IMPROVING PROCESS CONTRO! aes Enhance process control performance Properly incorporating summers into a control configuration can increase benefits for nominal cost CL. SMITH, Cecil L. Smith, Inc., Baton Rouge, Louisiana tex deopng ore cnguaion, fino sch VY) Seer sie 3 pepo! enon, Simpson hold attained carer bt arpa eos Whi ‘Slemols sme way redo nde bing Ofc Shey ean be appli improve conte psooance a ml varbleappinione infer al poe consalappictins are massa vahfipors al ene some degeneration ich eas thar thellowngsesencns An contol cement ae ve or morfthe messed siting to hcl he coal ae. This Sctanent pis onto mre fc condemn SA ee wae tw or more al comnel dont Tis stone apis wove or a of ie Sono rab Tier option for arin sich sop ee 1 ean inge loop FID con trations, Tha ech of tec al uel bs conta by mpage of ido Tvenage Simple approach Dinas net dee pefomator cfc ot moe hogs por Taiyo the pin thy cy do torincon coupe cone wih in detains (umn 0 Sars gen MD cone stiedy manips 0 (omar) find cul denen ‘vantage deed prope signify improve lop perrane yang noose ey se wih Peprey cone (DCS, PLC ov my multancon con roller). Diedvantage No igaous design mahalo vse 3 erly oe om mola piv conte chology Aneta Be psle one perorance Dedvttage Soin conan ceive requied wo theca faring snd implementing he ml pe: Sone snc: Mos economia sue piso’ of stl pein coal accu vi opine ore * lbsanal mune of piconet eon ca ego In nary epinions.com simply a po Sd pedive console be api Pas en fave to ‘make do” with a single-loop PID configuration, even though its performance is poor. In the absence ofa rigorous design methodology, engineering practice becomes to some degree an “ar.” Bur with regard ro incor porating summers and other simple functions into control configu rations, guidance can be derived from one’ undersanding of the process. A good starting point isto write the applicable material and/or energy balances. These are best expresed in erms of flows through the control valves, notin terms of valve positions. Bur where ow measurements are not available (and often they are nov), the final control configuration has tobe in cerms ofthe valve positions. ‘Two examples illustrate this approach. The first isa simple ‘one—specifcally, a warm water process where the control con: figuration consists of wo PID controllers and two summers. Most industrial applications will be more complex, often involving func tions such as selectors (or auctioneer), split-range logic or other. Our second ‘example is recycle process involving, ‘wo tanks and three valves. We will first examine control configurations that rely on spli-range logic, Then we will show how some simple process relationships lead us o a control con- figuration using ewo summers and a low selector (and no split-range) Warm water process. The pur- pose of the process illustrated in Fig. 1 is quite basic: mix hor and cold water to provide water at a specified flow and temperature. There ate (wo variables fo control: warm water flo, F and warm water temperature, T There are two final concrol elements: The cold water valve position will be designated Mc and flow through the valve as Fe ‘The hot water valve position will be designated Myrand flow through the valve as Fy Note chat the following statements apply: ‘© Fis affected by both control valves. ‘© Tisaffected by both control valves. 1 The cold water valve affeces both warm water flow and cem- perature, ‘© The hot water valve affects both warm water flow and tem= PerThsresulsin a2 X 2 mukivaiable procs. TThe two possible single-loop PID configurations are illustrated in Fig. 2. Their performance has three possibilities:SPECIALREPORT cold water OO eee {@) Temperature with hot wate valve flow with cold water valve. Py Gold water (by Temperature with cold water vlve, flow with hot water valve. 1. The Fig. 2a configuration performs satisfactorily. That is, control cemperature with hot water valve, low with cold water valve 2. The Fig, 2b configuration performs satisfactorily. That is, cootioltemperatuce with cold water valve low with hot water valve 3, Nether configuration performs satisfactorily. Selecting the appropriate configuration is often ceferred to as ‘paring controlled and manipulated variables (inal control elements) For simple processes such as the warm water proces, simple statements usually apply «othe choice of the pairing. Applying teative gain analysis! to the warm water process leads tothe fol= lowing evo starements > Conaolfow with the supply cold or watm