Control Using Two

Manipulated Inputs

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 1 Control Using Two Manipulated Input
Control Using Two Manipulated Parameters
Under specified
problem that has
multiple solutions for
Two(2) Manipulated unlimited operation.
One(1) Controlled Parameters
Parameter Extra degree of
freedom is used to
achieve unique
solution that satisfied
FY specific control
Controller Process objective.
SP
Most common
techniques are: split
range, valve position,
and ratio control

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 2 Control Using Two Manipulated Input
Basis Split Range
In some cases,
two or more
inputs to the
process are used
AC as one input.
111
The inputs to the
FY
111 process are
AT
maintained in a
111 fixed relationship
Process as determined by
a splitter station
characterization
and station
setpoint.

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 3 Control Using Two Manipulated Input
Steam Header Example

1475# Header
Boiler

IP FY PIC
104A 104 104

IP
104B Turbo
PT
104 Generator

400# Header

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 4 Control Using Two Manipulated Input
Split Range Output (FY104) - Capacity

100

Valve
Position
(% of Span)
Valve 104A

Valve 104B

0
0 100
PIC104 Output (% of Span)

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 5 Control Using Two Manipulated Input
Calculating Splitter SP Ranges
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%
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 6
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.
Process Control
Control Using Two Manipulated Input
Example - Split Range Control
Temperature
TIC
control using
104 cooling and
FY heating
104
Valves are
IP
104A IP
sequenced in a
104B TT fixed
104
COOLER
relationship to
HEATER
the
temperature
controller
output

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 7 Control Using Two Manipulated Input
 Split Range Output (FY104)

100

Valve
Position
(% of Span)
Cooling (IP104B)

Heating (IP104A)

0
0 100
TIC104 Output (% of Span)

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 8 Control Using Two Manipulated Input
 Testing Process to Determine
Splitter SP Ranges
With the process at
Example: Temperature controlled using heating steady state and AOs
and cooling valves in Auto mode,
determine the
Controlled magnitude of change
in the controlled
Temperature 1.1degF 2.2degF parameter for a 1
percent change in each
valve.
Calculate the splitter
Heating 1% SP span and range for
each output based on
Cooling 1% the observed response

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%
2006 Fisher-Rosemount Systems, Inc. Process Control
Slide 10 - 9 Control Using Two Manipulated Input
Split Range Control in DeltaV

Splitter bock is used

to implement split
range control.
Split range control
is most often
implemented using
AO blocks for direct
interface to valves.

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 10 Control Using Two Manipulated Input
Splitter Block Calculation

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 11 Control Using Two Manipulated Input
Splitter Block
OUT_1
100
OUT_2 OUT_ARRAY
0 100 0 100
IN_ARRAY
0 100 0 100
0
0 100

100 OUT_ARRAY
100 0 0 100
IN_ARRAY
0 40 35 100

0
0 100
100
LOCK_VAL holds OUT_ARRAY
0 100 0 100
IN_ARRAY
LOCK_VAL is zero 0 40 35 100
0
0 100

SP
2006 Fisher-Rosemount Systems, Inc. Process Control
Slide 10 - 12 Control Using Two Manipulated Input
IN_ARRAY Parameter
The SP range
associated with each
output is defined by
IN_ARRAY.
SP range of outputs
may be defined to
overlap
SP range The SP upper end of
associated range must be greater
with OUT1 that lower end of range
for each output

SP range
associated
with OUT2

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 13 Control Using Two Manipulated Input
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
OUT1 Range for for OUT1.
associated SP range
No restrictions are
placed on the output
range.

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 14 Control Using Two Manipulated Input
Example - Neutralizer
Reagent Coarse IP
Valve 105A
Fine
Valve
IP
105B
FY
105

AIC
105
Neutralizer

AT
105
Discharge

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 15 Control Using Two Manipulated Input
 Split Range Output Valve Sequencing

100

HYSTVAL
Valve
Position
(% of Span)
Fine Valve (IP105B)

Coarse Valve (IP105A)

0
0 100
AIC105 Output (% of Span)

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 16 Control Using Two Manipulated Input
Split-range Control Workshop
Split-range

TIC
104
FY
104

IP
104A IP
104B TT
104
HEATER COOLER

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 17 Control Using Two Manipulated Input
Split-range Control Workshop
Split-range
Step 1. Open the EXAMPLE_G module and go to on-line
operation in Control Studio. Change the mode of the
Splitter block to Auto.
Step 2. Change the splitter SP (setpoint) over the following range
- 0, 25, 50, 75, 100 - and observe the change in the
valves and process outlet temperature.
Step 3. Change the splitter SP (setpoint) to 50 and wait until the
temperature settles to a fixed value.
Step 4. Make a step change in the FEED_TEMP disturbance and
manually adjust the splitter setpoint to get the
OUT_TEMP back to its initial value.
Step 5. Change the splitter mode to Cascade, change the
temperature control setpoint and observe the response.

