CONTROL LOOP CHARACTERISTICS

By: John Rendell V. Morales

OBJECTIVES
The objective of this lesson is to:
1. Discuss the control loop characteristics.
2. Identify the characteristics of a single variable, compound, cascade, and multivariable
control.
3. Explain the Ziegler-Nichols method process control loop tuning.

MOTIVATION

The student is similar to an individual who has acquired detailed knowledge of all the
elements of an airplane. Such a person, however, knowledgeable about the airplane parts, is
certainly not competent to pilot the aircraft.

DEFINITION OF TERMS

Configuration - an arrangement of elements in a particular form, figure, or combination.

System connected things performing a complex whole.
Variable - an element that is liable to vary or change.
Parameters - a numerical factor forming one of a set that defines a system.
Loop a process which connects the ending to the beginning.
Compound a thing that is composed of two or more separate elements.
Cascade an arrangement in series or sequence.
Analog information represented by a continuous variable physical quantity.
Exothermic self sustaining and heat producing.
Optimum best.
Quality the degree of excellence in something.
Transient lasting only for a short time.
Nominal Value below the real value.

Deviation the action of departing from an established course.

Oscillation the back and forth movement at a regular speed.
Dynamic a process characterized by constant change.
Amplitude maximum extent of a vibration or oscillation.
Bode Plots type of graph normally used to plot the gain and phase of the control system versus
frequency.
Damped control or restrain.
Tuning adjust.
Integral it is necessary to make a whole complete.
Derivative something that is based on another source.
Empirical based on experience rather than theory.

CONTENT

CONTROL SYSTEM CONFIGURATION

- The arrangement/setting of a control system based on the goal of the process relative to
production requirements, and the physical characteristics of operations under control.

A. Single Variable Control System

- The system is designed to maintain control of a given process variable by manipulation of
-

controlling variable, regardless of the other process parameters.

The most elementary process control loop.

Types of Single Process control:

a. Independent Single Variable
- a control system which acts regardless of other control systems in a process.

Level control through direct flow control.

b. Interactive Single Variable
- a single process control system which interacts with other control systems in a process.

Two variable process control loop that interacts.

B. Compound Variable a single process control used to provide control of the relationship
between two or more variables which is often confused with cascade control.

C. Cascade Control inherent interaction occurs between two control systems to provide better
overall control.

General Features of cascade process control system

D. Multivariable Control System

- multivariable refers to the processes wherein many strongly interacting variables are
involved.

have such a complex interaction pattern that the adjustment of a single setpoint causes a
profound influence on many other control loops in the process.

Two Types of Multivariable Control:

a. Analog Control
- a multivariable control system which operates with the help of human beings or
-

personnel.
a carefully prepared instructional set must be provided to the process personnel
regarding the procedure for adjustment of setpoints.

b. Supervisory and Direct Digital Control

- uses computer to solve the type of problem presented by the multivariable control
-

system.
The computer makes any necessary adjustments of system operating point in an
incremental fashion, according to a predetermined sequence, while monitoring process

parameters for interactive effects.

Needs an algorithm that the computer follows.

CONTROL SYSTEM QUALITY

- The control system that is developed or designed should satisfy the present design criteria for
optimum performance.
-has no absolute answer.

A. Loop disturbance
- Disturbance in the process control is not always constant but the control system is
supposed to have deviations so that the disturbance will only cause minimum
-

deviation of the controlled variable to the setpoint value.

It is the disruption of the system which affects the loop process.

Three Basic Types of Disturbance

a. Transient
o Temporary change of some parameter in the system that affects the controlled
variable.
o Its nature cannot be well defined.
b. Set Point Change
o Instantaneous change of the loop setpoint from an old value to a new value.
c. Load Change
o Also occurs instantaneously in time.
o Can come from sudden parameter change of any of the process parameters that
constitute the process load.

Step function change in setpoint

Step function change in load

B. Optimum Control
- Universal definition of quality in a control system
- The best control possible.

Optimum Control and Control Quality can be defined in the terms of the three effects
resulting from a load or set point change.
-

Stability
Minimum deviation
Minimum duration

a. Stability
o The most basic characteristic in defining the process loop quality.
o The dynamic variable does not grow without limit.
Have two types of unstable responses.
o
o

Disturbance causes the dynamic variable to increase without limit.

The variable begins to execute growing oscillations, where the amplitude is
increasing without limit.

Instability in a process control loop refers to the uncontrolled growth of the controlled variable

b. Minimum Deviation
o When there is a change in set point, there will be an overshoot or undershoot of
a variable in achieving the new set point.
c. Minimum Duration
o The length of time before the controlled variable regains or adopts the setpoint
value, or at least acceptable limits of the value.
If stable operation is achieved some disturbance may cause:
a. Over Damped
o The setpoint approaches the value smoothly with no oscillations.
o The duration is not minimum
o Deviation is not minimum
o The response is safe in ensuring that no instabilities occur and that certain
maximum deviations never occur.
b. Critically Damped
o The duration is minimum for a non cycling response.
o This is the optimum response for a condition where no overshoot and
undershoot is desired.
c. Under damped
o Natural result of further adjustments.
o The deviation executes a number of oscillations about the set point.
o Possible of giving minimum deviation and duration in some cases.

