INSTRUMENTATION FOR OPERATORS Unit 3 Controllers and Control Modes Section 1 ControllersPILOT SIX— INSTRUMENTATION FOR OPERATORS UNIT THREE — CONTROLLERS AND CONTHOL MODES Section 1 Canter E Why We Need Cont How a Contruber Woke "The Comte Loop =. Sytem Response Ofer nd Oeesation Types of Comeoliany sos On-087 Cortraiers Pooblems with ax Ox OH Contra Proportional Controlize “rhe Thrattiing Rare of the Valve ‘The Tarotae Range a the Conroe Tho the Properional Bund Aats# Conte wiew snd Senne Section 2 Proverianal Conirliors with Bate and Heset Aion rows Cou ‘seedtaek Helos i Lat Chee ater Proprtna rare Riot Aevion « ‘Automatic Reset How Razah Action in ae Action How tie Boo Section 3 ‘Working with Coatecers Tntrehation rable with Covtraler dating How Contra «One Procsi Affects Anois How Reret aud Rate Action AM Centr ‘Working with she Contel Sede Who Shouit Aatunt Cantroos on = a % a “ a “ ta 3a 1“Unie Taven of Instrumentation fer Operators explain the pure ose aid operation if aniortie cntraliers and of control ‘esi in prooets contr Inteucvent, tn Section 4 you will turn now conteallers work, the sere fm control lee, ane the factors in svatem response, You ‘wil Tourn no offer and eellatton, onl? coutrelers and Sroportiona) eonteabers, the thyokting tangs of she valve An of te controler, anc tow the peaportional oud affects entra 1m Seetion 2 you wil arn bow changes in proces loud affest repersenal eantrollers an how changes 1n proces al eat he eompentated for by ase of feedback bellow» wid by vevet ‘nd race secon, 1m Seevion & you wil learn how fo work with contellers and Control modes ead how to iletlty wolaetier problem‘This ie a programed loarning couse. Progremed learning vos information in a series of steps called frames. Hach fame ees some tncermation and asks you to make use of it Heo ig bow it worl, Dist, comer the reapers column at the ight wth a mane Reavt this frame and ase the ineoemabion it gives to in the Hat [A micrometer in an instenment designed to mensire in ‘housed oF an Ine {A mierometer ng tend fer measuring weey Aiforencer is sin. Move the mask canen ta imeower tha word at the right of the frame, TF you have filet he blank with that woed oF a word, hal wun Che aaa, you are evady Uo go aead to Ue west fra. ‘The draowine of a micrometer provides. nformtion Ut will lp you B11 he next blank. opsecr wae Beasuaee 7 2 Ee Seven major parts aro shown in the drewingy bal oaly fhe ind the contact the bjoct #6 be mensured, ‘smallina Oe a (OF tho two parts that contuet the object, only he (envi spine) raves. ‘A program in hav J deme series of frames that ork ike he ones yen ‘eu he Ecure ‘Use he stformation to HH fn the Uanks or rake a coe Move the mask down and chek the resp enema. Go on to the nox frame, ‘enember to cover the response eoluma with a male before you begin each pa. sinaieWhy We Need Contrellers 1. Proows warlabten are sontrotiak by opening and eloe ine, 2 valves 2 ets say that you want a ow rate of L00 galls per minute for & prove. Phe contra fc set te allows jet 10 valve salloat of Hquid por saute inte the procs A. TE the few rte never change from 100 game per minut Ac peu don't oad to nae the central a ‘alow 5. you have to eayast th entra yee tone stany. 4. Lata vey that thor few change in the pressure acting In he liquid whien apples the proce [When thy lvol in this tune changes, the prassare on he tanta nges. oF doerenst 5. The low ae tothe prove A. ny a 100 atone por mint 8 oneme B 6 To maintain the proper flow rate, the enim] valve must pened, or jadet be a pera ‘ 2 can he nn Snatrment (6 fam be either an perotar oF an Stew & Tes: madern Insulation, Ove controler i key to be tn (stron pest) 9, he conta gone iy action only whew there ie 1. Te amene tv peers change, he oen. — doe 11, TE procentyafublen ona be held perfoey eoealaal, there would ly ay weed for w votoller. Is this key ta happen in atypical Insalaton? Yes x ow a Controller Werks 12, ‘The contre