Level 1 Fundamentals Training
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RMT Sales Training - 05 /98 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
RMT Training - 05 /98
Level 1 - Control
Process Control Terminology
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 hot to cold, liquid to gas a chemical reaction grinding coal
Types of PROCESS VARIABLE:
Pressure Flow Level Temperature Liquid Interface Specific Gravity of liquid Density Mass Conductivity Composition Moles
Level 1 - Control
RMT Training - 05 /98
Process Control Terminology
What is a CLOSED LOOP ? A combination of instruments or functions that are interconnected to measure and control a process variable with feedback. input PROCESS A System with Feedback CONTROLLER
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output
FINALCONTROL ELEMENT
MEASUREMENT
Level 1 - Control
Process Control Terminology
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 Capacitance pressure sensor module Piezo-resistive pressure sensor module RTD Thermocouple
Example:
RMT Training - 05 /98
Level 1 - Control
Process Control Terminology
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
RMT Training - 05 /98
Level 1 - Control
Process Control Terminology
ADVANTAGE OF 4-20mA CURRENT SIGNAL Lower installation cost
simple, twisted pair wiring
Better noise immunity
current vs. voltage
Insensitive to wire resistance
current vs. voltage
Better suited for hazardous locations
intrinsic safety
RMT Training - 05 /98
Level 1 - Control
Process Control Terminology
What is a CONTROLLER ? Used to keep a process variable at a desired value (set point).
Closed loop vs. Open loop control
Difference: Open loop control has no feedback
Control Modes
ON/OFF (Binary) Proportional (P) Proportional-plus-Integral (PI) Proportional-plus-Integral-plus-Derivative (PID)
RMT Training - 05 /98
Level 1 - Control
Process Control Terminology
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.
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.
Level 1 - Control
RMT Training - 05 /98
Process Control Terminology
What is a FINAL CONTROL ELEMENT? The last control element in the process control loop that manipulates the process variable.
Control Valves modulates flow rate operated by actuator Louvers and Dampers operated by pneumatic actuators Variable Speed Drives operated by electronic control signals
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4 - 20 mA
Level 1 - Control
RMT Training - 05 /98
Control Principle
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RMT Training - 05 /98
Level 1 - Control
Control Principle
FEED PROCESS CORRECTING UNIT PRODUCT
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MEASURING UNIT
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
RMT Training - 05 /98
100 % Gain
I O
x 100%
Level 1 - Control
Control Principle
Process Variable (PV)
the actual measurement of the state of the process
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Set Point (SP)
the desired state of the process variable
Control Algorithm
the predefined response of the controller to PV-SP
Controller Output (O/P)
a signal determined by the control algorithm
Offset
the value of PV-SP when the system is in equilibrium
Direct Acting Controllers
as the value of the measured variable increases, the output of the controller increases.
Reverse Acting Controllers
as the value of the measured variable increases, the output of the controller decreases.
RMT Training - 05 /98
Level 1 - Control
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.
RMT Training - 05 /98
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Level 1 - Control
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
Panel Rear, or Rack Mounting
RMT Training - 05 /98
Level 1 - Control
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
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Indicate Light Point (Test Connection) Record Transmit Valve, Damper, Louver
Level 1 - Control
Control Principle
Signal Types (ISA)
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Connection to Process, Instrument Supply, or Direct Mechanical Link
Pneumatic Signal
Electric Signal
RMT Training - 05 /98
Level 1 - Control
Control Principle
Controller Types Pneumatic Analog Digital Single Loop Controllers Distributed Control System Fieldbus Control System
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Level 1 - Control
Basic Control Loop
Pressure Control Loop
I/P PIC
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Pressure Loop Issues:
May be a Fast Process Liquid Small Volume May Require Fast Equipment
PT
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Level 1 - Control
Basic Control Loop
Temperature Control Loop Temperature Loop Issues:
Fluid response slowly to change in input heat Requires advanced control strategies Feedforward Control
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Load Disturbance
TIC
Cold Water
I/P TT
Steam
Hot Water
RMT Training - 05 /98 Level 1 - Control
Basic Control Loop
Flow Control Loop Flow Loop Issues:
May be a Very Fast Process Noise in Measurement Signal May Require Filtering May Require Fast-Responding Equipment Typically Requires Temperature Compensation
I/P FIC
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FT
TT
RMT Training - 05 /98
Level 1 - Control
Basic Control Loop
Level Control Loop (Inflow)
I/P LIC
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Level Loop Issues: Control At Inflow or Outflow Non-Self Regulating
LT
RMT Training - 05 /98
Level 1 - Control
Basic Control Loop
Level Control Loop (Outflow)
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LIC
I/P
LT
RMT Training - 05 /98
Level 1 - Control
Advance Control Loop
What is CASCADE CONTROL ?
