Bachelor Degree in Chemical Engineering: Control Station - Loop-Pro Trainer S/W

UNIVERSITÁ DEGLI STUDI DI SALERNO
FACOLTÀ DI INGEGNERIA
Bachelor Degree in Chemical Engineering
Course:
Instrumentation and Control of Chemical Processes
FEEDBACK AUTOMATIC CONTROL
CONTROL STATION – LOOP-PRO TRAINER s/w
Rev. 4.3 – September 19, 2017

INTRODUCTION
The software LOOP-PRO of CONTROL STATION® is at the same

time:
• an instrument for the design and the tuning of continuous
controllers;
• a simulator of dynamic behavior and automatic process control.
It is used in industry and academic on a worldwide scale for:

 modeling and simulation of dynamic processes;
 design of continuous controllers with simple structure;
 analysis and tuning of single loop & multiple loop automatic
controllers;
 evaluation of the performance;
 training of the staff of process control.
25/06/2018 Instrumentation and Control of Chemical Processes - Prof. M. Miccio 2

SOFTWARE LICENSE
The website LOOP-PRO of CONTROL STATION® is:

http://www.controlstation.com/
CONTROL STATION® also provides a low price Student License Option:

“We provide an option whereby students license directly from Control
Station. If you choose to do so, students can use their personal credit card
to purchase 1-year licenses for $35.00. We provide them with access to the
software, the textbook and workshop exercises. We do not provide access
to the Answer Key.
The URL for them to do so is:”
http://secure.softwarekey.com/solo/products/ProductOption.aspx?ProdOptionID=6002

OUTLINE OF THE PRESENTATION
• SOFTWARE MODULES
– Case Studies
• Example No.1 – TWO NON-INTERACTING TANKS
• Example No.2 – THE PUMPED TANK
• Custom Process
• Companion and Web-based Materials

SOFTWARE MODULES
The software includes 3 modules:
Case Studies:
Design Tools:
Custom Process:

CASE STUDIES
CASE STUDIES
The case studies provide to the staff training presenting example
of simple, but significant industrial process by means of synoptic
figure (“animated” in such case).
The software allows to operate on the process variables
(manipulated and disturbances), the control structure, the
controller parameters, etc.
The processes available for the simulation are:

• Two non-interacting tanks;
• Pumped tank;
• Counter-current heat exchanger;
• Jacketed reactor;
• Cascade reactors;
• Distillation column;
• Combustion process with regulation of the air/fuel ratio;
• Finisher mill of clinker (cement)
• Others…
PUMPED TANK

COUNTERCURRENT HEAT EXCHANGER
disturbance
variable cooling
flow exit
manipulated variable
controller
output
measured
temperature sensor
process variable
& controller

JACKETED STIRRED REACTOR
Jacket

DISTILLATION COLUMN

FURNACE
WITH REGULATION OF AIR/FUEL RATIO

FINISHER MILL OF CLINKER

NON-INTERACTING TANKS
Synoptic Scheme
manipulated variable
controller
output
measured
process variable level sensor
& controller
disturbance
variable

EXAMPLE NO.1:
TWO NON-INTERACTING TANKS
Two non-interaCting tanks
The software allows to the user to simulate this process.

• study the open-loop dynamic response (controller in manual mode)
• choose the type of continuous controller and the tuning
• study the closed-loop dynamic response (controller in automatic
mode)
Fin(t)
Mathematical model
F1 (t) A1
d
h1 ( t )  V ( t )   h ( t ) 1/ 2
in 1 1
dt
h 2 ( t )  1 h1 ( t )    2 h 2 ( t )   V
d 1/ 2 1/ 2  (t)
A2 p
F2 (t) dt
Fp(t)
CI : h1 (0)  h1s ; h1 (0)  h1s

Loop-Pro Control Station® - Example No.1
The OBJECTIVES are:
1. the representation the dynamic process with an

approximate FOPDT model
2. the tuning of the PID controller
3. the comparison of the closed-loop response for the
different tuning methods
4. Sensitivity analysis on the PID controller parameters

• from the opening windows we select ”gravity drained

tanks” of the drop-down menu of CASE STUDIES
• the next window shows the synoptic figure of the C
process (in manual mode) in which we can change the

controller output and the disturbance (PUMPED FLOW);
• the window also shows the trend charts or moving
strip charts which are the diagram of the controller
output and the level of the second tank (controlled
variable) with the time;
• the first step consists of starting the data recording (A);
• starting from a steady state, the second step consists of
forcing a step input change of the controller output (B),
for example of 5 % (STEP TEST in the Controller Output)

