CONTROL LOOP
CONTENTS
1. BASIC COMPONENTS OF
CONTROL LOOP
2 CONTROLLER ACTIONS
3 CONTROL STRATEGIES
4 CONTROL MODES
CONTROL LOOP
A GROUP OF COMPONENTS WORKING
TOGETHER TO CONTROL A PROCESS
BASIC COMPONENTS
SENSOR TRANSMITER CONTROLLER CONTROL VALVE
FUNCTION OF COMPONENTS
MD&A
• M FOR MEASUREMENT
• D FOR DECISION
• A FOR ACTION
• MEASUREMENT Done by sensor and transmitter
• DECISION done by controller
• ACTION done by final control element i.e.
control valve
SENSOR
A DEVICE USED TO CONVERT A PHYSICAL
VARIABLE TO AN EQUIVALENT SIGNAL,
(USUALLY ELECTRICAL)
TYPES OF SENSOR
PRESSURE SENSING ELEMENT
TEMPERATURE SENSING ELEMENT
FLOW SENSING ELEMENT
LEVEL MEASUREMENT
Note: Primary elements are float, orifice, venturi, flow nozzle, Diaphragm
level detector, magnetic type gauges, bimetallic thermometer,
thermocouple, RTD, bourdon tube gauges, diaphragm gauges, bellow
gauges.
TYPES OF SENSORS
PRESSURE TEMPERATURE FLOW LEVEL
MEASURMENT MEASURMENT MEASURMENT MEASURMENT
BIMETALLIC -TH ORIFICE PLATE DIPHERM LEVEL
DETECTOR
BOURDON TUBE
GAUGE
FLOW NOZZLE
THERMO COUPLE
WEIGHT GAUGE
DIPHERM GAUGE
RTD
MEGANETIC
BELLOWS GAUGES VENTURI TUBE TYPE GAUGE
TYPES OF SENSOR
THERMOMETER RANGES
• LIQUID FILLED GLASS THER/ 200- 620C
• BIMETALIC 130- 540
• THERMOCOUPLE 185- 1620
• RTD 270- 650
• PYROMETER 1100-1760
• BIMETALIC THERMOMETER/
• IT WORKS ON THE PRINCIPLE OF UNEVEN EXPANSION OF
TWO DIFFERENT METALS ON HEATING.
• THERMOCOUPLE
• IT PRODUSE ELECTRICT CURRENT WHEN SUBJECTED TO
• TEMPERATURE CHANGES.
• RTD. IT CONVERT TEMP. CHANGES TO VOLTAGE SINALS BY
MEASURING RESISTANCE.
TRANSMITTER
TYPES OF TRANSMITTER
Pneumatic Transmitters.
Electronic Transmitters.
Pneumatic Transmitters.
Convert the measured value into an air pressure signal.
Electronic Transmitters.
Employ electrical energy to convert the measured value into an electrical
signal.
TRANSMITTER SIGNALS
1. Pneumatic Signal
2. Electronic Signal
3. Digital Signal
4. Hydraulic Signal
CONTROLLER
TYPES OF CONTROLLERS
1. PNEUMATIC
CONTROLLERS.
2. ELECTRONIC
CONTROLLERS.
3. MICRO PROCESSOR
BASED
CONTROLLERS.
