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Fundamentals Training
Contents
Topics:
Slide No:
Process Control Terminology
Control Principles
11 - 18
Basic Control Loop
19 - 23
Advance Control Loop 24 - 31
Control Algorithm
32 - 46
Control System 47 - 54
Exercise 55 - 59
2
3 - 10
What is a PROCESS ?
Any operation or sequence of operations involving a
change in the substance being treated.
Examples:
A change of energy state
A change of composition
A change of dimension
gas
input
FINALCONTROL
ELEMENT
PROCESS
output
A
MEASUREMENT
System
with
Feedbac
k
CONTROLLER
What is a TRANSDUCER
A device that registers a non-electrical parameter (eg. process
variable) and outputs a corresponding useable electrical signal.
Pressure to Capacitance
Pressure to Resistance or mV
Temperature to Resistance
Temperature to mV
Example:
What is a TRANSMITTER
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
ON/OFF (Binary)
Proportional (P)
Proportional-plus-Integral (PI)
Proportional-plus-Integral-plus-Derivative (PID)
What is a SIGNAL ?
An event that conveys data from one point to another.
What is an INDICATOR ?
An instrument which visually shows the value of the variable.
Example : UM331,UM451,UM551,UM151
What is a RECORDER ?
An instrument that makes and displays a continuous graphic, acoustic or magnetic
record of a measured variable.
Example : Paperless Recorder DX Yokogawa , FX Yokogawa
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.
4 - 20 mA
1
0
Control Principle
1
1
Control Principle
FEED
PRODUCT
PROCESS
CORRECTING
UNIT
1
2
MEASURING
UNIT
O/P
PV
SP
CONTROLLING
UNIT
OPERATOR
100 %
Gain
I
O
x 100%
Control Principle
Process Variable (PV)
Control Algorithm
Offset
1
3
Control Principle
Inherent Regulation
A plant possesses inherent regulation
when, in the absence of a controller,
equilibrium is re-established 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.
1
4
Control Principle
1
5
Instrument Symbols
Example Instruments
TT
I/P Current-to-Pressure
Transducer
Temperature Transmitter
PT Pressure Transmitter
TE Temperature Element
(Thermocouple, RTD)
P/P Pressure-to-Pressure
Transducer
Instrument Location
Local
Mounting
Panel Front
Mounting
Panel Rear,
or Rack Mounting
Control Principle
1
6
Instrument Symbols
Letter Designations
A
C
D
F
I
L
P
Q
R
T
V
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
Indicate
Light
Point (Test
Connection)
Record
Transmit
Valve, Damper,
Louver
Control Principle
1
7
Connection to Process,
Instrument Supply,
or Direct Mechanical Link
Pneumatic Signal
Electric Signal
Control Principle
Controller Types
Pneumatic
Analog
Digital
Single Loop Controllers
Distributed Control System
Fieldbus Control System
1
8
1
9
PIC
PT
2
0
Load
Disturbance
TIC
Cold
Water
UT151
UT351
UT551
I/P
TT
Steam
Hot
Water
2
1
FIC
FT
TT
2
2
LIC
UT351
UT451
LT
2
3
LIC
LT
I/P
2
4
r1
Primary
controller
FBC
c1
r2
Secondary
controller
FBC
c2
Multi-Variable Control
m
Disturbance
Secondary
Process
Primary
Process
2
5
Temperature
controller
Measurement
Output
Measurement
Jacket
OUT
Valve
SINGLE-LOOP CONTROL
Pressure
transmitter
Pressure
controller
Steam
2
6
2
7
Multi-Variable Control
Steam
Feedwater
FT
FT
Flow
controller
PV
O/P
LT
Boiler
SP
Level
indicating
controller
SP
Feed
forward
2
8
2
9
Multi-Variable Control
Controlled
flow, B
Wild
flow, A
SP
Remote set
controller
Output
Controlled
flow, B
Wild flow, A
SP
Ratio
controller
Output
3
0
Manual
water
regulator
Water
Set
FT Flow
transmitter
Flow A
Measurement
FC
Magnetic
flowmeter
Flow B
Control valve
Pickle tank
Other Application : Fuel/air ratio control system on combustion equipment, e.g.
boilers.
Multi-Variable Control
O/P
PIC
PV
Low select
O/P
RS
Speed
PIC
Control
O/P
PV
Pump
3
1
Control Algorithm
On/Off
Multi-step
Proportional
Integral
Derivative
3
2
Control Algorithm
3
3
On-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.