set co mel che tarot Cor te proces fenily ning controle "The eontoller wack aut: the the prow Fariblen on target tw ken 19, ‘The tare fr dhe corti el ue sek point Les aay a toripratiaw mexsaromant son tango ‘The controller (rend deen ont yo) a Ube at point 14, 1a temperatrs i not on Suet, the feauperatice tne Alenton des vee mae the ff the conten 16, A vantrller goes into ction when: A. the proeess Je off tage 5K th proves fen fare 1M, Wha: tho proneen strep from the eet point on amy rocet variable (4! sma) canteens affecting that “arlable sould toact dnsteanent hangs, 07 vpsct conical Ne sm pointPOF Complete bre eons] A MEASURE. B COMPARE C CONTROL, "The eontrller i bhe a opartor 18. Hts anny of __ is enaperauce indice tous 19. Ws spo or elas the v4 ond 20, Hts couch given him information, He already “knows” Sw the ea pint hone To nd out whesker the process is on target, Ne ea ‘via he fale to tho eek pont compar 21, The comiolior fie receives information trom deyieg and then il la ecssiring, oF sensing ‘he desired eh pot. compares 22 Li the provers miaeurement and the got plat are the same, the operator A, motos en aster =. tw thin B 22, But Ifthe meamacemeat and the act point exo diferent, hw aj the onto! —— valve ‘2A, Lot's any bo ences the contra vale to cool tho prowss, owe ean be il if the proce am ened? Hie sense of ‘deaton thle, ouch2 ‘want has happencl 3h Une prevlous exsuple, the operator gels eetiack information trom hie ‘Phoso are tho stops nooled bs ecnleol x presess Slep 1: "The process variable ie massa Step 2: ‘The mowsurement ——to the st point Step A IF there in a diffrenen, the ie moved. Slap 4: Some device gives the controller information Step 1 ‘This foodback “tae” the whet su hayponod 1 the feedbnok dos wot math the ret pont on # med fen entra A. the contelley stone working B, the controler Keene working pint is reached, the seb [Put an A on the drawing to how Whore measuring fs being done, Put « Hi ta show where comparing i belay done. ute € toekow where valve positioning is being dane. ut » Dts show whorsfondback in ven, ‘toueh, o- bad eso controler20, a at THERMOMETER A MEASURE B COMPARE CCONTROL, / “The operator gets a measurement ané feeTack trom: , vare seni h, é ~ Sh mete Bg ny oo an "The controler ir Ua ‘The valve in ed}xetod (hy an} /outomatlealy) ‘This i an automatic eonteol situation 1 SUPPLY + ©} WATER sTEAN ‘The procese temperature is measure! at ¢A)B/C). AL 1 the pracem monsursment Ss aot the set patat, AL C, the provost pevator, oF man vy hand 4 compared controlled, oF ropulated43, This elvgram shows « gonmplele control lop. CONTROLLER (ERROR DETECTION NEASUREWENT COMPARISON) [MEASUREMENT | mee SET Font vatyi POSITION CONTROL ‘A conten! loop) senaivts of all thy elements needed to ET tie movement of w valve, Bh, Accontro! Joop a above above A. Je streular and dosed, SB i oponconded 25, inst the provien measuring element sends @ stnal te the centroie= ‘The controler is the detentor. 80, At the same time, tho already determined —_ Pf fed nto the eontoller (error detector). 9%, Thr error detector mules a — elvoon ‘fir emal from the process aad (he set polnt siz 38. IF theve te a eliterence Vetween the measared signal ‘and tho act point: A. nothing, happens 1. an error seal & wank to the positioner ‘of the onkeeh valve 20, ‘Tho positioner adjasts the setting 40, "The contro) valve changes the process. ‘formation ae this chanue 5 ploked mp by the ot EN ostrament an fe into tho controlar. 