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Control
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Phase I - Control Fundamental
Contents
Topics: Process Control Terminology Control Principles Basic Control Loop Advance Control Loop Control Algorithm Control System Exercise Slide No: 3 - 10 11 - 18 19 - 23 24 - 31 32 - 46 47 - 54 55 - 59
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FINALCONTROL ELEMENT
MEASUREMENT
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Example:
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A device that will translate the transducers interpretation of the measured variable into a standard transmission signal.
3 - 15 psi pneumatic signal 4-20 mA dc electrical signal 1-5 V dc electrical signal
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What is an INDICATOR ?
An instrument which visually shows the value of the variable.
What is a RECORDER ?
An instrument that makes and displays a continuous graphic, acoustic or magnetic record of a measured variable.
What is a DCS ?
Distributed Control System consisting of functional integrated subsystems. The subsystems are connected by a communication linkage (eg) data bus,data highway.
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4 - 20 mA
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Control Principle
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Control Principle
FEED PROCESS CORRECTING UNIT MEASURING UNIT PRODUCT
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O/P
CONTROLLING UNIT
PV SP
OPERATOR
Control theory can be encapsulated as the matching of a measured variable (PV) to the plant requirement (SP). A controller implements a Control Algorithm so that an output signal (O/P) activates a correcting unit. The ratio of output signal (O) to input signals (I) is Gain (K). Proportional band 1 % =
K 100 % = Gain I x 100% O
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Control Principle
Process Variable (PV)
the actual measurement of the state of the process
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Control Algorithm
the predefined response of the controller to PV-SP
Offset
the value of PV-SP when the system is in equilibrium
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Control Principle
Inherent Regulation A plant possesses inherent regulation when, in the absence of a controller, equilibrium is reestablished after a disturbance.
For example, a tank with constant inflow is in equilibrium. The outflow valve is then opened a little more. The outflow pressure decreases as the tank level falls until inflow again equals outflow. Manipulation of the outflow valve result in different, unique equilibrium states.
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Control Principle
Instrument Symbols
Example Instruments TT Temperature Transmitter I/P Current-to-Pressure Transducer PT Pressure Transmitter P/P Pressure-to-Pressure Transducer
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FIC Flow Indicating Controller TE Temperature Element (Thermocouple, RTD) Instrument Location Local Mounting Panel Front Mounting
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Control Principle
Instrument Symbols
Letter Designations First Letter Measured or Modifier Initiating Variable Analysis User's Choice User's Choice Differential Flow Rate Ratio (Fraction) Current (Electrical) Level Pressure, Vacuum Quantity Integrate, Totalize Radiation Temperature Vibration Succeeding Letters Readout or Output Passive Function Function Alarm Control
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A C D F I L P Q R T V
Indicate Light Point (Test Connection) Record Transmit Valve, Damper, Louver
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Control Principle
Signal Types (ISA)
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Pneumatic Signal
Electric Signal
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Control Principle
Controller Types Pneumatic Analog Digital Single Loop Controllers Distributed Control System Fieldbus Control System
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PT
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Fluid response slowly to change in input heat Requires advanced control strategies Feedforward Control
Load Disturbance
TIC
Cold Water
I/P TT
Steam
Hot Water
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Control
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FT
TT
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LT
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Control
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LIC
I/P
LT
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Multi-Variable Control
m
Disturbance Secondary Process Primary Process
r1
FBC
r2
FBC
c1
c2
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Pressure controller
OUT
Valve
Steam
SINGLE-LOOP CONTROL
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RSP
TIC
_
Major Load B: Steam Header Pressure
FT
FC
I/P
TT
Condensate
Load A (Demand)
TIC
FC
Temperature Process
FT TT
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Control
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Multi-Variable Control
Feedwater
Steam
SP
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FFD
Feedforward Loop Feedback Loop
FT TIC
Cold Water
I/P
TT
Steam Hot Water
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Control
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An uncontrolled flow determines a second flow so that a desired ratio is maintained between them. The ratio factor is set by a ratio relay or multiplying unit which would be located between the wild flow transmitter and the flow controller set point. Flow B is controlled in a preset ratio to flow A.
