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    Controllers

    Copyright:

    © All Rights Reserved
    Download as DOC, PDF or read online from Scribd
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    10 views29 pages

    Controllers & Control Mode, Unit 1

    Uploaded by

    Numankhawaja
    Controllers

    Copyright:

    © All Rights Reserved
    Download as DOC, PDF or read online from Scribd
    Flag for inappropriate content
    of 29
    INSTRUMENTATION FOR OPERATORS Unit 3 Controllers and Control Modes Section 1 Controllers PILOT SIX— INSTRUMENTATION FOR OPERATORS UNIT THREE CONTROLLERS AND CONTROL MODES Section 1 Page Controllers annie 3 Why We Need Centeviles) a How a Contralion Works 4 "Whe Gonteal Loop cane INRSAR 8 Bystern Response 9 Offset ant Osesiation u ‘ype of Ge “ 2 On." Cortroliere : 2 Probleme with ax O2-OF Contesor Fs Proportional Controllers... uw ‘The Thratting Baunge of the Vale i aston ‘The Trotting Lang of the Cantroiler ee How the Preparsonal Bind AdTeets Central 2 Review and Summary ss 25 Section 2 Proarbonst Contraliers with Hate and Keser Action a Proven Land ti i a eedsck Bellows Loa Haw Load Chante Ata Proportional Cire Ragot Aetlen vse sens asees a ‘Automatic Weyer = coe a How Reset Aetinn ts Mosse 2 oa Rate AGtION ses ences ; a Thaw the Predinace Be a Section 3 Workleg with Conteotees , i Introduction «0.00.0 : 3 Problems with Controller Sobicas 5 How Control oa One Process AMfeets Another Process s How Rovet aos! Baio Action Affest Control sianscieanaas ot Working with the Grate Mode ae a rene Who Shouit Adium Controters 6 ‘Unit Thres of Intrumentation for Operators explana the pars power aud operation of aitomatic contealiees and of control les aed in proces control Intruments In Section 1 you will arn how controllers wors, the natnee ‘of w control loop, ane! the factors in syntem rexponae, You Swill learn about offset and oeelllation, eno0T centroliery ane proportional controllers, Ube Uhrotting. range of the valve lint af the controller, xiv How the proporsional band acts control 4m Section 2 you wil Ieuan how anys in procees load affect ‘proportional controle and. how changes process load ax be compensated for hy use of feedback bellows au by rene and vate setion. I Seetion 1 you will Joaen Now to work with controllers and ‘eanteo! modes and AoW to Klentify eunteoller protien INSTRUCTIONS ‘This fo a progennied lousning course Programed lerrning gives information in a seriot of stops called Frames. Hach frame gives some information and asks you to make use oF I Hore te how iC wrk, ist; cover the Koapanse column at the ight with a man, ea this frame ances the mformation it ives to Allin the an A. micrometar itn instenment designed to mensen in ‘thouasndlihe of an inch, ‘A mierometer is a xoa tool for measuring very differences in nize. ove the mase cen ta imeover the word’at the right of the ‘frame, If you have filled the blunk with that word or a word hat mein Che same, you ure rexdy bo uo anead to the ext frarte, he drawinye of a micrometer provides information that wi help you fill i the next Blanka. opuecr Toe Ueasunes Seven major parts are shown In the drawing, bab only the and the eamtaet the object to be measured. spindle ‘The next frame calla for « eboieo, Citeld or undurline the ap propriate word Of tho two parts that contact Chu cbjoct only Qhe (uavil/ pindle) moves A program in « secios of frames that work like the ones you have jst dona? ‘Bod the fewane, Use the fnformation to fl bv the blanks or make o eho. Move the male down and check the yompone cela. Go on to the noxt treme, Teniember to cover the response column with a mask before ‘you begin each page. pinata SECTION 1 CONTROLLERS Why We Need Controllers Process vatlables ire controlled by opening and elbs- — valves Let's say thut you want a ow rate of LOO gallons per minute for & proces The contre! ty et tallow jst TO valve fallons of quid yer minute into the process. A the flow rate newer changes from 100 gailans per rain A. you don't need to adjust: the: eonteol A valve, 4B, you have to eajust the eamtesl valve c tantly. 