Two non-interacting tanks:
1. Representation with an approximante FOPDT model
V a r ia b le /S e tp o in t
Control Station: Case Studies
Proc e ss: Gra vity Dra ine d Ta nk Cont.: Ma nua l Mode
5 .0
4 .5
4 .0
u t p uP t r o c e s s
Process Reaction Curve Method  3 .5
3 .0
75
O
74
C o n tr o lle r
73
72
71
70
6 9 12 15 18 21 24 27 30 33 36
T im e (m in s )
• when a new steady-state is reached, the data recording will

be stopped (A);
• after the opening of the directory containing the saved data
of the step test (D), it is possible to open directly Design
Tools from the button Navigate (C) and select (E) the
approximate/representing model. It is a FOPDT in our case.
• selecting Start Fitting (F), the software will calculate the
best fitting FOPDT curve of the process (following the
method of the minimum SSE) and will evaluate the
parameters:
KP, tP, P
from which the controller parameters will be evaluate.

DESIGN TOOLS
The Design Tools module provides powerful instruments for the design and the analysis of
the controller. Automatically it is possible to find the best dynamic model for the data
computing and for the controller tuning by means of IMC correlations.
The linear models available in the module are:

• FOPDT (first order plus dead time)
• SOPDT (second order plus dead time)
• SOPDT w/L (with lead time)
• FOPDT integrating
• SOPDT integrating
• SOPDT underdamped
The Design Tools module allows to import “external” data of a dynamic response for a step input change in a “text” file
and to compute it in order to find the best dynamic model for the tuning controller by means of IMC correlations.

1. Representation with an approximante FOPDT model
l e
b
C o n t r o l S t a t io n : D e s ig n T o o ls
r i a
a
V
4 .5 0
ls e s
FOPDT fitting 
be
4 .2 5
V P a r ro i ac
4 .0 0
KP = 0.1252 m/% d
t e 75
74
tP = 1.60 min
l a
73
u
P = 0.779 min
i p
72
n
71
a
M
70
N
SSE = å [Measured Data i - Model Data i ] =
0 5 10 15 20 25
2 T im e
i=1
= 0.0256
2. Tuning of the PID controller with IMC correlations
• The software calculates the parameters of the

Parameters
chosen PID controller with the IMC correlations
Kc tI tD
PID controller tuning  Controllers
• Now it is possible to implement directly the
calculated and optimized parameters into the
controller with the button Implement (G) 0.202
(td / tp )1.219
P Kp
--- ---
tp
PI K P (td  tc ) tP
---
1  tp  0.5td  tp td
PID   tp  0.5td
K P  tc  0.5td  2tp  td
NOTE:
tc is the larger between 0.8td and 0.1tP

In this example, the optimized parameters of

the PID controller calculated with the IMC
correlations are:
Kc=15.87 % / m;
H
tI=1.98 min; tD=0.313 min
 now we move from the Manual Mode to the

Automatic Control clicking on the controller (LC)
in the synoptic figure
 the Controller Design window will be opened.

The controller parameters are already
implemented in the relative fields
 in the Controller Design window, we select “Ideal

PID” from the drop-down menu (H)



 in this mode we can evaluate the system response with the feedback control
changing the set point and the disturbance in different way

3. Tuning of the PID controller with other correlations
• using other correlations for the open loop tuning, the software cannot perform the estimate of the
optimized PID controller parameters. It has to be done off-line.
 it is always possible to move from the Manual Mode to the Automatic Control clicking on the controller
(LC) in the synoptic figure
 the Controller Design window will be opened. In this case, the controller parameters evaluated off-line
have to be inserted by a manual mode in the relative fields
 in the Controller Design window, PID is selected from the drop-down menu (H)
In our example,
the optimized PID controller parameters
for the open loop tuning
calculated with other correlations are:
PID controller parameters Kc tI tD
Ziegler e Nichols – 1st 19.70 1.557 0.389

meth.
Cohen e Coon formulas 23.88 1.609 0.260

P roc e ss: Gra vity Dra ine d Ta nk Cont.: P ID ( P= RA, I= AR W , D= Ide a l (me a s), F = off)
V a r ia b le /S
4.48
Two non-interacting tanks: 4.20
IMC tuning rules
C o n t r o l l e r O u t p uP t r o c e s s
3.92
4. Comparison between the 3.64
closed loop dynamic