watee) with the largest flow. > ‘Control remperature with the supply whose temperature is mos differen from the warm water emperaure ‘Actually, these two statements are equivalent. I che warm water temperature iclose to the hot water temperature (therefore, con {tol temperature with cold water supply) the hot waer flow wil be larger than the cold water flow (cherefore, control flow with the hoe water supply) “Two situations cause problems with choosing the proper pait- 82 Warm water tempenture i midvay betwen the eo and hot IMPROVING PROCESS CONTROL ‘water temperatures. In this case, cold water flow will equal hot ‘water flow, This ease presents the greatest degree of interaction, © Actimes, the process is operated with the warm water tem- peratute close to the hot water temperature, for which the Fig. 2b ‘configuration is appropriate. Burr other times, the proces is oper= ated with the warn water temperature close to the cold water ‘em perature, for which the Fig. 2a configuration is appropriate. Tn either case, performance of the selected control configura sion will suffer. (One limitation of relative gain analysis is that i only assesses steady-state interaction. Dynamics also play a role. Specifically, if one loop is much faster than the other, the control configuration ‘will function even in the face of severe steady-state interaction. Simply cune the fast loop fist, and chen cune the slow loop. For the ‘varin water pracess, both loops wil be fst, bu he flow loop will be the faster of the wo, Further separation of the dynamics can be realized when the controllers are tuned, A well-known approach to situations wher« interaction is problem, i to intentionally rune one ofthe loop to respond much more slowly than the other. Applying thi approach ¢o the warm water process would result in a slowly responding temperacure controller. But even though both loop, ‘operate in automatic, temperature control petformance suffers. Let's examine how the Fig. 2b configuration would respone to an increase in the warm water flow serpoint. Assuming tha, both flow and temperature are at their sespoints atthe star, ch sequence of events is as follows: 1, Warm water flow serpoint is increased, 2. Flow controller opens the hot water valve, thus increasing he ‘water flow. Note chat this hot water flow change is a disturbance to the warm water temperature. 3, Hlot water flow increase causes the warm water temperactr ‘0 increase above its seepoint. 4, Temperature controller opens the cold water valve, chu increasing cold water flow and, consequently, warm water flov [Note that this hor water flow change isa disturbance to the wart water flow. ‘When the warm water temperature controller is tuned € respond slowly, its response co disturbances from the flow loo will also be slow. Consequently, control actions taken by the flor controller will have a significane effect on che warm water torr perature, The approach of runing the temperature controller + respond slowly can only be applied where this can be tolerated. Fone is 0 increase warm water flow without disturbing cl temperature loop, what must be done? The hot and cold wats flows must increase simultancously. That is, both valves mu. ‘open by the appropriate amount. Neither Fig. 2 configuratic does this. In each configuration, che low controller opens one « the valves and relies on the temperature controller ro eventual ‘open the other. "What is needed is a control configuration in which the flo controller opens both valves. Summers, ratios and other simp Fanetions can be incorporated into control configurations to pr: vide this type of behavior. The challenge i to determine how insete these functions, This is where a rigorous design method ogy would be quite useful. But in practice, one must insere the based on one’ understanding of process behavior. For the warm water process i should be inruitively obvious ch: warm water temperature depends on the ratio ofthe hor water fle to cold water flow, Fy/Fc. Alternatively, the ratio Fe/F couldIMPROVING used, From a control perspective, either ratio could be used. The deciding factor is magnitude of the respective flows. The preference isto ratio a small low toa large flow. This gives ratio coefficients less than one, which ateenuate any erors in the lage flow measurement. That the warm water temperature depends on the flow ratios is confiemed by writing the equations for the warm water pro- ‘cess, Since out focus is on process behavior, che equations are best ‘uiren in terms of