SELECTIVE CONTROL: Process Control – Unit 5

Selective control is a control strategy used in process control systems where multiple inputs or
measurements are available, and only the most critical or appropriate input is selected for
control. This method is commonly employed in complex industrial processes to ensure the
process remains within safe and efficient operational limits.

Types of Selective Control

Selective control can be categorized into the following types:
1. Override Control:
o Override control is used when there are safety or operational constraints.
o For instance, in a reactor system, the temperature controller may override the
pressure controller if the temperature approaches unsafe levels.
o It ensures that critical parameters are prioritized, preventing accidents or
equipment damage.
2. Auctioneering Control:
o In this type, the system chooses the minimum or maximum value from multiple
measurements to control the process.
o For example, in a gas compressor, the anti-surge controller selects the lowest
pressure measurement to avoid compressor surge.
o Auctioneering logic ensures process stability while avoiding extreme conditions.
3. Split Range Control:
o Split range control uses a single controller output to operate multiple control
elements like valves or actuators.
o For example, a control signal may direct one valve to open while closing another,
based on the process needs.
o It is used for processes requiring switching between control elements, such as
heating and cooling.
Applications of Selective Control
1. Safety Systems:
o Override control is vital in systems like boilers, reactors, and compressors to
handle abnormal operating conditions.
2. Power Plants:
o Auctioneering control is used to manage steam flow or turbine speed, ensuring
maximum efficiency and safety.
3. Chemical Processes:
o Split range control is employed in distillation columns for precise temperature and
pressure management.
Advantages
1. Enhances process safety by prioritizing critical variables.
2. Improves efficiency by selecting the optimal parameter for control.
3. Reduces risks of equipment failure or process downtime.
Disadvantages
1. Requires advanced control systems and logic, increasing complexity.
2. May lead to abrupt transitions between control modes, causing wear on equipment.
3. Demands regular maintenance and monitoring to ensure proper functioning.
Selective control plays a crucial role in industrial automation, ensuring processes operate within
safe and efficient parameters. By prioritizing critical inputs and providing flexibility, it
significantly enhances system reliability and safety, making it indispensable in modern process
industries.

RATIO CONTROL:
Ratio control is a specialized control strategy where two or more variables are maintained in a
fixed ratio relative to one another. It is widely used in industrial processes to ensure proper
mixing, blending, or proportioning of materials. The primary objective of ratio control is to
maintain the desired proportion between a controlled variable (dependent) and a reference
variable (independent).

Working Principle of Ratio Control

• In a ratio control system, one variable is chosen as the primary variable or reference
variable (e.g., flow rate of one component).
• The other variable is the secondary variable or controlled variable, which is adjusted to
maintain the desired ratio with respect to the primary variable.
• A ratio controller calculates the required setpoint for the secondary variable based on the
reference variable and the desired ratio.
Key Elements of Ratio Control
1. Ratio Setting:
o Defines the proportion between the primary and secondary variables (e.g., 1:3,
where one unit of component A is mixed with three units of component B).
2. Primary Measurement:
o The flow, pressure, or temperature of the primary variable is measured and used
as the reference.
3. Secondary Measurement and Control:
o The secondary variable is adjusted using a control element (e.g., valve or pump)
to achieve the specified ratio.
4. Feedback Loop:
o The ratio control system operates as a feedback loop to maintain the ratio despite
disturbances.
Applications of Ratio Control
1. Chemical Blending:
o Ensures the correct proportion of reactants in chemical reactions, such as in
polymer production or fertilizer manufacturing.
2. Fuel-Air Mixture in Combustion Systems:
o Maintains the proper fuel-to-air ratio for efficient combustion in boilers or
engines.
3. Food and Beverage Industry:
o Used in mixing ingredients in precise ratios to maintain product quality.
4. Pharmaceutical Industry:
o Ensures the correct proportion of active ingredients and solvents during drug
formulation.
Advantages
1. Improved Product Quality:
o Ensures consistent and precise control of proportions.
2. Efficiency:
o Optimizes resource usage by avoiding overuse or underuse of materials.
3. Flexibility:
o Adapts to changes in the primary variable automatically.
4. Reduced Waste:
o Minimizes errors in mixing or blending processes, leading to less material
wastage.
Disadvantages
1. Complexity:
o Ratio control systems may require advanced equipment and monitoring.
2. Maintenance:
o Requires regular calibration and upkeep of sensors and controllers.
3. Sensitivity to Disturbances:
o Performance can be affected by changes in environmental conditions or
inaccurate measurements.
Ratio control is a vital control strategy in process industries where maintaining precise
proportions is essential for product quality, efficiency, and safety. By automating the control of
variables in a fixed ratio, it enhances process reliability and minimizes human error, making it a
cornerstone of industrial automation.

