‘Instrumentation |for OperatorsPILOT SIX— INSTRUMENTATION FOR OPERATORS UNIT THREE— CONTROLLERS AND CONTROL MODES Section 1 Page Controllers .... : 3 ‘Why We TB cee 3 How a Controller Works .......... :4 ‘The Control Loop . 8 System Response : 9 Offect and Oscillation iu ‘Types of Controllers .. Seeeteeervetecs +22 On-Off Controllers. ......ccescosessesee ele Problems with an On-Off Controller . 215 Proportional Controllers . Ww The Throttling Range of the Valve 17 ‘The Throttling Range of the Controller 2 aL How the Proportional Band Affects Control 1 2 Review and Summary . veces BB Section 2 Proportional Controllers with Rate and Reset Action ........-....++ Process Load . Hear tea Feedback Bellows . peenteuetea tee needes How Load Changes Affect Proportional Controllers ‘Automatic Reset How Reset Action Is Measured Rate Action .......0...eseeseeeeeee ‘How the Feedback Bellows Can Affect Rate Action Section 3 Working with Controllers : 58. Introduction ... 7 - 58 Problems with Controller Settings ..... + BS How Control on One Process Affects An * 56 How Reset and Rate Action Affect Control . : 61 Working with the Control Mode ......... +. 6B ‘Who Should Adjust Controllers ... ee a - 65 3717INSTRUMENTATION FOR OPERATORS Unit 3 Controllers and Control Modes Section 1 ControllersUnit Three of Instrumentation for Operators explains the pur- poses and operation of automatic controllers and of control modes used in process control instruments. In Section 1 you will learn how controllers work, the nature of a control loop, and the factors in system response. You will learn about offset and oscillation, on-off controllers and proportional controllers, the throttling range of the valve and of the controller, and how the proportional band affects control. In Section 2 you will learn how changes in process load affect proportional controllers and how changes in process load can be compensated for by use of feedback bellows and by reset and rate action. In Section 3 you will learn how to work with controllers and contro] modes and how to identify controller problems.INSTRUCTIONS ‘This is a programed learning course. Programed learning gives information in a series of steps called frames. Each frame gives some information and asks you to make use of it. Here is how it works. First, cover the response column at the right with a mask. Read this frame and use the information it gives to fill in the blank. A micrometer is an instrument designed to measure in thousandths of an inch, A micrometer is a good tool for measuring very differences in size. Move the mask down to uncover the word at the right of the frame. If you have filled the blank with that word or a word that means the same, you are ready to go ahead to the next frame. ‘The drawing of a micrometer provides information that will help you fill in the next blanks. oBsecT TO BE MEASURED ANVIL, nye THIMBLE SPINDLE Ris RATCHET CAP FRAME Seven major parts are shown in the drawing, but only the_______and the _______ contact the object to be measured. small‘The next frame ealls for a choice. Circle or underline the ap- propriate word. Of the two parts that contact the object, only the (anvil/ spindle) moves. A program is a series of frames that work like the ones you have just done: Read the frame. Use the information to fill in the blanks or make a choice. ‘Move the mask down and cheek the response column, Go on to the next frame. Remember to cover the response column with a mask before you begin each page. spindleSECTION 1 CONTROLLERS ‘Why We Need Controllers 1 Process variables are controlled by opening and clos- gy See ee Let’s say that you want a flow rate of 100 gallons per minute for a process. ‘The control______is set to allow just 100 gallons of liquid per minute into the process. If the flow rate never changes from 100 gallons per minute: ‘A, you don’t need to adjust the control valve. —— B. you have to adjust the control valve con- stantly, ‘Let's say that there is a change in the pressure acting in the liquid which supplies the process. OLD LEVEL When the level in this tank changes, the pressure on the liquid _____. The flow rate to the process: A, stays at 100 gallons per minute. ——B. changes. To maintain the proper flow rate, the control valve must be valves valve changes, or decreases opened, or adjusteda. 10. ue ‘The control valve is adjusted by a controller. ‘The controller: ‘A. can be an operator. —-—B. can be an instrument. ©. can be either an operator or an instru- ment. In a modern installation, the controller is likely to be an (instrument/operator). |. The controller goes into action only when there is a process If there is no process change, the ______ does nothing. If process variables could be held perfectly constant, there would be no need for a controller. Is this likely to happen in a typicsl installation? Yes No How a Controller Works 12, 13. 14. 16. 16. ‘The controller is set to meet the target for the process variable being controlled. ‘The controller must adjust the —_____ to keep the process variables on target. ‘The target for the controller is called the set point. Let’s say a temperature measurement is on target. ‘The controller (reads/does not read) at the set point. If a temperature is not on target, the temperature in- dicator does not match the of the controller. A controller goes into action when: A. the process is off target. —_B. the process is on target. ‘When the process strays from the set point on any process variable, (all/some) controllers affecting that variable should react. instrument change, or upset controller No valve set point all17. The drawing represents a simple temperature control situation. A MEASURE B COMPARE ¢ CONTROL, The controller is the 18. His sense of ________ is the temperature indicator. 19. His_______opens or closes the valve. 20. His touch gives him information. He already “knows” what the set point should be. To find out whether the process is on target, he what he feels to the set point. 21, The controller first receives information from a ——______ device, and then ____ it to the desired set point. 22, If the process measurement and the set point are the same, the operator : A. makes an adjustment. B. does nothing. 28, But if the measurement and the set point are different, he adjusts the control 24, Let's say he closes the control valve to cool the process. How can he tell if the process has cooled? iis sense of ______indicates this. operator touch hand ‘compares measuring, or sensing; compares valve touch25. For every adjustment the controller makes, the meas- uring device must feed information back to indicate ‘what has happened, In the previous example, the operator gets feedback information from his. 26. These are the steps needed to control a process: ‘Step 1: The process variable is measured. Step 2: The measurement is. to the set point. Step 8: If there is a difference, the. is moved. Step 4: Some device gives the controller information. Step 5: This feedback “tells” the what has happened. 27. If the feedback does not match the set point on a mod- ern controller: A. the controller stops working. ——B. the controller keeps working until the set point is reached, 28, Put an A on the drawing to show where measuring is being done. Put a B to show where comparing is being done. Put a C to show where valve positioning is being done. Put a D to show where feedback is given. touch, or hand compared valve feedback controller29, 30. 31. 