Faculty of Chemical Engineering

UiTM Pulau Pinang

CEV544
PROCESSCONTROLAND
INSTRUMENTATIONS
 LEARNINGOUTCOMES
At the end of this chapter, student should be
able to:

Designalternativecontrolstrategy.
BlockDiagramforFeedforward,
Cascadeand
Feedforward/feedbackControl
Unit1:Controlstrategies 8:36AM

Feedbackcontrol I/P TC

Heatexchanger TT
Manipulatedvariable
(saturatedsteam) 100C 80C

Loadvariable 30C controlledvariable

100L/min (temperatureof
(Flowofsalinesolution)
sterilisedsaline)

What is feedback control? 95C

Manipulatedvariable
A method of control that the action taken is based (Saturatedsteam)
on past result.

Merit?
Simple design. Easy to tune (for linear, fast & short
deadtime processes: flow, level & pressure).
Demerits?
Slow recovery for slow process such as temperature
control upon load disturbance or change in setpoint.
A process with long deadtime may exhibit oscillatory
process response with long settling time.
The Process
Saline solution at 30C is sterilized by heating
the solution in a heatexchanger system to
80C. The temperature of the sterilized saline
solution is maintained by regulating the
control valve of steam input to the heat
exchanger.

AbdulAzizIshak,UniversitiTeknologiMARAMalaysia(2009)
 BLOCK DIAGRAM

Feedbackcontrol
D
R
M C
Feedback Process
controller

R=setpointD=disturbance
M=manipulatedvariableC=controlledvariable
Unit1:Controlstrategies

Feedforwardcontrol I/P FFC

Cp
Ws Wp T2 T1
Hs

Manipulatedvariable
(saturatedsteam) Heatexchanger 80C
FT TT
Loadvariable 30C controlledvariable
100L/min (temperatureof
(Flowofsalinesolution)
sterilisedsaline)

What is feedforward control? 95C

Manipulatedvariable
A method of control based on process model: mass (Saturatedsteam)
and energy balances.

Merit? Characteristicoffeedforwardcontrol:
Faster recovery than cascade or SISO. Compensate Measurements of load variables online and
for disturbances before they effect the controlled Utilization of computational blocks.
variable.

Demerits?
Cannot work if any of the sensors fail esp. load
variable.
Requires process model in order to design
feedforward system.

AbdulAzizIshak,UniversitiTeknologiMARAMalaysia(2009)
 Feedforward control
D

R M C
Feedforward Process
controller

R=setpointD=disturbance
M=manipulatedvariableC=controlledvariable
Unit1:Controlstrategies
SP
Cascadecontrol I/P FC TC

FT Heatexchanger TT
Manipulatedvariable
(saturatedsteam) 100C 80C

Loadvariable 30C controlledvariable

100L/min (temperatureof
(Flowofsalinesolution)
sterilisedsaline)

What is cascade control? 95C

Manipulatedvariable
A method of control of which the inner loop (Saturatedsteam)
controller obtains its setpoint from an outer loop
controller.
Characteristic of cacade control:
Merit? Two transmitters, two controllers and one
Faster recovery time as compared to SISO feedback control valve (2level cascade).
control.

Demerits? Application: Transform from SISO to cascade

Controllability will be worst than SISO if both
strategy if faster recovery time is desired.
controllers were not properly tuned.

AbdulAzizIshak,UniversitiTeknologiMARAMalaysia(2009)
Cascade control

Y(s)
Primary Secondary C
ProcessII ProcessI
controller controller
Unit1:Controlstrategies

Feedforward/ +
I/P TC
Feedbackcontrol +

Ws
Cp
Wp T2 T1
FFC
Hs TT
Manipulatedvariable
(saturatedsteam) Heatexchanger 80C
FT TT
Loadvariable 30C controlledvariable
100L/min (temperatureof
(Flowofsalinesolution)
sterilisedsaline)

What is feedforward/feedback control? 95C

Manipulatedvariable
Feedback compensation added to feedforward (Saturatedsteam)
control

Merit?
Feedforward control compensates for major
disturbances, while feedback control compensates
for all other disturbances.

AbdulAzizIshak,UniversitiTeknologiMARAMalaysia(2009)
 D
Feedforward
controller

R +
+ M + C
Feedback Process
controller +
+
 Exercise1
Theobjectiveofthefollowingfigureisto
controlthetemperatureinthetank.Drawthe
blockdiagramforthefollowingfeedfoward
control.
 Drawtheblockdiagramforthefollowing
cascadecontrol.
SelectiveControl
and
OverrideControl
 SelectiveControland
OverrideControl
Usuallyimplementedforsafetyand
optimizationconsiderations.
Protectivestrategytomaintainprocess
variableswithinlimits.
 SelectiveControl

HigherandLowerSelectors:HS,LS
Measureonevariable
toselectthehigher(lower)ofseveral
measurementsignals
topassonastheprocessvariabletoafeedback
controller
 Example
Considertheplugflowreactorwhereanexothermic
catalyticreactiontakeplace.
Thefigureshowsthereactortemperaturecontrol
Thesensorprovidingthetemperaturemeasurement
shouldbelocatedatthehotspot.
Asthecatalystinthereactorages,orasconditions
change,thehotspotmoves.
Itisdesiredtodesignacontrolschemesothatits
measuredvariablemovesasthehotspotmoves.
 Acontrolstrategythataccomplishesthedesired
specification
Thehighselectorinthisschemeselectsthe
transmitterwiththehighestoutput,andthusthe
controlledvariableisalwaysthehighestorclosestto
thehighesttemperature.
 OverrideControl/ConstraintControl
BasicIdea:
selectorselectsbetweenthehigherorlowerofseveralcontroller
outputsforimplementation

Normaloperation:
oneprocessvariableisthecontrollingvariable

Abnormaloperation:
someotherprocessvariablebecomesthecontrollingvariableto
preventitfromexceedingaprocessorequipmentlimit

Thelimitingcontrollerissaidtooverridethenormalprocess
controller
 Example
NormalControl:levelinthetankis atheighth1

Iftheliquidleveldropbelowh2,willcause
cavitationsatthepump.
Itisnecessarytodesignacontrolschemethat
avoidsthiscondition.
 Undernormalcondition,thelowselectorselectstheoutput
signaloftheflowcontrollertomanipulatethepumpspeed.
Thelevelcontrollerisnotconnectedtothepumpbecausethe
levelisnotatanundesiredstate.
Assoonastheleveldropsbelowthesetpointonthelevel
controller,thiscontrollerwillslowdownthepumpby
reducingtheoutput.
Whenthelevelcontrolleroutputdropsbelowtheoutputof
theflowcontroller,thelowselectorselectstheoutputofthe
levelcontrollertomanipulatethepump.
levelcontrolleroverridestheflowcontroller.
Exercise
Explainthebasicprincipleof
Feedbackcontrol
Feedforwardcontrol
Cascadecontrol
Ratiocontrol
Selectivecontrol
Overridecontrol