43, ‘Phin information fs eal process ‘the comroler. et control point compariscn salve ‘oadbaek42, It takos timo fer the nerta of the control Loop to detect procese chara, ako a valve sdjuetment, and gol ‘recess feedback ‘Tho Lom time ft takes, the (ereuter/leseer? the ett. dency of the control Ine 48, ‘The inatruments should rewet as fast as it tb practical for them to reset whon the —— bung, 44. Sometimes there tt a time lag in the instruments, hese inetrmmerts nre operating by: (pneamtis/stecs seal) ele, 65, The greater t o diatares the signals. muse bie sent, the it takes ta pocaive shen. 46, This menus ast Ue lasteaments /M not react: imme Aiately to 9 1m pees. AT, Seanelisnes ene ov Liste lng belweon insteument changes anc process changes, PROCESS -—~ CONTROL VALVE ‘This control valve is (close to/lar away from) the ence 48. A change in dhe control valve position would effect the: proesm Cimmmiatly/aftar nome tims Tag). ° reat process noumatic longer change tur away from ath ema time ne‘With tho amount of hent boing applied to tho brsker, tn fnoresee ix lraporative frome ADP to M1201 re ‘quires 16 minutes, ‘Turning the beat up under this ela (oil/will not) ‘anive 10 W reich 212° ustantly 50, The temperature of she wiecr Changer “tees not ange) imenedtely with an Increase In het 51. A wmperaiony chung in « process A. wil atwaye over tmmeiintly with Contra waive change. 8. may Lake time to eeu, no matter now ‘much the contrel valve is changed. 52, The tim il talces for foth the tnstroments and the process to chara in ead Phe suntom reopen. ‘he system response mateares how cankrol loup is moving: BB. Which pf the following events cesur in « system - sponse? ue Prvenis measurement ror detection Error signal te coutrel valve CContral valve najnatment Process change oecbaek from proves [l= He 5, Which of the folowing neeur tn the aystem response? ‘A, Instrument response B. Provess response Ret A and B 0 will not ves yo ehange fast Yer YerSF TVarEcoe WTET TNFR aremont iene ‘rom the vt pola SETPOINT NEASUREMENT * . nsteument: (4/8) shows oe B ‘58, acovtinginitrements can be aed to show process “eet POINTER B ‘A pointer sows whore the see polit Ion Gh emnpera fre rescrdee A Tras the proces temperature a8 pen time passe, 57. tant at thie Arar {When Mae process (empeatnn in at the ac point the rem anel the pninier near the ata. ume $8, When Ge pon mows away from the painter, an has aceatted, tice, oF cage uSer POINT uw a * Reverdor {5B} chowe un meaing proce, 1. What ia guing on in hia proce, pressure eecarders | i atthe at point ‘Thore i am ofactnecoeded in Fi 0 heh B and 6 ‘The procont Ls vacating fa — ‘TYPES OF CONTROLLERS. On OFF Controllers 1, ‘hero ayo thro» basic srcions to any ineirurent ror eal pete: instrument to ‘the proces: treat t the st pain to ‘hia moatorement sy Starumomt C0 positon and adjont the control An ono vontrtlor one. wives Keeps the contro alee either Zuly open or fully 12 oth B and © e cempare valve eedoo ELECTRICAL, SET pont CONTACTS ADJUSTMENT BOURDON Tune: ‘ouTPUT SOLENOID, VALVE “Th process resem 1s measaret tw = vouraon ‘ibe. ‘The bousdon (ube is vonneetad Co a pointer When thy pointer movoe hele and forth, Se opens and lone 10 ‘entaets lection ‘thse ponition of ths noun tun nets ma the (ira ‘et pont signal roeess ‘The sot point in Tadiented by: the poxition of one Of ‘het ele contacts ‘Tha valve fx pottoned by « wil mole ‘Which of these ports is the onevr detector? A. Mourden tuive TE Pointer nnd eletrionl contacts B Solana el ‘Wien he ounton lle senses «pressure chan, the pointer moe, or changes When Oe o nlscin ape ole, current. ow to Oe say rote When Oty volonoid ty enerkized, positions the ee valve ‘The pointer by either opeaing or cloning elsetfeed com fats, nels like (ax onolf ts an lotrel ame rrmer) an ovate with 18I ELECTRICAL POINTER | CONTACTS Inpur To SENSOR ourrut ‘Th letra! oontsote (open/close) 0 Use penn falls thaw 20 PSIG ‘This activates the alonoid, whieh Inte ths canta valve, If prensare elses ayeto, the chris conti open, and the eoxteol eave it — iy the slenald "the pomtar esas the exear dbtewor but can vay ftve twp err sale: valve oF ale Sino tava x0 the anly two ottings, this ine of ems ‘eller eat 0 7 ‘contra entity the warts this emf contre lop, ——, ‘Tho muxsariny device is —_ ‘The contol (error dtextor) te he ‘Compan the tpl Lo Uhe aeusured signal fn ane br the The valve ts owitened by thecal