C t l Loop

Control
L
Hardware
H d
The valve is a control engineers best
f i d!
friend!

Georgia Institute of Technology

School of Chemical Engineering

Control Relevant Aspects of

Control Loop Hardware
Necessary for control loop troubleshooting:
To determine if each subsystem (control
computer, actuator system, and sensor system)
is functioning properly
To understand the proper design and operation
of all the components that make-up each of the
subsystems of a control loop

Georgia Institute of Technology

School of Chemical Engineering

Control Diagram of a Typical

Control Loop
Actuator
System
F1

F2

T1

T2
Sensor
System

Controller

TC

T
TT

Georgia Institute of Technology

School of Chemical Engineering

Components and Signals of a

Typical Control Loop
F1

F2

T1

T2
Thermowell

3-15 psig

T
Air

I/P

Operator
Console

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4 20 ma
4-20

Tsp

D/A

DCS
Control
Computer

Thermocouple
millivolt signal

A/D

4-20 ma

Transmitter

School of Chemical Engineering

Controllers/Control Computers

Pneumatic controllers
Electronic analog controllers
Supervisory control computers
Distributed Control Systems (DCS)
Fi ldb ttechnology
Fieldbus
h l

Georgia Institute of Technology

School of Chemical Engineering

Pneumatic Controllers - Phase I

Introduced in the 1920
1920ss
Installed in the field next to the valve
Use bellows, baffles, and nozzles with an
air supply to implement PID action.
Provided automatic control and replaced
manual control for many loops

Georgia Institute of Technology

School of Chemical Engineering

Pneumatic Controllers - Phase II

Transmitter type pneumatic controllers
began to replace field mounted controllers
in the late 1930s.
Controller located in control room with
pneumatic transmission from sensors to
control room and back to the valve.
valve
Allowed operators to address a number of
controllers from a centralized control room.
Georgia Institute of Technology

School of Chemical Engineering

Pneumatic Controller Installation

F1

F2

T1

T2
Thermowell

3-15 psig

T
Air

Tsp

Georgia Institute of Technology

Pneumatic
Controller

Th
Thermocouple
l
millivolt signal
3-15 psig

Air
Transmitter

School of Chemical Engineering

Electronic Analog Controllers

Became available in the late 1950
1950ss.
Replaced the pneumatic tubing with wires.
Used resistors, capacitors, and inductors to
implement PID action.
Out sold pneumatic by 1970.
1970
Allowed for advanced PID control: ratio,
feedforward, etc.
Georgia Institute of Technology

School of Chemical Engineering

Analog Controller Installation

F1

F2

T1

T2
Thermowell

3-15 psig

T
Air

I/P

4-20 ma
Th
Thermocouple
l
millivolt signal
Tsp

Georgia Institute of Technology

Electronic
Analog
Controller

4-20 ma

Transmitter

School of Chemical Engineering

Computer Control System

Based upon a mainframe digital computer.
computer
Offered the ability to use data storage and
retrieval, alarm functions, and process
optimization.
First installed on a refineryy in 1959.
Had reliability limitations.

Georgia Institute of Technology

School of Chemical Engineering

Supervisory Control Computer

Video Di
Vid
Display
l
Unit

Al
Alarming
i
Functions

Printer

Supervisory Control Computer

Analog
Control
Subsytem

Interfacing
Hardware

Data Storage
Acquisition
System

...
Georgia Institute of Technology

School of Chemical Engineering

Distributed Control System- DCS

Introduced in the late 1970
1970ss.
Based upon redundant microprocessors for
performing control functions for a part of
the plant. SUPERIOR RELIABILITY
Less expensive
p
per
p loop
p for large
g pplants.
Less expensive to expand.
Facilitates use of advanced control.
Georgia Institute of Technology

School of Chemical Engineering

DCS Architecture
System
Consoles

Host
Computer

Data
Storage
Unit

PLC

Data Highway
(Shared Communication Facilities)

Local
Console
C
l

Local
Control
Unit

Local
Control
Unit

..............

Local
Console
C
l

Process Transmitters and Actuators

Georgia Institute of Technology

School of Chemical Engineering

DCS and Troubleshooting

The data storage and trending capability of
a DCS greatly facilitate troubleshooting
control problems. That is, the sources of
process upsets can many times be tracked
down through the process by trending a
group of process measurements until the
source of the process upset is located.

Georgia Institute of Technology

School of Chemical Engineering

Control Relevant Aspects of a

DCS
The most important control aspect of a DCS
is the cycle time for controller calls. The
shortest cycle times are typically around 0.2
seconds while most loops can be executed
every 0.5 to 1.0 seconds. These cycle times
affect flow control loops and other fast
control loops.