9 0 .1 2
8 2 .6 1
responses of the different 7 5 .1 0
6 7 .5 9
tuning methods 6 0 .0 8
8 10 12 14 16 18 20 22 24
T im e (m in s )
)
e s s V a ria b l e /S e tp o in t (le v e l, m
C o n tro l S ta tio n : P ID tu n e d w ith Z ie g le r-N ic h o ls 1 s t m e th o d
Tuning: Ga in = 15.87, Re se t Time = 1.98, De riv Time = 0.3131, S a mple Time = 1.00
P r o c e s s : G r a v it y D r a in e d C To an nt . k: P I D ( P = R A , I = A R W , D = I d e a l ( m e a s ) , F = o ff)
5 .0
4 .5
IMC 4 .0
1st met. Ziegler & Nichols

tuning rules
3 .5
C o n t r o l l e r O u t p u t ( P% r o )c
3.a 1st meth. 3 .0
100
Ziegler &
90
80
method based on Nichols

70
60
open loop tuning Cohen &

50
40
8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Coon
)
T im e ( m in s )
C o n tro l S ta tio n : P ID tu n e d w ith C o h e n -C o o n
P r o c e s s : G r a v it y D r a in e d C To an nt . k: P I D ( P = R A , I = A R W , D = I d e a l ( m e a s ) , F = o f f )
T u n in5 .0g : G a in = 1 9 . 7 , R e s e t T im e = 1 . 5 6 , D e r iv T im e = 0 . 3 8 9 , S a m p le T im e = 1 . 0 0
4 .5
4 .0
3 .5
Cohen & Coon
3 .0
100
90
tuning rules
80
70
60
50
40
8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
T im e ( m in s )
T u n in g : G a in = 2 3 . 8 8 , R e s e t T im e = 1 . 6 1 , D e r iv T im e = 0 . 2 6 , S a m p le T im e = 1 .0 0

4. Comparison between the
closed loop dynamic 3.b
responses of the different
tuning methods method based on
closed loop tuning
SUMMARY
•The method acts on the proportional controller
•Integral and derivative actions are deactivated 2nd meth.
•The procedure starts from a steady-state of the process Ziegler &
•A step input change is forced on the set point and the Nichols
and error
by trial
dynamic response y(t) is monitored
•The gain Kc is increased up to a stable cycle (constant
amplitude oscillation of y(t)) (with the control final element
far from the saturation)
•The specific value Ku = Kc is recorded, for which a stable
oscillation of the closed loop response y(t) occurs Ziegler-Nichols (2nd Method) Tuning Chart
•The distance from two consecutive peaks is measured controller Kc tI tD
(natural period of oscillation Pu o t0 o T)
•La natural frequency of oscillation is f0=1/ t0 P Ku/2
•La crossover frequency is ωco =2π/ t0
PI Ku/2.2 Pu/1.2
PID Ku/1.7 Pu/2 Pu/8

4. Comparison between the closed loop dynamic responses
of the different tuning methods
C o n t r o l l e r O u t p uP tr o ( c% e s) s V a r i a b l e / S e t p o i n t ( l e v e l , m )
P c o n tro lle r: C lo s e d -lo o p c o n tin u o u s ly o s c illa tin g s te p re s p o n s e
• The two non-interacting tanks are P r o c e s s : G r a v it y D r a in e d T a n k C o n t. : P ID ( P = R A , I= o ff, D = o ff, F = o ff)
3.0
at the steady state, in the closed loop
configuration, only with the
proportional controller (P-only) and
the gain Kc=90 % /m
2.5
• The level of the 2nd tank

(controlled var.) corresponding to the 2.0
set-point is h2=1.9 m
• A step input change 100
(2.4 – 1.9) = 0.5 m 80
of the set-point is forced 60
• The simulated dynamic response is 40
showed in figure  20
0
10 20 30 40 50 60 70
T im e ( m in s )
In this condition, the controller gain is called T u n in g : G a in = 9 0 . 0 , S a m p le T im e = 1 .0 0
ultimate gain: Ku=Kc=90 %/m  MORE GENERAL SUGGESTION