u“ lone opens lowea pen hse owt Yourden tabe pointer, or contacts pointer, or contacts rolenolaATT NTETWT centeater ts that tt can poalfon a vue tr only ie 90 torent satin 0, These grap how process Rew. VALVE OPEN VALVE CLOSED 05 io is a0 a5 90 MINUTES a YALYE OPEN [VALVE CLOSED 0 5 10 1 4 25 90 MINUTES Graph (\7P) soprevente Awe acjonted ty an onal A sytem, E, The following indicators show two oflet ensure: ment, SET PONT VALVE CLOSED An on off controler changes th valve sntting the aume famount/dilorenly; fr dierent procaw hanes, the some emonnt 6the same an 8, On of eonteolens (x¥e/a06 not) sonsitive to iiflerencer sre nt Jn the amount 9 ose 184. Keven Af the mount of offsets tay, the vals opens all the wey 07 — all the way, eee 85, Which graph veprosants Her mate being controll by fn omit tentralien? = =~ ser For ‘cHANGE| or z | ser pont FLOW CHANGE ——w 8 Geuph (A/B) A NG ‘The on-of control lop (i not) able to matncatn 4s not A emoorh, even Dow eats 16Te tw: A. coatinaally bouneat above and below the set point mth anette 18, OK een (alow lio the pode to connate 88, ‘Tho process oniloter noesune the valve is sonstanty Flies 90, An on-alfconteller (ive /eonuol xiv slowly eel ‘at the proces. Proportional Contollars The Thvotting Range of the Vaive $1. Oxf eonerotiry cannot give oct conte! of a procter Ieounne they react (the tame way tovdieronty Soe) Junge aul geal downtime from the Set pin 22 Mor mone exec. cont tn the presser shanxe ‘onuare tHe controller must respond soportion tothe ammount of Lange ehorges should cavan Phe eemtriler to make ——.ehanes the valve seting. ond ema Bangeo should cate — valve hasan. a Allow pening; stag ‘the sume way to saree staalA. turn settings Bi a rage cf posiions between fally epened fed fally doe, ‘A proportions eontaller mist be abi 1 wend (39 Aifferen:nlgnol/a vuag of signals) the coteal salve DA. A conten thet sends rane of wil to th oon trol lve inca n ‘ontele. 5, Mere ix valve operat hy 2a air molor, The Orel ‘lag rage of thie val 1 tm 15 PSIG. AIR PRESSURE Why tho wav in he psitin shown inthe dean, ‘the ar peessare on the plston Te (@ PSIG more than 3 PEIGy, 8, This valve does aot ope Zlly wll the pre ‘he platen resches "iG, 9, This va Te oe Hallovray wher he power ot Ue piston ie Pte. 98, Thawe lo 5 PSIG ie Ue ____ sanyo of thls valve 98, The cleo stale to Ube wala ave must rl ee of the wale, 100, ‘The controller moves the valve propetioally to com ursile for difurent rater nad amounts of precas a8 1 rae of igre Devpertonal swore thas PSIG 6 ‘eating throng range change, or varlationFEET We ser 4 POINT 9->| ‘The valvo must be shut compietely when te qu 1¥8) roaches tat 109. Ten fot i (anve bola) the wet point 108, ‘The ot point Ie at & fost FEET we ser POINT 9, The valve (revit some flow’ doesnot paemlt flow) ‘whan tho qu lovl te ne @ fot, 104, ‘The Toul ove ha Caen bo & fee reer w-| ser POINT 9-+| "Phe salve mud new Be Ply 1 w we Doomits some flow ened106, wn, 1a, 8 RESTRICTION ORIFICE aie surPLy ‘This system sents (pneunuie electric!) smal, Poets aw rate ia being mene ya meta. ‘The flow meter sends preuuire sinal tothe (mente ucomoat ct polst) bellows In the cowtolse. “There are tn lows in this controle. ‘One dows he prucess moucurlags the other gives the ‘The apper pivored between the two Dellows ae 8 the error dovectar, ‘Ac lng: proce protsurn and ae pint year sty ‘he same the ersor detector (espa changing, dct nat cenange) pation, Tatts say prose in the precaae decrease "The wrvar detootow (moves toes noe more) ‘As the flapper moves away rom the nese, presmare In tho pnsamatie bveiem connotea to the alr mator "This change in poate presure acts as tie sisal The pnoumatic nigral eparates the le ator ‘The alr motor postions the —__. » preunatie ‘ew seruroment vt pola oes not change ‘hans, daeressee6. a7, us. fs «range of (oneumsie system prestares/procese meusurement). 