Chapter 8

Process Dynamics and Control
Chapter 8
FEEDBACK CONTROLLERS
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CCB3013 - Chemical Process Dynamics, Instrumentation 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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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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Introduction
Consider the following blending process (Fig. 8.1).
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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 (I/P) transducer

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Block Diagram
Figs. 8.2 & 8.3: Flow control system/loop (top) and its
block diagram (bottom).
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Block Diagram
Fig. 11.8: Standard block diagram for a feedback

control system.
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Proportional, Integral and Derivative
THREE MODE CONTROLLER
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CCB3013 - Chemical Process Dynamics, Instrumentation
Feedback Control Error

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

ym = 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
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(6.2)
p(t) = controller output

p = bias value (adjustable, manual reset)
Kc = controller gain (dimensionless, adjustable,
tuning)
10
Function of proportional term
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11
Proportional Band, PB:

Definition :
100%
PB
Kc
(6.3)
Applies when Kc is dimensionless
Small (narrow) PB corresponds to large Kc

Large (wide) PB corresponds to small Kc
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12
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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13
Remarks
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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14
Ideal vs. actual

Ideal controller does not
include physical limits
A controller saturates
when its output reaches a
physical limit, either pmax
or pmin.
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15
Reverse or Direct Acting Controller

Kc can be made positive or negative
Reverse-Acting (Kc > 0)
controller output (p)
increases as input (ym)
decreases
p p Kc e p Kc ( ySP ym )
Direct-Acting (Kc < 0)

controller output (p)
increases as input (ym)
increases
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16
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:
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P(s)
1
E(s) I s
(6.8)
17
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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18
Function of integral term
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19
PI Controller
Integral control is used in conjunction with
proportional control as the proportional-integral (PI)
controller:
t
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
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(6.10)
20
PI Controller
The response of the PI controller to a unit step
change in e(t) is shown in Fig.
1/ I
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- repeats per minute, aka, reset rate.

21
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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22
Reset windup
SP=setpoint
PV=process
variable to
control
Valve
movement
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23
Anti wind-up
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24
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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25
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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26
PID Controller
PID control algorithm is given by
t
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
K c 1
D s
E(s)
Is
(6.14)
Transfer function actual (Series form)

s 1 D s 1
P(s)
K c I
E(s)
1
I D
= [0.05, 0.2]
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(6.15)
Derivative filter
27
ON-OFF controllers
(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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28
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
Response time reduced
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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 D tends to improve the
response by reducing the maximum
deviation, response time, and degree
of oscillation
If D is too large, measurement noise
is amplified and the response may
become oscillatory.
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30
Increasing I makes the controller more sluggish.
Offset will be eliminated for all values of I.

For large values of I, it takes very long time to return to
the set-point.
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31
Summary
1. Two Position (On-Off):
Inexpensive
Extremely simple
2. Proportional:
Simple
Inherently stable when properly tuned

Easy to tune
Experiences offset at steady state
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32
3. Proportional + Integral:
No offset
Better dynamic response than reset alone
Possibilities exist for instability due to lag introduced
4. Proportional + Derivative:
Stable
Less offset than proportional alone (use of higher gain
possible).
Faster response time.
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5. Proportional + Integral + Derivative :

Most complex
Rapid response
No offset
Difficult to tune
Best control if properly tuned.
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34
Conclusion
Concept of feedback control
P, I, D controller modes
ON-OFF as a special case of P-controller
Advantages and disadvantages

Motivation for additional modes
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35

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Process Dynamics and Control

CCB3013 - Chemical Process Dynamics, Instrumentation and Control

Process Dynamics and Control

Explain the concept of feedback control

Explain P, I and D controllers

CCB3013 - Chemical Process Dynamics, Instrumentation and Control

Process Dynamics and Control

1940s Widespread acceptance of pneumatic

CCB3013 - Chemical Process Dynamics, Instrumentation and Control

Process Dynamics and Control

CCB3013 - Chemical Process Dynamics, Instrumentation and Control

Process Dynamics and Control

Measurement : Composition AnalyzerTransmitter (AT)

Current-to-pneumatic (I/P) transducer

CCB3013 - Chemical Process Dynamics, Instrumentation and Control

Process Dynamics and Control

CCB3013 - Chemical Process Dynamics, Instrumentation and Control

Process Dynamics and Control

Fig. 11.8: Standard block diagram for a feedback

CCB3013 - Chemical Process Dynamics, Instrumentation and Control

Process Dynamics and Control

Proportional, Integral and Derivative

THREE MODE CONTROLLER

CCB3013 - Chemical Process Dynamics, Instrumentation

Process Dynamics and Control

Feedback Control Error

where y sp = set point

CCB3013 - Chemical Process Dynamics, Instrumentation and Control

Process Dynamics and Control

For proportional control, the controller output is

p(t) = controller output

CCB3013 - Chemical Process Dynamics, Instrumentation and Control

Process Dynamics and Control

Function of proportional term

CCB3013 - Chemical Process Dynamics, Instrumentation and Control

Process Dynamics and Control

Proportional Band, PB:

Applies when Kc is dimensionless

Small (narrow) PB corresponds to large Kc

CCB3013 - Chemical Process Dynamics, Instrumentation and Control

Process Dynamics and Control

Taking Laplace transform of (6.5) and rearranging

CCB3013 - Chemical Process Dynamics, Instrumentation and Control

Process Dynamics and Control

CCB3013 - Chemical Process Dynamics, Instrumentation and Control

Process Dynamics and Control

Ideal vs. actual

CCB3013 - Chemical Process Dynamics, Instrumentation and Control

Process Dynamics and Control

Reverse or Direct Acting Controller

Direct-Acting (Kc < 0)

CCB3013 - Chemical Process Dynamics, Instrumentation and Control

Process Dynamics and Control

where I is an adjustable parameter and referred to

CCB3013 - Chemical Process Dynamics, Instrumentation

Process Dynamics and Control

For the process being controlled to be at steady state, the

CCB3013 - Chemical Process Dynamics, Instrumentation and Control

Process Dynamics and Control

Function of integral term

CCB3013 - Chemical Process Dynamics, Instrumentation and Control

Process Dynamics and Control

The corresponding transfer function is:

CCB3013 - Chemical Process Dynamics, Instrumentation and Control