the Hows through the various control valves, or the warm water process, che warm water flow and temperature are related to the flows through the control valves as follows: Foko+Fy TF=ToFo+TyFy Replacing Fby Fc Fyn che warm water temperature equa- tion permits the equation to be expressed a follows TeFo+TyFy Fe + Fig _Te(Fo/Fu)+T (Re/Fu)+1 To +Tu(Fu/Fe) T+(Ful Fe This equation clearly shows that warm water temperature depends on the ratio of cold water flow to hor water flow, or on its inverse, the ratio oF hot water flow to cold water flow, “This analysis suggests a control configuration consisting ofthe following: > Control warm water flow by manipulating cold water flow Fe. In Fig, 3, the warm water flow controller is actually manipu- lating che cold water control valve position Control warm water temperature by manipulating the ratio FulFe, Doing this literally requites flow measurements for Fe and Fy, as iluscrated in Fig 3 "Two modifications to the Fig. 3 configuration should be con- sidered ‘© Ratio the hot water valve position co the cold water valve position. This raises issues a co how wel che valves have been sized and to their installed characteristics. "© Sum the cold and hor water flows to obtain the warm water PROCESS CONTROL SPECIALREPORT & Warm water temperature, °C + 0510 15 20° 25°30 35. 40 Ratio of hot water flow fo eold water flow ep eee erie) Cea 2 eed flow, thus eliminating one flow measurement. But in instead of pursuing these, we need to address another characteristic of the Fig. 3 control configuration 'A previously cived case it a process that a times must be operated to give warm water temperatures close ro the cold water temperature, but at ocher times operated to give warm water temperatures close to the hor water temperacure. Warm water temperatures close r0 the cold water temperature require small ratio of hot to cold water ows. However, warm water temperatures close to the hot water temperature require a large ratio of hot to cold water flows For the warm water temperatute controller in Fig. 3, the fol- lowing apply: CConerolled variable: Warm water temperature, T Manipulated variable: Ratio of hot to cold water flows, Fy)/Fe Fora control oop, the process operating line is the plor of che controlled variable as a function of the manipulaced variable. Fig. 4 presents the process operating line for che warm water tem- peracure loop, specifically, a plot of warm water temperature asa function of the ratio of hor to cold water flows. This operating line exhibits sgnificanc nonlinearity. For ratios less than 1.0 (warm svater temperature close to cold water temperature, sensitivity (gain) of warm water temperatute tothe flow ratio is high. But for ratios greater than 1.0 (warm water temperarure close to hot water temperature), sensitivity of warm water temperature to the fovr ratio is significantly lower. For processes that must be oper- ated in both regimes, this will lead to cuning difficulties for the warm water temperature controller. ‘An alternative approach, anfortunately, is not incuitively obvi- ‘ous, For a constant warm water flow, F let's examine the rla- tionship berween the hot water temperature, 7; and the difference between Fy, and Fc. Note that this difference is bounded as T=Te: Fe Fy > Fy-Fe Tey: Fe Fy =F Fy-Fo=F ‘When the difference is zero, then Fe and iy are equal, and Tis the average of T-and Ter Fig, 5 presents a plot of Tas a function ofthe difference berweenSPECIALREPORT Fy and Fc. A very appealing aspect of tis relationship is that it islinear. Therefore, les construct a control configuration on the following bass: 1. Consider warm water flow controller output, Mp, to be Ft Fe 2, Consider warm waeer temperature controller ourput, Mr, t0 be Fy ~ Fe. ‘The values for Fyy and Fc can be computed as Mp+Mr) These cleularions can be implemented with two summers ‘Toimplement tis approach iteraly woud equi ow mea: surements on both hot and old wate Rows, Consider the fo- lowing modification vo te contol formulation Tahoe water ave postion, Miyin eu of Fi 2 Use cold water vale postion, Mein lie of Fe The contol coniguation then constructed on telling © Consider M10 be My + Me. > Consider M tobe My — Me. “The values for Mr and Me can be computed (utp +Mr) ‘This approach raises isues regarding installed characteristics of the control valves, that i, how J varies with My, and Fe varies, with Mc, Neithe relationship is likely co be linear, which will have some effect on performance. However, provided che two