INFERENTIAL CONTROL:
Inferential control is a control strategy where a process variable that cannot be directly measured
or measured in real-time is estimated or inferred using mathematical models and measurements
of related variables. The inferred variable is then used to maintain control over the process. This
technique is widely used in industries where real-time measurement of a variable is impractical
due to cost, complexity, or technical limitations.
Working Principle of Inferential Control
1. Unmeasured Variable:
o The variable of interest (e.g., product quality or composition) cannot be directly
measured continuously.
2. Inferential Model:
o A mathematical or empirical model is developed to estimate the unmeasured
variable using data from related process variables.
o For example, the composition of a distillation column product can be inferred
from temperature and pressure measurements.
3. Control Action:
o The inferred value of the unmeasured variable is compared with a setpoint.
o The controller adjusts the manipulated variable (e.g., flow rate, temperature) to
maintain the inferred variable at its desired level.

Components of Inferential Control

1. Measurement Devices:
o Sensors to measure process variables (e.g., flow, pressure, temperature).
2. Inferential Model:
o Algorithms or mathematical equations that relate the unmeasured variable to the
measured variables.
3. Controller:
o A control device (e.g., PID controller) that uses the inferred value to perform
corrective actions.
4. Actuators:
o Devices (e.g., valves, pumps) that implement the control actions.
Applications of Inferential Control
1. Distillation Columns:
o The composition of the product stream is inferred from temperature and pressure
measurements.
2. Chemical Reactors:
o Reaction conversion or concentration is estimated using temperature, pressure, or
flow data.
3. Oil Refineries:
o Inferential control is used to optimize fuel blending by estimating fuel quality
parameters.
4. Heat Exchangers:
o Heat transfer rates or fluid properties are inferred for better energy management.
Advantages
1. Cost-Effective:
o Eliminates the need for expensive or complex analyzers.
2. Real-Time Control:
o Enables continuous control of variables that would otherwise require manual
sampling and analysis.
3. Improved Efficiency:
o Enhances process efficiency by maintaining optimal operating conditions.
4. Flexibility:
o Can adapt to a wide range of processes with appropriate model development.
Disadvantages
1. Model Dependency:
o The accuracy of inferential control depends heavily on the accuracy of the model.
2. Complexity:
o Developing and maintaining models can be challenging and requires expertise.
3. Sensitivity to Disturbances:
o Inaccuracies in measurements or model assumptions can lead to suboptimal
control.
4. Calibration Needs:
o Models need periodic updates and validation to ensure they reflect actual process
behavior.
Inferential control is a powerful strategy for managing processes where direct measurement of
critical variables is infeasible. By leveraging mathematical models and related measurements, it
enables real-time control, improves efficiency, and reduces costs. However, its success relies on
accurate modeling and robust process monitoring, making it a sophisticated yet indispensable
tool in modern process industries.

SPLIT-RANGE CONTROL:
Split-range control is a control strategy in which a single controller output is used to regulate two
or more final control elements (e.g., control valves, actuators) operating in different ranges. This
approach is used when a process requires multiple control actions based on the controller's
output signal. It is common in processes where heating and cooling, pressure control, or other
opposing actions are required.