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 18 Control Using Two Manipulated Input
EXAMPLE_G Split Range

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 19 Control Using Two Manipulated Input
 Valve Position Control
pH Example
PID control is
implemented using the
AIC actuator with finer
106
IP resolution or fastest
106A
Fine Valve
impact on controlled
ZC IP parameter
106 106B AT
SP= The actuator with
I-Only 106
Target Process coarse resolution or
Valve Controller A/O slower impact on the
Position Coarse controlled parameter is
Valve adjusted by an I-only
controller to maintain the
pH long term output of the
PID controller at a given
Fine Valve target
Target Valve
Coarse Valve
Position
Time
2006 Fisher-Rosemount Systems, Inc. Process Control
Slide 10 - 20 Control Using Two Manipulated Input
 Example --Boiler
Boiler BTU Demand

BTU Demand
FY FIC IP
109 109 109A

FT
109B
HI BTU Fuel Boiler
ZC IP
109 109B
FT
109A
Low BTU Waste Fuel

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 21 Control Using Two Manipulated Input
 Example Reformer
Reformer Air Demand

Total Air
ZC FIC Demand
110 110

IP
SC
110
110
FT Secondary
110 Reformer

Air
Machine

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 22 Control Using Two Manipulated Input
Valve Position Control in DeltaV
The OUT of
the PID used
for control is
wired to IN on
the PID block
used for I-
Only
regulation of
slower
responding or
coarse
resolution.

PID configured for I-

Only control
2006 Fisher-Rosemount Systems, Inc. Process Control
Slide 10 - 23 Control Using Two Manipulated Input
Configuring PID for II-Only
-Only Control
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

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 24 Control Using Two Manipulated Input
Valve Position Control Workshop

FIC
110
ZC
110
FT
110
Small
Valve

Big Valve

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 25 Control Using Two Manipulated Input
 Valve Position Control Workshop
Step 1. Open the EXAMPLE_H module and go to on-line
operation in Control Studio. Change the mode of the flow
controller to Auto.
Step 2. Change the flow control SP (setpoint) over the following
range 40, 50, 60 - and observe the change in the two
outputs.

Why Is the small valve maintained at 50%?

Step 3. Change the SP of the valve position controller and
observe the response.

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 26 Control Using Two Manipulated Input
Example H Valve Position Control

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 27 Control Using Two Manipulated Input
Basis Ratio Control

To fully automate a large process, it

Input = SP or PV is often necessary to provide
of independent coordinated adjustment of multiple
loop loops.
The technique of ratioing control
FC
1 loops is an effective way to provide
this coordination.
RC FT
2 1 Ratio station is used to specify ratio
and to calculate setpoint of the
SP FC dependent loop.
2
Ratioing based on the independent
FT loop setpoint provides a noise free
2 remote setpoint but will be incorrect
if the independent loop can not
SP= (Ratio * Indep Loop Input ) maintain its setpoint
2006 Fisher-Rosemount Systems, Inc. Process Control
Slide 10 - 28 Control Using Two Manipulated Input
Example Reactor Feed Ratio Control
Catalyst flow
must be
maintained in
correct
Catalyst proportion to
SC the feed flow for
9 Reactor correct reactor
RC
9 operation and
final product.
FC
8 Ratio control
FT
8
automatically
Feed provides the
correct
proportion of
catalyst to feed.
2006 Fisher-Rosemount Systems, Inc. Process Control
Slide 10 - 29 Control Using Two Manipulated Input
Automatic Ratio Adjustment

A process output that

indicates the impact of
RC AC
2 1 the ratio of process
inputs may be
FC
1
maintained at target by
FT using feedback to
1 AT
1
adjust the ratio target
To the feedback
FC
1 control, the ratio station
FT
1
and associated flow
loops are considered to
be part of the process

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 30 Control Using Two Manipulated Input
Example Slaker Control

Effective Alkali.
EA, is
maintained at
RC
8
AC
9
target though
the adjustment
of lime to green
SC Lime liquor flow ratio.
FC 8
7 As green liquor
feed is
FT
increased, then
7 lime flow is
Green Conductivity
AT
9
automatically
Liquor increase in a
proportion to
maintain the
target EA.

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 31 Control Using Two Manipulated Input
Ratio Control in DeltaV

The Ratio block is

used to implement
ratio control.
IN_1 may be a
flow measurement
(wild flow) or
setpoint of another
loop
The true ratio is
calculated base on
IN_1 and IN and
reflected in the
ratio block PV.

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 32 Control Using Two Manipulated Input
Ratio Block Function

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 33 Control Using Two Manipulated Input
Ratio Control Workshop
AC
1-1

FC
1-2
RC % Solids
1-2 AT
FT 1-1
Static Mixer
1-2
Main Flow

FC
1-2

FT
1-2
Blend Flow

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 34 Control Using Two Manipulated Input
 Ratio Control Workshop
Step 1. Open the EXAMPLE_I_CNT module and go to on-line operation
in Control Studio. Change the mode of the Ratio block to Auto.
Step 2. Change the Ratio SP (setpoint) over the following range 0.3,
0.5, 0.8 - and observe the change in the blend flow and the
process outlet concentration. Set the Ratio SP to 0.5 percent
and wait for the concentration to settle to a steady value.
Step 3. Make a step change in the FEED and observe the way the ratio
changes the dependent loop. Did the concentration change?
Step 4. Change the ratio block to Cascade mode. Change the setpoint
of the analytical loop to 40% and observe the impact on the ratio
setpoint. Does the measured concentration reach setpoint?
Step 5. Open the EXAMPLE_I_PROC module and examine the process
simulation used in this workshop.
Question: What are the advantages of structuring the process simulation as a
separate module? What are the disadvantages of this approach?
2006 Fisher-Rosemount Systems, Inc. Process Control
Slide 10 - 35 Control Using Two Manipulated Input
EXAMPLE_I_CNT

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 36 Control Using Two Manipulated Input
EXAMPLE_I_PROC

2006 Fisher-Rosemount Systems, Inc. Process Control

Slide 10 - 37 Control Using Two Manipulated Input
2006 Fisher-Rosemount Systems, Inc. Process Control
Slide 10 - 38 Control Using Two Manipulated Input