The period of the oscillating response is called
ultimate period Pu.  if the TF of the process is available, the
From the diagram of the response of the step input change, ultimate gain can be previously calculated with
it can be evaluated: Pu=2.1 min the Bode stability criterion

4b. Comparison between the closed loop dynamic responses
of the different tuning methods
4.48
4.20
IMC tuning rules
3.92
3.64
9 0 .1 2
8 2 .6 1
7 5 .1 0
6 7 .5 9
6 0 .0 8
8 10 12 14 16 18 20 22 24
T im e (m in s )
)
C o n tro l S ta tio n : P ID tu n e d w ith Z ie g le r-N ic h o ls 2 n d m e th o d
Calculation of the P r o c e s s : G r a v it y D r a in e d C To an nt . k: P I D
5 .0
( P = R A , I= A R W , D = Id e a l (m e a s ), F = o ff)
optimized PID controller parameters 4 .5
4 .0
2nd meth. Ziegler & Nichols

tuning rules
3 .5
Kc = Ku/1.7 = 90/1.7 = 52.94 % /m 3 .0

100
90
tI = Pu/2 = 2.1/2 = 1.05 min 80
70
60
tD = Pu/8 = 2.1/8 = 0.262 min 50
40
8 10 12 14 16 18 20 22 24
T im e ( m in s )
T u n in g : G a in = 5 2 . 9 4 , R e s e t T im e = 1 . 0 5 , D e r iv T im e = 0 . 2 6 2 5 , S a m p le T im e = 1 .0

5. Sensitivity analysis on PID controller parameters
• It is possible to evaluate the effect of each PID controller parameter (Kc, tI, tD) on the system, by means of the analysis of
the dynamic response of a step input change of the set-point or the disturbance in a closed loop configuration (automatic
control).
• The analysis is performed starting from an optimized tuning configuration changing one at the time the three parameters
calculated by the IMC correlations.
In our case, the optimized PID controller parameters obtained from the IMC correlations are:
Kc=15.87 % /m; tI=1.98 min; tD=0.313 min
Remember 
Overshoot: ratio between the two

segments A e B, overshoot=A/B;
Decay ratio: ratio between the segments C
e A;

Remember 
period of oscillation T: time interval between

two points having the same vertical position in the
curve gone in “increasing way”;
Remember 
response time: the time needed for the

response to reach the value y(t) within ± 5% of
its asymptotic value.
rise time: time for which the response reaches
its final asymptotic value for the first time.

REFERENCE CASE

3.78
3.51
3.24
IMC tuning rules

2.97
2.70
8 3 .1 0
7 4 .7 9
6 6 .4 8
5 8 .1 7
4 9 .8 6
10 12 14 16 18 20 22 24
T im e (m in s )

P roc e ss: Gra vity Dra ine d Ta nk

4.56
Cont.: P ID ( P= RA, I= AR W , D= Ide a l (me a s), F = off) Effects of the variation of Kc:
4.32
4.08
Kc/3 From the diagrams it was observed an increase

3.84
3.60 of KC produces the following effects,

7 6 .2 3
while a decrease produces opposed effects:
7 2 .6 0
6 8 .9 7
6 5 .3 4
6 1 .7 1
rise time DECREASE
12 14 16 18 20 22 24 26 28
T im e (m in s )
Control
se t TimeStation:
= 1.98, DeCase Studies
overshoot INCREASE
Tuning: Ga in = 5.30, Re riv Time = 0.3131, S a mple Time = 1.00
4.65
4.34
4.03 recay ratio INCREASE

3Kc
3.72
3.41
9 7 .1 0
7 7 .6 8
period of oscillation DECREASE
5 8 .2 6
3 8 .8 4
1 9 .4 2 response time INCREASE

0 2 4 6 8 10 12 14 16
T im e (m in s )

Effects of the variations of tI:

5.04
Considering the increase of tI, the diagrams evidence:

4.62
4.20
3.78
3.36
103.20 tI/3 rise time INCREASE
9 2 .8 8
(eventually it loses its physical meaning)
8 2 .5 6
7 2 .2 4
overshoot DECREASE
6 1 .9 2

12 14 16 18 20 22 24 26
T im e (m in s )
Control
Tuning: Ga in = 15.87, Re se t TimeStation:
= 0.66, DeCase Studies
riv Time = 0.3131, S a mple Time = 1.00
decay ratio DECREASE
4.50 (eventually it loses its physical meaning)

4.25
4.00 period of INCREASE

3 tI
3.75
oscillation (eventually it loses its physical meaning)
3.50
8 3 .4 9
response DECREASE
7 5 .9 0
6 8 .3 1
time (eventually it loses its physical meaning)
6 0 .7 2
5 3 .1 3
10 12 14 16 18
T im e (m in s )
20 22 24 26 The loss of the physical meaning occurs when the process
moves from an underdamped system to an overdamped
system.

