Process Control

Block Diagrams
Chapter 4.4: Marlin
Chapter 3.52: Smith & Corripio
Chapter 4.2: Seborg
 Learning Objectives

• Understand how to represent a process using block

diagrams
• Rules for drawing block diagrams
• How to collapse and expand block diagrams

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 Review of topics so far…
Dynamic f(t) Laplace F(s) Transfer
mass & energy
Transform Function
balances
UNIT STEP f(t)
F(s)
Input increases Laplace
F(s)=1/s
By one unit Df=1 Transform

FIRST ORDER
f(t) F(s) Y(s) K

dy '
 y '  Ku '
Laplace

dt
Transform
U(s) s  1
SECOND ORDER

Y(s) K
2
d2 y '
 2
dy '
 y '  Ku '
f(t) Laplace
 2 2
dt 2
dt
Transform
U(s)  s  2s  1
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 Block Diagrams & Transfer Functions

Each TF is single input, single output

• Block diagram

Input Output
TF
G(s)

G(s) = a “general”
• In control: Transfer Function of s
– Use TF to represent dynamics
– Use Block diagram to represent the process
– Combine transfer functions

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 Combine TFs to build block diagrams

input output
unit step TF 1storder TF
1/s K/(s+1)

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 Use block diagrams
to represent other disturbances
input output
Sine TF 1storder TF
A K/(s+1)
s 2  2

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 Use block diagrams
with other transfer functions
input unit step TF 2nd order TF output
1/s K/(2s2+2ζs+1)

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Block Diagram Modelling

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Block Diagram Modelling

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Block Diagram modelling

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 Block Diagrams :
Two Tanks with Temperature Control
F0 F1

Tank 1 T2
T4
TI
Tc 0 Tc1 Tank 2
T3

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 Block Diagrams :
Two Tanks with Temperature Control
F0 s  F1 s  T2 s 
GTank1 s  
F1 s 
F1 s 
Gvalve s  
F0 s 
T4  s 
G sensor  s  
Tank 1 T2 s  T3  s 
T4 s 
TI
Tc0 s  Tc1 s  Tank 2
T3 s 
T3  s 
G Tan k 2  s  
T2  s 
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 Block diagrams of a process
F0 s  F1 s  T2 s  T3 s  T4 s 
Gvalve s  GTank1 s  GTank 2 s  Gsensor s 

F0 s  T4 s 
G s 

T4 s 
G s    Gvalve s GTank1 s GTank 2 s Gsensor s 
F0 s 
 F1 s    T2 s    T3 s    T4 s  
    
  
 0  1  2  3 
F s F s  T s  T s 
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 Block diagrams of a process
F0 s  F1 s  T2 s  T3 s  T4 s 
Gvalve s  GTank1 s  GTank 2 s  Gsensor s 
m3/s m3/s K K K

F0 s  T4 s 
G s 

T4 s 
G s   K.s
F0 s  m3

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 Non-interacting Blocks
F0 s  F1 s  T2 s  T3 s  T4 s 
Gvalve s  GTank1 s  GTank 2 s  Gsensor s 
U s Y s 

Y s n
  Gi s 
In general: U  s  i 1
Y s n Ki

If all TFs are first order: U  s  i 1  is  1
• overall gain is product of gains,
• overall TF is no longer first order,
• overall TF is slower than any single element

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 Block Diagram RULES
Allowed NOT Allowed
U1  s 
a) U s G s  Y s  a)

Y s   G s  U s  U2 s  G s  Y s 
b) U1  s 
b)
 U3  s  U2 s  G s  Y1 s 
U2 s 
U3  s   U1  s   U 2  s  Y2 s 
c) U2 s 
c) U1  s 
U1  s 
U3  s   U3  s 
U2 s 
U1  s   U 2  s   U 3  s 

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 Multiple Inputs, only one output

Responses are additive:

F1 F2
Process
Level F1 G1
L

Process
F2 + L
G2
Product +
L  F1G1  F2G2
Block Diagram Hint: Start at Output on the right, and work back towards the inputs

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 One variable has 2 output effects
• Flow of water into a tank containing salt:
• When the flow F changes, it affects the level L and the salt
concentration C
Tank
Concentration
G1=C/F
Flow C
F
Level
G2=L/F
L

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 Feedback Loop
Block Diagram
A

SP LC
101

Control Objective: Maintain tank level LT

101

Product
Approach: Manipulate input flow

SP Error Controller Signal Flow Level

Valve Tank
(LC) to valve
+
-
Signal Sensor
(LT)
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 Feedback Loop Block Diagram +
Disturbance
NOTE: Each block is described
mathematically by a transfer function.
CV = controlled variable
MV = measured variable U = signal (generic only)
SP = setpoint F = Flow (generic only)
D
E = error D = Disturbance Disturbance
LP = Level of process
LD
LD = Effect of D on L
+ CV
SP E U U F F L LP
GC  GV  GP  P
+ E U F +
-
MV MV
GS 
CV
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 More complex:
Multi input and output block diagrams

Y1  G p11U1  G p12U 2
Y2  G p 21U1  G p 22U 2

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Parallel Structures

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 Block Diagrams of
recycle systems

Feed

Product
Effluent

Exothermic
Chemical
Reactor

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 Recycle Structures

Inside Heat
exchanger

This example
is in the
tutorial!

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 Simulation of two tanks

F0 s  F1 s  T2 s  T3 s  T4 s 
Gvalve s  GTank1 s  GTank 2 s  Gsensor s 

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 Simulation of two tanks

F0 s  F1 s  T2 s  T3 s  T4 s 
Gvalve s  GTank1 s  GTank 2 s  Gsensor s 

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Simulation of tank level loop

SP Error Controller Signal Flow Level

Valve Tank
+ (LC) to valve
-

Signal Sensor
(LT)

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 Simulation of tank level loop

SP Error Controller Signal Flow Level

Valve Tank
+ (LC) to valve
-

Signal Sensor
(LT)

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Next lecture…

•Dead time
•Lead-lag
•Inverse responses

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