valves are not grossly oversized, acceptable performance can be expected. Fig. 6 presents the control configuration that utilizes this approach, To some, the Fig. 6 configuration might appear unnec- esarily comples. But compared ro the Fig. 2 single-loop contig- trations, note che following 1, Number of measurements (two) isthe same, 2. Number of final control elements (ewo) isthe same. IMPROVING PROCESS CONTROL Hot water cs 3. Only addition is the two summers, ‘With digial conceols, summers are readily avilable. Behavior of the two controllers is Flow controller. On increasing warm water flow, the flo controller decreases its output (How controllers reverse acting ‘This causes both control valves to close by the same amount. “Temperature controller. On increasing warm water tempe azure, che temperature controller decrease its ourput (emperatu ‘ontcller is reverse acting) Tis closes the hot water valve by el Same amount thatthe cold water valve opens “Mos digital controls now permit an engineering span to | specified fora PID controller output In implementing the Fig, configuration, one approach is Forte low controller vo drive both valves flly open, eng neering span forthe flow controler output must be 0 v0 200% * For the temperature controller to cover dhe complete ran fiom cold wate only to hot water only, the engineering span f the temperature controller output must be -100% co + 100% ‘# A cocficien of 0.5 must be applied by each summer toc ofits inputs ‘An altemate approach isto let the ousput span for each €o teller be 0 to 100%, and accomplish the equivalent using coe! dents and biases within the summers “Trevathan? presented a configuration that utilizes summers 4 similar fashion. However, he gave no explanation as to how © decides to use summers ‘Two-tank recycle process. In the process illustrated. Fig. 7, the discharge stream from tank 2 isa feed steam co main process. However, this same material is subsequently rece cred ftom the proces, flowing into tank 1 from the recovery ut For this process, wo possibilities ar: 1, Feed flow to the process exceeds flow from the recovery The difference must come from storage. This makeup sere: from storage enters tank 2. 2. Flow from the recovery unit exceeds feed flow to the proc: Excess is dumped to che drain, Exess flows to the drain via a ¢ ‘charge stream from tank 1 No flow measurements are available. Level measurements the two tanks provide the only information for determining wmust be done, i.e. makeup material from storage or dump mate tial to drain. ‘There are rwo controlled variables: ‘Tank 1 level. We will designate cis as). level controller will be configured. We shall designate this level controller output 2s My “Tank 2 level, We will designate thisas HA level controller will ‘beconfigured. We shal designate ths level controller output as My "There are three final control elements Recycle valve. Flow from tank 1 to rank 2s the material being recycled. We will designate this valve position as My and flow through the valve as Fa. ‘Drain valve. Ths valve determines flow from tank 1 to drain. We will designate this valve position as Mp and flow through the valve as F, ‘Storage valve. This valve determines flow from starage 10 tank 2. We will des ignate this valve position as Mg and flow through the valve as F. "The number of final control elements exceeds the number of controlled variables by one. But it makes no sense for the drain and storage valves to be open at che same time, Which valve is being used to control level depends on the process conditions: Feed flow exceeds flow from recov- xy. Flows should be: Drain flow: zero Recycle flow: same as flow from Srorage flow: difference between feed flow and flow from In this situation, the two tank levels ‘must be controlled using the recycle and. storage valves Flow from recovery exceeds feed flow. “The flows should be: Storage flow: 2er0 Recycle flow: same as fed flow | Drain flow: difference between flow from recovery and feed flow. In this situation, che two tank levels must be controlled using the recycle and drain valves. “The traditional approach to such con- trol requirements is to apply split-range logic, Ata point in time, either the stor age or the drain valve is being used for con- trolling a level. A single signal could be used to drive these valves ifthe following split-range logic is applied to this signal: Mid-range (50%): Both valves are closed. ‘Above mid-range (50%): The drain | valve opens, the storage valve is fly closed, ‘When