EPC503: Process Control III

Electrical and Electronic Engineering

Ahram Canadian University

Dr. Sayed Ahmed Zaki

Assistant Prof. in Electrical Engineering
Faculty of Engineering
Cairo University
Lecture 5: Controller
Principles

Chapter 9
In: Process Control Instrumentation
Technology
 Controllers Principles

Process Control
Example
Terminologies

Controlled variable
T = F (QA , QB , QS
,TA , Ts, To )

Controlling variable TL

Process Lag (finite time delay that the process take to respond to
load change)

Self regulation (tendency of the controlled variable to settle with no

control operation)
Termenologies
DIRECT or REVERSE ACTING CONTROLLERS ?

■ In both configurations a & b, the goal is to control the level of

the liquid in the tank
■ What is the correct control action if the level becomes higher
than the desired setpoint?
 Types of Controllers
• Discontinuous
- On-Off
• Continuous
- Proportional (P)
- Integral (I)
- Derivative (D)
- PID Controller (Most used in industry)
- Others
 Discontinuous controller Mode
1. Tow position Mode / On-Off Controller

BANG BANG - Two position - On or Off Uses

a threshold to trigger
Actual Implementation
• Deadband lies between the on/off
threshold
• Usually, an acceptable error
exists

Deadband = Neutral zone = differential gap =hysteresis

□ EXAMPLE

■ 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.

SOLUTION
■ This controller is a direct-acting one, because as the process
variable increases (passes +DE of SP), the controller will increase
the control variable from 0% (OFF) to 100% (ON).

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 Discontinuous controller Mode

For a temperature control of a water tank

Example 2
Heater off , temperature drops by 2K/min.
Heater on , temperature rises by 4K/min
SP = 323 K
Controller has 4% neutral zone of SP
∆𝑇
Controller has 0.5 min lag. = 𝑆𝑙𝑜𝑝𝑒
∆𝑡
Draw the PV with upper and lower limits with corresponding CO
hysteresis band
Determine, the time of one cycle,

■ This controller is a reverse-acting one, because as the process variable

decreases (passes of SP- error), the controller will increase the control
variable from 0% (OFF) to 100% (ON).
 338 K
soluton
SP = 323 K
336 K
4% neutral zone of SP = 0.04*323 =
12.9~=13C
When falling, it will reach 323-13 = 310.
In addition to 0.5 min lag when falling = 1K ∆𝑡2
So, Pmin=310-1=309 K ∆𝑡1
Δt=323-309=14 K (It will take

∆𝑇 323 − 309 ∆𝑡3

∆𝑡1 = = = 7 𝑚𝑖𝑛
𝑠𝑙𝑜𝑝𝑒 2
When rising, it will reach 323+13 = 336
Controller has 0.5 min lag rising = 2K, So
Pmax=336+2 = 338 K 310 K

AT = 338 - 309 = 29 K (It will take 309 K

∆𝑇 338 − 309
∆𝑡2 = = = 7.25 𝑚𝑖𝑛
𝑠𝑙𝑜𝑝𝑒 4
When falling to SP again it will take
∆𝑇 338 − 323
∆𝑡3 = = = 7.5 𝑚𝑖𝑛
𝑠𝑙𝑜𝑝𝑒 2

So, Total cycle period =

309 K 338 K
7+7.25+7.5= 21.75 min
 Discontinuous controller Mode

2. Multi-position Mode
EXAMPLE
■ Graphically illustrate the reaction of a three-position controller
output to the steam heating system. Include the effect of the
controller’s lag.

Steam heating system controlled by a three-position control

 SOLUTION
■ The following figure shows the controller output (CV) for this three-
position discrete-mode controller. Note that the response plot shows that
an overshoot is present, indicating a lag in steam actuation. The same
lag also creates an undershoot condition when both V1 and V2 are ON.

(a) Response plot and (b) controller output of the heating system in
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 Discontinuous controller Mode

• In this mode, the controller output will

change initially from old point p(0) if
the error is out of range.
• Then, it will settle at any position percentage may rather than 0, 50, or
100%.
• Floating mode is similar as multi position mode but without presetting
for positions