Georgia Institute of Technology

School of Chemical Engineering

Fieldbus Technology
Based upon
p smart valves,, smart sensors and
controllers installed in the field.
Uses data highway to replace wires from sensor to
DCS and to the control valves.
Less expensive installations and better reliability.
Can mix different sources of sensors, transmitters,
and
d controll valves.
l
Now commercially available and should begin to
replace DCSs.
Georgia Institute of Technology

School of Chemical Engineering

Fieldbus Architecture
Plant-Wide Network

Local
Area
Network

Smart
Sensors

.................
Smart
Sensors

Smart Control
Valves and
Controllers

Fieldbus Network

Local
Area
Network

Smart Control
Valves and
Controllers

Fieldbus Network
a

Georgia Institute of Technology

School of Chemical Engineering

Actuator System
Control Valve
Valve body
Valve actuator

I/P converter
Instrument air system

Georgia Institute of Technology

School of Chemical Engineering

Typical Globe Control Valve

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School of Chemical Engineering

10

Cross-section of a Globe Valve

Georgia Institute of Technology

School of Chemical Engineering

Balanced vs. Unbalanced Valves

Balanced Plug Valve

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Unbalanced Plug Valve

School of Chemical Engineering

11

Valve Characteristics

Georgia Institute of Technology

School of Chemical Engineering

Types of Globe Valves

Quick OpeningOpening used for safety by-pass
by pass
applications where quick opening is desired
Equal Percentage- used for about 90% of
control valve applications since it results in
the most linear install characteristics
Linear- used when a relatively constant
pressure drop is maintained across the valve
Georgia Institute of Technology

School of Chemical Engineering

12

Installed Valve Characteristic

The linearity of the installed valve
characteristics determine the
operating range over which a control
valve can effectively operate.
Outside that range,
range the deadband of
the control valve will increase
significantly.
Georgia Institute of Technology

School of Chemical Engineering

Valve Deadband
It is the maximum change in instrument air
pressure to a valve that does not cause a change in
the flow rate through the valve.
Deadband determines the degree of precision that
a control valve or flow controller can provide.
Deadband is affected by the pressure drop across
the valve
valve, the wear on the valve,
valve and the design of
the valve plug and seat.

Georgia Institute of Technology

School of Chemical Engineering

13

Optional Equipment
Valve Positioner- a controller that adjusts the
instrument air in order to maintain the stem
position at the specified position. Greatly reduces
the deadband of the valve. Positioners are almost
always used on valves serviced by a DCS.
Booster Relay- provides high capacity air flow to
the actuator of a valve. Can significantly
g
y increase
the speed of large valves.

Georgia Institute of Technology

School of Chemical Engineering

Control Relevant Aspects of

Actuator Systems
The key factors are the deadband of the
actuator and the dynamic response as
indicated by the time constant of the valve.
Control valve by itself- deadband 10-25%
and a time constant of 3-15 seconds.
Control
C t l valve
l with
ith a valve
l positioner
iti
or in
i a
flow control loop- deadband 0.1-0.5% and a
time constant of 0.5-2 seconds.
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School of Chemical Engineering

14

Sensor Systems
Sensor

temperature sensors
flow sensors
level sensors
pressure sensors
composition analyzers

Transmitter
Georgia Institute of Technology

School of Chemical Engineering

Sensor Terminology

Span
Zero
Accuracy
Repeatability
P
Process
measurementt dynamics
d
i
Calibration

Georgia Institute of Technology

School of Chemical Engineering

15

Span and Zero Example

Consider a case in which the maximum
temperature that is to be measured is 350F
and the minimum temperature is 100F.
Then the zero is 100F and the span is 250F
In addition, if the measured temperature is
k
known
att two
t different
diff
t sensor output
t t levels
l l
(i.e., mas), the span and zero can be
calculated directly.
Georgia Institute of Technology

School of Chemical Engineering

Smart Sensors
Sensors with onboard microprocesssors that
offer a number of diagnostic capabilities.
Smart pH sensors determine when it is
necessary to trigger a wash cycle due to
buildup on the electrode surface.
Smart flow meters????????
Smart thermocouples??????
Georgia Institute of Technology

School of Chemical Engineering

16

Temperature Sensing Systems

Thermocouple and RTDs are most common forms
RTDs
RTD are an order
d off magnitude
it d more precise
i but
b t
are less rugged and cost more than thermocouples.
Typical dynamic response time constant is 6-20
seconds.
Additional thermal resistance on inside or on the
outside of the thermal well can result in an
excessively slow responding temperature
measurement.

Georgia Institute of Technology

School of Chemical Engineering

Pressure Measurements
Usually based on strain gauges
Very fast measurement dynamics
time constant 0

Repeatability less than 0.1%

Georgia Institute of Technology

School of Chemical Engineering

17

Flow Measurements
Orifice plate/DP cell most common approach.
Good repeatability and fast dynamic response.
response
Magnet flow meters and vortex shedding flow
meters are also used in certain situations. They
are more expensive but more reliable and require
less maintenance.
A straight run of pipe before and after the meter is
required for good accuracy for all flow meters.

Georgia Institute of Technology

School of Chemical Engineering

Orifice Plate/DP Cell Flow

Indicator in a Flow Control Loop

FC

Flow Setpoint

FT

Georgia Institute of Technology

School of Chemical Engineering

18

Level Sensors
Usually based on the hydrostatic head in a
vessel measured by the differential pressure.
Has a repeatability of about 1% with a
time constant less than 1 second.
Level measurements based upon
p a float or
x-rays are also used in special situations.

Georgia Institute of Technology

School of Chemical Engineering

Typical Differential Pressure

Level Measurement
Upper Tap
Diaphragm

Vapor
DPT

Liq id
Liquid

Lower Tap
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School of Chemical Engineering

19

Analyzer Sensor Systems

GC- most common composition analyzer. Based
on plug flow of a volatile sample through a packed
bed--behaves as deadtime. Deadtime and
repeatability depend on the particular components
being measured.
Radiation absorption- infrared, ultraviolet, and
visible. Can be effective for certain components.
Sampling system can affect dynamics and
reliability of composition measurement.

Georgia Institute of Technology

School of Chemical Engineering

20