Working Principle of Split-Range Control

1. Single Controller Output:
o A single controller generates an output signal, typically ranging from 0% to
100%.
2. Split Action:
o The controller output is divided into two or more segments, each corresponding to
a specific control element.
o For example:
▪ 0% to 50% may control a cooling valve.
▪ 50% to 100% may control a heating valve.
3. Opposing or Complementary Actions:
o The control elements act either in opposition (e.g., heating and cooling) or
complementarily (e.g., two valves managing flow rates).
4. Implementation:
o Split-range control is implemented using electronic, pneumatic, or software-based
systems.
Applications of Split-Range Control
1. Heating and Cooling Systems:
o One valve controls hot water flow, and another controls cold water flow to
maintain a desired temperature.
2. Pressure Control in Boilers:
o One control element releases excess pressure, while another adds more steam to
maintain the desired pressure.
3. Flow Control:
o Two valves are used to regulate different streams, such as blending or switching
between gases or liquids.
4. Energy Management Systems:
o Heating and cooling actions are managed to optimize energy usage.
Advantages of Split-Range Control
1. Efficiency:
o Allows the use of a single controller for multiple control actions, reducing system
complexity.
2. Flexibility:
o Supports processes requiring opposing or complementary control actions.
3. Cost-Effective:
o Reduces the need for additional controllers and instruments.
4. Improved Process Stability:
o Enables smooth transitions between control actions.
Disadvantages of Split-Range Control
1. Complex Configuration:
o Requires careful tuning and configuration of the controller and control elements.
2. Interference Between Actions:
o Poor tuning can lead to conflicting actions, such as simultaneous heating and
cooling.
3. Calibration Needs:
o Periodic calibration of control elements is required to ensure accuracy.
4. Limited to Specific Applications:
o May not be suitable for processes requiring highly independent control loops.
Example of Split-Range Control
Temperature Control Example:
• A chemical reactor requires its temperature to stay at 60°C.
• The controller output range is split as follows:
o 0%–50%: Operates a cooling water valve to reduce temperature.
o 50%–100%: Operates a steam valve to increase temperature.
• If the reactor temperature falls below 60°C, the steam valve opens. If it rises above 60°C,
the cooling water valve opens.
Split-range control is an effective strategy for managing processes that require multiple control
actions with a single controller. It enhances operational efficiency and provides flexibility in
handling complex process requirements. However, it demands careful design, calibration, and
tuning to avoid conflicts and ensure stable control performance.

ADAPTIVE CONTROL:
Adaptive control is a control strategy where the controller parameters are adjusted automatically
to cope with changes in the process or the environment. This approach is beneficial in systems
with varying dynamics or where operating conditions change frequently, making a fixed-
parameter controller insufficient.
The main components in a typical adaptive control system are shown in the block diagram
below.
1. Reference Model: The reference model defines the desired behavior of the system,
serving as a benchmark for the adaptive controller. The adaptive controller will adjust its
parameters to match the output of the process as closely as possible to this model's
response.
2. Parameter Adjustment Mechanism: This block is responsible for adjusting the
controller’s parameters based on feedback from the tracking error. The tracking error is
the difference between the output of the reference model and the actual output of the
system. The parameter adjustment mechanism uses this error to change the control
parameters, often using algorithms like the Model Reference Adaptive Control (MRAC)
or Self-Tuning Regulators (STR).
3. Adaptive Controller: The adaptive controller itself applies the control signal to the plant
or process. Unlike a traditional fixed-parameter controller, this controller has adjustable
parameters that are continually updated by the parameter adjustment mechanism.
4. Process/Plant: This is the system or process being controlled. It could be any dynamic
system, such as an industrial machine, a robotic arm, or an aircraft.
5. Process Output: This is the output of the process/plant that we want to control. The goal
is for this output to match the reference model output as closely as possible, even when
there are changes in the system or environment.
Applications of Adaptive Control
Adaptive control has several important applications, especially in fields where system dynamics
change over time, or precise control is needed under varying conditions:
1. Aerospace and Aircraft Control: Adaptive control is widely used in flight control
systems, where the aircraft's dynamics change with altitude, speed, and payload.
Adaptive control systems can adjust the control laws to maintain stability and
performance under these varying conditions.
2. Industrial Process Control: Many industrial processes, such as chemical reactors or
distillation columns, experience changes in parameters due to variations in feedstock or
environmental conditions. Adaptive control helps maintain product quality and process
efficiency despite these changes.
3. Robotics: Adaptive control is crucial in robotic systems that interact with unpredictable
environments, such as automated manufacturing robots or surgical robots. It allows
robots to adapt their movements and forces in response to changes in load, position, or
surface conditions.
4. Automotive Systems: In modern cars, adaptive control is used in engine management
systems, anti-lock braking systems (ABS), and adaptive cruise control. These systems
continuously adjust to changing conditions, like road friction, vehicle speed, and driver
input.
5. Power Systems: Adaptive control is used in power systems to manage frequency and
voltage stability. With the increasing penetration of renewable energy sources, the system
dynamics change frequently, and adaptive control helps maintain stability under varying
loads and generation conditions.
6. Biomedical Engineering: Adaptive control is applied in medical devices, such as
ventilators and insulin pumps, where patient-specific tuning is necessary. It ensures the
devices can adapt to a patient’s physiological changes over time.

