COMPUTERISED PROCESS

CONTROL
BY
SADASIVAN J
 Fundamentals of automatic
process control
• Process:
• As a set of different sub processes and activities
between them
• Control variable: the parameter which we want to
control is called control variable
• manipulated variable : The variable which is
manipulated to correct the control variable is called
manipulated variable or controlled variable
•
• In water heating system , we have to control the temp.
of the water coming out. This can be controlled by
varying the steam flow rate . Asume that the temp.
of the steam is constant. Out put temp. can be
varied by steam flow rate.Here the tem.of the water
which we want to control s called control variable
• Temp is controlled by
manipulating steam flow rate .so
steam flow rate is called
manipulated variable or
controlled variable
• Other factors that affect the
output temp. are temp. of the
incoming water , atmospheric
temp etc. These are called load
variables
 AUTOMATIC PROCESS
CONTROLLER


 IS DEFINED AS A MECHANISM THAT MEASURES

THE VALEU OF CONTROL VARIABLE AND
MANIPULATES THE MANIPULATED VARIABLE OR
CONTROLLED VRIABLE TO LIMIT THE DEVIATION
OF CONTROL VARIABLE FROM THE SET POINT
 FEED BACK CONTROL
• A closed loop system or feed back
system measures the actual
system output compares it with set
value and determines the error .
The error value is then used to
control the system output in order
to get the desired output
Basic of principles of f/b control
• Here the level to be controlled is
sensed and transmitted by Level
Transmitter and sends a signal to
the controller proportional to the
level in the tank
•
• The contoller consists of three basic
parts
• 1. Memory for the desired level or
set point in the tank
• 2. Comparator for set point Vs
measured value as reported by the
transmitter , producing the
difference between the them,
• 3. an amplifier amplifies the error
and produces the output of the
controller
 VARIOUS TYPES OF
CONTROLS
• 1 Two position control
• 2 Multi position control
• 3 PID control
• 4 Ratio control
• 5 Cascade control
• 6. Feed forward control
 Two position control (on/off
control)
`
• The simplest and cheapest form of
control is two position control
• In this mode of control the final
control element is moved quickly
from one of the two fixed positions
to other depending upon wheather
the control variable is greater than
the set point
 On/off control with
differential gap
• The valve is closed as the control
variable crosses the high set value
and shall remain closed till it
crosses the low set value , then the
valve is opened again
2.MULTI POSITION CONTROL
• In this the final control element is
moved to one of three or more
fixed positions .In this control the
valve is closed when the control
variable is above the high set value
. When it ismid band , the valve is
half open and when it is lower than
the low set value the valve is fully
open
 PID control
• As the name suggests, the PID algorithm
consists of three basic modes:
the Proportional mode,

the Integral mode

& the Derivative mode

 Definitions
• In the time domain:
t de(t )
• u (t ) = K p e(t ) + K i ∫ e(t )dt + K d
0 dt
 1 t de(t ) 
= K p  e(t ) + ∫ e(t )dt + Td 
 Ti 0 dt 
in te g ra l tim e co n sta n td e riv a tiv e tim e co n sta n t
Kp Kd
where Ti = , Td =
Ki Ki d e riva tive g a in

p ro p o rtio n a l g a in in te g ra lg a in
 Controller Effects

• A proportional controller (P) reduces error

responses to disturbances, but still allows
a steady-state error.
•
• When the controller includes a term
proportional to the integral of the error (I),
then the steady state error to a constant
input is eliminated, although typically at
the cost of deterioration in the dynamic
response.
•
• A derivative control typically makes the
 Closed-loop Response
Rise time Maximum Settling Steady-state
overshoot time error
P Decrease Increase Small Decrease
change
I Decrease Increase Increase Eliminate

D Small Decrease Decrease Small

change change
 Conclusions

• Increasing the proportional feedback gain

reduces steady-state errors, but high
gains almost always destabilize the
system.
•

