Two Man Ip Control

Control Using Two
Manipulated Parameters
2006Fisher-Rosemount Systems, Inc.

Slide 1- 1
Control Using Two Manipulated Parameters
Introduction
Overview Typical Examples
Split-Range Control
Concept, variations in implementation
Setup in field vs. Splitter Block and IO for each valve.
Using Splitter Block, Example.
Valve Position Control
Concept and typical implementation
Setup of I-only control in implementation
Impact of mode/status, Example.
Combining Split Range and Valve Position Control
How to implement in DeltaV
Example
Summary

Slide 1- 2
Process Control
Introduction Historic Perspective
Control Using Two Manipulated Parameters

One(1) Controlled
Parameter
Controller
SP
Under specified problem

that has multiple
solutions for unlimited
operation.
Extra degree of freedom

is used to achieve
unique solution that
satisfied specific control
objective.
Most common
techniques are: split
range, valve position
control.
Combination of these
techniques offer new
capability to address this
class of problems
Two(2) Manipulated
Parameters
Process
Unmeasured
Disturbance

Slide 1- 3
Process Control
Split Range Traditional Implementation
TIC
101
Temperature Example
Sequencing of valve accomplished

through calibration of positioner,
selection of actuator (A/O or A/C)
IP
101
Pro Less expensive installation (1

pair of wires to field and 1 I/P)
Con -Difficult to initially calibrate

and continuously improve to get
best gap and most constant gain.
Con -Individual valves not

accessible for trouble shooting loop
and actuator/valve problem.
Con The actuator, pneumatic

positioner, and I/P performance
shift with time and field conditions
Con I/P failure disables 2 valves.

Replacements in the night may not
have the special settings
4-20ma
3-15PSI
A/C
Cooling
A/O
Heating
100
Valve
Position
(% of Span)
0
Process
TT
101
Cooling
Heating
3
IP Output ( PSI )

Slide 1- 4
15
Process Control
Split Range Traditional Implementation

pH Example
AIC
102
4-20ma
IP
102
3-15PSI
PS
102
100
Valve
Position
(% of Span)
0
3
Sequencing of fine and coarse

valve requires pressure switch,
two solenoid valves and
associated wiring and tubing
Con Complex installation
Con -Difficult to initially calibrate

and continuously improve to get
best gap and most constant gain.
Con -Individual valves not

accessible for trouble shooting
loop and actuator/valve problem.
Con The switch, actuator,

pneumatic positioner, and I/P
performance shift with time and
field conditions
pH
A/O
A/O
Coarse Valve
Fine Valve Process
AT
102
Fine Valve
Coarse Valve
I/P Output ( PSI 1) 5

Slide 1- 5
Con I/P failure disables 2

valves. Replacements in the
night may not have the special
settings
Process Control
Split Range DeltaV Implementation

AI
PID
SPLT
Splitter bock is used

to implement split
range control.
When using
traditional valves,
split range control
may implemented in
DeltaV Controller
using two(2) current
outputs
Split range control

may be partially or
fully assigned to
fieldbus devices.
AO
AO
AI
PID
SPLT
AO
AO

Slide 1- 6
Process Control
Split Range Control in DeltaV

Slide 1- 7
Process Control
Splitter Block Calculation

Slide 1- 8
Process Control
IN_ARRAY Parameter
SP range
associated
with OUT1
The SP range
associated with
each output is
defined by
IN_ARRAY.
SP range of
outputs may be
defined to overlap
The SP upper end

of range must be
greater that lower
end of range for
each output
SP range
associated
with OUT2

Slide 1- 9
Process Control
OUT_ARRAY Parameter
When SP is outside
defined range, then
the value at the end
of range is used to
determine the
output.
LOCKVAL
determines if OUT1
value is held if SP is
greater that the
upper end of range
defined for OUT1.
No restrictions are
placed on the output
range.
OUT1 Range for

associated SP range

Slide 1- 10
Process Control
Splitter Block
OUT_1
100
OUT_2
OUT_ARRAY
0 100 0 100
IN_ARRAY
0 100 0 100
0
0
100
OUT_ARRAY
100 0 0 100
IN_ARRAY
0 40 35 100
100
0
100
0
100
LOCK_VAL holds
HYSTVAL
LOCK_VAL is zero
0
0
OUT_ARRAY
0 100 0 100
IN_ARRAY
0 40 35 100
100
SP
Slide 1- 11
Process Control
Slaker Heating/Cooing Example

AI
PID
TT103
TIC103
SPLT
AO
IP103A
FY103
AO
IP103B
TIC
103
FY
103
IP
103A
HEATER
Slide 1- 12
IP
103B
TT
103
COOLER
Process Control
Split Range Output (FY103)
100
Valve
Position
(% of Span)
Cooling (IP103B)
Heating (IP103A)
0
0
TIC103 Output (% of Span)
Slide 1- 13
100
Process Control
Steam Header Example

AI
PID
PT104
PIC104
SPLT
FY104
AO
IP104A
AO
IP104B
1475# Header
Boiler
IP
104A
FY
104
IP
104B

