CONTROL

LOOP
PRESENTED BY:
AMANULLAH SHAR

REVIEWED BY:
SAB / SARDAR ALI
 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

BOURDON TUBE DETECTOR

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:-
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
POSITION
AIR 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