P roc e ss: Gra vity Dra ine d Ta nk

2.85
Cont.: P ID ( P= RA, I= AR W , D= Ide a l (me a s), F = off) Effects of the variation of tD:
2.66
2.47
Considering the decrease of tD, the diagrams evidence
3 τD
2.28
2.09
1.90
rise time DECREASE
8 7 .8 0 (eventually it loses its physical meaning)
7 0 .2 4
5 2 .6 8
overshoot INCREASE
3 5 .1 2
1 7 .5 6
26 28 30 32 34 36 38 40 42
T im e (m in s )

decay ratio INCREASE
P roc e ss: Gra vity Dra ine d Ta nkTuning: Ga in = 15.87, Re se t Time = 1.98, De riv Time = 0.94, S a mple
Cont.: P ID (Time = 1.00
P= RA, I= AR W , D= Ide a l (me a s), F = off)
2.66
2.47
period of DECREASE
τD /3
2.28
2.09 oscillation (eventually it loses its physical meaning)

1.90
6 3 .2 0
response DECREASE
5 9 .2 5
5 5 .3 0
time (eventually it loses its physical meaning)
5 1 .3 5
4 7 .4 0
14 16 18 20 22 24 26 28
The loss of the physical meaning occurs when the
T im e (m in s )
process moves from an underdamped system to an
overdamped system.

EXAMPLE NO.2:
A PURELY CAPACITIVE SYSTEM
Example No.2:
The plot shows the dynamic response to a step input change of a tank with an unknown dynamic behavior with
a open loop configuration: the step change of the input (see Manipulated Variable reported in % in the
lower part of the figure) and the record of the level (see the curve Tank Level in figure).
a) Describe the qualitative behavior of the response curve

b) What is the asymptotic behavior of the dynamic response of the system?
c) For the general case of the step test, describe what are the parameters of a FOPDT fitting model.
d) Can the evaluation procedure of a FOPDT model be applied for this case?
e) What would you suggest for the tuning if a PI controller is to be adopted in a feedback system for the
Pumpe d ta nk: fit with "FOPDT Inte gra ting"
control of the tank level?
4
3
Tank level, m
1
80
Manipulated Variable, %
70
0 4 8 12 16 20 24 28
Time

Example No.2:
SOLUTION
a)
It is a monotonically decreasing linear curve, which starts from a steady state value
with a delay time following the step input change imposed at t  4.8 min.
The static gain is negative  KP' < 0
b)
The dynamic response decreases continuously. The asymptotic behavior suggests an
approach to -; actually, dealing with a tank, the level approaches zero.
d)
NO.
The procedure for the estimate of FOPDT model parameters cannot be applied because
the tank level does not reach a new steady state value.
e)
3 different routes can be outlined:
• adopting a FOPDT integrating model, calculating the parameters and applying the
“IMC (lambda) correlations for integrating processes”
• estimating the PI controller parameters by an empirical correlation
• taking the process in a closed loop configuration with the only proportional
controller and trying to apply the 2nd Ziegler-Nichols method.

“FOPDT integrating” MODEL
from
Control
Station®
help
screen

Example No.2:
position of the pole on the complex plane
'
Im
Kp
G (s) 
s
Only 1 pole at
the origin of
the axes:
Re
s=0
DYNAMIC RESPONSE TO STEP INPUT CHANGE