32. ‘This operating situation is slightly different from the previous one. THERMOMETER A MEASURE B COMPARE - C CONTROL ‘The operator gets a measurement and feedback from: A. his sense of touch. B. a reading on the thermometer dial. ‘The controller is the ‘The valve is adjusted (by hand/automatically). ‘This is an automatic contro! situation. SET POINT AIR SUPPLY tO} WATER STEAM ‘The process temperature is measured at (A/B/C). At B, the process measurement is ___to the set point. At C, the process is __. operator, or man by hand A ‘compared controlled, or regulatedThe 33, 84, 35. 36. 8T. 40, 41, Control Loop This diagram shows a complete control loop. CONTROLLER (ERROR DETECTION MEASUREMENT ‘COMPARISON ) MEASUREMENT, SET POINT $— error puuaee SIGNAL POSITION CONTROL A control loop consists of all the elements needed to ‘the movement of a valve, A control loop as shown above: ————A. is circular and closed. ——B. is open-ended. First, the process measuring element sends a signal to the controller. The controller is the _____ detector. At the same time, the already-determined —__ is fed into the controller (error detector). The error detector makes a____ between this signal from the process and the set point signal. If there is a difference between the measured signal and the set point: A. nothing happens. ——B. an error signal is sent to the positioner of the control valve. ‘The positioner adjusts the ______setting. The control valve changes the process. Information about this change is picked up by the instrument and fed into the controller. ‘This information is called process ______to the controller. control set point comparison valve measuring feedbackSystem Response 42, It takes time for the parts of the control loop to detect a process change, make a valve adjustment, and get process feedback. ‘The less time it takes, the (greater/lesser) the effi- ciency of the control loop. 43. The instruments should react as fast as it is practical for them to react when the ____ changes. 44, Sometimes there is a time lag in the instruments. JCONTROLLER These instruments are operating by (pneumatic/elec- trical) signals. 45. ‘The greater the distance the signals must be sent, the it takes to receive them. 46, This means that the instruments will not react imme- diately to 2 in process. 47. Sometimes there is a time lag between instrument changes and process changes. PROCESS CONTROL VALVE This control valve is (close to/far away from) the Process. 48, A change in the control valve position would affect the process (immediately /after some time lag) 9 greater Process pneumatic longer change far away from after some time lag49, 60. 51. 58. Once an adjustment has been made, it takes time for the process to change. 15 MINUTES With the amount of heat being applied to the beaker, an inerease in temperature from 40°F to 212°F re- quires 15 minutes. ‘Turning the heat up under this beaker (will/will not) cause it to reach 212°F instantly. ‘The temperature of the water (changes/does not change) immediately with an increase in heat. A temperature change in a process: A. will always occur immediately with a control valve change. —_B. may take time to occur, no matter how much the control valve is changed. ‘The time it takes for both the instruments and the process to change is called the system response. The system response indicates how control loop is moving. F Which of the following events occur in a system re- sponse? Yes © No Process measurement Error detection Error signal to control valve Control valve adjustment Process change Feedback from process Which of the following occur in the system response? A. Instrument response B, Process response ——. Both A and B 10 will not does not change fost ‘Yes Yes Yes Yes YesOffset and Oscillation 55. Offset occurs when the process measurement differs from the set point. SET POINT MEASUREMENT A B Instrument (A/B) shows offset. B 56. Recording instruments can be used to show process offset. A pointer shows where the set point is on this tempera- ture recorder. A_______.__ draws the process temperature as pen time passes. 57. Look at this drawing. When the process temperature is at the set point, the pen and the pointer are at the ____ point. same 58. When the pen moves away from the pointer, an —has occurred. i offset, or change59. When the process measurement keeps bouncing above and below the set point, the process is oscillating, SET POINT A B Recorder (A/B) shows an oscillating process. 60. What is going on in this process, according to these pressure recorders? ‘The process is at the set point. in ‘There is an offset recorded in: B. ac both B and C. ‘The process is oscillating in. TYPES OF CONTROLLERS ‘On-Off Controllers 61. There are three basic sections to any instrument con- trol system: an instrument to__________ the process; an instrument to_______the set point to this measurement; an instrument to position and adjust the control An on-off controller is one which keeps the control valve either fully open or fully 2 both B and C c ‘measure ‘compare valve closed63. This drawing represents the control loop for a simple on-off controller. ELECTRICAL SET POINT CONTACTS ADJUSTMENT ZZPQINTER BOURDON TUBE: OUTPUT SOLENOID VALVE ‘The process pressure is measured by a. 64. The bourdon tube is connected to a pointer. When the pointer moves back and forth, it opens and closes two _________ contacts. 65. The position of the bourdon tube acts as the (process/ set point) signal. 66. The set point is indicated by the position of one of these electrical. 67. The valve is positioned by a_______ coil. 68. Which of these parts is the error detector? A. Bourdon tube —_B. Pointer and electrical contacts —— 6. Solenoid coil 69. When the bourdon tube senses a prescure change, the pointer 70. When the contacts are closed, current flows to the 71. When this solenoid is energized, it positions the 72. The pointer, by either opening or closing electrical con- tacts, acts like (an on-off switch/an electrical trans- former). 18 bourdon tube electrical process contacts solenoid moves, or changes solenoid valve an on-off switeh78. Let’s say the set point for pressure is 20 PSIG. 74. 1. 76. 17. 8. SET POINT SOLENOID (ON-OFF) INPUT x. ELECTRICAL T= contacts: INPUT TO SENSOR. ‘The electrical contacts (open/close) if the pointer falls below 20 PSIG. ‘This activates the solenoid, whieh in turn the control valve, If pressure rises again, the electrical contacts open, and the control valve is______by the solenoid. ‘The pointer acts as the error detector, but it can only give two error signals: valve , or valve Since these are the only two settings, this kind of con- troller is called an controller. Identify the parts of this on-off control loop. ‘The measuring device is a The controller (error detector) is the Comparing the set point to the measured signal is done by the ‘The valve is positioned by the 4 coil, close opens closed open close on-off bourdon tube Pointer, or contacts pointer, or contacts solenoidProblems with an On-Off Controller 79. The most serious drawback with an on-off controller is that it can position a valve in only different settings. 80. ‘These graphs show process flow. VALVE OPEN VALVE CLOSED 0 5 10 15 20 25 30 MINUTES VALVE CLOSE 0 5 10 15 20 25 30 MINUTES B Graph (A/B) represents flow adjusted by an on-off system. 81. The following indicators show two offset measure- ments. SET POINT VALVE CLOSED An on-off controller changes the valve setting (the same amount/differently) for different process changes. 15 two the same amount83. 85. 86. An on-off controller treats a large offset (the same as/ differently from) a small offset. On-off controllers (are/are not) sensitive to differences in the amount of offset. Even if the amount of offset is tiny, the valve. all the way or _____alll the way. Which graph represents flow rate being controlled by an on-off controller? ~~~ {SET POINT FLow CHANGE TIME—___- A => --\----] SET POINT FLow CHANGE TIME B Graph (A/B). ‘The on-off control loop (is/is not) able to maintain a smooth, even flow rate. 16 the same as are not, opens closes is not87. A graph of flow controlled with an on-off controller Jooks like thi /ALVE OPEN SET POIN VALVE CLOSED. ‘The flow: ——— A. continually bounces above and below the set point. —_.B. is smooth and steady. 