• Integral control provides robust reduction

in steady-state errors, but often makes
the system less stable.
•

• Derivative control usually increases

damping and improves stability, but has
almost no effect on the steady state error
•
 MULTIVARIABLE CONTROL
• In real ,the control depends on many
control variable s, though there is
only one controlled variable for
each control loops. Such control
loops are known as multi variable
control
• They are
• Cascade control
• Ratio control
4. CASCADE CONTROL
 C a sca d e S yste m s
C a sca d e C o n tro lS yste m s co n ta in
in te g ra te d se ts o f co n tro llo o p s
Prim a ry Lo o p : M o n ito rs th e co n tro l
va ria b le a n d u se s d e via tio n fro m its
se tp o in t to p ro vid e a n o u tp u t to th e
se co n d a ry lo o p .
S e co n d a ry Lo o p : R e ce ive s its
se tp o in t fro m th e p rim a ry lo o p a n d
co n tro ls th e re fe re n ce va ria b le
a cco rd in g ly.
B e n e fits o f C a sca d e C o n tro l
E ffe ctive ly a cco u n ts fo r exte rn a l
d istu rb a n ce s
R e d u ce s d e a d tim e in va ria b le
re sp o n se
C o m p a tib le w ith o th e r C o n tro l
S yste m s, su ch a s Fe e d -B a ck a n d
Fe e d - Fo rw a rd C o n tro lA rch ite ctu re s
 D isa d va n ta g e s o f C a sca d e
C o n tro l
M u ltip le co n tro llo o p s m a ke p h ysica l
a n d co m p u ta tio n a la rch ite ctu re m o re
co m p lex
A d d itio n a lco n tro lle rs a n d se n so rs ca n
b e co stly
 RATIO CONTROL
• In ratio control system , a dependent
variable ( called secondary variable
) is measured as a function of an
independent variable
• Objective:To maintain the ratio of two
variables at a specified value R=
u/d
• U and d are physical variables
 Examples
• 1.In automobile. : a particular ratio of
‘tetra ethyl lead’ to gasoline is to
be maintained to produce the
desired octane number
• 2 In chemical reactor: particular ratio
of different components is to be
maintained
• 3. Cement kiln: speed of rotor Vs
slurry flow rate is to be controlled
• 4. In boiler control: control of air flow
Vs steam flow
FEED FORWARD CONTROL
.
Feedforward control : Measure feed
temperature Ti,,makes adjustments in the
steam flowrate to the heating coil for
changes in Ti.

Feedforward control : compensate

measured disturbance before process is
affected
Process output : never measured in
feedforward control
Compare Feedback with Feedforward
Control
Feedback Feedforward

Advantages

Not require identification and Acts before a disturbance has been

measurement of disturbance felt by the system.

Insensitive to modeling errors. Good for slow systems or

significant dead time.
Insensitive to parameter Not introduce instability in the
changes. closed-loop response.
Disadvantages

Control action is taken after Requires all disturbances and

disturbances have been felt. their direct measurement.

Unsatisfactory for slow and Cannot cope with unmeasured

significant dead time process. disturbances.

It may create instability in Sensitive to process parameter

the closed-loop response. variations.
ELEMENTS OF PROCESS CONTROL

•Process
•Measurement
•Error Detector
•Controller
•Control Element
PROCESS CONTROL BLOCK
p
DIAGRAM
Control Element

e = r - u
b
r Controller Process

Summing c
Point

Measurement
b

p = Controller output c = Controlled variable b = measured value of c

e = Error signal r = Set point u = Controlling variable
Block diagram of basic process control loop.
Example:

Physical diagram for flow process control system

 Final Control
Element
Controller I/P Converter,
Actuator, Valve
(Error
Detector)

r (Controller) Pipe & Flow

Process

Measurement Orifice plate, DP

Cell, P/I Converter

Block diagram for flow process control system.

 ANALOG DATA REPRESENTATION
Analog Standards for representing range of
variable in Process Control Systems:
•Current Signal : 4 to 20 mA
•Pneumatic Signal : 3 to 15 psi (20 to 100kPa)
Why Current Signal?
•Current is used instead of voltage because the
system is then less dependent on load.

