Princess Sumaya Univ.

Electronic Engineering Dept.

3442
Industrial Instruments 2
Chapter 9
Controller Principles
Dr. Bassam Kahhaleh
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9: Controller Principles
Process Characteristics
Process Equation
A process-control loop regulates some dynamic
variable in a process.
Example:
The control of liquid
temperature in a tank.
The controlled variable is
the liquid temperature TL

TL is a function:
TL = F(QA, QB, QS, TA, TS, TO)
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9: Controller Principles
Process Characteristics
Process Load

Identify a set of values for
the process parameters
that results in the
controlled variable having
the setpoint value.

This set = nominal set.

Process load
= all parameter set the controlled variable
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9: Controller Principles
Process Characteristics
Process Change
Process Load Change
A parameter changes value from its nominal value
causes the controlled value to change from its
setpoint.
Transient Change
A temporary change of a parameter value.
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9: Controller Principles
Process Characteristics
Process Lag
The time it takes for the process to respond
after a process load or transient change
occurs, to ensure that the controlled variable
returns to the setpoint.
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9: Controller Principles
Process Characteristics
Self Regulation
The tendency of some processes to adopt a
specific value of the controlled variable for
nominal load with no control operations.
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9: Controller Principles
Control System Parameters
Error
e = r b.

Percentage

c c min
cp x 100%
c max c min
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9: Controller Principles
Control System Parameters
p: percentage

u: actual

r b
Error ep x 100%
b max b min

Control Parameter u u min

p x 100%
u max u min
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9: Controller Principles
Control System Parameters
Example
A controller outputs a 4 20 mA signal to control
motor speed from 140 600 RPM with a linear
dependence. Calculate: Speed (RPM)
a) Current corresponding
600
to 310 RPM
310
b) The value of (a) in
percent. 140

I (mA)
4 20
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9: Controller Principles
Control System Parameters
Example Speed (RPM)
Sp = m I + S o
600
140 = 4 m + So
310
600 = 20 m + So 140
m = 28.75 rpm/mA
I (mA)
So = 25 rpm
4 20
310 = 28.75 I + 25
9.91 4
I = 9.91 mA p x 100% 36.9 %
20 4
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9: Controller Principles
Control System Parameters
Control Lag
The time it takes for the final control element to adopt a
new value (as required by the process-control loop
output) in response to a sudden change in the
controlled variable.
Dead Time
The elapsed time between the instant a deviation (error)
occurs and when the corrective action first occurs.
Cycling
The cycling of the variable above and below the
setpoint value.
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9: Controller Principles
Control System Parameters

Controller Modes
Continuous / Discontinuous
Smooth variation of the control parameter versus
ON / OFF.
Reverse / Direct Action
An increasing value of the controlled variable
causes an decreasing / increasing value of the
controller output.
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9: Controller Principles
Discontinuous Controller Modes
Two-Position Mode
0% ep 0
p
100 % ep 0

Neutral Zone
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9: Controller Principles
Discontinuous Controller Modes
Two-Position Mode
Example
A liquid-level control system linearly converts a
displacement of 2 3 m into a 4 20 mA control
signal. A relay serves as the two-position controller
to open or close an inlet valve. The relay closes at
12 mA and opens at 10 mA. Find:
The relation between displacement level and
current
The neutral zone
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9: Controller Principles
Discontinuous Controller Modes
Two-Position Mode
I (mA)
Example
H = K I + HO 20

2 = K (4) + HO
3 = K (20) + HO 4

K = 0.0625 m / mA
HO = 1.75 m
2 3
HH = 0.0625 * 12 + 1.75 = 2.5 m Displacement (m)
HL = 0.0625 * 10 + 1.75 = 2.375
The neutral zone = HH HL = 2.5 2.375 = 0.125 m
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9: Controller Principles
Discontinuous Controller Modes
Two-Position Mode
Example
As a water tank loses heat, the temperature drops
by 2 K per minute. When a heater is on, the system
gains temperature at 4 K per minute. A two-position
controller has a 0.5 min control lag and a neutral
zone of 4 % of the setpoint about a setpoint of
323 K.
Plot the tank temperature versus time.
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9: Controller Principles
Discontinuous Controller Modes
Two-Position Mode
Example
Neutral zone = 310 336 K