INTERNAL MODEL CONTROLLER:

Internal Model Control (IMC) is a control strategy that utilizes a model of the process within the
controller structure to predict and counteract process disturbances. IMC is widely used due to its
ability to handle process uncertainties and disturbances more effectively than traditional control
methods. It is popular in industries that require robust performance, such as chemical processing,
power generation, and manufacturing.

Structure of the Internal Model Control

The IMC structure consists of the following components:
1. Process (G): This is the actual system or process being controlled.
2. Process Model (G_m): This is a mathematical model of the process, which is assumed to
closely represent the behavior of the actual process.
3. IMC Controller (Q): The IMC controller is designed based on the inverse of the process
model. It generates control actions by using the predicted process output from the model.
4. Disturbance (d): Disturbances represent unmeasured changes affecting the process, such
as environmental conditions or variations in raw material quality.
Explanation of Each Component in IMC
• Process (G): The process represents the real system being controlled. It has an output (Y)
that responds to both the control input and any disturbances present.
• Process Model (G_m): The model simulates the process behavior and predicts the output.
It is designed to closely resemble the actual process but may not capture every detail
perfectly.
• Disturbance (d): Disturbances are unmeasured variables that can impact the process. The
IMC structure is designed to minimize the impact of these disturbances on the process
output.
Need for Internal Model Control
1. Disturbance Rejection:
o IMC can reject disturbances effectively by predicting the effect of disturbances on
the output through the model and applying corrective actions preemptively.
o This leads to faster disturbance rejection than traditional feedback-only control, as
the IMC controller anticipates disturbances before they impact the process.
2. Robustness to Model Mismatch:
o In real-world processes, an exact model is hard to obtain due to system non-
linearities and parameter variations.
o IMC provides a robust design that can handle model inaccuracies and
disturbances by adjusting control actions based on model predictions.
3. Improved Stability and Performance:
o The IMC structure naturally provides a stable control system by accounting for
both feedback and feedforward control elements.
o It is designed to minimize the effects of slow or poorly tuned controllers, which
are less effective in responding to changes in the process.
4. Ease of Controller Tuning:
o IMC design simplifies controller tuning, often using a single tuning parameter
(the filter parameter) that directly affects system performance and stability.
o This makes IMC easy to configure for specific performance criteria like speed of
response and robustness.
5. Predictive Control:
o IMC uses the process model to predict the future behavior of the output. This
predictive capability enables the controller to anticipate process changes and
make proactive adjustments.
o This feature is particularly useful in handling time delays and improving overall
response times.
Applications of Internal Model Control
IMC is widely used in processes that require stable and precise control, such as:
• Chemical and petrochemical processes where temperature, pressure, and composition
control are critical.
• Power generation where precise turbine and boiler control is essential.
• Pharmaceutical manufacturing where quality control depends on stringent process
control.