é K ' ù
1 é K 'ù
y(t) = L-1 [ y(s)] = L-1 [ G(s) f (s)] = L-1 ê p ú = L-1 ê 2pú = K p' tu(t)
ë s sû ës û
NOTE:
marginally stable dynamic system  NON-self-regulating for some inputs
25.06.2018 Instrumentation and Control of Chemical Processes - Prof. M. Miccio 40
THE PUMPED TANK as A PURELY CAPACITIVE SYSTEM
• from the opening windows select ”pumped tank”

from the drop-down menu of CASE STUDIES
• the next window shows the synoptic figure of the

process (in manual mode) in which we can change the
controller output and the disturbance (DISTURBANCE
FLOW); A
• the window also shows the trend charts or moving B
strip charts that are the diagram of the controller output
and the level (controlled variable) with the time;
• the first step consists of starting the data recording (A);
• starting from a steady state, the second step consists of
forcing a step input change of the controller output (B),
for example of 5 % (STEP TEST in the Controller Output)

Pumped tank:
1. Representation with thePumpe
integrating FOPDT model
d ta nk: fit with "FOPDT Inte gra ting"
Tank level, m
2
1
80
Manipulated Variable, %
70
0 4 8 12 16 20 24 28
Time
• being a pure capacitive dynamic system, a new steady

state is not reached
• the data recording is stopped (A) after a proper time interval
• in order to stop the diverging behavior the CONTROLLER
OUTPUT has to be restored with an inverse step input change
(B) of - 5 %
• open the directory of the saved data of the step test (D),
with the button Navigate (C), select (E) the
approximate/representing model of the process which, in out
case, is FOPDT integrating

Pumped tank:
1. Representation with the integrating FOPDT model
• selecting Start Fitting (F), the software will calculate the best representing FOPDT integrating line of
the process (with the minimum SSE), estimating the related parameters:
KP*, P
from which the controller parameters can be calculated.
V a r ia b le / S e t p o in t
C o n tro l S ta tio n : C a s e S tu d ie s
P ro c e s s : P u m p e d T a n k C o n t. : P ID ( P = D A , I= A R W , D = o ff, F = o ff)
fitting with 4 .0
FOPDT integrating 3 .2

2 .4
C o n t r o l l e r O u t p u tP r o c e s s
1 .6
KP*= -0.0241 m (min)-1 (%)-1

7 6 .5
7 1 .4
P = 1.04 min 6 6 .3
6 1 .2
-16 -8 0 8 16 24 32 40 48 56 64
T im e ( m in s )
N
SSE =  [Measured Data i  Model Data i ]
2
T u n in g : G a in = - 1 8 . 8 2 , R e s e t T im e = 6 . 8 9 , S a m p le T im e = 1 .0 0
i =1

Pumped tank:
2. Tuning of PI controller with IMC correlations
G
• The software estimate the parameters of
chosen PID with IMC correlations
• We can now introduce the optimized
parameter directly into the controller by means
the button Implement (G)
• In this case, the optimized parameters with
IMC correlations for the case of the PI controller
are:
Kc = -18.82 (%) (min) m-1
(direct acting controller)
tI = 6.89 min

Pumped tank:
 we double-click on the controller (LC) in H

the synoptic figure
 the Controller Design window will be

opened. The controller parameters are
already implemented in the relative fields
 in the Controller Design window, we

select “PID” or "ideal PID" from the drop-
down menu (H)
 we can set ON or OFF the integral and

the derivative action
 when we click “Done”, the LC is turned

from Manual Mode to Automatic Control 
Pumped tank:


 Now we can evaluate the system response of the Pumped Tank with the feedback
control when changing the set point and the disturbance

Pumped tank:
3. closed loop response to a step in set point (P-only
controller)
C o n t r o ll e r O u t p u t P( %r o )c e s s V a r i a b l e / S e t p o i n t ( m ) c lo s e d lo o p re s p o n s e to a s te p in s e t p o in t (P -o n ly c o n tro lle r)
P ro c e s s : P u m p e d T a n k C o n t . : P ID ( P = D A , I= o ff, D = o ff, F = o ff)
5.2
4.8
4.4
4.0
70 
65
0 5 10 15 20 25 30 35 40
T im e (m in s )
T u n in g : G a in = - 5 . 0 7 , S a m p le T im e = 1 .0 0

Pumped tank:
Open Loop Transfer Function
d(s)
Forward path
ySP(s) + ε(s) CO(s)
y(s)
Gc GP
-
Feedback path
Definition: GOL(s)=Gc(s)Gp(s)
 Kc and KP have always the same sign !

see:
Ch.14 - Stephanopoulos, “Chemical process control: an Introduction to theory and practice”, Prentice Hall,1984
25/06/2018 Prof M. Miccio 48