88. On-off controllers (allow/do not allow) the process to oscillate. 89, The process oscillates because the valve is constantly and 90. An on-off controller (gives/cannot give) steady control of the process. Proportional Controllers The Throttling Range of the Valve 91. On-off controllers cannot give exact control of a process because they react (the same way to/differently for) large and small deviations from the set point. 92. For more exact control, the controller must respond to the process change in proportion to the amount of change. Large changes should cause the controller to make ——______ changes in the valve setting, and small changes should cause _________valve changes. Ww allow opening; closing cannot give the same way to large small98, 95. 96. 97. 100. ‘To make proportional control possible, the valve must have: two settings, -—B. a range of positions between fully opened and fully closed. A proportional controller must be able to send (two different signals/a range of signals) to the control valve. A controller that sends a range of signals to the con- trol valve is called a_______ controller. Here is a valve operated by an air motor. The throt- Wing range of this valve is 8 to 15 PSIG. AIR PRESSURE When the valve is in the position shown in the drawing, the air pressure on the piston is (3 PSIG/more than 3 PSIG). This valve does not open fully until the pressure on the piston reaches_____ PSIG. This valve is open halfway when the pressure on the piston is__.__ PSIG. Three to 15 PSIG is the ______ range of this valve. ‘The controller's signals to the control valve must match the _______________ of the valve. The controller moves the valve proportionally to com- pensate for different rates and amounts of process 18 ‘a range of signals proportional more than 8 PSIG 16 throttling throttling range change, or variation+ 101. This control valve operates through a range of settings. ‘The valve must be shut completely when the liquid level reaches _______ feet. 10 102. Ten feet is (above/below) the set point. above 108. The set point is at 9 feet. FEET vo- SET POINT 9> s-| The valve (permits some flow/does not permit flow) permits some flow when the liquid level is at 9 feet. The valve must now be fully. opened 19105. The drawing shows a proportional control loop. ERROR DETECTOR (CONTROLLER) SET POINT MEASUREMENT RESTRICTION TAY ORIFICE This system sends (pneumatie/electrical) signals. 106. Process flow rate is being measured by a meter. 107. The flow meter sends a pressure signal to the (meas- urement/set point) bellows in the controller. 108. There are two bellows in this controller. One does the process measuring; the other gives the 109. The flapper pivoted between the two bellows acts as the error detector, As long as process pressure and set point pressure stay the same, the error detector (keeps changing /does not change) position. 110. Let’s say pressure in the process decreases. The error detector (moves/does not move). 111. As the flapper moves away from the nozzle, pressure in the pneumatic system connected to the air motor 112. ‘This change in pneumatie pressure acts as the signal. 118. ‘The pneumatic signal operates the air motor. ‘The air motor positions the 20 pneumatic flow measurement set point does not change moves changes, or decreases error valveThe Throttling Range of the Controller 114. 115. 16. ut. 118. The throttling range of a control valve is a range of (pneumatic system pressures/process measurements) . There is a range of process measurements within which the controller must keep the process. ‘This range of process measurements is the throttling range of the (controller/control valve) ‘The throttling range of a controller is sometimes called the proportional band. Which one of these values could represent a propor- tional band? 68 gallons per second —_ 68°F to 88°F ——— 100 PSIG ‘The range of process measurements between the con- trol valve being completely open or closed is called the ______ ef the controller. This pressure gage and controller are regulating proc- ess pressure. Identify the following points. A is the Bis the_____of the C is the ______of the 21 pneumatic system pressures controller 68°F to 88°F throttling range, or proportional band set point throttling range, or Proportional band; controller throttling range; valve119. 120. Set point is found on: proportional controllers only. all controllers. Throttling range is found on: proportional controllers only. on-off controllers only. How the Proportional Band Affects Control 121. Here are the dials of two controllers which have the 122, 123. 124. same set point. OPEN CLOSED OPEN CLOSED On controller A, the pressure must increase to PSIG to completely close the control valve and decrease to... PSIG to completely open the control valve. On controller B, pressure must increase to only PSIG to completely close the control valve and decrease to only _.___ PSIG to completely open the control valve, It takes a change of 5 PSIG from the set point to com- pletely open or close the valve on controller A. It takes a change of only. PSIG from the set point to completely open or close the valve on con- troller B. Controller (A/B) has the wider proportional band. 2 all controllers proportional controllers only 45 BL 49125. Let’s say process pressure changes 4 PSIG. SET POINT SET POINT 4 PSIG VALVE VALVE = VALVE VALVE OPEN CLOSED OPEN CLOSED A B Controller (A/B) would make the biggest change in B the valve setting. 126. Controller (A/B) reacts more sensitively to a change B in process pressure. 127. There are both advantages and disadvantages to mak- ing a controller more sensitive. One advantage of the more sensitive controller is that it ean keep the process closer to the —__ set point 128. But proportional controllers can be too sensitive, Making the proportional band narrower means that for every process change, the controller moves the control valve (more/less) more 129. Let's say that a proportional controller fully opens a valve for a change of 1 PSIG from the set point. 1 PSIG 5 PSIG FULLY OPENS FULLY OPENS VALVE VALVE A change of 5 PSIG gets (the same/a different) re- the same sponse as a change of 1 PSIG. 28180. If the process constantly changes by more than 1 PSIG, the controller will be treating all the changes above 1 PSIG (the same/differently). the same 181. Also, within its throttling range, the valve may be moved too far for the process change, OPEN CLOSED A B Graph (A/B) represents the valve movement of an A oversensitive proportional controller. 132. The proportional band can be made so narrow that the controller acts almost like an controller. on-off 188. Oversensitive controllers may cause the process to oscillate, or eyele 184. These graphs show valve setting changes during a Process change. VALVE FULLY OPEN VALVE FULLY CLOSED A B Graph (A/B) represents valve movement made by a A controller with the widest proportional band. 24185. The proportional band can be made so wide that it takes a very large process change to affect the valve setting. Assume that the controller is adjusted to a very wide proportional band setting, and the valve setting has not changed for 10 minutes. ‘Has the process remained steady during this time? Yes No Can't tell from the information given Review and Summary 186. A controller goes into action only when there is a Process 187. Here is what happens in a control loop: A. The process variable is B. This measurement of process is compared to the in the controller. C. If there is a difference, the controller's output changes, and the control setting is changed. D. The measuring device continues to send process in- formation back to the Thi information is called process E. If the last valve change did not correct the upset, the controller makes a further 188. Which graph shows offset? SET POINT Graph (A/B). Can’t tell from the informa- tion given change measured set point valve controller feedback change139. Which graph shows oscillation? SET POINT ve A Graph (A/B). 