Consist of one controller (primary, or master) controlling the variable that is to be kept at a constant value, and a second controller (secondary, or slave) controlling another variable that can cause fluctuations in the first variable. The primary controller positions the set point of the secondary, and it, in turn, manipulates the control valve.
Primary controller Secondary controller
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Multi-Variable Control
m
Disturbance Secondary Process Primary Process
r1
FBC
r2
FBC
c1
c2
RMT Training - 05 /98
Level 1 - Control
Advance Control Loop
Example of CASCADE CONTROL
The temperature of the liquid in the vessel is controlled by regulating the steam pressure in the jacket around the vessel.
Temperature transmitter IN Temperature controller
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Measurement Output Measurement Jacket Pressure transmitter
Pressure controller
OUT
Valve
Steam
SINGLE-LOOP CONTROL
RMT Training - 05 /98
Cascade Control Loop
Level 1 - Control
Advance Control Loop
Implementing Cascade Control
Steam Header
Cold Water
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RSP
TIC
_
Major Load B: Steam Header Pressure
FT
FC
I/P
TT
Steam Major Load A: Outflow Rate Hot Water (Demand)
Condensate
Load B (Header Pressure) SP RSP
Load A (Demand)
TIC
FC
Steam Flow Process
Temperature Process
FT TT
RMT Training - 05 /98
Level 1 - Control
Advance Control Loop
What is FEED FORWARD CONTROL ?
Applies to a system in which a balance between supply and demand is achieved by measuring both demand potential and demand load and using this data to govern supply. It gives a smoother and stable control than feedback control.
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Multi-Variable Control
Feedwater
Steam
FT FT Flow controller PV O/P LT Boiler Level indicating controller SP Feed forward
SP
RMT Training - 05 /98
Level 1 - Control
Advance Control Loop
Implementing Feedforward Control
Feedforward Equations Summing Junction
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FFD
Feedforward Loop Feedback Loop
FT TIC
Cold Water
I/P
TT
Steam Hot Water
RMT Training - 05 /98 Level 1 - Control
Advance Control Loop
What is RATIO 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
RMT Training - 05 /98
Output
Level 1 - Control
Advance Control Loop
Example of RATIO CONTROL
Pickling Process
Set
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Acid supply
Measurement
Manual water regulator Water
FT Flow transmitter
FC Magnetic flowmeter
Flow B
Flow A
Control valve
Pickle tank Other Application :
RMT Training - 05 /98
Fuel/air ratio control system on combustion equipment, e.g. boilers.
Level 1 - Control
Advance Control Loop
What is SELECTIVE CONTROL ?
The more important condition between two or more candidates is selected. They are used mainly to provide protection to a piece of equipment which could suffer damage as a result of abnormal operating conditions.
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Multi-Variable Control
Low select O/P PIC PV RS Speed Control O/P Pump
Level 1 - Control
O/P PIC PV
RMT Training - 05 /98
Control Algorithm
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On/Off Multi-step Proportional Integral Derivative
RMT Training - 05 /98
Level 1 - Control
Control Algorithm
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.
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Measured variable
differential
Controller output Time
RMT Training - 05 /98 Level 1 - Control
Control Algorithm
Multi-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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Time
4 3 2 1
Multi-step action
RMT Training - 05 /98
Time
Level 1 - Control
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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Open-loop response of proportional mode
RMT Training - 05 /98 Level 1 - Control
Control Algorithm
Proportional Action (P)
The Algorithm is : - (PV - SP) O/P = + Constant Proportional Band (Constant is normally 50% )
50 O/P % 100
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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
RMT Training - 05 /98
Level 1 - Control
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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Level 1 - Control
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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Level 1 - Control
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{ b{ Time RT = Reset Time min./rpt a=b
% Measurement
Set Point
% Output Time
Open-loop response
Integral mode
RMT Training - 05 /98
Proportional plus Integral mode
Level 1 - Control
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
RMT Training - 05 /98
Level 1 - Control
Control Algorithm
Derivative Action (D)
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
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% Measurement
Set Point
% Output (I/D) Time
Open-loop response
Proportional + Derivative
Derivative mode
RMT Training - 05 /98
Proportional plus Derivative mode
Level 1 - Control
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
RMT Training - 05 /98
Level 1 - Control
Control Algorithm
PID Control
% Scale Range
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80 Measurement 60 40 20 Proportional A
Controller Output or Valve Position
Proportional + Integral B Proportional + Integral + Derivative Time - minutes
Open-loop response of three-mode controller
RMT Training - 05 /98 Level 1 - Control
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
RMT Training - 05 /98 Level 1 - Control
Control Algorithm
Controller Selection
Start
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Step change in
valve travel Use PID Can offset be Yes tolerated ? No Yes Is dead time excessive ? No No Is noise present ? Yes Use P+I Use P-only
63.2 % C
Reaction curve
of measured variable
Capacity Dead Time Time (sec)
RMT Training - 05 /98
Level 1 - Control
Control Algorithm
Controller Adjustment
Controlled Variable
Period P-only PID PI
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Time
Control loop Flow Level Temperature Analytical Pressure
RMT Training - 05 /98
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
Level 1 - Control
Control System
Adaptive Control
An automatic control scheme in which the controller is programmed to evaluate its own effectiveness and modify its own control parameters to respond to dynamic conditions occurring in or to the process which affect the controlled variables.