Reaction to a set point change

Reaction to a load change

C. Process Loop Tuning

- Last aspect of process control technology.
- The actual start-up and adjustments of a process control loop.

a. Open Loop Transient response method

o Developed by Zeigler and Nichols
o Referred to as process reaction method.
o The basic approach is to open a process control loop so that no control action
o

occurs.
Usually done by disconnecting the controller output from the final control

element.
o All process parameters are help at their nominal values.
o Used only for systems with self regulation.
b. Zeigler Nichols method.
o Also called the ultimate cycle method.
o Based on adjusting a closed loop until steady oscillations occur.
o Control setting is based on the conditions that generate the cycling.
o Can be used for systems without self regulation.
STEPS
o Reduce integral and derivative actions to their minimum effect.
o Gradually increase the proportion gain while providing periodic small
o

disturbances to the process.

Note the critical gain at which the dynamic variable begins to exhibit steady

cycling.
Note the critical period of these oscillations measured in minutes.

c. Frequency response method

o Tuning involves using bode plots for the process and control loops.
o This method is based upon the application of bode plot stability criteria and the
effects that proportional gain, integral time, and derivative time on the bode
o

plot.
The tuning

operations

using

the

frequency

response

method

involves

adjustments of the controller parameters until the stability is proved by the

o

appropriate phase and gain margins.

If the process and control elements transfer functions are known, the correct
settings can be determined analytically. If not, the bode plot can be determined
experimentally by opening the loop and providing a variable frequency
disturbance of the controlling variable.

APPLICATION:

Independent Single Variable

The flow control system is used to regulate flow in to a tank at a fixed rate determined by the
setpoint. This system then makes adjustments in valve positions as necessary following a load
change to maintain flow rate at the setpoint value.

Level control through direct flow control.

Interacting Single Variable

The figure shows a second single variable control loop, which regulates the temperature of
liquid in the tank by adjustment of heat input. This also is a single variable loop that maintains the
liquid temperature at the setpoint value. Under nominal conditions, the flow in to the tank is held
constant and the temperature is also held constant, both at their respective setpoint values. Note,
however, that a change in the setpoint of the flow control system appears as a load change to the
temperature control system, because the fluid level in the tank or rate of passage through the tank
must change. The temperature system now responds by resetting the heat flux to accommodate the
new load and bring the temperature back to the setpoint.

Two variable process control loops that interact.

Compound Variable
A compound system for which the ratio of two flow rates is controlled e.g. control of the
ratio of two reactants. In this case, one of the flow rates is measured but allowed to float (that is,
not regulated), and the other is both measured and adjusted to provide the specified constant
ratio. In the figure, flow rate of reactant A is measured and added, with appropriate scaling, to
the measurement of flow rate B. The controller reacts to the resulting input signal by adjustment
of the control valve in the reactant B input line.

Cascade Control
Two measurements are taken from the system and each is used in its own control loop. In the
outer loop, however, the controller output is the setpoint of the inner loop. Thus, if the outer loop
controlled variable changes, the error signal that is input to the controller effects a change in
setpoint of the inner loop. Even though the measured value of the inner loop has not changed,
the inner loop experiences an error signal, and thus new output by virtue of the setpoint change.
Cascade control generally provides better control of the outer loop variable than is accomplished
through a single variable system.

Level Control through Cascade flow Control

Multivariable Control Analog

Suppose we have a reaction vessel in which two reactants are mixed, react, and the
product is drawn from the bottom. We are now concerned with controlling the reaction
rate. It is also important, however, to keep the reaction temperature and vessel pressure
below certain limits, and finally, the level is to be controlled at some nominal value. If the
reactions are exothermic, then the relation among all of these parameters can be critical.
If the temperature is low, then an indiscriminate increase in steam flow setpoint could
cause an unstable runaway of the reaction. Perhaps, in this case, the level and reaction
flow rates must be altered as the steam flow rate is increased to maintain control. The
necessary steps are often empirically determined or from numerical solutions of
complicated control equations.

Multivariable Control Supervisory and Direct Digital

A process requires adjustment of set points to increase production. A particular sequence
must be followed to provide the increase. SP1, SP2 and SP3 are the setpoints, P and PCR are
the pressure and a critical pressure, respectively, and T and TCR are the temperature and
critical temperature, respectively. Develop a flowchart that increases the setpoints as follows:
1. Increase SP1 by 1 %
2. Wait for 10 s, test for pressure compared to critical
3. If the pressure is less than critical, then
a. Decrease SP2 by %
b. Increase SP3 by %
c. Wait for T < TCR
d. Increase SP2 by 1%
e. go to step 1
4. If the pressure is above critical,
a. Decrease SP1 by %

b. Decrease SP2 by %
c. Go to step 2