140. So far, we have discussed two basic types of con- trollers : —_——-—_-_________ controllers, and controllers, 141. A throttling range is a feature of trollers. _____eon- 26 on-off proportional proportionalSection 2 Proportional Controllers with Rate and Reset ActionSECTION 2 PROPORTIONAL CONTROLLERS WITH RATE AND RESET ACTION Process Load 1. The load on a process is like the load on an engine. ‘This engine is driving an empty truck at 50 MPH. The load on the engine is the: road surface. size of the engine. ———— empty truck. 2. As long as the truck stays empty and is driven on a level road at 50 MPH, the load (changes/does not change). 3. What happens now that the weight of the truck has increased? ‘The speed of the truck unless. more fuel is fed into the engine. 4. Putting more weight on the truck is the same as in- creasing the__________on the engine, if speed stays the same. 27 empty truck does not change decreases: load10. 1. 12. 13. ua. Let's say that we want the truck to move faster. More_____is fed to the engine. Demanding more speed from the truck (incresses/ decreases) the load on the engine. ‘The total weight to be moved and the speed at which it must be moved is the ______on the engine. As long as the weight moved by the engine stays the same, and the speed at which the truck is driven on a evel road stays the same, the _________stays the same. Sometimes the truck will come to a curve and must slow down. 50 MPH 50 MPH THROTTLE ADJUSTMENT, 40 MPH ‘The throttle will have to make an adjustment to change the ___*____ of the truck. ‘What will happen if we do not adjust the throttle again after passing the curve? A. The truck will return to 50 MPH. ———B. The truck will continue going 40 MPH. Even a temporary adjustment for a curve changes the on the engine. After the truck is returned to 50 MPH, the load on the truck has (changed/returned to the same level). Which of the following can cause a load change? ‘The weight on the truck is reduced. (Yes/No) ‘The truck must be driven up 2 hill at the same speed. (Yes/No) The truck slows down for a curve. (Yes/No) In the truck, we demand output from the engine. Do we demand output from an industrial process? (Yes/No) 28 fuel increases load load speed B Toad returned to the same level Yes Yes Yes Yes15. There is a_______on each process. 16. The load on a process acts like the load on an engine. KEROSINE DISTILLATE 500 BARRELS PER HOUR This process is required to separate barrels of kerosine per hour. 17. The amount of material and the speed at which it must be produced is the _______on this process. 18." Reducing this output to 100 barrels an hour, under the same conditions, is the same as reducing the 19. Let's say that the pressure of liquid entering this proc- ess drops. The process must be adjusted to maintain Production of 500 barrels an hour. 30 PSIG COSI aad 500 BARRELS BARRELS PER HOUR PER HOUR ‘This (is/is not) the same as an increase in load. 29 load load20. ‘The drawing shows three different valve settings. 30 PSIG ar Psig 20 PSIG nee Psi 10 PSIG =e a PSIG ‘The pressure pushing liquid through the valves is (the same/different). 21, For each valve setting there: are several flow rates. is one flow rate. 22, We want to open a valve so that the flow rate equals a specified set, point. Under one load condition, how many valve positions will give us the desired set point? —— Several positions ‘One position 28. Proportional controllers are aligned for one load con- dition. With these controllers, there (are several valve posi- tions/is only one valve position) that will give the set point as long as the load does not change. 24. Sometimes there is a hill or “curve” in the process, or slight variations in load, that the controller must adjust for. ‘The controller must move the 25. But, after the adjustment, if the load has not changed, ‘the control valve should (move to a new/go back to the old) set point position. 80 the same is one flow rate ‘One position is only one valve position valve go back to the old26. Look at the pressure gage in this pneumatic controller. FLAPPER For each pressure setting in the pneumatic system: A. there are several valve positions. B, there is only one valve position. B 27. When this contrdller is at set point, there is just one output setting to the control valve. pressure 28. Each flapper position produces (one/several) pressure one setting (s). 29. Under one load condition, in this controller: ——— A. there is just one flapper position which A will maintain the process at the set point. ——B. there are several flapper positions which ‘will maintain the process at the set point. 30. If the flapper moves, the control valve (moves/does not move). moves 81. To change the control valve the right amount to keep the process stable at its desired set point, the output —_____—to the control valve must become bal- pressure anced to the need of the process, and the —___ flapper ‘must be returned to its set point position. 31Feedback Bellows 82. This pneumatic controller is controlling liquid flow. © If the flow falls below the set point, the controller the control valve. 88. Does the process change occur immediately when a valve position changes? (Yes/No) 34, The controller is normally at a distance from the Process. When the flow rate changes, does the controller get this feedback information immediately? (Yes/No) 85. Are there any time lags between events in the system response? (Yes/No) 86, Let’s say that flow rate in the process reached the set point. ‘Would the controller get this information immediately? (Yes/No) 87. The controller cannot find the correct valve position until it gets ________from the process measure- ment. 88. Since feedback is not immediate, the controller con- ~ tinues to keep the valve position open as if the process were not at the — 89. The controller will probably: A. find the set point. B. overshoot the set point. 32 opens No No Yes feedback set point40. ‘This is what happens when the controller does not get immediate feedback. ERROR DETECTOR (CONTROLLER) ALIGNMEN’ ADJUSTMENT. Flow rate starts to fall, and a steadily decreasing sig- nal is sent into the controller. ‘The control valve starts to 41. The control valve brings the flow rate back to the right rate, but the controller does not get this information immediately. The signal to the controller: A. is still decreasing. B. has started to increase. 42. If it does not get process feedback information, the con- troller may continue to move the control valve to a fully position. 48. Finally, the controller receives the process feedback, and the control valve starts to close. With the lag in process feedback, the control will probably: A. find the set point position. B. overshoot the set point position. With delayed process feedback, this controller acts more like an controller than a proportional controller. 