Pumped tank:
Closed Loop Transfer Function
Proportional Control only
d(s)
ySP(s) + ε(s) CO(s) y(s)
Kc KP'/s
-
G c (s)G p (s) K c K 'p s K c K 'p

Servo Problem (Hyp.: d(s) = 0): G CL ,SP (s)   
1  G OL (s) 1  K c K 'p s s  K c K 'p
y(s)=GCL,SP(s)ySP(s)
G p (s) K 'p s K 'p
G CL ,load (s)   
Regulator Problem (Hyp.: ySP(s) = 0): 1  G OL (s) 1  K c K 'p s s  K c K 'p
y(s)=GCL,load(s)d(s)
see:
Ch.14 - Stephanopoulos, “Chemical process control: an Introduction to theory and practice”, Prentice Hall, 1984
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Pumped tank:
Im
K c K 'p
G CL ,SP (s) 
s  K c K 'p
Re
Only 1 pole on the negative real axis:

s = - KcKP'
 BIBO stable dynamic system  self-regulating for all bounded inputs

Pumped tank:
Im
K 'p
G CL ,load (s) 
s  K c K 'p
Re
Only 1 pole on the negative real axis:

s = - KcKP'
 BIBO stable dynamic system  self-regulating for all bounded disturbances

Pumped tank:
LTI Dynamic response plots


Pumped tank:
LTI Dynamic response plots
Pumped tank:
PID Controller
d(s)
ySP(s) + ε(s) CO(s) y(s)
Kc(1+tDs+1/tIs) KP'/s
-
Servo Problem
(Hyp.: d(s) = 0):
y(s)=GCL,SP(s)ySP(s) 
K c K 'p t Dt Is 2  t Is  1 
G c (s)G p (s) K c 1  t Ds  1 t Is   K 'p s t Is 2
G CL ,SP (s)    
1  G OL (s) 1  K c 1  t Ds  1 t Is   K 'p s K c K 'p t Dt Is 2  t Is  1
1
t Is 2


K c K 'p t Dt Is 2  t Is  1
t I 
 K c K 'pt Dt I s 2  K c K 'pt Is  K c K 'p
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Pumped tank:
PID Controller
Root Locus
G OL (s) 

K c K 'p t Dt Is 2  t Is  1  2 open-
t Is 2
loop poles
Data: at the
All constants origin
set to 1
2 open-
loop
zeroes in
the
negative
half-plane
G CL ,SP (s) 

K c K 'p t Dt Is 2  t Is  1
t I 
 K c K 'pt Dt I s 2  K c K 'pt Is  K c K 'p  BIBO stable closed-loop system for any Kc
CUSTOM PROCESS
CUSTOM PROCESS
This module is a working environment which allows to implement

custom a process e/o the structure of a controller
In particular, we can introduce the Transfer Function, also selecting it
from a menu, with specified parameter value.
Simulations allow a wide range of analysis both for single-loop and
multi-loop processes.
With the module Custom Process is also possible to import descriptions
about disturbances and real process in order to simulate and analyze it.

CUSTOM PROCESS
 single loop custom process

OVERDAMPED PROCESS MODEL FORMS
• THE OVERDAMPED PROCESSES DO NOT SHOW OSCILLATION IN OPEN LOOP RESPONSE
• MANY OVERDAMPED PROCESSES ARE ALSO SELF REGULATING

CUSTOM PROCESS
EXAMPLE OF A LINEAR DYNAMIC SYSTEM
A process Gp is the result of 2 linear systems in series, each having

the following transfer function:
G rat 
 1n
 n  0.5 2 n  0.5 
 s s 
 n  0.5 n  0.5 
n
 s
where n = 5
G dt  e 4

CUSTOM PROCESS
UNDERDAMPED LINEAR MODEL
 0.82
G rat 
 
0.66s 2  0.815s  1

CUSTOM PROCESS
UNDERDAMPED LINEAR MODEL
 0.82* e 1.25s

G rat
0.66s2  0.815s  1

OTHERS
MULTI-LOOP PROCESS CUSTOM PROCESS
• IT ALLOW THE SIMULATION OF A WIDE RANGE OF 2x2 “MIMO” PROCESSES WITH THIS GENERAL
LAYOUT:

LOOP-PRO TRAINER – CONTROL STATION®
Companion Written Materials
Practical Process Control Book