the signal is 100%, the drain valve is fally open. | ‘Below mid-range (<50%): The storage SPECIALREPORT valve opens, the drain valve is fully closed. When the signal is 0%, the storage valve is fully open. Fig. 8a is one approach for a control configuration that uses this split-range logic. The two level controllers are configured as: Tank 1 levels Controlled using the recycle valve. This level controller must be direct acting (on increasing level, open the recycle valve) ‘Tank 2 levels Controlled using the spit-range logic. This con: troller must be direct acting (on increasing level, increase con- troller output, which either opens the drain valve or closes the MEET FUTURE im SULFUR REGULATIONS P6200 SERIES Process/OneLine A: \yzers ‘Wide dynamic range: ppb to & levels ile, proven UV.Fluarescence (ASTM D 5453) Excellent reproduetbilty& linearity fast cycle ie pavances Dual range. cua seam analysis No colum switening ar backllushing necessary Class |, Di 1 of 2, Groups C & 0 ‘Add total nitragen (ASTM 0 4623 ance, low cost of ownership @ANTEK iwstRuMeENTs Le Real World Solutions Select 81 at woncydrcarbonProcessng comSPECIALREPORT storage valve) ‘When feed flow exceeds flow from recovery tank 2 level is being controlled using the storage valve. This should perform propery. Buc when flow from recovery exceeds feed flow, tank 2 level is being controlled using the drain valve. Suppose tank 2 level is increasing. The control action and its consequences would be: 1. Tank 2 level controller increases its output. 2. Sple-range logic opens the drain valve (flow from recovery exceeds the feed flow) 3. Increased flow to drain decreases tank I level 4. Tank 1 level controller decreases its output. 5. Decreased flow from tank 1 to tank 2 decreases tank 2 level, ‘The problem with chis approach les in step 4, which involves 62 | OCTOBER 203 HYOROCARON PROCESSING IMPROVING PROCES: the tank I level controller. The tank 2 level controller is dependent ‘on the tank 1 level controller to function. There are two conse- quences ofthis dependence: D Lfthe tank | level controlleris on manual, the rank 2 level controller cannot function. > When one controller is dependent on another, a dynamic separation of about 5-0-1 is required for the controllers to fine tion propery. That is, the rank 2 level loop must be slower than the tank | level loop by about a factor of 5. While undesirable, the first consequence could be tolerated. However, the second cannot. The tank 2 level loop would be 50 slow that its performance would be unacceptable. Fig. 8b isan alternace approach for a control configuration that also uses the spli-range logic. The two level controllers are con- Figured as: ‘Tank 1 levels Controlled using the split-range logic. This con- troller must be direct acting (on inereasing level, increase con- troller oucpuc, which either opens the drain valve or closes the storage valve) ‘Tank 2 level: Controlled using the recycle valve. This level controller must be reverse acting (on increasing level, close the recycle valve). ‘When flow from recovery exceeds feed flow; tank 1 level isbeing, controlled using the drain valve. This should peeform properly. But ‘when feed flow exceeds low from recovery, tank level is being con- ‘rolled using the storage valve. In this mode of operation, the tanke 1 level oop is dependent on the tank 2 level loop in a manner analo~ {ous to that previously described for the Fig. 8a configuration, ‘When flow from recovery exceeds feed flow, the levels should be controlled as Tank 1 level: Drain valve Tank 2 level: Recycle valve ‘When feed flow exceeds flow from recovery, the levels should be controlled as: Tank 1 level: Recycle valve Tank 2 level Storage valve This could be implemented by providing splie-range logic for cach level controller: ‘Tank 1 level: For a 0% conctoller ouspus, the drain and re cle valves re fully open. On decreasing level, ist close the drainIMPROVING PROCESS CO valve and chen the recycle valve “Tanlc2 level: Fora 0% controller ourput, the storage and recy- cle valves are filly closed, On decreasing level, first open the recy- cle valve and then the storage valve ‘The Fig. 9 control configuration provides such split-range logic. In addition tothe split range, alow-signal selector is sed to determine which controller is positioning the recycle valve. Let's frst examine the situation where flow from recovery exceeds feed flow. Tank 1 level controller ourput will be below mid-range. Tank 1 splic-range logic ousputs will