Basic Process Control

Basic Control Principles

Level
(Controlled Variable)
Overflow
Pump
Inflow
Supply
l
l
l
l
l
l
Open vs Closed Loop
! Closed loop
! Automatic control
! Open Loop
! Manual control
! Person takes the place of the controller
Feedback Control
Comparator Amplifier Process (Tank)
Error
(SP - M)
Manipulated Output
(Controlled
Variable - Level)
Disturbances
Variable
Process
Sensor
Signal
Measurement
Set Point
Controller
Feedback vs. Feedforward
! Feedback
! Control action after an error exists
! Feedforward
! Reacting to the disturbance before the
error occurs
Typical ON/OFF Control System
P1
L1
L2
V
Qin
SP
Qout
1
P1 closes @ L1
P1 opens @ L2
Power Supply
Solenoid
Solenoid valve
Electrically Operated
Inflow
l
l
l
l
l
l
Typical ON/OFF Response
L2
Periodic Time
L1
SP
time
Proportional Control
Level Control of Open Tank
Qout
LT
SP
Qin
V
1
20 - 100 kPa
A/C
l
l
l
l
l
l
Simple Proportional System
Pivot
Outflow
Float
Valve
Inflow
l
l
l
l
l
l
Open Tank Control
Qin
Qout
SP
LT
20 - 100 kPa
A/O
LIC
Controller Action
Qin
Qout
SP
LT
20 - 100 kPa
A/C
LIC
l
l
l
l
l
l
Qin
Qout
SP
LT
20 - 100 kPa
A/O
LIC
l
l
l
l
l
l
Direct
Reverse
Proportional Control
+
-
ke
Setpoint
Measurement
Error
Bias
+
+
Output
m= k(SP-M) + bias
Proportional Band and Gain
Proportional Band
the input change required to
change the output 100%
PB
gain
% 100
!
input
output
gain
"
"
!
Narrow, Wide, High & Low
Wide PB Low Gain
Narrow PB High Gain
Out In
Proportional Control Response
Curve
Offset
Outflow
Loss in Volume
New mass balance
occurs here
New level
below setpoint
time
t
1
1
t
0
t
0
t
time
at setpoint
Level originally
Input/Output
Level
t
Inflow
Proportional Response with
Narrower PB
Level originally
Offset
t
t
0
time
1 Level
at setpoint
below setpoint
New level
New mass balance
occurs here
Loss in Volume
Inflow
Input/Output
0
t
1
t
t
Outflow
time
Response Versus PB, Proportional
Control Only
time
Step Disturbance
L
o
a
d

C
h
a
n
g
e
Offset
Offset
time
S
y
s
t
e
m

R
e
s
p
o
n
s
e
SP
SP
SP
"Wide" PB
"Moderate" PB
"Narrow" PB
Decay Response Curve
A
A/4
A/16
S
y
s
t
e
m

R
e
s
p
o
n
s
e
time
For You To Do
! Read pp. 89-105
! Answer Questions pp. 121-122, #1-19
Reset or Integral
Response Curve: Proportional
Control Only
S
y
s
t
e
m

R
e
s
p
o
n
s
e
SP
Step Disturbance
time
Offset
Additional Control Signal Restores
Process to Setpoint
Setpoint
Initial mass balance
Inflow
Outflow
Final mass balance
Reset Action
time
Offset
Removed
Integral Action
bias edt
TR
ke m #
$
%
&
'
(
)
# !
*
1
+
-
ke
Setpoint
Measurement
Error
Bias
+
+
Output
*
edt
TR
1
Units
! Minutes per repeat
! MPR
! The length of time that it will take the
integrator to add an amount equal to the
proportional response
! Repeats per minute
! RPM
! The number of times the proportional
response is repeated in one minute
Proportional Plus Reset, Open Loop
Response
time
e
F
a
s
t

R
e
s
e
t
N
o
r
m
a
l

R
e
s
e
t
S
low
R
e
se
t
error
ke
Proportional
Response
}
C
o
n
t
r
o
l

S
i
g
n
a
l
A problem
Output initially 50%, Gain = 2, reset = 2 minutes per repeat
A direct acting controller control is subjected to a sustained
error of 5%
What is the output after 4 minutes?
Proportional Response = ke = 2x5=10%
Integral Action- in 4 minutes the control will go through 2 repeats.
Integral action = 2 x 10 = 20%
Total output change is proportional + integral = 30%
A Couple More Things
! Reset Windup
! Instability because of lag
For You to Do
! Read over text pp. 89 110
! Answer questions pp. 121-122, 1-24
Rate or Derivative
Proportional and Derivative Open
Loop Pressure
time
I
n
p
u
t
O
u
t
p
u
t
Derivative
Derivative ceases as
error stops changing
Proportional
Action
Derivative Control
+
-
ke
Setpoint
Measurement
Error
Bias
+
+
Output
*
edt
TR
1
dt
de
TD
+
+
+
bias
dt
de
kT edt
T
ke m
D
R
# #
$
$
%
&
'
'
(
)
# !
*
1
Simple Flow Control System
l
l l
FT
FC
A/C
+
,
The open Loop Response of Proportional Plus
Derivative (PD) Action to Rapidly Changing
Error Signals
0
t
1
t
2
t
0
t
1
t
2
t
time
time
A
B
C
Rate action due to cessation of increase in e
Rate action
B -C
Rate
action
A - B
Proportional action
A - B
Proportional
action B - C
Rate action due to cessation of increase in e
Control signal at end of excursion
Control
Signal
%
P
r
o
c
e
s
s
Large System Under Proportional and
Proportional Plus Derivative Control
time
Control Signal
Setpoint
Level
Load
Disturbance
Applied
Prop. + Derivative
Prop. Only
Multiple Control Modes
! Virtually all controls have a proportional
response
! Integral and derivative are added to
improve performance
! Majority have proportional and integral
! Some, typically heat exchangers have
derivative added
Open Tank Level Control With
Valve In Inflow
Qi
A/O
l
l
l
l
l
l
Qo
SP
LIC LT
Typical Flow Control Loop
l l
FT
FIC
A/O
+
,
SP
Pressure Control Constant
Bleed
PIC PT
A/C
Feed
SP
Pressure Vessel
Pressure
Bleed
Split Ranged Feed and Bleed
Pressure Control
PIC PT
A/C
Feed
SP
Pressure Vessel Bleed
A/O
Representative Hot Bleed/Cold Service
Water Heat Exchanger
TT TC
A/C
SP
Cooled Bleed
Hot Bleed
Cold
For You To Do
! Read pp. 106-120
! Answer Questions pp. 122-123, #20-38