NAME

Babarinde Michael Bamidele

MATRIC NUMBER
20/205CHE/072

DEPARTMENT
Chemical Engineering

FACULTY
Engineering

COURSE CODE
CHE 512 (C)

COURSE TITLE
Process Control

ASSIGNMENT TITLE
Write on the different process control
strategies/configuration, their basic
principle/theor, advantages and disadvantages and
industrial applications.

LECTURER’S NAME
Aabdulfatai Jimoh, Ph.D.

ASSISTANT LECTURER’S NAME

Engr. Ridwan Suleiman
 PROCESS CONTROL STRATEGIES/CONFIGURATION
Process control can be defined as the systematic application of
techniques and technologies to monitor and regulate industrial
processes to ensure they operate within desired parameters. These
parameters could include factors such as temperature, pressure,
flow rate, pH level, concentration, and more, depending on the
specific requirements of the process. The ultimate goal of process
control is to maintain consistency, efficiency, and safety while
producing high-quality products or outcomes.

In a simple control system, a process variable (PV) is measured

and compared with a setpoint value (SP). A manipulated variable
(MV, or output) signal is generated by the controller and sent to a
final control element, which then influences the process variable to
achieve stable control. The algorithm by which the controller
develops its output signal is typically PID (Proportional-Integral-
Derivative), but other algorithms may be used as well.

Process control strategies are the methodologies used to manage

and regulate the operations of a process system. These strategies
determine how the controller responds to the error between the
setpoint and the process variable. The choice of strategy considers
process nature, performance needs, and variable characteristics.
There are two types of process control strategies which are

The On-Off control strategy is the simplest form of process

control. In this strategy, the controller switches the actuator, such as
a control valve or a heater, on or off based on the error. When the
process variable is below the setpoint, the controller turns the
actuator on, and when the process variable is above the setpoint,
the controller turns the actuator off.

This strategy is more suitable for simple processes where

precision is not critical. However, it can lead to oscillations around
the setpoint, as the controller continually switches the actuator on
and off. This is known as cycling, which can cause wear and tear on
the actuator and instability in the process.
 The on-off control strategy is often used in systems where the
process variable can only be in one of two states, such as a light
switch that can be either on or off. It is also used in systems where
the actuator can only be in one of two states, such as a valve that
can be either fully open or fully closed. [5]

Despite its simplicity, the On-Off control strategy is not suitable

for processes that require smooth and precise control of the process
variable. More advanced control strategies, such as PID control, are
used for these processes.

Proportional-Integral-Derivative (PID) Control Strategy

The Proportional-Integral-Derivative (PID) control strategy is a

more advanced form of process control. It combines three different
control actions: proportional, integral, and derivative, to provide a
smooth and precise control of the process variable.

The proportional action (P) adjusts the control action in

proportion to the error. This means that the larger the error, the
larger the control action. The proportional action provides a quick
response to changes in the process variable. Still, it cannot
eliminate the steady-state error, which is the difference between the
process variable and the setpoint in a steady state.

The integral action (I) accumulates the error over time and
adjusts the control action accordingly. This helps to eliminate the
steady-state error, ensuring that the process variable reaches the
setpoint in a steady state. However, the integral action can respond
slowly to sudden changes in the process variable.

The derivative action (D) predicts the future behavior of the error
based on its rate of change and adjusts the control action
preemptively. This provides stability to the system, preventing
oscillations around the setpoint. However, the derivative action can
be sensitive to noise in the process variable, leading to erratic
control actions.
 PID control, popular in process control for its adaptability and
efficiency, is implementable in various processes. Tuning involves
adjusting proportional, integral, and derivative gains for desired
performance.

Despite the benefits of process control, PID control strategy

requires a good understanding of the process dynamics and careful
tuning of the controller parameters. It may not be suitable for
processes with complex dynamics or significant time delays. More
advanced control strategies, such as model predictive control, may
be used for these processes.

Model predictive control (MPC)

Model predictive control (MPC) is an advanced method of process

control that is used to control a process while satisfying a set of
constraints. It has been in use in the process industries in chemical
plants and oil refineries since the 1980s.

