20150827-25-Evolution of Control Modes

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to
Evolution
of
Control
Modes
29-08-2015 Instructor: Narendra Gole 1
Process control
Process control is an extremely important field of engineering.

However, all processes are not controllable. For example
terestial events can only be observed,
observed they can not be
controlled. So, for conceiving any control, the controllability
of the p
process needs to be established first.
Having established the controllability of the process, we have

to identify the parameter to be controlled. For example let
us assume that we wish to control the room temperature.
Then room temperature becomes the controlled
parameter. How can room temperature be controlled? Simple
answer is using g a fan. So,, the fan becomes the final control
element (FCE). The ON/OFF switch or the regulator
becomes the controller.
Evolution of
control modes-I
1. On/Off Control:
Consider the situation below.
H1 Heater’s
H1- H t ’ h heating
ti ratet can be
b
1, 2 or 3 kws
H2- Heat leak rate of the system,
H2 system
let us say 0.5 kws
Heat energy flow Power KW KW KW

H1 Energy Input Rate in KW 1 2 3
H2 Energy Leakage Rate in 0.5 0.5 0.5
KW at the set point (SP)
Effective heat rate (H1‐H2) kw 0.5 1.5 2.5
Cycling Period T1 T2 T3
Frequency of oscillation F1 F2 F3
The frequency ‘f’ & amplitude of temp. oscillations depend

on: 1. Heating/Cooling time constant of the system and
2 Rate of energy accumulation (H1-
2. (H1 H2).
H2)
Then T1>T2>T3 and f3 >f2 >f1

The frequency of energy input devices also depends on
heat rates.
High switching frequency can cause damage to the

energy input switching device.
ON/OFF controls are thus preferred only if the system

capacity to store energy is high.
The amplitude of oscillation can be limited to the

acceptable level by properly choosing H1.
H1 But then there
also we end up in to a contradictory requirement. Namely,
if H1 is increased then the amplitude
p increases and if H1
is decreased then the period increases, making the
system control sluggish.
Example 1.
Another thermocouple mounted in thermowell, in the tank

as shown, has a time constant of 100 seconds and is used
to measure the tank temperature varying as above. How
much is the amplitude variation of the temperature as
recorded by this thermocouple and what is its phase shift,
shift
compared with the actual temperature variation.
Solution:
Assume that, amplitude A=100°C,

C the Set
S Point SP=400°C
S C
and the signal varies with a frequency of 0.1 Hz. The
attenuation suffered by the recorded signal using the
thermocouple having time constant of 100 seconds can
be g
given as:
Wr is the signal freq. relative to the corner freq. of the
thermocouple response, in Hz/Hz units. Here
Wr =0.1 Hz/( 1/100s )=10 Hz/Hz. Hence attenuation=0.l,
and the amplitude of the recorded signal would be 10
times reduced. Resulting phase shift: Ф = tan wr = 84.28°.
2. On/Off control with differential gap:
‘A' is increased by (SPH-SPL)/2, but ‘f' is reduced in the

process. We can adjust the diff.gap and locate it around the
SP at a suitable place so as to meet the process needs.
3. Two-Step Control
The cost of fabrication increases with ‘n'.

n step control as ‘n'
‘n' n tends to ‘∞'
∞ becomes a proportional
control if the step size is equal, since
((Energy
gy input)
p ) α ((Deviation of
controlled parameter from the SP) .
• Frequency of switching for each heater element is
reduced.
d d
• Amplitude of temperature oscillations is reduced
because of gradual switching of energy input devices.
devices
• Frequency of temperature oscillations is reduced.
• Temperature
p remains closer to the SP since its
variations are gradual and are of lower peak amplitude.
Th number
The b off steps
t ‘n'
‘ ' can thus
th beb increased
i d to
t achieve
hi
• reduced frequency of switching individual elements of

the energy input device, and
• close control w.r.t. the SP.
4.
Floating
control
action
The Final Control Element (FCE) is made to move
towards one of the two extremes, depending upon
whether the controlled parameter is above or below the
SP, with a predetermined speed.
In the modes of control seen earlier, the position of the

C was
FCE as made
ade to vary
a y in acco
accordance
da ce with
t tthe
e de
deviation
at o
in the controlled parameter from the set point. Here in
the floating control mode, it is not the position but the
speed of travel of the FCE which is varied in accordance
with the deviation of the controlled parameter from the
set point
point.
With the introduction of the neutral zone,, the FCE can be

made motionless at or near the set point (i.e. its rate of
travel is made zero). This scheme can reduce deviation
almost to zero and can, if correctly adjusted, eliminate
FCE motion, except following
29-08-2015 load or set point changes.
Instructor: Narendra Gole 12
5. Proportional Control
dl 1
 ( fi  fo )
dt A
Where A - Area of tank.,
So, sL(s)-Lo = [Fi(s)-Fo(s)]/A ------------ (1)
and L (s) = [Fi(s)-Fo(s)]/sA + Lo/s ------------ (2)
Also fi = bKv + (LR-l)KpKv
H
Hence Fi( ) = bKv/s
Fi(s) / +[ LR/s-L(s)]
/ L( )] KpKv ------------ (3)
Therefore from (1) and (3) we get
L(s) = ( Lo + [bKv + LR KpKv - Fo(s)]/sA )/( s+ KpKv/A)
------------- (4)
Assume that the initial value of level is set at SP, i.e. Lo=LR
Thus Lss = Lim ss->0