IMC - PID (INTERNAL MODEL CONTROL – PID) CONTROLLER:

An Internal Model Control (IMC) PID Controller is a PID control strategy derived from the
principles of Internal Model Control (IMC). It uses a process model to design a robust and
effective PID controller, ensuring improved performance, disturbance rejection, and stability in
systems with time delays or dynamic complexities.
Concept of IMC in PID Design
The IMC design philosophy is based on incorporating a model of the process within the
controller to predict and compensate for process behavior. When applied to PID controllers, the
IMC approach provides a systematic method to derive the PID parameters, ensuring the
controller performs well even in the presence of model uncertainties or external disturbances.
Steps to Design an IMC PID Controller
1. Process Modeling
The process is represented by a transfer function, typically in a First-Order Plus Time Delay
(FOPTD) form:
Advantages of IMC PID Controllers
1. Robustness:
o Handles model inaccuracies and disturbances effectively.
2. Systematic Tuning:
o Provides clear, model-based guidelines for setting PID parameters.
3. Improved Stability:
o Particularly effective in systems with time delays.
4. Enhanced Performance:
o Ensures better disturbance rejection and control precision.
Disadvantages of IMC PID Controllers
1. Model Dependency:
o Requires an accurate process model for optimal performance.
2. Complexity in Design:
o More involved than traditional PID tuning methods.
3. Limited Adaptability:
o Needs re-tuning if the process characteristics change significantly.
Applications of IMC PID Controllers
1. Process Industries:
o Used in chemical reactors, distillation columns, and heat exchangers.
2. Power Plants:
o Controlling steam pressure, temperature, and turbine speed.
3. Food and Beverage:
o Ensures precise temperature and ingredient control.
4. Pharmaceuticals:
o Maintains strict quality control in drug manufacturing processes.
The IMC PID controller combines the robustness and systematic approach of Internal Model
Control with the simplicity of PID control. By leveraging process models and a well-defined
tuning methodology, it provides superior performance in handling complex processes, making it
a valuable tool in industrial control applications. However, its dependence on accurate process
modeling requires careful design and periodic validation.

MODEL PREDICTIVE CONTROL (MPC):

Model Predictive Control (MPC) is an advanced control strategy used extensively in process
industries due to its ability to handle multivariable control problems and constraints on inputs,
outputs, and state variables. MPC uses a model of the process to predict future behavior and
optimize control actions, making it well-suited for complex systems with multiple interacting
variables, such as those found in the chemical, petrochemical, and energy sectors.