be: ‘Drain valve: Parca open (0% < Mp < 100%) Recycle valve: Fully open (100%). This assures that the low- signal selector will select che tank 2 level controller signal “Tank 2 level controller ourpue will also be below mid-range. ‘The tank 2 splic-range logic outputs wil be: Recycle valve: Partially open, Since the other input tothe low selector is 100%, this signal determines recycle valve position, ‘Storage valve: Fully closed. (Ms = 0%), ‘Now lets examine the situation where feed flow exceeds flow from recovery. Tank 2 level controller output will be above mid- range. Tank 2 split-range logic output will be: Storage valve: Partially open (09% $ Mz = 100%) Recycle valve: Fully open (100%). This asures that the low signal selector will selec the tank 1 split-range loge signal. “Tank | level controller ourpus will also be above mid-range. “ane | spliceange logic outputs will be: Reeycle valve: Partially open. As the other input to the low selector is 100%, this signal determines the recycle vale postion. Drain valve: Fully closed. (Mp = 0%). The Fig. 9 configuration will function quite well for ether sit- uation. But its behavior on a transition is not satisfactory. The problem is associated with the low-signal selector. In most (but hot al) control configurations that apply a signal selector to con- troller outputs, tracking or initialization logics required to make 2 smooth transition. The basic question is: are cere times that the controller output has no effece on the process? When the answer is yes, the PID calculations are suspended and the con- troller output is determined by tracking or initialization calcla- tions. Let’ firs show that the answer tothe question is yes, Fig, 10 presents behavior of the Fig, 9spt-range configuration fora transition. Initially, flow from recovery exceeds feed flow (drain valve is partially open, storage valve is Fully closed). The ‘transition is toa stuation where fed flow exceeds flow from recoy- cy (storage valve is patally open, drain valve is lly closed). The following times are noted on Fig, 10: ‘Time 0. Feed o the processis increased so that it now exceeds flow from recovery ‘Time A (approximately 12 minutes). The drain valve fully loses ‘Time B (approximately 17 minutes). The ewo inputs to the low select are equal “Time C (approximately 22 minutes). The storage valve begins ro open. “The transition proceeds as follows Prior to time 0: As flow from recovery exceeds fed flow, the following conditions exis: * Drain vale is partially open (42.3%). *# Storage valve is closed. + Ouspats ofboth level controllers are below mid-range (28.9% for tank 1 level controller, 36.9% for tank 2 level controller. SPECIALREPORT Level contraller output Bo 3 Input to low select, 8.8 8 88 3 8 Valve opening. ae) Time, minutes 05120 Beween time and time A: Increasing fed flow initiates the following sequence of events: 1. Level in tank 2 decreases. 2. Tank 2 level contzoller opens the reeyle valve (increases flow from tank Ito tank 2). 3. Level in tank I decreases 4 Tank I level controller closes the drain valve. Approximately 12 minutes are required forthe tak 1 level controller co filly close the drain valve ‘Attime A: Ar this insane, outputs ofthe ewo level conwlles, “Tank evel controller 50% (mid-range). The spli-range out- puware: Drain valve: 0% (closed) Inpuc #1 tothe recycle valve low selec: 100%. “Tank 2 level controller: 40.380. The split-range ouepuss are Storage valve: 0% (closed) Input #2 to the recycle valve low select: 80.6%. Berween times A and B: The following occurSPECIALREPORT D Since tank 1 level i below its sespoint, che tank 1 level con- ‘roller continues to increase its output, which is now above mid- ange. > ‘The splitrange output ro input #1 ofthe recycle valve low select decreases below 100%. D Recycle valve low-select inputs are a. Input #1 (from tank I level concrollersplit-range logic) ‘Value is ess than 100%, bue grester than 80.3%. b. Input #2 (from tank 2 level controller split-range loge) Value is approximately 80.396 and is the selected input. This input determines recycle valve position. During this interval, level in tank 1 is not being controlled. ‘Tanke {level controller output has no effect on any of the valves. Avoiding such a sicuation requires tracking ot initialization logic for the tank 1 level controller. ‘At time B: Recycle valve low-select inputs are equal. Between times Band C: The following occur: ® Tank 1 level sstill below its sepoine so the tank I level con- troller continues to increase its output. 