45. What do we want this controller to do if there is a temporary change in load? Yes No Correet for any flow change Return to the set point position Overshoot the set point 88 || | open open on-off ‘Yes Yes No46. To prevent overshooting, the controller needs feedback (before/after/at the time that) the process measure- ment can supply it. 41. The controller feedback bellows is a device that can supply feedback to the controller before the process measurement can. SET POINT MEASUREMENT (OOH +0000 ouTPuT FEEDBACK BELLOWS SUPPLY ‘The feedback bellows is attached to the 48. The measurement bellows and the set point bellows are also attached to the . 49. The feedback bellows receives its pressure from the ——_____ going to the control valve. 50. Any change in the controller's output will the feedback bellows. 51. Let's say there is an inerease in the process flow rate. SET POINT MEASUREMENT SUPPLY m7. Cees FEEDBACK BELLOWS SUEY ‘The measuring bellows moves the flapper to the (right/ left) and (opens/closes) the flapper nozzle. 34 before flapper flapper output, or air move, or operate, or change left; closes62. Pneumatic output pressure and starts increases to close the control valve. 58, Pressure in the feedback bellows also ____. increases, 54, ‘The bellows expands and moves the flapper to the (right/left). right 55. So the feedback bellows is allowing the flapper to move (in the same direction as/in the opposite direction from) the measurement bellows. in the opposite direction from 56. The feedback bellows is “anticipating” the process change while the valve is changing the process and before the controller gets the process feedback. ‘Thus, the controller's feedback bellows keeps the con- troller from moving too for a given much, or far process change. 57, While the feedback bellows is acting, there (is/is not) is an offset between the measurement pen and the set point, How Load Changes Affect Proportional Controllers 58, The set point on a proportional controlle A. is set for one load condition. A ——— B. changes everytime the load changes. 59. Sometimes the load on a process changes. A unit may have to increase its production from 100 barrels an hour to 300 barrels an hour with all other conditions the same. ‘This is an increase in load 60. ‘The original valve position (can/cannot) handle this cannot oad increase. 3561. Steam is being used in this process. ‘The controller is set to keep the pressure somewhere around 50 PSIG. Let’s say that there is a drop in process temperature, ‘causing some of the steam to condense. STEAM INPUT => 727% VALVE CONTROLLER ‘The pressure (increases/decreases). decreases 62. To keep the pressure within operating limits, the con- troller must allow ____ steam into the proe- more ess than before. 63. Will the steam pressure return to the old level, if some of the steam keeps condensing out? (Yes/No) No 64. The load (has/has not) increased. has 65. The set point probably (will/will not) handle the new will not, load requirement. 66. Here is another situation. This controller is maintaining liquid level 3667. The pressure on the liquid decreases, and the liquid evaporates at a much higher rate. ‘The controller must ___ ineoming liquid flow. 68. If the liquid keeps evaporating at a high rate, has the load changed? (Yes/No) 69. Here is what happens to a proportional controller de- signed for one load when the load requirements change. 100 PSIG SET POINT 50 PSIG 0 PSIG ‘The controller is controlling . ‘The set point of this controller is___ PSIG. 70. ‘The process load changes, and a higher flow rate is needed to keep the process pressure within limits. The original valve position (lets/will not let) enough liquid in to keep to the set point. 71. Process pressure starts to 72. As it receives process feedback, the controller starts to______ the control valve proportionately. 78. Finally, the valve is opened enough to stop the decrease. Incoming flow is finally balanced to the outgoing flow in the process. 100 PSIG ORIGINAL LOAD SET POINT 50 PSIG NEW LOAD 0 PSIG ‘The process (is/is not) at the original set point. aT increase Yes pressure 50 will not let decrease open is not [Now turn the [tum the book74, To get this pressure back to the set point, the control valve must be still more. ‘opened 7. Suppose the pressure in the process measurement bel- lows starts to increase again in this controller. SET POINT MEASUREMENT SUPPLY OUTPUT FEEDBACK BELLOWS SUPPLY ‘The flapper will be moved back toward the nozzle, and the control valve will start to. close 76. This (raises/does not raise) the process pressure to does not raise the original set point. 77. Look at the record on this process pressure recorder. SET POINT ‘At A, the process ___ starts to decrease. pressure 78. At B, the set point pointer and the pen (are/are not) are not together. 79. The controller (stops/does not stop) the decrease. stops 3880. After this change, there is still an_______in the process. 81. In certain processes, the load does not change very much, or a little offset is not a problem. ‘The controller shown (can/eannot) work for these processes. 82. Other processes need more precise control, even during changing load conditions. ‘The controller shown (can/eannot) work for these Processes. Reset Action 88. For more precise control, a device is needed to increase or decrease the output to the control valve beyond the changes which the proportional controller can provide. SET POINT MEASUREMENT Aeeeeea eae eee SUPPLY ar ouTPUT FEEDBACK B faa SUPPLY In this situation, the proportional action is balanced, but a further increase in flow is needed to get the proc- ess back to the set point. ‘The flapper must be moved to (open/close) the nozzle. 84. By opening the nozzle more, we can open the control valve, and return the process to the ‘The output air to the control valve changes and moves the control valve to a new 39 offset cannot open set point position85. Here is the controller when the pressure in the set point bellows is equal to the pressure in the measure- ment bellows. NOZZLE FLAPPER| BOTTOM Do the measurement and set point bellows always re- turn to this position when the process is at set point? (Yes/No) 86. The linkage between the two top bellows can have (one position /several positions) when the process is at set point. 87. How can we move the flapper to a more open position without changing the set point? SET POINT 0 See ee eeeereeereere eee ooo. SUPPLY MEASUREMENT ouTPUT A. Move the top of the flapper ——.B. Move the bottom of the flapper 88. To open the valve more when this controller is at set point, we would move the of the flapper (toward/away from) the nozzle. 40 Yes one position bottom, away from89. ouTPUT 91. 92, 93, 94, Changing the controller’s output and the valve position to keep the process at set point during a load change is called reset. In the situation shown above, which of these actions is reset? ——A. Moving the top of the flapper when the process changes. ——_B. Moving the bottom of the flapper to get a new valve position. Here is a proportional controller that can be reset manually, SET POINT MEASUREMENT SUPPLY FEEDBACK BELLOWS SUPPLY The bottom of the flapper has an adjustment screw on it as well as a feedback bellows. ‘The screw can move the ________ back and forth. When there is @ load change, and the recorder shows an offset, we can correct this offset by moving the By moving the flapper, the control___*__posi- tion can be changed (by/without) changing the set point. But every time there is a load change and offset, the flapper setting will have to be _____ manually. Having an operator reset the controller manually every time the process load changes (is/is not) practical. a1 flapper Amob, or serew, or flapper valve without changed, or moved, or reset, is notAutomatic Reset 95. A proportional controller is a single-mode controller. This is a two-mode controller with proportional and automatic reset action. SET POINT __ MEASUREMENT =m ‘ SUPPLY ielceeah FEEDBACK | RESET ourpuT Instead of an adjustment serew, there is a bellows connected to the flapper. 