental conditions
around the process
5. Adjust the set point based on operator
input

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Which control mode reacts to the rate of
change of the error signal to predict
future errors?

1. Proportional Control (P)

2. Integral Control (I)
3. Derivative Control (D)
4. Proportional-Integral-Derivative (PID) Control
5. Feedforward Control

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What is the purpose of using
feedforward control in a process?

1. To correct disturbances after they affect the process variable.

2. To enhance control accuracy by using nested loops.

3. To anticipate and counteract disturbances before they affect the

process.

4. To maintain a fixed ratio between two or more process variables.

5. To simplify the control strategy by using only one loop.

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Which of the following control strategies combines
proportional, integral, and derivative actions to achieve
precise control?

1. Proportional Control (P)

2. Proportional-Integral Control (PI)

3. Proportional-Derivative Control (PD)

4. Proportional-Integral-Derivative Control (PID)

5. Cascade Control

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What is a key advantage of
single-loop feedback control?

1.It predicts future process disturbances.

2.It simplifies the control system design.
3.It requires no measurement of the process variable.
4.It automatically corrects for disturbances in the process.
5.It eliminates the need for a setpoint.

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