1 Recycle valve low-select inputs are a. Input #1 (from tank I level controler split-range logic): Value is less chan 80.3% and is the selected input. This input now determines recycle valve postion, so the recy- cle valve begins to close. b Input #2 (from tank 2 level controller spit-range logic): Value is increasing above 80.3%, * Closing the recycle valve decreases flow from tank I to tank 2, which affects the tank levels as: 4. Tank 1 level increases. . Tank 2 level decreases. * A decrease in tank 2 level causes the tank 2 level controller ro increase its output. * Prior to time C, tank 2 level controller outputs below mid range. Therefore, the split-range logic is increasing input #2 +o the recycle valve low select. However, this has no effect on recycle valve position since this is che larger input to the low select. ‘During ths interval, tank 2 level isnot being controlled. Tank 2 level controller ourput has no effect on any of the valves. Avoid- ing sucha situation requires tracking or initialization logic for the tank 2 level concrollr. At time C: Tank 2 level controller output is at mid-range. As the rank 2 level controller continues to increase its output, the storage valve opens. 4 | octosen 2003 HyoROCARBON ROCESS IMPROVING PROCESS CONTROL ‘Subsequent to time C: Once the transition is complete and eh tank 2 level is being controlled with the storage valve, the con ‘wols function acceptably. The problem is with the transition. As soon as the drain valw isflly closed, che storage valve should begin to open. But there 1 a lapse of 22 minutes from the time the drain valve loses and the storage valve begins to open. During part ofthis time, tank 1 leve controller ourput has no effect on any of the valves, This calls For ‘tacking or initialization logic forthe tank 1 level controller. Duar: ing the remainder ofthis time, the tank 2 level controller output ‘has no effect on any of the valves, This calls for tracking ot ini tialization logic for the tank 2 level controller. (Customary forms of the tacking ot initialization logic compute value for the PID controller output. When an input is not selected, the tracking or initialization logic is activated for the PID controller that supplies that input. While tracking or ini tializarion is active, the usual PID calculations are not performed. But forthe Fig. 9 configuration, suspending the contiol calcula ‘ions is not entirely appropriate. Both tank levels must be con- trolled at all times, which means that both level controllers must be performing the PID control calculations at all times. ‘While there are some possibilities for addressing the problems exhibited by the Fig. 9 control configuration on a transition, this will increase implementation complexity, An alternative is to use summers in conjunction with a low select. This configuration is both simpler and does noc require tracking or initialization logic. ‘To understand how ro incorporate summers into the logic, lets examine the following aspects ofthe process: 1, Whar really determines tank I level? Ir isthe sum of the fol- lowing: ‘4. Drain flow, Fy . Recycle flow, Fy, from tank 1 to tank 2, 2. What realy determines tank 2 level Ie is the sum ofthe Fol- lowing: ‘4. Recycle flow, Fg from tank I to tank 2 b. Flow from storage, Fs, Consider tank 1 level controller output, M;, to be Fp + Fp. Consider tank 2 level controller output, My, to be Fy + Fy. OF cours, either Fp ot Fy should be zero, Therefore, les proceed as: smin(Mj,42) Mi-Fe Fig. 11 presents che control configuration based on these rela tionships. In developing this configuration, the flows have been replaced by valve positions, ic, pin lieu of F, Mpin leu of Fe and Msin liew of Fs, The resulting configuration consists of > PID controller for tank 1 level > PID concrolier for tank 2 level D Low select to determine recycle valve position as the smaller of the two level controller ousputs Summer to determine drain valve position asthe differ- ence beoween tank 1 level controller output and recycle valve position Summer co determine storage valve position a the difer- ence between tank 2 level conteoller ouput and the recycle valve position, One issue must be addressed in the Fig. 11 configuration. ‘The recycle valve normally operates about 75% open. Ifthe con.IMPROVING PROCESS CONTROL Elon ft | a troller ourpus are limited co 100%, maximum output from tach summer would be 259%. How ean we get arger valve open ings Two options are: ® Specify the engineering