5. hore is «range of peveesa messrements within whieh ‘he contrllar mnt kesp the ron "This range of pracoss messuremenls ie the Uarllling ‘ange of tha. [eontrelien/ sont valve) ‘Tho theotting raege uf vom i sometimes call ‘he prepexticnal baa Which ono of theso yilioe comlé represent a propor. onal baal? 08 gallons per neon 688 to aor 100 PSIG ‘The vange of process meannmements Hebwoen tha cane ‘rol valve being carplealy pen ot cloud ix ella the a of she controler, ‘This preoure guge and conteoller are regia prec: os pressure. Ident the tollnsing patnte Bak ues) (CONTROLLER Aly the S55 Bint Os Ce te a da, a newrmate epstom presearen conteeller Oe to a toenteig eange, or propartionn) hand sot point throttling rans, oF propostisnel bend; controler hrotling range: valve120, ——— all contallers, ‘Theettling exnze Is found on: provortionsl controler ——— ent eoptrollers onl nly. How the Premeortinnn! Ront Affects Contyot an ae 108. 1 Kare are the disls of fo cantrolterssehich have the same set pote On controner A the pressure must inerease to SIC to compleely clove the control valve and deoreans ta SIG to eampletaly open tee control valve, {On controller B, proseury must inerane te only PSIG to completly cle the control valve and secrease to only PSIG ‘to completely ope the contr valve. Tt fakor a change of 5 PSIG from tho set paiat to com. pletely open cr close the valve on contreller A, It takes a change of only (PSIG from the set point to completely open ov close the aive on eon titer 1 Contellor (AJR) has the wider proportional bad 2 a controls proportional eontrallers only 5 40YALYE. VALYE YALYE VALVE OPEN = CLOSED OPEN CLOSED. oh 8 Controller (8) would make the bigeest change in B hs onl waitin. 126, Controller (AB) reacts mors nensitively to a change ® ny procers pressure, 127, ‘There are bath advantages and csadvantagen ta make ing a conteclles mre sensitive One advantage of the more vertive contraller fx that ran Keen the prowess closer to the wet point 2A. Hist proportional comtroftew san be tow se Making the proportions band marvorsee mesoe that for every yracaat chara, the eontvlor moven the rol sale {mores} more 129, Let's may thal a proporiional cuntealler fully opens & valve for a chinge of 1 PSIG from the set paint, yesic 5 pic FULLY opens FULLY OPENS VALVE VALVE A change of 5 PSIG wete (the samen diferent) vo. the same syouse ao a change of 1 PSIG,the seme YN. Albo, within ft throtlyg range, the valve anny Ye rave ten far fw the peneste hinge, Losey Graph (Ae) presente the valve moeement of an a coversenstive neeportional contecile 182, Tho prenartivna) ton be mac nate Hak the contretlr acti almont Like 8 s controller onvolt 45, Oversonstiye contollerd may enuse the pracess to oscillator epee IRL. Thoto graphs ahow valve tating charge daring « Drecoes chase. VALVE FULLY OPEN VALVE FULLY CLOSED A 8 Ceaph (A/T) repevsunle selve sauvemonl mide by a 4 controller with the widest proportional ban. aPOF Complete 7 | pein te ralre retin Amsnmno that the contzllos is june to a vorg wide Drovercional band setting ant the valve eating ho chaiget Sor 10 minuto, ‘Hs the procems ema stanly daring this time? Yo xe Cant tall fram the information given Can't toll from the Harm ‘ion ven Review and Summary WA erntzellor goot into aetion only shan. tharw proce change 207, Mery by wht hapyous a & Control Lovo AL The pencese variale is ee rmoesured B. Thy moaeurement of pooeen compared te the a ~ in the vonteoler, st point G1 there is a iterence, the contreller's ontpat cuoges, ani the eontra sing fe valve ‘hanged D. The menausing device rantinnen te sent proven fi Sermation hack 11 the ceanteten 1h Herein Is called process ——_ ‘eeaoncte TR. If the iat valve change didnot ecevect the wpe ‘eo contzellor mekos a futher ir change 138, Whien emnpn shave oftet? ser pomf] | s 8 Graph (A). aA & Gcaph ca) A M0, Bo tae, wo Ive disused two Waele TEE of com trellers otros, and eno ——eaairators Drepnetonal UL, A throttling renge isa feaune of eons propretionsl ‘rollers.