A companion 280 page Practical Process
Control textbook provides extensive discussion
and detail on the modern methods and best
practices for control of parameters such as
temperature, pressure, level, flow and
composition on processes with streams
comprised of gases, liquids, powders, slurries
and melts. Like the slides, the book covers
basic through advanced process control topics,
always focusing on the practical application of
most benefit to industry practitioners.
Workshop Challenges
The Hands-On Workshop Series companion
book offers 18 workshop challenges for you to
confront and overcome. adapted from:
http://www.controlstation.com/cs-products/trainer.html

LOOP-PRO TRAINER – CONTROL STATION®
Web-based Materials
About ControlGuru e-Book

The Controlguru.com e-book is an online textbook covering
proven methods and best practices in automatic process
control.
The focus of the e-book is on PID control and related
architectures such as cascade, feed forward, Smith predictors,
multivariable decoupling, and similar classical and advanced
process control strategies.
Applications of interest are processes with streams composed
of gases, liquids, powders, slurries and melts as found in broad
range of manufacturing, production and development
operations.
Chemical, bio-pharma, oil and gas, paints and coatings, food
and beverages, cement, minerals and ore, polymers and
plastics, metals, pulp and paper, materials, personal care
products, and water processing are examples of industries that
operate such plants.
Measured process variables common for these processes and
industries include temperature, pressure, pressure drop, level,
flow, density, concentration, viscosity, chemical composition,
and more.
Final control elements tend to be valves, variable speed pumps
and compressors, cooling and heating elements, and the like.
adapted from:
http://www.controlguru.com/

Bachelor Degree in Chemical Engineering: Control Station - Loop-Pro Trainer S/W

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UNIVERSITÁ DEGLI STUDI DI SALERNO

Bachelor Degree in Chemical Engineering

FEEDBACK AUTOMATIC CONTROL

CONTROL STATION – LOOP-PRO TRAINER s/w

Rev. 4.3 – September 19, 2017

The software LOOP-PRO of CONTROL STATION® is at the same

It is used in industry and academic on a worldwide scale for:

25/06/2018 Instrumentation and Control of Chemical Processes - Prof. M. Miccio 2

The website LOOP-PRO of CONTROL STATION® is:

CONTROL STATION® also provides a low price Student License Option:

25/06/2018 Instrumentation and Control of Chemical Processes - Prof. M. Miccio 3

25/06/2018 Instrumentation and Control of Chemical Processes - Prof. M. Miccio 4

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The processes available for the simulation are:

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25/06/2018 Instrumentation and Control of Chemical Processes - Prof. M. Miccio 11

25/06/2018 Instrumentation and Control of Chemical Processes - Prof. M. Miccio 12

25/06/2018 Instrumentation and Control of Chemical Processes - Prof. M. Miccio 13

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The software allows to the user to simulate this process.

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The OBJECTIVES are:

1. the representation the dynamic process with an

25/06/2018 Instrumentation and Control of Chemical Processes - Prof. M. Miccio 17

• from the opening windows we select ”gravity drained

• the next window shows the synoptic figure of the C

process (in manual mode) in which we can change the

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• when a new steady-state is reached, the data recording will

25/06/2018 Instrumentation and Control of Chemical Processes - Prof. M. Miccio 19

The linear models available in the module are:

25/06/2018 Instrumentation and Control of Chemical Processes - Prof. M. Miccio 20

• The software calculates the parameters of the

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In this example, the optimized parameters of

 now we move from the Manual Mode to the

 the Controller Design window will be opened.

 in the Controller Design window, we select “Ideal

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PID controller parameters Kc tI tD

Ziegler e Nichols – 1st 19.70 1.557 0.389

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Two non-interacting tanks: 4.20

IMC tuning rules

4. Comparison between the 3.64

closed loop dynamic

responses of the different 7 5 .1 0

1st met. Ziegler & Nichols

method based on Nichols

open loop tuning Cohen &

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• The level of the 2nd tank

(2.4 – 1.9) = 0.5 m 80

of the set-point is forced 60

• The simulated dynamic response is 40

In this condition, the controller gain is called T u n in g : G a in = 9 0 . 0 , S a m p le T im e = 1 .0 0

ultimate gain: Ku=Kc=90 %/m  MORE GENERAL SUGGESTION

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IMC tuning rules