Key Features of Model Predictive Control

1. Prediction of Future Outputs: MPC uses a dynamic model of the process to predict future
outputs over a defined prediction horizon. This predictive ability helps it anticipate and
counteract disturbances before they significantly impact the process.
2. Optimization of Control Actions: MPC formulates control actions by solving an
optimization problem at each sampling instant. The objective is to minimize a cost
function, usually involving deviations from the setpoint and control effort, subject to
constraints.
3. Handling of Constraints: MPC can incorporate constraints on inputs (e.g., flow rates,
pressures), outputs (e.g., product quality specifications), and states (e.g., temperature
limits), which is essential in industries where safety, quality, and regulatory compliance
are critical.
4. Multivariable Control Capability: MPC is inherently designed to handle multivariable
systems where multiple inputs influence multiple outputs, making it ideal for complex
industrial processes with interacting variables.
5. Rolling Horizon Optimization: MPC operates over a receding or rolling horizon, which
means it recalculates the control action at each time step as new data become available,
adapting continuously to changes in the process.
Basic Structure of MPC
The structure of MPC can be described with the following steps:
1. Process Model: A mathematical model (typically linear, though nonlinear models are also
used in some cases) of the process is established. This model describes how the process
variables evolve over time in response to control inputs and disturbances.
2. Prediction Horizon: MPC uses the process model to predict the future outputs over a
fixed horizon (prediction horizon), based on current and past inputs and outputs.
3. Cost Function: MPC defines a cost function that includes terms for tracking error
(deviation from the setpoint) and control effort. The goal is to minimize this cost function
to achieve desired performance.
4. Constraints: The MPC algorithm incorporates constraints on the control inputs and
process variables. For example, limits on valve positions or temperature thresholds are
often essential in industrial applications.
5. Optimization Solver: At each time step, MPC solves an optimization problem to
determine the control inputs that minimize the cost function while satisfying the
constraints.
6. Control Action: The first element of the optimized control sequence is applied to the
process, and the entire procedure repeats at the next time step.
Applications of MPC in Industries
MPC has found widespread applications in various industries due to its ability to handle
complex, multivariable processes with constraints:
1. Chemical and Petrochemical Industry
o Distillation Columns: MPC is commonly used to control distillation columns,
where it can handle the interaction between reflux flow, reboiler heat input, and
product purity. It ensures that product specifications are met even in the presence
of feed disturbances or changes in demand.
o Reactor Control: In chemical reactors, MPC helps maintain temperature, pressure,
and composition within safe limits, ensuring optimal conversion and selectivity
for desired products.
o Blending and Refining: MPC optimizes blending processes to achieve product
quality specifications and minimize costs. In oil refineries, MPC is applied to
units like hydrocrackers and reformers for efficient operation.
2. Energy and Power Generation
o Boiler Control: MPC can control the combustion process in boilers, ensuring safe
operation while optimizing fuel consumption and steam generation.
o Power Plant Load Dispatch: MPC is used in combined cycle power plants to
manage the coordination between gas and steam turbines, optimizing power
output and fuel efficiency while meeting environmental regulations.
o Grid Management: In power grids, MPC is applied for load forecasting, demand
response, and managing renewable energy sources to ensure stability and
efficiency.
3. Food and Beverage Industry
o Pasteurization and Sterilization: MPC ensures that processes reach and maintain
the necessary temperatures and hold times to kill pathogens without
compromising product quality.
o Mixing and Blending: MPC optimizes ingredient mixing and blending operations,
reducing waste and ensuring consistent product quality.
o Fermentation Processes: MPC controls temperature, pH, and nutrient levels in
fermentation, maximizing yield and quality in products like beer, yogurt, and
biofuels.
4. Pharmaceuticals and Biotechnology
o Bioreactor Control: MPC is used in bioreactors to control variables such as
temperature, pH, and dissolved oxygen, which are crucial for cell growth and
product yield in biopharmaceuticals.
o Drying and Granulation: MPC optimizes the drying and granulation processes,
which are important for consistent drug quality and potency.
o Tablet Coating: MPC is applied to control coating thickness and uniformity,
ensuring that tablets meet regulatory quality requirements.
5. Metallurgy and Steel Manufacturing
o Furnace Control: In steel and aluminum production, MPC is used to control
temperature and fuel input in furnaces, ensuring optimal energy usage and
consistent product quality.
o Rolling Mills: MPC controls thickness, tension, and speed in rolling mills to
ensure the precise dimensions of metal sheets and strips.
o Casting: MPC helps maintain stable conditions in casting processes, improving
yield and reducing defects.
6. Pulp and Paper Industry
o Digester Control: MPC controls the chemical reactions in digesters, optimizing
pulp yield while minimizing energy and chemical usage.
o Paper Machine Control: MPC manages parameters like moisture content, basis
weight, and sheet thickness to ensure high-quality paper production.
o Bleaching Process: MPC optimizes chemical dosage and reaction conditions,
balancing product quality and environmental compliance.
Advantages of MPC in Industrial Applications
• Handling of Constraints: MPC’s ability to incorporate constraints is crucial in industries
where safety and regulatory compliance are essential.
• Multivariable Control: Many industrial processes involve multiple interacting variables
that MPC handles effectively.
• Predictive Capability: By predicting future outputs, MPC allows proactive control
adjustments, which are beneficial in processes with time delays or significant
disturbances.
• Improved Product Quality and Efficiency: MPC enhances product consistency, optimizes
energy usage, and reduces waste, leading to higher efficiency and profitability.
• Adaptability: MPC is versatile and can be reconfigured or retuned for different
operational conditions, which is essential for industries with varying demands or
feedstock qualities.
Challenges of Implementing MPC
1. Model Accuracy: The performance of MPC depends heavily on the accuracy of the
process model. Building and maintaining an accurate model can be challenging,
especially for nonlinear and time-varying processes.
2. Computational Demands: MPC requires solving an optimization problem at each control
interval, which can be computationally intensive, particularly for large-scale systems.
3. Complexity of Design and Tuning: MPC systems require expertise to design, tune, and
maintain, which can increase the cost and complexity of implementation.
4. Sensitivity to Measurement Errors: As MPC relies on feedback from process
measurements, it can be sensitive to sensor errors or delays, impacting control
performance.