4, Tats any ebat thece io-a chunga ta the pressure eeting in the Lauid whieh supplies the proces ‘When the lovel In thls tank changes, the pressure on the guid hams, oF drone 5. The ow rate to the presen A. stmya at 100 gallons per minute, 5 changer, i 8. To maintain tho proper flow rates the emteal valve rnnst be opened, or adj 1. The control valve ie ajusted by a controler ‘The centralier: A. ean be ant operator can be an instrument an he either an operator ox an instr ment. & Tia mdern fstletion, he controller i likely 10 be tn (inatrament/operator) 9. ‘The rite oes toto action only whom tnere te rece 10. Te there is no process change, tho —_____ dows nothin. LL 2 proceat varhiblos could e held perfectly eonebank, there woul he my aged for « controller ln this Wely to happen in a typiew) Fstallation? —__ Ye one Hoy ¢ Controller Works 2, The contre Ip Ht co mde the tare for the protean variable buiny contri. “The eamtreer matt nc he ho proeoss variables on target te hoe 19, ‘The target for the eemtolle in alle the sot point Lave eay & tomperatary measurement fy on target ‘The Gatreller (reudsdeme act prac) Ube ae pot 14. Kf a temperature i uot ou luo, the teniperatice ticator does not-match the = fof the eontraller. 15, A controller goes into aetfon when he process i oft target the process ie on target. 16. When the process strays from the get point on amy prncess variable, (all/some} controllers attesting that Yariatle should teoct Jnetrument change, or upset controler valve oad set point all 17, ‘The drawing represents « simple temperature control situation 21 23, "The eantroller the: ‘A WEASURE B COMPARE what the ast point whould be © CONTROL 3. Hiswonse of __ is the lmperature indicator, 1. Is pons o8 elhaea the vale, Wis touch gives him information, He aiready “knows? ‘To find out whether the process is on target, he ine what he feos io the sot point ‘The controller first ecetves informntion trom a the desined se, point luriew, and Une it to Lf Ue process messturement and the set point are dhe same, the operator B, duos nothing. ‘A, mase an adjustment, Bue if the measarement and the vt point axe different, fiw adjusts Uw eonkot Lots say ho class the eintrol valve to eso tho proces, row can he tel if the process has cooled? His sense of ‘ndenter this, ‘operator touch hund compares muasaring, oF sensing compares ‘el 2. Bor every adjustment the controller makes, the meass luting device muse feed information back to indicate ‘what hs happened. Tn. the previous xan information trom hie flue operator sobs fewtbacke ‘Those are the steps needed ty eonirel » proves: Slep 1; The proves variable ie measured. Step 2: The measurement ty to the tet point, Step 1 If there in difference, the in moved. Siep 4: Some device gives the controller information Step 5: Thie fesdbaele “tells” the what has happened, the feedback does not matek the ser point on a m0 cer coniruller A. the cantraiter stops werking BB, the controller keeps working until the sal olut is reveled, Put an A on the drawing to show where measuriey by being do Put a H to show where comparing is being done. Pat a C to ehow whory sve positioning is bing dane Put a D to show where feweltack is given, aN a soneh, or hand sompared valve ‘eetbnek controller 28. This operating aituation is slightly diferent from the previous one. THERMOMETER A MEASURE B COMPARE a ¢ CONTROL, STEAM ge —¥ ‘The operator get # mensavement and febdbick from: “A. his sense of toudh, Ha vending om the thermometer dia. 0, ‘The controller iy Ube — 81, ‘The valve is adjusted (hy han /automattealy), 82, ‘This Is an autornatic control situation STEAM ‘The process temperature is mewsurei at (A)B/C) ALB, the maven mensuroment is to ‘the set point. ALC, the process is B operator, oF man by hand A compared tontroled, of regulated The Control Loop {8 This diagram shows a eomplels corto loop. CONTROLLER (ERROR DETECTION MEASUREMENT COMPARISON) MEASUREMENT SET POINT — SIGRAL VALVE Position CONTROLS A-conienl loop conalita of al! the dloinonte needed to ‘the movenunt of a valve 84, A control Ieop as shown above A. 18 creular and closed. B. is open-ended. 86. Firvl, the process measusing slorisht send a. algmsl Ww the controler. ‘The controller is the — erect. 86, At the same time, the elready-determined gel into the eontroller (errar detector). 87, ‘The error detector mation a —_______._alwomn ‘thie signal from the process aud the seb point signal 38. If there is a difference between the measured signal and the set point: A. nothing: happens. 