>0 sL(s) = Steady state value of level
= LR + [b/Kp - Fo(s)/ KpKv ]
This clearly shows that level settles at the SP only for the
initial load value. For any other value of the load, there will
be a steady state error (offset).
This error is observed to be inversely proportional to the gain
The proportional controller characteristic is shown below.
From eq
eq. (1) and (3) discussed earlier
earlier, of level control system
can be represented, block diagram as follows:
LO=LR is adjusted manually and then auto-control is put ‘ON'.
A K → ∞, offset
As ff t → 0.
0
But this is impossible to achieve

achieve.
Hence to reduce offset, either bias is adjusted

j or ‘LR' is
adjusted such that the output with the offset is equal to SP.
Thi iis a manuall reset.

This t
6. Proportional plus reset control
Automatic reset can be achieved by integrating the error
signal
g over time and proportionately y add a component in
the controller output. This is a proportional plus reset control
mode. Where:
Co = Kp (e + [1/TI]∫e dt) or
Co(s) = Kp(1 + 1/TIs)e(s) becomes the controller equation
equation.
Putting Kp (1+1/TIs)=Kp (TIs+1)/TIs for Kp in equation (4)

we get:
Lss = lim
li sL(s)
L( ) as s →0
0 = LR
Thus it is clear that integral action totally removes "offset"

offset .
Integral time ‘TI‘ is the time required for the reset action to
produce the output that would be produced by proportional
action for a step disturbance. However, the ‘reset' action has
t accumulate
to l t error for
f quite
it some titime tto force
f the
th ‘offset'
‘ ff t' to
t
zero. Hence this is an inherently slow process.
Therefore an action proportional to the rate of change of error
(slope of error curve) is added. This anticipates the correction
required in future and corrects controlled parameter in the
present, causing it to quickly converge to the steady state.
7. Proportional + reset + rate control
Which is Co = Kp e + (Kp/TI) ∫e dt) + (Kp TI) de/dt
Thus Co(s) = Kp(1 + 1/TIs+ TIs) e(s)
becomes the controller equation. 3-mode controller overcomes
1.instability (proportional)
2.offset (reset action) as well as
3 l
3.sluggish
i h response (rate
( t action)
ti )
8. Various types of process time lags
S Instantaneous Distance- Capacity T
Transfer
f Lag
L
response Velocity Lag Lag
1
2 Output follows Output is Output Output rises

the input delayed slowly rises sluggishly
3 E
Example:l Example:
E l Example:
E l Control
C t l action
ti
Pressure Process with Liquid level passes through
control of liquid dead time control resistive network
filled vessels
4 Use wide Use wide PB Use narrow Use PD or PID
Proportional and slow reset PB or on/off modes of control
Band (PB) and Do not use rate control with
slow reset action diff gap
diff.
Examples
Instantaneous Distance- Capacity Lag Transfer
response Velocity Lag Lag
After you press
y p Water storage
g Keep a ketle full
p 2 adjacant
j
a button an tank located on a of water on the rooms are
incandescent hill 10 km away gas stove. The cooled by a
lamp starts from a township water desert
glowing almost receiving the temperature cooler
instantaneously
instantaneously. water After
water. After starts rising
starts rising placed in
placed in
opening the slowly, untill one room.
outlet at the tank, , the whole The other
water reaches the capacityful room cools
town after this water heats up. only after
delay. this dalay.
9. Various types of control systems
(1) Feed Back Control System (FBCS)
1. Corrective control
2 Corrects for load changes on sensing their effect
2.
3. Closed loop control
Controlled parameter is fed back for correcting deviations.
(2) Feed Forward Control System (FFCS)
a)) P
Preventive
i controll
b) Takes care of known incoming loads before they affect
the process
c) Open loop control & so cannot consider unknown
loads
Load variation is fed to the controller before it affects the
process.
(3) Cascade control system (CCS)
Set point of one system (shown by dotted rectangle)

is controlled by another controller
controller.
(4) Adaptive control system (ACS)
Parameters of controller are varied

to meet environmental effects

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Wecome

Process control is an extremely important field of engineering.

Having established the controllability of the process, we have

Heat energy flow Power KW KW KW

The frequency ‘f’ & amplitude of temp. oscillations depend

Then T1>T2>T3 and f3 >f2 >f1

High switching frequency can cause damage to the

ON/OFF controls are thus preferred only if the system

The amplitude of oscillation can be limited to the

Another thermocouple mounted in thermowell, in the tank

Assume that, amplitude A=100°C,

‘A' is increased by (SPH-SPL)/2, but ‘f' is reduced in the

The cost of fabrication increases with ‘n'.

• reduced frequency of switching individual elements of

In the modes of control seen earlier, the position of the

With the introduction of the neutral zone,, the FCE can be

Thus Lss = Lim ss->0

This error is observed to be inversely proportional to the gain

LO=LR is adjusted manually and then auto-control is put ‘ON'.

But this is impossible to achieve

Hence to reduce offset, either bias is adjusted

Thi iis a manuall reset.

Putting Kp (1+1/TIs)=Kp (TIs+1)/TIs for Kp in equation (4)

Thus it is clear that integral action totally removes "offset"

2 Output follows Output is Output Output rises

Set point of one system (shown by dotted rectangle)

Parameters of controller are varied

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