In recent years it has also been used in power system balancing

models and in power electronics. Model predictive controllers rely on
dynamic models of the process, most often linear empirical models
obtained by system identification. The main advantage of MPC is the
fact that it allows the current timeslot to be optimized, while
keeping future timeslots in account.

This is achieved by optimizing a finite time-horizon, but only

implementing the current timeslot and then optimizing again,
repeatedly, thus differing from a linear–quadratic regulator (LQR).
Also MPC has the ability to anticipate future events and can take
control actions accordingly. PID controllers do not have this
predictive ability. MPC is nearly universally implemented as a digital
control, although there is research into achieving faster response
times with specially designed analog circuitry.

The models used in MPC are generally intended to represent the

behavior of complex and simple dynamical systems. The additional
complexity of the MPC control algorithm is not generally needed to
provide adequate control of simple systems, which are often
controlled well by generic PID controllers. Common dynamic
characteristics that are difficult for PID controllers include large time
delays and high-order dynamics.

Basic principle of process control strategies

Feedback control

In feedback control system, the controlled variable is measured

using sensors or transducers. The measured value of controlled
variable is compared with the setpoint. Based on the deviation of
controlled variable from the setpoint, the controller changes the
action of final control element, on the process. The key component
of a feedback control system is the controller, which uses the error
signal to make necessary adjustments to the input. The error signal
is the difference between the actual output and the desired output,
and it serves as the driving force for the control action.

The effectiveness of a feedback control system depends on the

accuracy and speed of the error detection and correction process.
The controller must quickly detect deviations from the desired
output and make necessary adjustments to the input to correct the
error. This requires a high degree of precision and responsiveness,
which is achieved through advanced control algorithms and high-
speed processing capabilities.

One of the main advantages of feedback control is its ability to

handle disturbances and uncertainties in the system. Since the
control action is based on the actual output, the feedback control
system can automatically compensate for any disturbances or
changes, maintaining the output at the desired level. This makes
feedback control particularly suitable for complex industrial control
systems subject to a wide range of disturbances and uncertainties.

For example, in a chemical reactor, the reaction rate is

influenced by several factors, such as temperature, pressure, and
concentration of reactants. A feedback control system can
continuously monitor the reaction rate and adjust the temperature,
pressure, or reactant flow rate to maintain the desired reaction rate,
despite any changes in the process conditions or disturbances in the
system.

Feedforward Control

In feedforward control, instead of measuring the controlled

variable, disturbances affecting the process is measured. Using a
proper process model, the effect of disturbance in the variation of
controlled variable is calculated. The measured value of disturbance
is applied to the feedforward controller. The feedforward controller
evaluates the effect of disturbance on controlled variable and based
on the setpoint, generates a control signal U, which is used to
control the process.

Feedforward control is another fundamental concept in process

control, complementing the role of feedback control. Unlike
feedback control, which reacts to deviations in the output,
feedforward control is a proactive approach that anticipates changes
in the output based on changes in the input or disturbances.

The principle behind feedforward control is the prediction of

output deviations before they occur. This is achieved by measuring
the changes in the input or disturbances that are known to affect
the output, and making preemptive adjustments to the process to
counteract these changes. This proactive approach allows the
feedforward control system to maintain the output at the desired
level, even in the face of disturbances or changes in the input.

For instance, consider a heating system where ambient

temperature affects the heat input. A drop in the ambient
temperature would cause a decrease in the heat input, leading to a
decrease in the output temperature. A feedforward control system
can measure the drop in the ambient temperature and increase the
heat input in anticipation, thereby maintaining the output
temperature at the desired level.
 The effectiveness of a feedforward control system depends on
the accuracy of the prediction and the speed of the control action.
The system must be able to accurately predict the effect of the input
changes or disturbances on the output, and make the necessary
adjustments in a timely manner.

Feedforward control excels at handling disturbances that are

hard to measure at the output. It uses input or disturbance
measurements to counteract disturbances before they impact the
output, making it suitable for processes with hard-to-measure
outputs or fast disturbances.

