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8.Why is it necessary to choose controller settings that satisfy both gain margin and
phase margin?
The gain margin provides a measure of relative stability, because it indicates how much
gain in feedback loop component can increase before instability can occur. The phase
margin also provides a measure of relative stability, because it indicates how time delay
can be included in the feedback loop before instability can occur.
a) hs 1 ft
When hs = 1 ft, the discharge will be only through pump. The mass balance around the
tank is,
dh t
qi t qo A 1
dt
dH t
Introducing deviation variables, Equation (1) becomes Qi (t ) A
dt
H S 1
Now, the transfer function
Q S AS
b) when hs = 3 ft, there will be a discharge through both pump & valve. The mass
balance around the tank is,
dh t
qi t qo q1 (t ) A
dt
Introducing deviation variables & taking Laplace Transform,
Qi S Q1 S AS H S
H S
Where Q1 S
R
H S
Qi S AS H S
R
RQi S 1 ARS H S
H S R
Qi S 1 ARS
11.b. Explain the batch process and continuous process with the help of examples. Give
the comparison between them. [16]
Continuous Process: A process in which the materials are stationary at one physical
location while being treated. A chemical that is needed in a large amount is usually
made by a continuous process. Production goes on all the time.
Batch Process: A process in which the materials [or] work flows continuously through
a plant apparatus while being treated. A chemical that is needed in a small amount or
only as needed is usually made by a batch process. Production does not go on all the
time. Pharmaceutical drugs (medicines) are made by batch processes.
12.a.i) Explain about the characteristics of on-off control and the effect of differential
gap of ON-OFF controller. [8]
The two position control action or On-Off control is most widely used type of control
for both industrial & domestic services. Two position control is a position type of
controller action in which the manipulated variable is quickly changed to either a
maximum or minimum value depending upon whether the controlled variable is
greater or less than the set point. The minimum value of the manipulated variable is
usually zero.
The equations for two-position control are
P t Pon when e 0
Where
P(t) : Manipulated variable or controller output
Pon : Maximum value of manipulated variable
Poff : Minimum value of manipulated variable
e : Deviation or actuating error
If the actuating error signal e(t) is noisy, an ON/OFF controller will try to control the
noise. This effect can be reduced by modifying the original design to include a dead
band or hysteresis band or differential gap.
Pon if e e 0
P t nochange if e0 e e0
Poff
if e e 0
The input-output relationships of the ON/OFF controllers are illustrated in fig a.
operation of the moving parts, arcing at contacts, etc., & so prolong the life of the
apparatus. The wider Differential Gap causes less frequent cycling, but at the expense of
a larger deviation from the desired set point. The narrow gap causes an increase in
cycling with a smaller deviation from the desired set point as illustrated in Fig a & b.
12.a.ii) How to avoid bump less transfer and reset windup? [8]
One common problem resulting from the ideal PID implementations is integral or reset
windup. Following a large change in set point the integral term can accumulate an error
larger than the maximal value for the regulation variable (windup), thus the system
overshoots and continues to increase until this accumulated error is unwound. This
problem can be addressed by:
Disabling the integration until the PV has entered the controllable region.
Preventing the integral term from accumulating above or below pre-determined
bounds.
Back-calculating the integral term to constrain the regulator output within
feasible bounds.
When a controller is shifted from manual to automatic mode the controller output may
jump to another value even if the control error is zero. The reason is that the integral
part of the controller is not zero. The controller is a dynamic system and the integral
part represents one state that has to be known at all regulator mode changes. The
sudden jump of the controller output can be avoided and the transfer is then called
bumpless. We consider two situations:
Shifting between manual and automatic mode
Changing regulator parameters
To achieve bumpless transfer for an analog controller going from manual into
automatic mode, the control error can be made zero by manually controlling the system
until the measurement value is brought to the set point. Then the integral part is reset
(brought to zero). Since the error is zero, bumpless transfer is obtained. The same
procedure can be used for digital controllers.
Another method is to slowly bring the setpoint value up to its target value. Initially it is
set equal to the actual measurement value and is gradually adjusted. If sufficient time is
allowed then the integral part will be so small that the transfer is bumpless. This
method may be too slow for many applications.
12.b. Draw and explain the electronic circuit for realizing the P, PI, PID, PD controller
modes. [16]
Electronic P controller:
Implementation of this mode requires a circuit that has a response given by,
p(t ) kp e(t ) po
The op amp circuit implementation of this mode of controller is shown in Fig below.
R2
The gain of the controller is , kp
R1
Electronic PI controller:
Implementation of this mode requires a circuit that has a response given by,
t
kp
p t kp e(t )
i e t dt p o
0
The op amp circuit implementation of this mode of controller is shown in Fig below.