CONVENTIONAL CONTROL LOOP
INPUT BARRIER OUTPUT BARRIER
Rack room
(4-20 mA)
(4-20 mA)
Card Card
CONTROLLER
%age PSI mA VDC
( 0.25 - 1.25 V ) E/P
PV SP-PV = ERROR +/- FAS 20 PSI 0 3 4 .25
Process variable (4-20 mA)
25 6 8 .5
50 9 12 .75
Set Point 75 12 16 1.0
100 15 20 1.25
OUTPUT
(3 - 15 PSI)
POSITI ONER
INSTRUMENT
FAS = FILTERED AIR SUPPLY
I/P = CURRENT TO PNEUMATIC CONVERTER
Transmitter
SUPPLY 22 PSI
FT CONTROL VALVE
FRC
Regulator
AUS/- 7 kg
TYPES OF CONTROLLERS
ACTION
1- DIRECT ACTION CONTROLLER:-
IF MEASURED VALUE (P-V) OF CONTROLLER IS
INCREASING FROM SET POINT AND OUT PUT OF
CONTROLLER IS ALSO INCREASING THEN
CONTROLLER IS SAID TO BE DIRECT ACTING
2- REVERSE ACTION CONTRLLER:-
IF MEASURED VALUE (P-V) OF CONTROLLER IS
INCREASING FROM SET POINT AND OUT PUT OF
CONTROLLER IS DECREASING THEN CONTROLLER IS
SAID TO BE REVERSE ACTING
Direct controller actions
TAYLOR
TAYLOR
FIXED TAPE SCALE
SET-POINT INDICATOR
SET-POINT
ADJUSTMENT
UP SWITCH
OUT F S5
OUT F
OUTPUT SWITCH FAST SWITCH
S2 S4
DOWN SWITCH
S3
reverse controller actions
TAYLOR
TAYLOR
FIXED TAPE SCALE
SET-POINT INDICATOR
SET-POINT
ADJUSTMENT
UP SWITCH
OUT F S5
OUT F
OUTPUT SWITCH FAST SWITCH
S2 S4
DOWN SWITCH
S3
CONTROL VALVE SEAT
AIR
POSITION AIR TO OPEN AIR
AIR TO CLOSE
AIR TO OPEN
AIR
AIR AIR TO CLOSE
CONTROL STATEGIES
1. OPEN LOOP CONTROL
2. CLOSE LOOP CONTROL
2.1- FEED FORWARD CONTROL
2.2- FEED BACK CONTROL
2.3- CASCADE CONTROL
2.4- SPLIT RANGE CONTROL
OPEN LOOP: -
A CONTROL LOOP
WITHOUT FEED BACK
CLOSED LOOP
A CONTROL LOOP WITH
FEED BACK
FEED FORWARD CONTROL
IN THIS CONTROL STATEGY THE CHANGE IN
PROCESS VARRIABLE IS NOTED BEFORE IT
ENTERS TO THE SYSTEM AND CORRECTIVE
ACTIONS ARE TAKEN TO COMPENSATE THE
CHANGE
FEED BACK
A DIFFRENCE B/W SP VALUE & THE MEASURED PV VALUE
RESULTS IN A SYSTEMS CORRECTION THAT REDUCES SYSTEM
ERROR TO AN ACCEPTABLE VALUE.
ADVANTAGES DISADVANTAGES
1. COMPENSATE FOR THE LOOP WILL TAKE
ALL KINDS OF ACTION AFTER DEVIATION
PROCESS CHANGES OF PROCESS VARRAIBLE
2. IF THE PROCESS FROM THE SET POINT.
VARRAIBLE CHANGES, IT MEANS THE CHANGE
THE CONTROLLER WILL PROPAGATES
CHANGE ITS OUT PUT TO THROUGH ENTIRE
RETURN THE PROCESS PROCESS BEFORE
VARRIABLE TO THE THE FEED BACK CONTROL
SET POINT SCHEME CAN
IRRESPECTIVE OF COMPENSATE FOR IT
TYPE OF CHANGE
CASCADE CONTROL LOOP
Two or more control loops are
connected in series to provide
the proper control.
One loop is primary control &
the other is secondary control
loop.
The output signal from the
primary controller serves as the
set point of secondary
controller.
The secondary controller in
terms take information from
process & adjust the valve.
SPLIT RANGE CONTROL
In this control
strategy the control
action is performed
by two or more final
control elements.
The operating range
of the control valve is
splitted in to sub
ranges.
Control valve will full
open or full close
within these sub
operating ranges.
TYPES OF CONTROL MODE
1. On-Off
2. Proportional OR P
3. Proportional with reset OR PI
4. Proportional with rate OR PD
5. Proportional with reset & rate OR PID
ON-OFF ACTION
A two position controller (ON-OFF ACTION).
It can position a valve in only two different
settings either fully open or fully closed.
Its action for a large off set is same as small
off set.
This type of controller cannot maintain a
smooth even flow rate.
Temp
ON –OFF ACTION
Valve Open
Valve Closed
PROPORTIONAL ACTION
• Proportional or throttling control is used to
meet the demand of more precise
regulation of the controlled variable.
• The controller response to process change
is proportional to the change.
• The variation in the output is proportional
to the deviation.