Slide 1- 14
400# Header
PIC
104
PT
104
Turbo
Generator
Process Control
Split Range Output (FY104) - Capacity
100
Valve
Position
(% of Span)
Valve 104A
Valve 104B
0
0
PIC104 Output (% of Span)
Slide 1- 15
100
Process Control
Calculating Splitter SP Ranges
A 1% change in controller
output to the splitter should
have the same impact on
control parameter when
operating with either valve.
When manipulating the

same or similar material
e.g. steam flow to header,
then the range may be
calculated based on valve
rating.
Tests may be performed to

determine impact of each
valve on the controlled
parameter.
Example: Steam flow to Header, splitter

interfacing directly to PRVs, no overlap
Valve 1 rating = 50kph
Valve2 rating = 150kph
Desired Splitter Span valve 1 =

100*(50/(150+50)) = 25%
SP range for valve 1 = 0-25%

SP range for valve 2 = 25-100%

Slide 1- 16
Process Control
Testing Process to Determine

Splitter SP Ranges
Example: Slaker feed temperature controlled
using heating and cooling valves
Controlled
Temperature
Heating
1.1degF
With the process

at steady state
and AOs in Auto
mode, determine
the magnitude of
change in the
controlled
parameter for a 1
percent change
in each valve.
Calculate the
splitter SP span
and range for
each output
based on the
observed
response
2.2degF
1%
Cooling
1%
Time
Desired Splitter Span cooling valve =

100*(2.2/(1.1+2.2)) = 66%
SP range for cooling valve = 0-66%
SP range for heating valve = 66-100%
Slide 1- 17
Process Control
Example Split Range

Slide 1- 18
Process Control
Response to SP Change Split Range

Output To Large Valve/Small Valve
SP
Small
Valve
PID OUT
PV
Large
Valve

Slide 1- 19
Process Control
Split Range Strengths and Weaknesses
Pro - Process operation in simplified since two actuators

are treated as one control manipulated parameter.
Pro immediate change in target actuator position can be

achieved over the entire operating range independent of
the size of change in the splitter SP
Con To achieve stable control over the entire operating

range, controller tuning must be established based on the
slower responding manipulated parameter.
Con- Does not take advantage of difference in resolution

of actuator e.g. fine vs. coarse valve.
Valve position control may be used in place of split range

control when there are differences in dynamic response or
resolution in actuators.

Slide 1- 20
Process Control
Valve Position Control Traditional

Implementation
pH Example
AIC
106
Mode
Target
Valve
Position
IP
106A
ZC
106
Fine Valve
IP
106B
I-Only
Controller
A/O
Coarse
Valve
PID control is
implemented using the
actuator with finer
resolution or fastest
impact on controlled
parameter
The actuator with

coarse resolution or
slower impact on the
controlled parameter is
adjusted by an I-only
controller to maintain
the long term output of
the PID controller at a
given target
I-Only controller must be

disabled when the PID
controller is not in an
Automatic
mode.
Process Control
AT
106
Process
pH
Fine Valve
Coarse Valve
Time
2006Fisher-Rosemount Systems,
Inc.
Slide 1- 21
Target Valve
Position
Valve Position Control DeltaV

Implementation
AI
PID
PID
Slide 1- 22
It is possible to
implement valve
position control in the
DeltaV controller or for
this function to be
distributed to fieldbus
devices.
AO
Traditional
field devices
AO
I-Only
Fieldbus
devices
I-Only control is
achieved by
configuration of the PID
Block STRUCTURE,
GAIN and RESET
parameters.
AO
I-Only
AI
AO
Process Control
Valve Position Control in DeltaV
Actuator with fastest

impact or highest
resolution is used to
maintain the
controlled parameter
at setpoint.
The OUT of the PID

used for control is
wired to IN on the
PID block used for IOnly regulation of
slower responding or
coarse resolution.
PID configured for IOnly control

Slide 1- 23
Process Control
Configuring PID for II-Only

-Only Control

Slide 1- 24
The STRUCTURE
parameter should be
configured for I action
on Error, D action on
PV
The GAIN should be

set to 1 to allow normal
tuning of RESET (even
though proportional
action is not
implemented.
RESET should be set

significantly slower
than that the product of
the PID gain and reset
time used for control
e.g. 5X slower
Process Control
Precise Flow Using Big/Small Valve

AI
PID
FT107
FIC107
AO
IP107A
I-Only
ZC107
AO
IP107B
IP
107A
FIC
107
FT
107
ZC
107

Slide 1- 25
IP
107B
Process Control
Example --Boiler
Boiler BTU Demand
AI
FT109B
SUM
PID
FY109
FIC109
AI
AO
IP109A
I-Only
FT109A
ZC109
AO
IP109B
BTU Demand
FY
109
FIC
109
IP
109A
FT
109B
HI BTU Fuel
ZC
109
Boiler
IP
109B
FT
109A
Slide 1- 26
Low BTU Waste Fuel
Process Control
Example Reformer
Reformer Air Demand
AI
PID
FT110
FIC110
AO
IP110
ZC
110
SC
110
Air
Machine