Transmission of current signal is independent of line resistance

FINAL CONTROL OPERATION
Signal Actuator
Control Conversion
Signal

Final
Control
Element

Process

Elements of Final Control Operation

 ANALOG & DIGITAL I/P
MODULE
• These are the modules which
connect the process to the real
time system/data processing unit
• ANALOG I/P SIGNALS
• SENSORS measures the physical
quantities like pressure, position
,velocity , temp. etc
• SIGNAL CONDITIONER:takes the o/p
of the sensor, amplied, filtered,
isolated sothat it is accetable to the
real time system
• DIGITAL I/P SIGNAL
• refers to the ON/OFF positions of
various valves , limit swithes
etc,these signals can be inputted
directly into the real time system.
In some cases signal conditioner is
required to filter the noises .
•
Analog i/p module
• The module continuously scans the
analog input signals in the
predefined order and frequency
,converts them into digital and then
sends these values to processor
•
• more sophisticated input module
contains local intelligence , ie it
include processor also
•
• Analog I/P module with local
intelligence
• the processor initiates the multiplexer
by sending the address of input
channel
• The multiplexer connectesthe input
channel to ADC
• The processor sends the start of
convertion signal to ADC . The ADC
converts the analog signal to digital,
puts it at the output and issues end of
conversion signal
• Processor on receipt of EOC signal ,
reads the ADC output and stores it in
memory
• DIGITAL I/O MODULE
• The digital iputs can be given directly
to the processor, no ADC is
required
DIGITAL I/P MODULE WITH
INTELLIGENCE
ANALOG O/P MODULE
• ANALOG O/P MODULE
• The objective of the analog output
module is to provide control
signals to final control elements.
The demultiplexer switches the
digital output received from the
master processor to the out put
channel whose address is specified
by the processor(ie ,the master
processor).The DAC of perticular
channel converts the digital value
to equivalent analog signal which is
connected to final control element
• INTERRUPT CONTROL MODULE
• Interrupt signals: are generated
when there is abnormal situations
in the environment or in the
process . Common abnormalities
are
• 1. exceeding of certain limits of some
parameters like temp. , pressure ,
flow etc.
• 2. power failure in which case all
parameters must be stored and
work may be suspended
• One interrupt signal will corresponds
to one particular abnormality
• real time systems attends
abnormalities by executing special
programs called interrupt servicing
routines
DISPLAY CONTROL MODULE
• Display output signals: drive display
devices like LED, LCD, alarms
etc.signalsrelated to the status of
process , various control valve, limit
set for various parameters in the
process to be monitored are also
displayed
• Display control module consists of
following independent sub
modules
• 1. manual entry sub module
• 2. CRT controller sub module
• 3. LED/LCD control sub module
• 4. Alarm annunciator sub module
• 5. Printer controller sub module
•
• Manual entry sub module: include
ON /OFF command switches, key
boards etc.
•
• CRT controller sub module: interfaces
main processor to visual display
unit , which is used to show the
status of the process by displaying
the transducer values , present set
value entered through manual
entry sub module, historical trend
of various parameters etc.
• LCD/LED control sub module:
interfaces the LED/LCD to main
processor .this module accepts data
from main processor and displays it
on LED/LCD
• Alarm annunciatorcontroller sub
module: generates ON/OFF signal for
each type of alarm.Thesignals are
digital to light the incandescent bulbs
and audio alarms
•
• Printer controller sub module : is printer
interface to main processor .Generally
it has local intelligence for printer
control , data buffer to store the data
for printing
SCADA
SC A D A
•S C A D A is S u p e rviso ry C o n tro lA n d
D a ta A cq u isitio n
•SUPERVISORY CONTROL o f e q u ip m e n t,
e.g. closing and tripping of swith-gears
and tap changing of transformers in
power plants, controlling process
parameters in process plants.
•DATA ACQUISTION , i.e. ability to get
various information from the field by
some means
• The basic functions of SCADA are
• 1. channel scanning
• 2. Conversion into engineering units
• 3. Data processing
•
 Channel scanning
• Scanning is the process by which
microprocessor address various
channels and read the data.Thera
are two types scanning
• 1. polling
• 2. Interrupt scanning
 POLLING
• Polling is the process of scanning the
channel to read data
• The channel selection may be
sequential or in any perticular order
decided by the designer
• It is also possible to assign priority to
some channels over the other
• Channel scanning and reading of
data requires the following actions
to be taken
• 1. sending channel address to
multiplexer
• 2. sending start of convertion pulse
to ADC
• 3. reading the digital data
Channel scan array
• The channel can be polled
sequentially, in which case the
channel address is increased one
by one
• In another case a channel scan array
is maintained in memory ,the scan
array contains the address of the
channel in the order they should be
addressed
• In the above channel scanning array ,
the first channel to be scanned is
channel 9, followed by 10, 1,2 … as
• If a channel number is repeated in
the array , then that
perticularchannel will be scanned
repeatedly, in the above case
channel 9 is scanned 3 times ,
channel 2 is acanned 2 times while
other channels are scanned once
during a cycle
• it is also possible to schedule the
time gap between two channels
Channel scanning with time
 Interrupt scanning
• The transducer check for any
violation of limits , if the signal is
not within the high and low limit ,
then the limit checking circuit
would send interrupt request to
microprocessor which inturn would
monitor all parameters till the
parameter values come back with
in pre specified limits
Conversion into engineering
units
• The transmitter output should be in
the range of 0-5v or 4-20ma .
Depending on the input range of
measured value for transmitter a
calibration factor is determined
• If a transmitter is capable of
measuring parameter within the
input range x1 and x2 and provides
0-5v signal at output then caliration
factor is
• 1 volt=(x2-x1)/5 units
• If a 8bit unipolar ADC is used the
output rang 0 -255 ie for 0v output
is 0
• for 5v output is 255
• 1v=255/5 =(x2-x1)/5
• If ADC output is Y then the
corresponding value in engineering
units will be Y(x2-x1)/255
• The conversion factor is (x2-x1)/255
•
•
 Data processing
• The data read from the ADC for
various channel is processed by the
microprocessor to carryout limit
checking and performance
analysis . For limit checking the
highest and lowest limits for each
channels are stored in the array if
any of the two limits are violated
for any channel , appropriate action
is initiated
Limit checking routine
 Limit checking routine
• from the ADC output , the
microprocessor analysis the
performance of the system for
managerial level. This report will
enable the managers to visualize
the problem in the system and to
take decision regarding system
modification or alternate
operational strategy to increase the
system performance . The analysis
may include histogram generation,
standard deviation ,plotting one
Distributed SCADA system
Daisy chain configuratin
Remote terminal unit(RTU)