Measured
variable
differential
Controller
output
Time
Control Algorithm
3
4
Multi-Step Action
Input
Valve position
Time
4
3
2
1
Multi-step action
Time
Control Algorithm
3
5
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
Control Algorithm
3
6
O/P %
100
50
S - PV
Tan = Gain = 100 / Proportional Band
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
Control Algorithm
Low Proportional Gain: (Closed Loop)
3
7
Control Algorithm
High Proportional Gain: (Closed Loop)
3
8
Control Algorithm
3
9
Set
Point
Set
Point
% Output
Time
Integral mode
RT
Open-loop
response
a{
b{
Time
Control Algorithm
4
0
80
70
60
%
PV
50
Proportional
Plus Integral
Output
40
30
20
Proportional
Response
10
4
Time
Control Algorithm
4
1
%
Measurement
Set
Point
Set
Point
% Output
(I/D)
Time
Derivative mode
Open-loop
response
Time
Proportional + Derivative
Control Algorithm
4
2
80
70
60
PV
% 50
PID Output
40
30
20
10
4
5
Time
Control Algorithm
4
3
% Scale Range
PID Control
80
Measurement
60
40
20
Controller Output
or
Valve Position
Proportional
Proportional +
Integral
B
Proportional + Integral +
Derivative
Time - minutes
Control Algorithm
4
4
I/P
Pneumatic
Control
Valve
PID
Controller
PIC
PT Pressure
P
Transmitter
Process Vessel
Fluid Pump
Control Algorithm
4
5
Controller Selection
Start
Step change in
valve travel
Use
PID
Use
P-only
No
63.2
%
Yes
Is dead time
excessive ?
No
Is noise
present ?
Yes
Use
P+I
Reaction curve
of measured
variable
C
Capacity
Dead Time
No
Time (sec)
Control Algorithm
4
6
Controlled Variable
Controller Adjustment
Period
P-only
PID
PI
Time
Control loop
Flow
Level
Temperature
Analytical
Pressure
Proportional band
High (250%)
Low
Low
High
Low
Time constant
Fast (1 to 15 sec)
Capacity dependent
Capacity dependent
Usually slow
Usually fast
Derivative
Never
Rarely
Usually
Sometimes
Sometimes
Control System
Adaptive Control
4
7
Ex)
Digital Controller
- Sensors are run to the computers input.
- Servomechanisms are connected to the computers output.
- Future changes dont require re-wiring.
- Changing control functions (P,I, and D) and configurations
(between cascade mode and feedforward mode) will be
made on the computers program and not necessarily to any
hardware.
Control System
4
8
Supervisory Control
A control strategy where the process control computer performs
system control calculations and provides its output to the setpoints
inputs of conventional analog controllers. These analog controllers
actually control the process actuators, not the main-control
computer.
S
SP1
M.I.S
Supervisory
Control
Controller
S
SP2
Controller
S
SP3
Controller
Control System
4
9
I/O Rack
Controller
HW and
Software
Filtering
Measurement
Sampled
Value
I/O Rack
Controller
Control System
5
0
What is a FIELDBUS ?
Definition...
A digital, two-way, multi-drop communication link among
intelligent field devices and automation systems.
Fieldbus
P
T
Control room
operator stations
L
Control systems
(DCS or PLC)
F
Control System
5
1
Controller
H1
H1
H1
H1
124
H2 Bridge
Devices
H1
32 Devices
H1 - 31.25 Kbit/s
HSE - 100 M bit/s
(Fast Ethernet)
H1
32
Devices
Control System
5
2
Proprietary Bus
ADVANCED CONTROL
PID
PID
PID
PID
AI
AI
AI
AI
DCS
OPTIMIZATION
AO
AO
4 -20 mA
4 -20 mA
4 -20 mA
Control System
5
3
Built-In
Function
Blocks
Control
Anywhere
Valve
Transmitter
BKCAL_IN
OUT
AI
IN
OUT
PID
BKCAL_OUT
CAS_IN
AO
FIELDVUE
Local Control
Loop
DCS
DDC
Control in
the field
FCS
Digital
PID
PID
Analog
Loop 1
Loop 2
5
4
Analog
Loop 1
Loop 2
Digital
PID
PID
Loop 1
Loop 2
Control in the
device itself
Exercise
Which defined term is closest to the description or encompasses the example given?
A. Controller
F.
Primary element
B. Converter
G.
Signal
C. Instrument
H.
Transducer
D. Point of measurement I.
Transmitter
E. Process
1. Process temperature increases the measurable
resistance in a monitored electrical circuit.
[
]
2.
3.
5
5
Exercise
4.
Temperature transmitter.
5
6
7.
]
signal to an industry
Exercise
9. Identify the components indicated by the Arrows.
5
7
Exercise
5
8
Which defined term is closest to the description or encompasses the example given.
A.
B.
C.
D.
E.
Cascade control
Control algorithm
Control valve
Feed-forward control
Foundation Fieldbus
F.
G.
H.
I.
Gain
Offset
Proprietary Bus
Smart Device
Exercise
5
9