R
The gain of the controller is , kp 2
R1
The integral time is , i = RiCi . The adjustment of this controller are the PB
R kp
through kp 2 , and integral gain is , ki
R1 RiCi
Electronic PD controller:
Implementation of this mode requires a circuit that has a response given by,
de(t )
p t kp e(t ) kp d po
dt
The op amp circuit implementation of this mode of controller is shown in Fig below.
R2
The gain of the controller is , kp . The derivative time is , d = RdCd
R1
The op amp circuit implementation of this mode of controller is shown in Fig below.
R2
The gain of the controller is , kp . The derivative time is , d = RdCd . The
R1
R2 kp
adjustment of this controller are the PB through kp , integral gain is , ki and
R1 RiCi
correct the deviation. The control output signal is sent to the positioner, which responds
by increasing or decreasing the supply air to the actuator. Positioning of the actuator
and control valve is fed back to the positioner through the feedback linkage. When the
valve has reached the position demanded by the controller, the positioner stops the
change in supply air pressure and holds the valve at the new position. This, in turn,
corrects the controlled variable’s deviation from setpoint.
For example, as the control signal increases, a valve inside the positioner admits
more supply air to the actuator. As a result, the control valve moves downward. The
linkage transmits the valve position information back to the positioner. This forms a
small internal feedback loop for the actuator. When the valve reaches the position that
correlates to the control signal, the linkage stops supply air flow to the actuator. This
causes the actuator to stop. On the other hand, if the control signal decreases, another
valve inside the positioner opens and allows the supply air pressure to decrease by
venting the supply air. This causes the valve to move upward and open. When the
valve has opened to the proper position, the positioner stops venting air from the
actuator and stops movement of the control valve.
13.a.ii) Why does the flow-lift characteristic of a control valve change after installation
of the valve in a pipeline? [8]
When the liquid enters a valve and static pressure at vena contracta drops to
less than the fluid vapor pressure (Pv) and the valve outlet pressure is also less than the
fluid vapor pressure (Pv), the condition called flashing exists. In other words fluid
enters the valve as a liquid and exists as a vapor and illustrated in Fig.b.
A third condition called cavitations occurs in a valve when the pressure drop across the
valve first results in the pressure being lowered to below the fluid vapor pressure(P v),
and then recovers to above the fluid vapor pressure(Pv).This pressure recovery causes
an implosion or collapse of the vapor bubbles formed at the vena contracta and
illustrated in Fig.c.
Flashing & cavitations must be considered to ensure proper valve sizing & to
allow selection of valve that will resist their effects. If the presence of cavitations &
flashing is neglected when valves are sized, undersized valves will be selected & rapid
valve detoriation can takes place.
13.b. ii)Working of current to pressure converter.
Fig. shows the schematic of current to pressure converter. The current input passes
through coils mounted on a core which is attracted towards a magnet, the extend of the
attraction depends on the size of the magnet. The movement of the core causes
movement of the lever about its pivot and so the movement of a flapper above the
nozzle. The position of the flapper in relation to the nozzle determines the rate at which
air can escape from the system and hence the air pressure in the system. Springs on the
flapper are used to adjust the sensitivity of the converter so that current of 4 to 20 mA
produce a pressure of 3 to 15 psi.
is first or second order or whether it is an integrator. For FRM-based tuning none of this
is required; only the process data are needed.
The process frequency response is a graph of amplitude ratio and phase vs. oscillation
or sine wave frequency.
PID Tuning Based on Frequency Response
In most processes, both the amplitude ratio and the phase angle will decrease with
increasing frequencies. Assuming that the combined phase and amplitude ratio
decreases with frequency when the process and the controller frequency responses are
combined, the following general stability rule applies: A control system will be unstable
if the open-loop frequency response has an amplitude ratio that is larger than one when
the phase lag is 180 degrees.
To provide proper tuning, a margin of safety in the gain and phase is desired. Tuning
constants are therefore adjusted to result in the highest gain at all frequencies and yet
achieve a certain margin of safety or stability.
14.b.i) Write a note on Zeigher-Nichols tuning. [8]
This method is described as a closed loop method because the controller remains in the
loop as an active controller in an automatic mode. This method is also called the
continuous cycling method, is based on adjusting a closed loop until steady oscillations
occur. The ultimate gain Kcu and ultimate period Pu is computed from the frequency
response based on the model of the process.
Zeigler Nichols method is summarized as given below:
Excluding controller, the process and measuring elements are considered in
series and by applying Bode stability criterion, the phase cross over frequency is
obtained.
According to the Bode of stability criterion, amplitude ratio is equal to unity
at phase cross over frequency p when the system is on the verge of
instability. Thus by equating G ( j ) 1 the ultimate gain Kcu is
p
determined.
The ultimate period Pu is defined as the period of the sustained cyclic that would
2
occur if a proportional controller with a gain Kcu where used and Pu
p
The Ziegler Nichols setting for controllers are determined directly from K cu and Pu
according to the rule summarized in the table below.