However, feedforward control is not a standalone solution and is

often used with feedback control to achieve optimal control
performance. While feedforward control handles the disturbances
that can be measured at the input, feedback control handles the
disturbances that can only be detected at the output. Together, they
provide a comprehensive control solution that ensures the stability
and efficiency of the process.

Advantages Of The On-Off Control Strategy

1. On-off control is chosen for simplicity. The only

parameters that need to be set are the switching differential
and setpoint.
2. It is relatively cheap and it cost much less than other
process control strategies
3. it is suitable if the response delay is short when the
output is switched and the maximum rate of rise is small, or if
a very stable process isn’t needed

Disadvantages Of The On-Off Control Strategy

The main disadvantages are:

1. The controlled parameter will continuously switch around

the setpoint and
2. If the hysteresis is not correctly set, the deviation from
the setpoint could be quite significant.
Advantages of Proportional-Integral-Derivative (PID) Control
Strategy

1. An integral controller reduces the time-invariant error and

lags the output phase
2. A PI controller allows for reducing the rise time and
eliminating the steady state error.
3. A PD controller reduces the rise time, overshoot, and
oscillations in the plant.

Disadvantages of Proportional-Integral-Derivative (PID)

Control Strategy

1. One drawback of a proportional controller is that it

produces a steady-state error between the input and output
signals.
2. This error is also known as the offset. The offset becomes
constant after some time and cannot be eliminated.

Advantages Of The Model predictive control (MPC)

1. MPC is the fact that it allows the current timeslot to be

optimized, while keeping future timeslots in account.
2. MPC enables faster transient response, decreased
overshoot, and improved performance at steady-state. These
benefits surpass those offered by traditional PI or PID
controllers.

Disadvantages Of The Model predictive control (MPC)

1. MPC lies on its complex algorithm that needs longer time

than the other controller.
 Industrial Applications

On-Off Control Strategy;

1. On-off control is primarily used in non critical applications,

where the error between the setpoint and plant output can
vary with a relatively large amount. For example, temperature
control systems for houses (heating and cooling), freezers and
other home appliances are using on-off control.
2. On/Off control is one of the simplest methods for
controlling temperature. The basis of this style of control is
that full power is supplied to the system until the desired
setpoint is reached. Once the pressure feedback reaches and
surpasses the setpoint, the power is completely turned off to
the heater.
3. An on-off controller, or signaler as they're sometimes
called, will set its output so that it increases the process
whenever it is below the setpoint, it then changes its output to
decrease the process if it rises above the setpoint. In a typical
heating application, something called reverse action is used.

Proportional-Integral-Derivative (PID) Control Strategy;

1. PID controllers are widely used for process control

applications, such as chemical processing, power generation,
and manufacturing. The controller measures the process
variables, such as flow rate, pressure, or level, and adjusts the
input to maintain the desired process conditions.
2. PID controllers are widely used in a variety of
applications, including temperature control, flow control, and
motor control, due to the PID ability to provide stable and
accurate control with relatively simple implementation. Below
is an example with the Arduino-based Temperature Control
Lab.
3. Some of the main applications include: PID controllers are
extensively used to regulate temperature, including heating,
 cooling, and HVAC systems, where they help to maintain
precise temperatures in environments such as industrial
processes, buildings, and climate control systems.
4. PD controller is often used in control of moving objects
such are flying and underwater vehicles, ships, rockets etc.
One of the reason is in stabilizing effect of PD controller on
sudden changes in heading variable y(t). Often a "rate gyro"
for velocity measurement is used as sensor of heading change
of moving object.

Model predictive control (MPC);

1. Model predictive control (MPC) is a well-established

technology for advanced process control (APC) in many
industrial applications like blending, mills, kilns, boilers and
distillation columns.
2. Model predictive control (MPC) is a control scheme where
a model is used for predicting the future behavior of the
system over finite time window, the horizon.
3. Model predictive control (MPC) is an optimal-control
based method to select control inputs by minimizing an
objective function. The objective function is defined in terms of
both present and predicted system variables and is evaluated
using an explicit model to predict future process outputs.