Chapter 7 PDF

Process Dynamics and Control
Chapter 7
FEEDBACK CONTROLLERS
3/7/2012
CBB 3013 - Chemical Process Dynamics 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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Introduction
Consider the continuous blending process,

shown in Fig.
IP
Electrical Signal
Pneumatic signal
AC
x1, w1
xsp
x2, w2
AT
x, V
xm
x, w
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Feedback 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 transducer: I/P

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Historical Perspective of
Feedback Controllers
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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Block diagram of a feedback control

loop:
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Basic Control Modes

Proportional, Integral and Derivative
Proportional Control
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 )
(7.1)
where y sp = set point

ym = measured value of the controlled variable
(or equivalent signal from transmitter)
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Proportional Control
For proportional control, the controller output is

proportional to the error signal
p(t) p K c e(t)
where
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(7.2)
p(t) = controller output

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

Definition : Proportional band is the percentage
change in measured value required to give a 100%
change in output
100% Actuator span
PB
Kc
Input span
100%
PB
Kc
(7.3)
Applies when Kc is dimensionless
Small (narrow) PB corresponds to large Kc

Large (wide) PB corresponds to small Kc
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10
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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11
Proportional controller
In order to derive the transfer function for an ideal
proportional controller, define a deviation variable
as
p(t ) p(t ) p
(7.4)
Then (7.2) can be written as
p(t ) K c e(t )
(7.5)
Taking Laplace transform of (7.5) and rearranging

we get
P ( s)
Kc
(7.6)
E ( s)
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12
Proportional controller
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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13
Reverse or Direct Acting Controller

Kc can be made positive or negative
Reverse-Acting (Kc > 0)
output increases as input
decreases (measured
value, ym(t))"
Direct-Acting (Kc < 0)
controller output increases
as input increases
(measured value, ym(t))"
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14
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
(7.7)
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
(7.8)
15
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. (7.7) 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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16
Function of integral term
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17
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
(7.9)
The corresponding transfer function is:
P(s)
1
K c 1
E(s)
Is
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(7.10)
18
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

19
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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20
Reset windup
SP=setpoint
PV=process
variable to
control
Valve
movement
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21
Anti wind-up
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22
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
(7.11)
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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23
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)
(7.12)
The derivative control action tends to stabilize the

controlled process.
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24
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
(7.13)
Transfer function of an ideal controller (parallel form)
P(s)
1
K c 1
D s
E(s)
Is
(7.14)
Transfer function actual (Series form)

s 1 Ds 1
P(s)
K c I
E(s)
1
I D
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lead / lag
units
(7.15)
25
ON-OFF controllers
Synonyms:
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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26
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
No offset
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27

control systems
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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28

control systems
Increasing the integral time makes the controller more

sluggish.
Offset will be eliminated for all values I
For large values of I , it takes very long time to return to
the set-point.
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29
Characteristics of the Most

Commonly Used Controller Modes
1. Two Position:
Inexpensive
Extremely simple
2. Proportional:
Simple
Inherently stable when properly tuned

Easy to tune
Experiences offset at steady state
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30

3. Proportional plus reset:
No offset
Better dynamic response than reset alone

Possibilities exist for instability due to lag introduced
4. Proportional plus rate:
Stable
Less offset than proportional alone (use of higher gain
possible).
Reduces lags, i.e., more rapid response.
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31

5. Proportional plus reset plus rate:
Most complex
Rapid response
No offset
Difficult to tune
Best control if properly tuned.
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Conclusion!
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Concept of feedback control

P, I, D controller modes
Advantages and disadvantages
Motivation for additional modes
33

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Process Dynamics and Control

CBB 3013 - Chemical Process Dynamics and Control

Process Dynamics and Control

Explain the concept of feedback control

Explain P, I and D controllers

CBB 3013 - Chemical Process Dynamics and Control

Process Dynamics and Control

Consider the continuous blending process,

CBB 3013 - Chemical Process Dynamics and Control

Process Dynamics and Control

Feedback Control System

Current-to-pneumatic transducer: I/P

CBB 3013 - Chemical Process Dynamics and Control

Process Dynamics and Control

1940s Widespread acceptance of pneumatic

CBB 3013 - Chemical Process Dynamics and Control

Process Dynamics and Control

Block diagram of a feedback control

CBB 3013 - Chemical Process Dynamics and Control

Process Dynamics and Control

Basic Control Modes

where y sp = set point

CBB 3013 - Chemical Process Dynamics and Control

Process Dynamics and Control

For proportional control, the controller output is

p(t) = controller output

CBB 3013 - Chemical Process Dynamics and Control

Process Dynamics and Control

Function of proportional term

CBB 3013 - Chemical Process Dynamics and Control

Process Dynamics and Control

Proportional Band, PB:

Applies when Kc is dimensionless

Small (narrow) PB corresponds to large Kc

CBB 3013 - Chemical Process Dynamics and Control

Process Dynamics and Control

Ideal vs. actual

CBB 3013 - Chemical Process Dynamics and Control

Process Dynamics and Control

Taking Laplace transform of (7.5) and rearranging

CBB 3013 - Chemical Process Dynamics and Control

Process Dynamics and Control

CBB 3013 - Chemical Process Dynamics and Control

Process Dynamics and Control

Reverse or Direct Acting Controller

CBB 3013 - Chemical Process Dynamics and Control

Process Dynamics and Control

where I is an adjustable parameter and referred to

CBB 3013 - Chemical Process Dynamics and Control

Process Dynamics and Control

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

On the other hand, proportional controller takes immediate

CBB 3013 - Chemical Process Dynamics and Control

Process Dynamics and Control

Function of integral term

CBB 3013 - Chemical Process Dynamics and Control

Process Dynamics and Control

The corresponding transfer function is:

CBB 3013 - Chemical Process Dynamics and Control

Process Dynamics and Control

- repeats per minute

Process Dynamics and Control