Temp. gain = 4 K per minute

Setpoint = 323 K

Temp. loss = 2 K per minute

Control lag = minute

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9: Controller Principles
Discontinuous Controller Modes
Multiposition Mode
0% ep e1

p 50 % e1 ep e 2
100 % e 2 ep
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9: Controller Principles
Discontinuous Controller Modes
Multiposition Mode
Example
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9: Controller Principles
Discontinuous Controller Modes
Floating-Control Mode
If the error is zero, the output does not change
but remains (floats) at whatever setting it was
when the error went to zero.
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9: Controller Principles
Discontinuous Controller Modes
Floating-Control Mode
Single Speed

dp KF ep eP

dt 0 ep eP

p K F t p ( 0) ep eP
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9: Controller Principles
Discontinuous Controller Modes
Floating-Control Mode
Single Speed
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9: Controller Principles
Discontinuous Controller Modes
Floating-Control Mode
Example
Suppose a process error lies within the neutral
zone with p = 25%. At t = 0, the error falls below
the neutral zone. If K = +2% per second, find
the time when the output saturates.
p K F t p ( 0) ep eP
Solution
100 % = (2 %/s * t) + 25 %
t = 37.5 s
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9: Controller Principles
Discontinuous Controller Modes
Floating-Control Mode
Multispeed

dp KFi ep ePi

dt 0 ep eP1
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9: Controller Principles
Continuous Controller Modes
Proportional Control Mode
p KP ep pO
r b
ep x 100%
b max b min
Direct (- K) & Reverse (+ K) Action
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9: Controller Principles
Continuous Controller Modes
Proportional Control Mode
p KP ep pO
% per %
Proportional Band:
100
PB
KP
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9: Controller Principles
Continuous Controller Modes
Proportional Control Mode
Example
Valve A: 10 m3/h per percent.
PO = 50 %
KP = 10 % per %
Valve B changes
from 500 m3/h
to 600 m3/h
Calculate:
The new controller output
The new offset error
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9: Controller Principles
Continuous Controller Modes
Proportional Control Mode
Example Solution
Valve A: 10 m3/h per percent. QA must go up to
PO = 50 % 600 m3/h
KP = 10 % per % QA = 10 m3/h * P
Valve B changes
from 500 m3/h P = 60 %
to 600 m3/h
Calculate: 60 = 10 eP + 50
The new controller output eP = 1 %
The new offset error
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9: Controller Principles
Continuous Controller Modes
Integral Control Mode
t

p (t ) KI ep dt p (0)
0

% per sec %
Integral Time: TI = 1 / KI

sec
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9: Controller Principles
Continuous Controller Modes
Integral Control Mode
Example
An integral controller is used for speed control with
a setpoint of 12 rpm within a range of 10 15 rpm.
The controller output is 22% initially.
The constant KI = - 0.15 % per second per % error.
If the speed jumps to 13.5 rpm,
calculate the controller output after 2 s for a
constant ep.
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9: Controller Principles
Continuous Controller Modes
Integral Control Mode ep
r b
x 100%
Example b max b min
setpoint = 12 rpm (range of 10 15 rpm)
P(O) = 22%
Solution
KI = 0.15
eP = (1213.5)/(1510)*100 %.
speed = 13.5 rpm
eP = 30 %
constant ep
2 seconds time P(t) = KI eP t + P(0)
t

p (t ) KI ep dt p (0) P(t) = ( 0.15) * ( 30) * 2 + 22

0

P = 31 %
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9: Controller Principles
Continuous Controller Modes
Derivative Control Mode
dep
p (t ) KD
dt
sec
Not used alone because it provides no output
when the error is constant.
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9: Controller Principles
Continuous Controller Modes
Derivative Control Mode
Example

dep
p (t ) KD po
dt
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9: Controller Principles
Composite Control Modes
Proportional Integral Control ( PI)
t

p (t ) KP ep KP KI ep dt p (0)
0
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9: Controller Principles
Composite Control Modes
PI t

p (t ) KP ep KP KI ep dt p (0)
Example 0

KP = 5
KI = 1 sec-1
P(0) = 20%
Plot a graph of the
controller output as
a function of time
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9: Controller Principles
Composite Control Modes
PI
Example
KP = 5
KI = 1 sec-1
P(0) = 20%
t

p (t ) KP ep KP KI ep dt p (0)
0
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9: Controller Principles
Composite Control Modes
Proportional Derivative Control (PD)
dep
p (t ) KP ep KP KD po
dt
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9: Controller Principles
Composite Control Modes
PD
Example
KP = 5
KD = 0.5 sec
Po = 20%
dep
p (t ) KP ep KP KD po
dt
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9: Controller Principles
Composite Control Modes
Three Mode Controller (PID)
t
dep
p (t ) KP ep KP KI ep dt KP KD p (0)
0 dt
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9: Controller Principles

End of Chapter 9