Basic Process Control

Basic Control Principles
Inflow Supply

l l l

l l l

Level (Controlled Variable) Pump Overflow

Open vs Closed Loop
!

Closed loop
!

Automatic control Manual control Person takes the place of the controller

!

Open Loop
! !

Feedback Control
Disturbances

Controller
Set Point

Comparator

Error (SP - M)

Amplifier

Manipulated Variable

Process (Tank)

Output (Controlled Variable - Level)

Measurement Signal

Process Sensor

Feedback vs. Feedforward
!

Feedback
!

Control action after an error exists Reacting to the disturbance before the error occurs

!

Feedforward
!

Typical ON/OFF Control System
V1 Inflow

SP

Qout

l l l

Qin

P1 closes @ L1 P1 opens @ L2

l l l

L2 L1

Electrically Operated Solenoid valve Solenoid Power Supply

P1

Typical ON/OFF Response

L2

SP

time

L1

Periodic Time

Proportional Control

Level Control of Open Tank
V1

SP

Qout

l l l

Qin

l l l

A/C

LT

20 - 100 kPa

Simple Proportional System
Inflow Valve

Pivot

l l

Float

l l l

Outflow

Open Tank Control
A/O Qin SP
LIC

20 - 100 kPa

LT Qout

Controller Action
A/C

SP

Qout

l l l

Qin

l l l

20 - 100 kPa
LIC

Direct

LT
A/O

SP

Reverse

Qout

l l l

Qin

l l l

20 - 100 kPa
LIC

LT

Proportional Control
Setpoint + Error k•e + + Output

Measurement

Bias

m= k(SP-M) + bias

Proportional Band and Gain
Proportional Band – the input change required to
change the output 100%

∆output gain = ∆input

100% gain = PB

Narrow, Wide, High & Low
In Wide PB – Low Gain Out

Narrow PB – High Gain

Proportional Control Response Curve
Loss in Volume New mass balance occurs here

Outflow Input/Output t0
t

Inflow t1 time

Level originally at setpoint Level t0 t1
Offset

New level below setpoint

time

Proportional Response with Narrower PB
Loss in Volume New mass balance occurs here

Outflow Input/Output t0
t

Inflow t1
Offset

time

Level originally at setpoint Level t0 t1

New level below setpoint time

Response Versus PB, Proportional Control Only
Load Change Step Disturbance

time

SP
System Response

"Wide" PB
Offset

SP

"Moderate" PB
Offset

SP

"Narrow" PB

time

¼ Decay Response Curve

System Response

A A/16 A/4 time

For You To Do
! !

Read pp. 89-105 Answer Questions pp. 121-122, #1-19

Reset or Integral

Response Curve: Proportional Control Only
Step Disturbance

System Response

time

SP
Offset

Additional Control Signal Restores Process to Setpoint
Initial mass balance Final mass balance

Outflow Reset Action Inflow Setpoint
Offset Removed

time

Integral Action
1 ∫ edt TR

Setpoint

+

Error -

k•e

+

+

Output

Measurement

Bias

  1 m = ke + ∫ edt  + bias   TR

Units
!

Minutes per repeat
! !

MPR The length of time that it will take the integrator to add an amount equal to the proportional response RPM The number of times the proportional response is repeated in one minute

!

Repeats per minute
! !

Proportional Plus Reset, Open Loop Response
error
e

Control Signal

Fa

st

ese R

t
No

s al Re rm

et

Slow Reset

}

ke Proportional Response

time

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
Input

Output

Proportional Action Derivative

Derivative ceases as error stops changing

time

Derivative Control
1 ∫ edt TR

Setpoint

+

Error -

k•e

+ + +

+

Output +

Bias Measurement

TD

de dt

 1  de + bias m = ke + ∫ edt  + kTD  T  dt  R 

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
Process B A t0 C t1 t2

time

Control Signal %

Proportional action A-B Rate action due to cessation of increase in e Rate Rate action action B -C A-B Control signal at end of excursion Proportional action B - C t0 t1 t2 Rate action due to cessation of increase in e

time

Large System Under Proportional and Proportional Plus Derivative Control
Control Signal

Load Disturbance Applied Prop. + Derivative Prop. Only Setpoint time

Level

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

A/O

LIC SP

LT

l l l

Qi

Qo

l l l

Typical Flow Control Loop

_l l √ FT
FIC SP

A/O

Pressure Control – Constant Bleed
SP PIC PT

Feed A/C

Pressure Vessel

Pressure Bleed

Split Ranged Feed and Bleed Pressure Control
SP PIC PT

A/O Feed A/C Pressure Vessel Bleed

Representative Hot Bleed/Cold Service Water Heat Exchanger
Hot Bleed Cold A/C

TT

TC SP

Cooled Bleed

For You To Do
! !

Read pp. 106-120 Answer Questions pp. 122-123, #20-38