96. A control relay has been added to the pneumatic air system to bleed out or add air to the system quickly. ‘The pressure to run the reset bellows comes from the output air going from the control relay to the 97. Pressure to operate the reset bellows comes from: A. the same source as the feedback bellow: B. a different souree from the feedback bel lows. 98. The reset bellows has a restriction ______in the air line to it. 99. The idea of the reset bellows is to push the flapper to a new position. ‘The idea of the feedback bellows is to (speed up/slow down) the movement of the flapper. 100. The reset bellows and the feedback bellows work (with/against) each other. 42 reset control valve valve slow down101. Let’s say that the air lines leading to the reset and feedback bellows are opened the seme amount. SET POINT Din LMEASUREMENT. SUPPLY RELAY OUTPUT If the reset restriction valve is wide open and the out- put to the control valve changes, the pressure in both bellows changes at (the same rate/different rates). the same rate 102. The bottom position of the flapper (is/is not) moved is not when this happens. 108. The flapper's position cannot be changed by the reset and feedback bellows unless the pressure in these bel- lows changes at (the same rate/different rates). different rates 104. Look at the controller now. SET POINT — uae SUREMENT SUPPLY FEEDBACK | RESET ‘The valve to the reset bellows has been partially —: closed 43105. 106. 107. 108. 109. ‘This means that air will enter and leave the (feedback/ reset) bellows faster and sooner. During a process change, the measuring bellows moves the flapper. ‘Then, the ____ bellows acts on the flapper. Later, after the feedback bellows has moved and the process has had time to respond, if we are off set point, the ___ellows goes into action. ‘There is still a pressure difference between the bellows shown in this sketch. SET POINT —— in SUPPLY MEASUREMENT ‘As Jong as there is a pressure difference between the feedback and reset bellows: ———A. the bellows will keep moving the flapper. ———B. the bellows will stop moving. ‘As long as there is a pressure difference between the feedback and reset bellows: ———A. the control valve position remains the same. —--B. the control valve position keeps moving. 44 feedback feedback reset110. This drawing represents a process change. SET POINT ‘The flow rate of the process increases, and the meas- uring bellows pushes the flapper toward the nozzle, Because of proportional action, if there is a big load change, the process flow rate (is/is not) decreased enough when the valve closes, and there is an offset. 111. When the flapper first moved, it created a difference between the feedback and reset bellows. 112. The feedback bellows starts moving the flapper back toward the old position. SET POINT MEASUREMENT SUPPLY FEEDBACK] RESET RELAY ouTPuT SUPPLY Later, after process response, the reset bellows starts to fill, and pushes (in the same/in the opposite) di- rection. 113. The measuring bellows starts to return the top of the linkage to the — Position. 45 MEASUREMENT is not pressure in the opposite set point114. The reset bellows keeps moving the flapper until the pressure in the reset and feedback bellows is ___. 115. While this is going on, the process is being corrected until the pressures in the _______bellows and the_________________ bellows are equal. 116. This happens when the controller gets the process back to the 117. Here is a record of a proportional controller with reset action. NEW CONTROLLER POSITION 100 SET POINT, ‘ LOAD CHANGE oe BELLOWS ° START. ‘The process measurement drops at A as the result of a load change. ‘The measuring bellows starts opening the control valve at 118. Finally, after the proportional settings have acted to stop the process change, the process measurement is — the set point at B. Is there a pressure difference between the feedback and reset bellows? (Yes/No) 119. The process stops decreasing. Now, the bellows starts closing the flapper more at C. 120. At D, the process gets back toward the set point. ‘The pressure difference in the reset and feedback bel- lows now becomes 121. At this point the measurement bellowa pressure is (equal to/different from) the pressure in the set point bellows. 122. The process pen (is/is not) at the desired set point. 128. The controller is now set for (the same/a different) Toad condition. 46 equal, or the same measurement set point set point Yes equal to a differentHow Reset Action Is Measured 124. The movements of the reset bellows are often called “repeats,” because the error signal is repeated to the control valve until the process gets back to the set point. ‘The time it takes for the reset action is measured in repeats per minute, or minutes per—_____. 125. Which one of these controller knobs controls the reset bellows? MIN, PER REPEAT A B Knob (A/B). 126. The only purpose of reset action is to get rid of offset and get the process back to the desired 127. A controller with proportional and reset action is a ——_—___-mode controller. Rate Action 128. Which reacts faster? A. Narrow band proportional controller B. Wide band proportional controller 129, When there is a rapid process change, we would like to have the controller reaet (faster/slower). 180. For quick response, a (wide/narrow) band propor- tional controller is preferred. 181. But narrow band proportional controllers are too sen- sitive for most process conditions. For slow response, a____ band proportional controller is preferred. aT repeat set point faster narrow wide182. An ideal controller would act like a. band proportional controller for fast process changes. It would also act like a. band propor- tional controller during normal conditions. 183. Some controllers have rate action. Rate action increases the effectiveness of the controller by letting it act like a__________band controller during fast changes and act like a___band controller during normal conditions. 134. A controller with proportional and rate action is a —___-________ controller. How the Feedback Bellows Can Affect Rate Action 185. This diagram shows a controller with a restriction valve hooked up to the feedback bellows. SET POINT MEASUREMENT SUPPLY —— ourPuT FEEDBACK BELLOWS SUPPLY By opening and closing this valve, the flowing amount of ______entering the bellows is increased or decreased. 136. Let's say we close this valve completely. The feedback bellows receives (none/a little) of the pneumatic air. 48 wide narrow wide two-mode air none187. This means that the bellows (will/cannot) act on the cannot flapper. 188. With the restriction valve closed, the controller acts as if ithasno_______ bellows. feedback 139. The valve (will/will not) overshoot the set point. will 140. The type of proportional band that is oversensitive and always overshoots the set point is a: A. narrow proportional band. A ——B. wide proportional band. 141. When the feedback bellows is turned off, it cannot pre- vent the controller from overshooting the set point. With the feedback bellows turned off, the controller acts like a (narrow/wide) band proportional controller. narrow 142. As a matter of fact, the controller may overshoot the set point so far that it moves the control valve com- pletely open or completely closed. ‘The controller without feedback may act like an paar te controller. on-off 143. Let’s say that the restriction valve to the feedback bellows is opened all the way. SET POINT MEASUREMENT COOH O00 SUPPLY ourPuT SUPPLY This means that the feedback bellows: A. fills at the fastest rate. A ———_B. fills at the slowest rate. ———C. doesn’t fill at all. 49144. When the process changes, the controller’s feedback bellows will resist changes in valve position, ‘The process will have to have a___ process change for the controller to move the valve any big amount. 