1h, an error signal ie snl tv the pestioner ‘of the control valve 29, ‘The positioner adjusta tho setting, 40, ‘The control valve changes the process. Tnformation about this change is picked up by. the ‘instrament and fed into the controller, 41, ‘This information {called process =i ‘tho controller control act point comparison valve -maannring feadback System Response 42. It takes timo for the porte of the control loop to detect 4 process change, make a valve adjustment, and gob proves Feedback ‘The less time it takes, the (eroater/lenser) the effi- szreater sieney of the euntrul lop, 48. The instruments should react as fast as it is practical for them to renet whon the — charige, process 44, Sometimes there i# w sme! lag im the inateumenta, "These instrimerits are operating Wy: (pneumatic elec trical) signals, pneumatic 45, "The greater the distance the signals mnst he sent, the 4 takes to recive them. Tonger 48, ‘This monsis that the instedments will not react tmmes Aintoly tos 1n proces. change AT. Sometimes chore is 4 Gwe lag between instrument changes and praceas changes PROCESS CONTROL VALVE ‘This contol valve is (close to/far away from) the far away rom, Proven. 48. A change in Gwe eonirol valve position would affect the provess (immediaiely/atter some time hs) after some time lag ° 49, 50, on. 2, a 4, Once an adjustment has been made, tt taker time for ‘tho process to chanse: 1S MINUTES With tie amount of heat Heng applied to the boaker, fan Increase in lomporatare from 40°F to 212"F ree quires 16 minutes, ‘Turning the ent up under this Weaker (ill/wil net) ceuise It to reich 212°F instantly ‘The temperature of Ube water (changes does not change) smuetiataly with an inovease in heat: A temperature change in % process: ‘A, will always o:tur immediately with control valve change, B, muy lake time to oeenr, ne matter how ‘much the control valve is changed. ‘The lime iL lakes for both the instruments and the prowess ty ebange is called! the Ayton reopowse "The avstem rospenne indientes how the coantrol Joop is moving. Which of the following events occur ina system ro- pons ‘Process menstiroment li Rrror detection —s Rrror signal to control exlve Control valve aadjnstment — Procean change — Feedback from process Which of the following aoeur in the system response? A. Instrument respoxse B. Process response © Roth A and B 0 will not clues nat change Yes Yen Yes Yes Yes Yes Offset ond Oscillation 1H. Offact occurs when the procons monsurement ator from the ret point. SET POINT WEASURENENT Instrument (A./B) shows offset B 50, Recording instruments can be wed to show procest offset POINTER ‘A pointer shows whore tho set point fs om thin tempera ture recorder A lirasee the prvecte temperature ae pen time passe, BT. Loe at this drearing ‘When the process lemperatnre is ar the set point, the pen and the pointer are at the ott, sume 58, When the pen moves away trom the pointer, an fins ecurred, offect, or change u 50, When the provese meaourement Meeps bounding above and below the set point, the process 1s osefllating. SET POINT he a . Aecorter (5B) stows wx ewan prove, 0. What iv going on Jn this proce, ueeording 40 thene pressure recorders? ‘The prose! Iv at the vet yo}ot in TDhove is an affect rosorded ins _B © Thoth B ava 0 ‘Ths procoes ie csillting ix ——__. TYPES OF CONTROLLERS On-Off Controllers 61, There are three basic rections to ny itrumment gon tral system ‘an instrument to ‘the process: sa inatvuraent tj —___the et point to ‘thie msarement | an lnsiroment (0 position and adjust the control 62, An uml Genteollar je one which eos the control valve either fully open oe fully a both B ana C © rmoasure compare valve closed 62, "This drwwing represents the woutrol loop for a simple onal controller, ELECTRICAL SET POINT CONTACTS ADJUSTMENT ourPUT SOLENOID VALVE “The process eeswnre is measured by 9 64, ‘The bourdon (ube is connected (o a pelt. Wher the pointer yaoweo Nace and forth, it opens and lotr two contacta 155. "The yonition of th eureon tube nets the (race! sat point) sgnal 66. "The sot point is indicated hy the position of one of ‘these elertreal GT. The valve is positioned by & ov. 68, Which of theve parts ip the error detextor? A. Bourdon tube H Ponnter and electrical contaets . Solenoid eof 69, Whies the hourdon lube senses a pressure chao, the pointe 7). Wher Oe contacts are coved current Sows to the TL When this solenoid ts onorgleed, t+ poston the 7% The yolnter, ny elther opexing or clone elvetelat con- fuels, acts Tike (an on-oll switeh an electrics) (rams former) 18 bourdon tube lectrfeat rows contact solenoid mows, of changes solenosa valve an on-off ewiteh ‘TR. Tuetn aay the point for pressure Ie 20 PSIG, Ser PoIT 6, 1 mm, INPUT TO SENSOR SOLENOID (ON-OFF) wpurs =ovreur ‘tine electric contacts (oie /cove) AP Uke sear Fala ‘alow 20 PSIG. ‘tse astiratus tho eolencid, whieh in tum the control valve, Tf pressure riser avaln, the electrics eomlacte open, ‘and the eonteal valow iy — be the salenata ‘The pointer acta ns the extor detestor, bat ff eam only dve two error signe: salve, valve ‘Siew these axe the ly Lu setiiems, hin kind wf ene ‘roller is eno contrller, IMentigy the paris of Chis on off control Loop ‘The momsuriny deviey is ‘The controller (error detortor) fv the CCompurins the set point tn the atexwured seal in cen by uw ‘The valve in positioned by the “4 ELECTRICAL CONTACTS il, lone pons loot ‘open lose ot ‘baron tube ‘inter, oF contacts pointer, er eonnets solenoid Problems vith an On-Off Centroller 70, ‘The moat serious drawback with an on-off exntrller 4s that ¢t eam peaition a valve in only litre settin BO. "These graphs Show prices fw. IVatve OPEN VALVE CLOSED & 10 15 20 25 30 MINUTES A VALVE OPEN _ VALVE CLOSED 0 5 10 15 20 a5 40 MINUTES 8 Graph (A/%) represents flow adusted ty an oma? A system, AL, ‘The following indicators show two offset mesure. mente SET POINT VALVE CLOSED An on-off sonteollor changos the valve setting (the sume amounl/dfforently) for dllferent process changes, the sume amount 6 ‘82, An on-off controller treato @ largo oftyct (Sho name iy ‘differently from) sina offset 88, Gna eontrotlons (are are not) sonuttiva to dferences in the ameunt of offset RA Reon the amon of ofa: tiny, tho valve all the way or — —all the way Which sereph repretents Row vate being controlled by fn oneaff controller? SET POINT FLOW CHANGE 1+ a S SET POINT FLOW CHANGE ——- 8 Groph (4/8). A 86. ‘The on-off control Joop (40:48 not) able to matncatn ts not {amocth even Mow rate ub 87. A graph of flow eontreled with an on-off contralle Took ike this lvALve OPEN Si Point | IALVE CLoseD "The few: A. soxtinually bounces abeve.and below the set point. iw aroath anit steady, Hi. Ona centroers (alls eet alle) the proces cvcllate, 89, ‘The proceze otillates heenuse the velve is constantly 90, Ans on-lf eonteoller (qi anil ive) steady control ‘the process Proportional Controllers The Theotting Range of the Valve $1. Ouait controties exmnot sree exact control of x process hwcause they react (the anme ny to/lffsrently for) ge and aml deviations frem the set pains 22. Ror more exact contra, the contioller mist tespond to the process change in proportion ta the amount of cage Large changes should cane the enntaolien te. make chaos in the valve rotting, and emall hanges shoul cause — valve elas w allow opening closing cannot give the same way to lage small 8, To make proportional contrat possible the valve mus have: As tro settings 3. a range of positions between fully opened B ‘vd Tally closed, A propoetional conteler rmst he able to sep (hee (Pflerent: sigmals/a ranze of sonal) to the control range of signals valve, 9A controler that sends a range of signal fo the seme tol valve is called s____cenfroler. proportional 95, Here isa valve peri Ly an ar motor, ‘he (role ‘ng range of this valve is 8 EO 18 PSIG. AIR PRESSURE ‘Whoa the valve fs iv the possion show in the drawing, ‘the afr pressure on the piston is (2 PSIG moze than aera ore thact 8 PBIG 9%, ‘This valve does not open fully nt the pressure on. ‘the piston resehes sid. 1“ 9%, "This valve is voen halla hen Che prossure on tho riston i sre. ° 98, "Three Wo 15 SIG is the —_raigo of this (rotting valve 99, ‘Tho courier’ wigna to tho contol valve ust match the of the ral thntting range 100, ‘The eonteuler mores the valve proportionally to erm Dpensiie for diferent rules and amounty uf process ‘change, variation 8 101. This control valve operates through a range of setting. ‘The valvo must be shut completely who the liquid level reaches ____ feel 0 on, Tei feck (kei) thi path sbowe 103, ‘Tho get point is at 9 feet reer 1 ser POINT 9 ‘The valve (permite seme flowe/does not permit low) pormits some flow hon the Uauld vel at 9 fout, 104, ‘The liquid level as fallen to 8 feu, FEET w-| ser POINT 9-| ‘The valve miet mow be filly pened 19 108, 10, 1m, 108, 108. ue. ua, ma ‘The drawing shows a proportional control lp, ERROR DETECTOR (CONTROLLER) ser POINT RESTRICTION ORIFICE his xyslam sonsds (ynusmatie'loctslend) algeale Procoes fow vabr is being mensnred tye a meter, ‘The flow mater sends © yresaune sipnal th the (mens uroment se goint) bellows tn the controller, ‘Those ane two bellows in this controties ‘Tre ttapper pivoted between the two bellows acts as the