span for ach level conller output tobe 0% ro 200%. Each level controller can now fly open both valves Apply a mulkipier coefficient a the summer. To compute the difference, she coefficient for the summer postive input would be +1,0 and the coefficient forthe negative input would be 1.0. Hlowever specifying ches coeficiens as +4.0 and ~4.0, especie effectively multiplies the summer output by a factor of 4. For the responses presented subsequently the later approach is used. ‘The Fig. 12 responses illustrate performance of the Fig. 11 ‘control configuration. The transitions are: Prot to time 0: Flow from recovery exceeds fed flow. Observe thar the drain valve is open and the storage valve is close, From time O to time 60: Feed flow is increased so that it exceeds flow from recovery. This causes the tank levels to decrease ‘The controllers frst drive the drain valve fll closed and chen immediately open the storage valve. ‘Afer time 60: Fed flow is reduced to is orginal value (low fiom recovery now exceeds feed flow). This causes the rank levels to increas, The controls fine drive the storage vale fllylsed and then immediately open the drain valve Th the Fig. 12sesponss, there isan immediate transition from controling level using the drain valve wo conollng aleve using, the storage valve and vice versa. No initialization logics asoci- SPECIALREPORT ated with the low select. Again les pose the following questions: ‘Are there times that che rank 1 level controller output has no effect on the process? The answers no. "Are there times thatthe tank 2 level controller output has no cffec on the process? The answer is also no. Consider the two possibilities forthe low select: Input #1 selected (ank 1 level controler output is less chan tank 2 level controller ousput). Any change in tank 1 level con- troller ousput is reflected in the reeycle valve position. Any change in nk 2 level controller output is reflected in the storage valve position. Tnpus #2 selected (ank 2 level controller output is less than tank I level controler ourput). Any change in tank 2 level con- troller outputs reflected in the recycle valve position. Any change in tank 1 level controller output is refleceed in the drain valve position. "No tracking oF initialization logics required to attain a smooth Other control functions. Our focus has been on how to incorporate summers into control configurations to achieve bet- ter performance. Another simple element chat is appropriate for some applications is a ratio (multiplier). Occasionally a charac terization Function (some cal ita function generator) is also use ful, Such functions are readily available within digital control Cost of incorporating such functions into a control configu tion is nominal Lack of rigorous design methodology certainly hinders their use, However, two other factors invariably arise: 1, The control configurations appear to be more complex than they actually are In reality, the increase in complexity is more apparent than real, and in some applications (such as the two-tank recovery process), configuration i simpler than the alternative. 2, Provided the plant can “make do” with the existing config tration, proposed changes co the P&I diagram always meet resi tance, The most objectionable is the “pocker vero," where a change is agreed to but never gets high enough on the priority list to be implemenced. ‘Most plants have now made substantial investments in some form of digital controls, One would ehink chat every opportu- nity to increase return from this investment would be aggres- sively pursued. He “se LITERATURE CITED "Beil, He, "On a New Menuze of Interaction for Mulivaible Proce Contr” JEEE Traction on Aatomenc Con, AC-11, Number 1 Tanuary 196, STromthan, V. Li "Proce Controle in the Chemical Indusuy” AICHE Sypoinon Serie, Volume 72, Number 138, 1976, pp. 40-48. Cecil L. Smith, m0, #, masa mene ofthe Lotian State Univers foe ton Rage, fom 1956 to 1979 and served 3s harman ofthe Computer Sree Orprtet fm 19720 1976. 11979, be esgnea hs postion of profesor of ema engineering and of con puter scence to pursue consulting fl tne Instead of part tne Di. Smith ful pracice devoted exe to industrial automation, enccmpssing both bth and continuous processes He ao ences arta educa cousescn v= igus aspect of proces conto. Oe Smit approach o procs cones rfeced9 these courts andin the computerbate raring (CBT package hat hes deve ‘ped on process conto, He can be esres aceelsnth@con net. vroRocasson ROCESSING OCTORER 2005 | 55