145. This means that when the feedback bellows is fully ~~ open, the controller acts like a: A. narrow band controller. —_B. wide band controller. 146. Let’s say that we close the restriction valve part way. SET POINT MEASUREMENT Poaceae Te SUPPLY ouTPUT FEEDBACK BELLOWS SUPPLY ‘The bellows takes a (longer/shorter) time to fill than when fully opened. 147. This means that during a process change, the feedback bellows will take ________to resist the correct- ing action of the controller. 148. For a slow change, even with its restriction valve partly closed, the feedback bellows will have time to oppose the motion of the flapper and slow down the output of the controller. For a fast change, the controller feedback bellows (will/will not) have as much time to slow down the output of the controller. 149. Thus, a big change (will/will not) be transmitted to the control valve. 150. This means that the faster the change, the (more/less) controller feedback action, and the (bigger/smaller) the correction action transmitted to the control valve. 50 longer longer will not bigger151. RELAY OUTPUT 152. 158. 154, 155. 156. 187. Here is a three-mode controller with proportional, reset, and rate action. SET POINT MEASUREMENT SUPPLY FEEDBACK RESTRICTION The controller is exactly like the proportional con- troller with reset action, except that there is a special rate restriction _____on the feedback bellows. By adjusting the rate restriction we ean delay the ac- tion of the feedback bellows. This means that for a rapidly changing process, the feedback bellows will act (ahead of/behind) the pro- portional action of the controller. During slow process changes, the feedback bellows ‘will have time to catch up to the proportional reset, and will work to (speed up/slow down) the controller action. So, during fast changes, the feedback bellows does not get a chance to work, and the controller acts like a: -__A. narrow band controller. —_B. wide band controller. During slow changes, the feedback bellows has time to act, and the controller acts like A. narrow band controller. ——B. wide band controller. Ordinarily, if a process has large and rapid load changes, the appropriate mode of control is A process with a slow speed of reaction and a fairly large resistance to flow can use an__ mode af control, 51 valve behind slow down proportional with rate and eset action158. In the choice between proportional control and propor- tional with reset action, an important factor is the of the load changes that will occur. size 159. Another important factor in this choice is the amount of _____that can be tolerated. offset 52Section 3 Working with ControllersSECTION 3 ‘WORKING WITH CONTROLLERS Introduction 1. Let’s review some of the facts about control and con- trollers. CONTROLLER (ERROR DETECTION COMPARISON) SET POINT YALVE——~| POSITION CONTROL, MEASUREMENT. A control loop consists of an instrument to_________ the process, and a —..to compare measurements to the set point. ‘When the measurement signal is (the same as/different from) the set point, an error signal is sent to the actuator. ‘When the process changes, ___ is sent to the controller from the measuring instrument. 2. The time it takes for both the instruments and the proc- ‘ess to respond is called the: A. instrument response. B. process response. 6. system response. 3. Must the process react immediately to a valve change? (Yes/No) Do instruments receive immediate feedback from a proe- ess change? (Yes/No) 4, ‘There are two basic types of controllers: on-off con- trollers and proportional controllers. ‘The (on-off/proportional) controller is the simplest in operation. 58 measure controller different from valve feedback No No5. The (on-off/proportional) controller is more likely to make oscillations in the process, 6. The__________controller has a range of settings for the control valve. 7. This graph shows process changes being controlled by proportional controller. SET POINT FLOW CHANGE TIME ‘The control valve is being operated by a (narrow/wide) band proportional controller. 8. This graph shows changes in the process (not valve movement). SET POINT ‘The controller of this process is allowing a lot of offset. ‘The proportional controller used here is a (wide/nar- row) band controller. 4 on-off Proportional wide9. Look at this graph showing changes in the process. SET POINT ‘The process is oscillating. ‘The controller is: A. too sensitive. ———B. not sensitive enough. 10. The proportional controller used here is a (wide/nar- row) band controller. Problems with Controller Settings 11. There are many different processes that must go on in a refinery to produce the many products sold. Different processes need ( the same type/different types) of control. 12. What is a safe and reliable controller setting for one Process could be dangerous for another process. ‘The _____ must fit the process. 13. A controller can be too sensitive. A controller that is too sensitive will cause a process to 14. A controller may not be sensitive enough. A controller that is “dead” will allow too much process (offset/oscillation) . 85 narrow different types controller, or control oscillate offset15. Sometimes a process recorder shows a “dead pen.” ‘A dead pen means that the controller or recorder (is/ is not) responding to process changes. is not 16. What could cause a “dead pen”? Yes No Instruments not hooked up to the process eee Pere Yes Instruments are undersensitive eceeeseeipietecsese Yes ‘Too wide a proportional band on the controller eee Yes On-off control — __ No How Control on One Process Affects Another Process 11. This boiler is producing steam. The amount of steam produced in the boiler depends on how much the water is 7 heated 5618. Let’s say a controller is regulating the amount of fuel going into the burners. A change in fuel rate means a change in the amount of in the boiler. heat 19. A change in the amount of heat means a change in the of steam produced. amount 20. If fuel rate oscillates, steam production (will/will not) will oscillate, 21, The steam from this boiler goes to many different Processes. PROCESS kg PROCESS B = Process [iy c The steam into these processes (will/will not) be oscil- will lating if fuel rate to the boiler oscillates. 22, ‘These processes may start to_______with the oscillate boiler. 723. Each process may have its own controller to regulate valves leading into and out of them. Process /=&> A peer dh PROCESS c ‘These controllers can adjust the rate of into each of the processes. 24, ‘These controllers may have a problem controlling oscil- lation if the incoming steam is oscillating, Steam leaving the boiler should: A. be kept as close to the set point as possible. —— B. be kept as steady as possible. 25. The controller to the steam boiler should be: A. an on-off controller. B, a wide band proportional controller. ——-C. a narrow band proportional controller. 26. The recorder in the boiler’s controller may show offset. Is this as important as keeping the control steady? (Yes/No) 58 steam27. Let's say that in another process we are processing ex- tremely volatile compounds. They are so sensitive to temperature changes that an offset of 5°F above the set point could pop the safety valve. ‘The controller must minimize __. 28. (Wide/Narrow) band proportional controllers keep the process closest to the set point. 29. The controller for this process should be a (wide/ narrow) band proportional controller. 