Multi-Variable Control
Controlled flow, B Wild flow, A Ratio Output = A x ratio relay Remote set controller Wild flow, A Controlled flow, B Ratio controller
SP
SP
Output
Output
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Acid supply
Measurement
FT Flow transmitter
FC Magnetic flowmeter
Flow B
Flow A
Control valve
Pickle tank Other Application : Fuel/air ratio control system on combustion equipment, e.g. boilers.
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Multi-Variable Control
Low select O/P RS Speed PIC Control O/P PV Pump
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O/P PIC PV
Control Algorithm
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Control Algorithm
OnOn-Off Control
It is a two-position control, merely a switch arranged to be off (or on as required) when the error is positive and on (or off as required) when the error is negative. Ex.. Oven & Alarm control.
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Measured variable
differential
Control Algorithm
MultiMulti-Step Action
A controller action that may initiate more than two positioning of the control valve with respect to the respective predetermined input values.
8 5 8 0 7 5
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Input
Time
Valve position
4 3 2 1
Multi-step action
Time
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Control Algorithm
Proportional Action (P)
It is the basis for the 3-mode controller. The controller output (O/P) is proportional to the difference between Process Variable (PV) and the Set Point (SP).
Process Load SP PV Controller Output
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Control Algorithm
Proportional Action (P)
The Algorithm is : O/P = - (PV - SP) + Constant Proportional Band (Constant is normally 50% )
50 O/P % 100
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When a disturbance alters the process away from the set-point, the controller acts to restore initial conditions. In equilibrium, offset (PVSP = constant) results.
PV Many controllers have a manual reset. This enables the operators to manipulate the constant term of the algorithm to eliminate offset. Time Recovery time
Offset
SP Time
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Control Algorithm
Low Proportional Gain: (Closed Loop)
100 90 80 70 60 % 50 40 30 20 10 Output
E0 E1 E2 E3 E4
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SP
PV
0
prop
4 5 Time
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Control Algorithm
High Proportional Gain: (Closed Loop)
100 90 PV 80 70 60 % 50 40 30 20 Output 10 SP
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0
higain
4 5 Time
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Control Algorithm
Integral Action (I)
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Whilst PV SP, the controller operates to restore equality. As long as the measurement remains at the set point, there is no change in the output due to the integral mode in the controller. The output of the controller changes at a rate proportional to the offset. The integral time gives indication of the strength of this action. It is the time taken for integral action to counter the offset induced by Proportional Action alone.
Set Point RT a{ % Output Time RT = Reset Time min./rpt a=b b{ Time
% Measurement
Set Point
Open-loop response
Integral mode
Control Algorithm
Integral Action: (Closed Loop)
100 90 80 70 60 PV % 50 40 30 20 10 Proportional Response Proportional Plus Integral Output SP
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4 Time
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Control Algorithm
Derivative Action (D)
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As the PV changes, the controller resists the change. The controllers output is proportional to the rate at which the difference between the measured and desired value changes. The derivative time is an indication of this action. It is the time that the open-loop P+D response is ahead of the response due to P only.
Set Point DT = Derivative Time (min) DT Proportional only Time Proportional + Derivative
% Measurement
Set Point
Open-loop response
Derivative mode
Control Algorithm
PID Action: (Closed Loop)
100 90 80 70 60 % 50 40 30 20 10 PV PID Output SP
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4 5 Time
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Control Algorithm
PID Control
% Scale Range 80 Measurement 60 40 20 Proportional Controller Output or Valve Position Proportional + Integral B Proportional + Integral + Derivative Time - minutes A
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Control Algorithm
P & ID Piping & Instrumentation Drawing
Compressed Air Pipe Converter PID Controller
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I/P
Pneumatic Control Valve
PIC
PT Pressure P
Transmitter Process Vessel
Fluid Pump
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Control Algorithm
Controller Selection
Start
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