Slide 1- 27
I-Only
AO
ZC110
SC110
FIC
110
Total Air
Demand
IP
110
FT
110
Secondary
Reformer
Process Control
Example Valve Position Control

Slide 1- 28
Process Control
Response to SP Change - Valve Position

Control with Large Valve/Small Valve
Target
position for
fine valve is
30%.
When the
fine valve
saturates,
then
response is
limited to be
reset of the
I-Only
control
PV
SP
Coarse Valve
Limited
Fine Valve

Slide 1- 29
Process Control
Valve Position Control Strengths and

Weaknesses
Pro Immediate control response is based on actuator with finest

resolution and/or faster impact on controlled parameter.
Pro Actuator with coarse resolution or slower impact on controlled

parameter is automatically adjusted to maintain the output of the
controller output long term at a specified operating point.
Con The controller output may become limited in response to a

large disturbance or setpoint change. For this case, the dynamic
response becomes limited by the slower tuning of the I-only
controller.
The features of split range control and valve position control may be
combined to provide immediate response to large changes in
demand while retaining the features of valve position control for
normal changes.

Slide 1- 30
Process Control
Combining the Best Features of

Split Range and Valve Position Control

Slide 1- 31
A composite
Block can be
created that
combines the
features of split
range and valve
position control
Support for
BKCAL_IN and
BKCAL_OUT
can be
implemented to
provide
bumpless
transfer
Process Control
Composite Algorithm
NORMAL
SP
FILTER_TC
CAS_IN
OUT_1
Filter
x
x
MODE
RANGE
SPAN
OUT_2
Scaling
BKCAL_IN1
Balance Calculation
BKCAL_OUT
BKCAL_IN2

Slide 1- 32
Process Control
Composite Implementation

Slide 1- 33
Parameters that
must be configure
are: FILTER_TC,
SPAN (of SP),
RANGE (of
OUT1), and
NORMAL
(desired position )
The FILTER_TC
should be
configured similar
to the reset time
of the I-Only
Controller that
would be used for
valve position
control.
Process Control
Demo Composite Combining Valve

Position and Split Range Control

Slide 1- 34
Process Control
Example: Response to SP Change
Small change
For small
changes in SP or
load disturbance,
the response is
similar to that
provided by
valve position
control
For large
changes in SP or
load disturbance,
the immediate
response is
similar to split
range control
Large change
SP, PV
OUT of
PID
Fine
Valve
Coarse
Valve

Slide 1- 35
Process Control
Summary
Split range control allows fully dynamic

response to major setpoint of load
disturbance changes.
Valve position control may be used to takes

advantage of any difference in control
response or resolution in the manipulated
parameters.
A composite block has been demonstrated

that combines the best features of split range
and valve position control.

Slide 1- 36
Process Control

Two Man Ip Control

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Two Man Ip Control

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Control Using Two

2006Fisher-Rosemount Systems, Inc.

Overview Typical Examples

Concept, variations in implementation

Setup in field vs. Splitter Block and IO for each valve.

Using Splitter Block, Example.

Valve Position Control

Concept and typical implementation

Setup of I-only control in implementation

Impact of mode/status, Example.

Combining Split Range and Valve Position Control

How to implement in DeltaV

2006Fisher-Rosemount Systems, Inc.

Control Using Two Manipulated Parameters

Under specified problem

Extra degree of freedom

2006Fisher-Rosemount Systems, Inc.

Split Range Traditional Implementation

Sequencing of valve accomplished

Pro Less expensive installation (1

Con -Difficult to initially calibrate

Con -Individual valves not

Con The actuator, pneumatic

Con I/P failure disables 2 valves.

2006Fisher-Rosemount Systems, Inc.

Split Range Traditional Implementation

Sequencing of fine and coarse

Con Complex installation

Con -Difficult to initially calibrate

Con -Individual valves not

Con The switch, actuator,

Fine Valve Process

I/P Output ( PSI 1) 5

2006Fisher-Rosemount Systems, Inc.

Con I/P failure disables 2

Split Range DeltaV Implementation

Splitter bock is used

Split range control

2006Fisher-Rosemount Systems, Inc.

Split Range Control in DeltaV

2006Fisher-Rosemount Systems, Inc.

Splitter Block Calculation

2006Fisher-Rosemount Systems, Inc.

The SP upper end

2006Fisher-Rosemount Systems, Inc.

OUT1 Range for

2006Fisher-Rosemount Systems, Inc.

Slaker Heating/Cooing Example

Split Range Output (FY103)

Steam Header Example

2006Fisher-Rosemount Systems, Inc.

Split Range Output (FY104) - Capacity

Calculating Splitter SP Ranges

When manipulating the

Tests may be performed to

Example: Steam flow to Header, splitter

Desired Splitter Span valve 1 =

SP range for valve 1 = 0-25%

2006Fisher-Rosemount Systems, Inc.

Testing Process to Determine

With the process

Desired Splitter Span cooling valve =

Example Split Range

2006Fisher-Rosemount Systems, Inc.