Type of Gc (S) kc i d
controller
P kc 0.5 Kcu ------ ------
14.b.ii) Explain the process of tuning feedback controller using process reaction curve
method. [8]
This method of tuning is an open loop method in which control action is removed from
the controller by placing it in manual mode and an open loop transient is induced by a
step change in the signal to the valve.
A typical control loop in which the control action is removed and the loop opened for
the purpose of introducing a step change M/S to the valve is shown in Fig.a
Fig. a). Block diagram of a control loop for measurement of the process reaction curve.
The step response is recorded at the output of the measuring element. The step
change to the valve is provided by the output from the controller, which is in manual
mode. The response of the system is called the process reaction curve; a typical process
reaction curve exhibits an S shape as shown in fig below
d 2c t
0 . The intersection of the tangent line with the time axis is the apparent
dt 2
transport lag (td); the apparent first order time constant ( ) is obtained from
= B /S where B – amplitude
S – slope of the curve at the point of inflection.
td - time elapsed until the system responded or dead time.
K = B/M where M is the amplitude of the step input.
Ke-t dS
Thus the approximated transfer function is G s =
τS+1
Using the values of KP, td & the controller settings are found from the relations given
in table.
Parameter Kp i d
32+ 6t d
1 τ 4 td
td td
τ 4
PID +
K t d 3 4τ t
13+8 d 11+2 t d
τ τ
Any change in either of the inputs will lead to change in the values of both the outputs.
This phenomenon persists even when two control loops are formed as in Fig. (a). This is
termed as control loop interaction. There are two types of effects of an input on an
output, viz . direct and indirect.
The control objective is to control c 1 and c 2 independently, in spite of changes in
M1 & M 2 or other load variables. Two control loops are added to the process as shown
in fig. a.
Because of the interaction present in the system, a change in R1 will also cause c 2 to
vary because a disturbance enters the lower loop through the transfer function G 21 .
Because of interaction both outputs will change if a change is made in either input
alone. If G21 and G12 provide weak interaction, the two controller will give satisfactory
control. In the extreme, if G21= G12 = 0, we have no interaction and the two control loops
are isolated from each other.
Because a manipulated input affects more than one controlled output there occurs a
problems with control loop interaction. One approach to overcome this problem is to
use de couplers.
The relationship between the input vector and the process output vector is
Y (S ) G(S ) D(S )U (S )
For a TITO process,
A three element boiler water level control system is one which typically uses the
measured water level, the steam flow rate from the boiler and the water flow rate into
the boiler to regulate the flow of into the boiler.
The three process variables are
Boiler level
Feed water flow and steam flow
Similar to feed flow, changes in steam flow can also cause large deviations in drum
level, and could possibly trip the boiler. Changes in steam flow rate are measurable and
this measurement can be used to improve level control very successfully by using a feed
forward control strategy.
For the feed forward control strategy, steam flow rate is measured and used as the set
point of the feed water flow controller. In this way the feed water flow rate is adjusted
to match the steam flow. Changes in steam flow rate will almost immediately be
counteracted by similar changes in feed water flow rate. To ensure that deviations in
drum level are also used for control, the output of the drum level controller is added to
the feed forward from steam flow. The combination of drum level measurement, steam
flow measurement, and feed flow measurement to control boiler drum level is called
three-element control.
y mGP 1 Gd 1 d
z mGP 2 Gd 2 d
Solving for d results in,
1 Gp 2
d z m
Gd 2 Gd 2
Using d in y results in,
G G
y Gp 1 d 1 Gp 2 m d 1 z
Gd 2 Gd 2
The above equation provides the needed estimator which relates the unmeasured
controlled output to measured quantities like m and z. Fig. b shows the structure of the
resulting inferential control system. Notice that the estimated value of the unmeasured
output plays the same role as a regular measured output; that is, it is compared to the
desired set point and the difference is the actuating signal for the controller.
The inferential control will function perfectly provided:
The process transfer functions Gp1, G p2, G d1, and G d2, are perfectly known.
The perfect estimator is available.
Two temperature control loops are used to keep the product compositions at their set
points. Temperatures on the 9th and 22nd trays are used as controlled variables. Reflux
flow rate and reboiler heat duty are used as the corresponding manipulated variables.
The parameters of temperature controllers are tuned by trial and error. Holdups of the
reflux drum and the reboiler are controlled by manipulating distillate and bottom
product flow rates, respectively.
Feed forward control scheme, measures the disturbance directly and then it anticipates
the effect that it will have on the process output. Subsequently, it changes the
manipulated variable by such an amount as to eliminate completely the impact of the
disturbance on the process output (controlled variable). Control action starts
immediately after a change in the disturbances has been detected. It is clear that
feedback acts after the fact in a compensatory manner, whereas feed forward acts
beforehand in an anticipatory manner.