RESPONSE CURVES FOR PROPORTIONAL CONTROLLERS
410°F
405°F
Temperature
Setpoint
400°F
Proportional band
A - too wide
B - too narrow
C - Correct
Decreased heat demand
Time
PRPORTIONAL WITH RESET (INTEGRAL)
ACTION
• For most systems, proportional control
would be quite acceptable except for the
existence of offset.
• Most process controllers contain an
additional mode namely the reset mode.
• That will automatically eliminate the offset.
• Where as the output of the proportional is
based on error, the output of the reset
mode is based on the integral of the error.
RESPONSE CURVES FOR PI CONTROLLER
410°F
Temperature stabilizes here without
reset
B
Temperature
Setpoint
400°F
A
integral time
A - too short
B - too long
C - Correct
Decreased heat demand
390°F
Time
PRPORTIONAL WITH RATE DERIVATIVE
ACTION
• The proportional mode respond the size of error.
• The derivative mode respond to how quickly the
error is changing.
• The derivative output is proportional to the rate
of change of error.
• The greater the rate of change, the greater the
output will change due to derivative response.
• The derivative action hold the output as long as
measurement stops changing.
RESPONSE CURVES FOR PD CONTROLLERS
Derivative time
410°F
A - too Long
B - too Short
C - Correct
A
Temperature
C
400°F
Decreased heat demand
390°F
Time
THREE OBJECTIVES OF CLOSED LOOP CONTROL
SYSTEM
Minimize the maximum error
Allowable Residual error
PV Maximum error
error
SP Time
Minimize the residual error
Setting time
Minimize the setting time
DIFFERENCE BETWEEN CONTROL
MODE
P PD ( TIME TO TIME
S PI ( TIME TO TIME ERROR
OFF SET AS PER ERROR RATE OF
NO. CALCULATION CHANGE OF ERROR)
CHANGE
RESET
SP PV ERROR OUTPUT SP PV ERROR OUTPUT IN OUTPUT
TIME
ERROR
01 38 39 1 6mA 38 39 1 20sec 8mA 0.4/sec LESS
for20sec
02 38 40 2 10mA 38 39 1 5sec 8mA for 0.2/sec MORE
5 sec
THANK YOU
OFFSET
Difference between PV & SP.
OSCILLATION
Bouncing of PV above and below SP.
PROPORTIONAL BAND
Due to error, controller sends range of
signals to control valve.
change in input
PB = ------------------- x 100
change in output
THERMOMETR RANTHGES
THERMOMETERS RANGE
LIQUID FILLED GLASSES THERM; 200-620 °C
BIMETALLIC THERM; 130- 540
THERMO COUPLE 185-1620
RTD 270- 650
PYROMETER 1100-1760
1* BIMETALIC THER.
IT WORKS ON THE PRINCIPLE OF UN EVEN EXPASION OF TWO
DIFFERENT METALS.
2* THERMOCOUPLE.
THERMO COUPLES PRODUCE ELECTRIC CURRENT WHEN
SUBJECTED TO TEMPERATURE CHANGE.
3* RTD.
CONVERT TEMPERATURE CHANGES TO VOLTAGE SIGNALS BY
MEASURING RESISTANCE.
( METAL USE IN SENSOR, PLATNUM, COPPER OR NICKEL .
4* PYROMETER.
SERIES OF ELECTROMAGNETIC RADIATION.
IT DETERMINING A BODY S TEMPERATURE BY MEASURING ITS
ELECTROMAGNETIC RADIATION.
IMPORTANT TERMS
• 1 RANGE.
VALUE OF VARIABLE FROM ONE POINT TO AN OTHER
POINT.
• 2 SPANE .
DIFFERENCE BETWEEN UPPER AND LOWER RANGE.
3 DEAD BAND.
THAT PART OF THE RANGE THROUGH WITCH AN
INPUT CHANGE WILL CAUSE NO OUT PUT CHANGE.
PRESSURE SENSING
• BOURDON TUBE.
– EXPANDABLE PRESSURE SENSING ELEMENT.
• DIAPHRAGM GAGES.
• FLEXIBLE DISK THAT CHANGES SHAPE WHEN THE PROCESS
PRESSURE CHANGES.
• BELLOWS GAGE
• EXPONDS OR CONTRACTS IN RESPONSE TO PRESSURE
CHANGES/
CONTROLLER
