PROCESS CONTROLLERS 1

From Books
CH5
Programmable Controllers Theory and Implementation
CH1
Instrumentation & Control
Process Control Fundamentals

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 PROCESS CONTROLLERS
A controller can have one of two modes that
describes its output signal:
• discrete (ON/OFF) mode
• continuous (analog) mode
Proportional Control (P)
Proportional +Integral Control(PI)
Proportional + Integral + Derivative (PID)

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TWO-POSITION DISCRETE CONTROLLERS
A two-position controller, also called an ON/OFF
controller, is the most basic type of process controller.

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The action of an ON/OFF controller can be described by:
(ON) IF error > - ΔE
(OFF) IF error < +ΔE

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EXAMPLE 1:
A two-position discrete-mode controller controls a
cooling system,
maintaining the system at a set point of 70°F. The
controller has a Deadband of ±3°F to allow for
deviations from the set point. (a) Plot the relationship
between the controller’s ON/OFF output, the process
variable response, and the error curve, disregarding
any overshoot or undershoot conditions. (b)
Determine whether this is a direct- or reverse-acting
controller.
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SOLUTION
(a) Figure 1a illustrates the response of the
process variable
(temperature) to the controller’s ON/OFF output.
Figure 1b shows the hysteresis curve of the
controller output versus the error.
(b) This controller is a reverse-acting one,
because as the process variable increases
The controller will decrease the control variable
from 1000% (ON) to 0% (OFF).

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EXAMPLE -2
Figure below shows a mixer tank that is heated by an
ON/OFF heating control system. The set point temperature
is 200°F with a dead band deviation of ±5% from the set
point. When the heater is not on( OFF), the system
linearly loses (cools) 4°F per minute; when the heater is
applied, the system gains 8°F per minute. The system
starting point is at the set point temperature with the
heater in the OFF mode. (a) Plot the oscillation response
(cycle period) of the system and controller, and (b)
calculate the response in part (a) taking into
consideration a heater lag time of 30 seconds (0.5 min).

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SOLUTION:
(a) Figure 15-16 illustrates the response of the process
variable over time, along with the controller’s output status.
The upper value of the deadband ( ΔE = +5%) is 210°F, while
the lower value (ΔE = –5%) is 190°F. This curve starts at 200°F
(SP) and declines at a rate of 4°F/min until the temperature
equals 190°F (SP – ΔE). At 190°F, the controller turns ON and
starts heating the system at a rate of 8°F/min until the
temperature reaches 210°F (SP + ΔE), at which point, the
controller turns off the heater. The process variable starts to
cool off again at the rate of 4°F/min until the temperature
reaches SP – ΔE, where the cycle is repeated.

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Controller output current loops

The simplest form of 4-20 mA current loop is the type

used to represent the output of a process controller,
sending a command signal to a final control element.
Here, the controller both supplies
the electrical power and regulates the DC current to the
final control element, which acts as an electrical load. To
illustrate, consider the example of a controller sending a
4-20 mA signal to an I/P (current-to-pressure) signal
converter, which then pneumatically drives a control
valve:

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