error detector, [AS Inn 6s proves presse and et pint yressnre stay the same, the error detector (Keeps chacing/does not change) pesttion, Tet eay pressure in the provess decreases, "The error detoctow (myves,dooe not move) MEASUREMENT. One dues the process menaurings the other aves the ‘An the flapper moves away from the nozzle, pressure ‘in tho pnenmatie tvytem eonnetted to the alr motor 3. This change in peumatie pressure aets asthe. smal, ‘Tre pnewmntiewignsl opwrstis the ale mater ‘The air motor positions the 20 pneumatic ‘mscuurement ow point dees not charge enya, or decrease The Thrattling Range of the Controiter 114, Tho throttling range ot a control valve is a range of (ameumatie syviem pressures process measurements) ‘There isn mange of procoa monuuroments within which the controller must Keep the prorom, ‘This range of process measurements 3 the Unroltiag range of the (emtroler contra) valve). 116. ‘The thrueling range of w controller fy eometinnes called ‘the proportional band, Which one of those valu could represent a propor: tional bun — 8 gallon pt secant 8 F to e'F — 10 B86 AIT. The ange of process masmnremente between Mh tt ‘ol valve being completely open or closed is elle the —— of the euntrolle, 118, This pressure gage and eontyollor are regulating peace ss prossure. Idontity the following point, i CONTROLLER Ab ihe Win the ——) Cie. otdw En ‘Preumntic system pressares vontroler 68°F 88°F tibrotting range, or proportional hat Set point Ahrottay range, oF proportional band; controler throttling range: valve 118, Set point 46 found om: — proportional controllers en}y. ull controllers, 120, Throttling range ts foand on: proportional controllers only. fn-off controllurs only. How the Propostinnal Rand Agfects Control LBL, Here ave the diuls of two entrollers which have the fame set point, OPEN oem, CLOSED OPEN CLOSED On controler A, the pressure must inereare to PSIG to completely close the control valve and decrease to PSIG to completely open Use contaul valve. 122, On controller B, pressure must inereane to only PSIC to complataly close the romtral valve and decroave to only ___PSIG to completely open the control valve 128, Tk takos a change of 5 PSIG from the sot point to eom- pletely open or close the valve on controller A, It takes a change of only PSIG from the art point to eompletaly onan or clove the valve on eon- trotler 1 124, Controller (A/H) has the wider proportional baud, 22 all controllers proportional controllers anly: 56 49 5 49 186, Lets aay proceas pressure changes 4 PSIG. SET PONT SET POINT Psic VALVE VALVE YALYE VALVE OFEN © CLOSED.“ OFEN =—CLoseD A 8 Contraller (48) wonkt make the blewest change tn B the valve selting, 126, Controller (A//B) rents more sensitively to a change ® in process yrevoure, 427. There are bith aivantages ave distelvantagen to-maks {ng a controller more sensitive, Onw alvantaye uf Gie more ssnsltiye controllir ty that i can keep the proess closer to the e et point 128, itut proportional contratiors can be too seusitive ‘Making the proportions basd natower means thet Tor aery process chavo, tho eontvoliar mover chi ccantrol valve (more/est) move 429, Let's vay that a proportional controller fully opens & valve for 1 chinge of L PSIG from the set point. 1 Psio 5 PSIG FULLY opens FULLY OPENS VALVE VALVE A change of 5 PSIG sete (the same/a different) re- ‘tho same, Spouse as a change of | PSIG, 10. 1 the pencess constantly changes by more than 3 PSIG, the sontroller sill he frearing all the changes hove 1 PSIG (the eame/difterently) the «ame WT. Also, seithin its voting range, the valve mixy Ie moved ton far forthe process hinge, OPEN CLosED Graph (AA vepredente the valve movement of an A ovursensitive propartional eontroller. 182, ‘The prepara fxn cam be wide 80 narrow Roitt the controller acts alma Ho en camtroller, on-off 18%, Oversonsttive controllerd: may ewine the process te covcitlete, or cpete 14. ‘These raphe show valve setting changes daring roves chung. VALVE FULLY OFEN VALVE FULLY CLOSED A 8 Graph (4/3) represents valve movenent made by a « ccontraller with the veidest proportional band. an 135, ‘The proportional band een de made so wide that it lakes a very large proses chan to affect the valve setting: ‘Anite that the eontroller is adjusted thw vewy wide prowwrtiont! bund vetting, ant the valve getting ba rot changed for 10 miiautes ‘Has the procens remained sendy during: thi time? Yet

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