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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.
RMT Training - 05 /98
Level 1 - Control
Control System
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
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M.I.S
Supervisory Control
SP2
Controller S Controller S
SP3
RMT Training - 05 /98
Controller
Level 1 - Control
Control System
Todays DCS System
Coax
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I/O Rack
Controller Tools for Process Analysis, Diagnostics.
HW and Software Filtering Measurement I/O Rack Controller
Sampled Value Tools for Process Analysis, Diagnostics.
Level 1 - Control
RMT Training - 05 /98
Control System
What is a FIELDBUS ? Definition...
A digital, two-way, multi-drop communication link among intelligent field devices and automation systems. Fieldbus
(Only Digital Signals)
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P T
Control room operator stations
L
Control systems (DCS or PLC)
F
RMT Training - 05 /98
Level 1 - Control
Control System
Fieldbus Control System
Work Systems Gateway Controller H1 H1 H1 H1 H2 Bridge H1 Total of approximately 35,000 devices (due to address limits) . HSE 124 Devices
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32 Devices
H1 - 31.25 Kbit/s HSE - 100 M bit/s (Fast Ethernet)
RMT Training - 05 /98
H1 32 Devices
Level 1 - Control
Control System
Proprietary Bus
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ADVANCED CONTROL
OPTIMIZATION
PID
PID AI AO
4 -20 mA 4 -20 mA 4 -20 mA
AI
DCS
Control in the control room
RMT Training - 05 /98 Level 1 - Control
Control System
Foundation Fieldbus Devices
Delta V
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Built-In Function Blocks
Transmitter
BKCAL_IN OUT IN OUT
Control Anywhere
Valve
FIELDVUE
BKCAL_OUT CAS_IN
AI
PID
AO
Control in the field with fieldbus
RMT Training - 05 /98 Level 1 - Control
Look at how the CONTROL migrate
Central Control Loop
DDC Digital PID PID Analog Analog
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Local Control Loop DCS
Control in the field
FCS
Digital
PID
PID
Loop 1
Loop 2
Loop 1
Loop 2
Loop 1
Loop 2
Control in the device itself
RMT Training - 05 /98 Level 1 - Control
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. Pulsed output from a turbine meter. Heat-injected plastic molding.
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[ [ [
] ] ]
2. 3.
RMT Training - 05 /98
Level 1 - Control
Exercise
4. 5. Temperature transmitter. Device which adjusts the measured value of the process to the requirements of the operator. [
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] ] ]
6. 7. 8.
Element, flow transmitter, controller and correcting unit. [ A pipe piece is tapped for a sample fluid. A device changes an industry standard pneumatic signal to an industry standard hydraulic signal. [
RMT Training - 05 /98
Level 1 - Control
Exercise
9. Identify the components indicated by the Arrows.
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RMT Training - 05 /98
Level 1 - Control
Exercise
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
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10. The predefined response of the controller to PV-SP. 11. The value of PV-SP when the system is in equilibrium. 12. The ratio of controllers output to input. 13. It is a final control element operated by an actuator.
[ [ [ [
] ] ] ]
RMT Training - 05 /98
Level 1 - Control
Exercise
14. Involves master & slave controllers. 15. The output of the loop drives the input. 16. A digital communication based control network with control action in the controller only. 17. A digital communication based control network that allow control in the field. 18. A device that provide both analog & communication signal in its loop wire pair. [ [ [ [ [
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] ] ] ] ]
RMT Training - 05 /98
Level 1 - Control