80. Another process must not have too much offset, but must stay fairly steady (without being dead). The best type of control here is: \ ————A. an on-off controller. —— B. a wide band proportional controller. ———C. a narrow band proportional controller. D. a proportional controller halfway between wide and narrow bands. 31, This controller is on a process that needs close set point control. This controller's setting is on narrow band proportional control. ‘The graph of the process shows that the controller is (steady/slightly unsteady). 82, This unsteadiness is: ‘A. expected when using a narrow band con- trol. ———B. should never occur, even when narrow band control fs used. 59 offset Narrow narrow slightly unsteady88. Let’s say someone tries to steady the process. This can be done by ____ the proportional band. 34, Suppose he adjusts the proportional band setting (prob- ably ignoring instructions he had received about leaving these adjustments strictly to the instrument depart- ment or to authorized operators). The chart should now show the process to be more 85. But bigger offsets are now (more/less) likely to occur. 86. If a serious upset of the unit could occur with a big off- set, this type of control setting change (is/is not) harm- ful and possibly dangerous. 87, It is true that adjustment of the proportional band set- ting steadied the process. But this adjustment produced __ conditions. 38. A furnace produces material feed for many processes, and control of furnace temperature must be very 89. Someone attempts to get less offset in the temperature controller of a furnace. ‘This can be done by ________ the proportional band. 40. But, for this particular process, the controller with a narrow proportional band is likely to be too and control will be (steady /unsteady). 60 widening more harmful, or dangerous narrowing sensitive unsteadyHow Reset and Rate Action Affect Control 41. Let’s review reset and rate action, With a change in load, the controller must be —__ to eliminate offset. 42. ‘The rate action in a controller makes the controller re- act ______ during rapid process changes than during slower ones. 43. Do rate action and recet action occur automatically in the controller? (Yes/No) 44, Can these be changed by changing controller settings? (Yes/No) 48. Look at this proportional controller with reset and rate action, SET POINT Tina LMEASUREMENT SUPPLY FEEDBACK | RESET To get rate and reset action, the restriction to the feed- back bellows and the reset bellows must be open (the same amount/different amounts). 46. Let's say that someone opens the rate restriction to the same size as the reset, restriction. Which of the following is true of this controller now? A. Both bellows can affect control. B. Only one of the bellows can affect control. ———C. Neither bellows can have any effect on control. 61 reset faster Yes different amounts41. 48, 49. 51. ‘Now this controller acts like (a proportional/an on-off) ‘4 proportional controller (with/without) reset. without This controller is on a process that needs steady control. Could the change in control settings result in a process upset? (Yes/No) Yes Let’s say that we open the reset restriction too much. SET POINT MEASUREMENT SUPPLY FEEDBACK | RESET Peon aa] Reset action occurs too (fast/slow) for the feedback fast bellows to contro! the valve movement. Reset action will probably be (steady/unsteady). unsteady Could this cause an upset if there were a process change? (Yes/No) Yes There must be proper_________in the control balance, or action, or tuning settings. Inexperience in adjusting control settings: Yes No can cause process upset, eseasaaee Yes can always be corrected for no matter how serious an error. ee eee No can cause harmful or dangerous conditions. eee Yes e‘Working with the Control Mode Let's say an operator who has not been qualified and authorized to tune instruments is looking at the instruments in the control room. As he looks at the name plates marked proportional, reset, and rate, he remembers what an instru- ment once told him... . “Now this is rate action, and that is the proportional band, but don’t ever touch them.” So, human nature being what it is, on some quiet morning, when everything is running smooth, he starts thinking about those settings. ‘The more he looks at them, the more he won- ders what would actually happen if he did change them. After two or three hours of look- ing, his curiosity gets him to the point where he tries to see what happens. He moves a dial and waits. 54. At the time the operator changed the settings, there were no significant process changes. ‘Will the controller move the control valve position dur- ing this period? (Yes/No) 55. If the control valve position is not changed, will there be a process change? (Yes/No) 56. Let's say that this operator changed the proportional band setting like this. ‘This will probably make the control (steady /unsteady) ‘when the process changes. 63 No unsteady‘57. What if the operator turned the reset action way down, nearly closing off the reset restriction? SET POINT Ip LMEASUREMENT TAT SUPPLY FEEDBACK| RESET [nnnn.nnnn A. Reset will occur very quickly. —_B. Reset will occur very slowly. 58. If there is no process change during the operator's shift, what will these control changes do? A. An emergency shutdown will occur. _——B. Conditions will stay normal. 59. Another operator comes on duty. Let’s say the first operator changed the proportional band setting and made it too narrow. A process change occurs that starts the process oscillating. A too sensitive controller will make this condition (cor- rect itself/get worse). 60. What might happen now? A. A serious plant upset could occur. ——B. Conditions will certainly stay normal. G1. Let’s say that the first operator closed the reset action way down. During the next work shift, a big change occurs in the process. ‘The controller (can/cannot) reset, properly. 62. Could this cause a serious upset, if we have to keep close to the set point? (Yes/No) 64 get worse cannot ‘Yes68. Who is at fault for these shutdowns? A. The second operator, because it happened on his shift. —_B. The first operator, because he improperly adjusted the control settings. Who Should Adjust Controllers 64, Let’s say that a whole series of processes are inter- related. PROCESS ASUREMENT a Vv PROCESS CONTROLLER v PROCESS ¢ ae Control of one process unit (affects/does not affect) control of other units. 65. An operator who has very good knowledge of his own units may not have or need knowledge of the other units. An operator must have: A. specific knowledge of his unit. —_B. specific knowledge of all units. 66. The type of control needed for a unit may affect other units. An operator (can/cannot) always determine the appro- priate control mode settings by observing only his own instruments. 67. Controller settings must be matched to the process. ‘They (can/eannot) be changed to smooth out a graph or to satisfy curiosity. 65 affects cannot68. Ordinarily, the instrument man or an especially trained and authorized operator is assigned to tune up control- Jers. ‘The operator who has not had special training and is not authorized to tune instruments can help the instru- ment man by: Yea = No helping him study process response time to get the instruments tuned up right, during startup; jsesenoe_poseeeee leaving the control instruments alone during operations; See reporting instrument malfunctions; —__ making contro! setting changes when it is necessary. eee 69. An operator who is not authorized (should/should not) try to make control mode changes when upsets occur, 70. When upsets occur that are larger than the controller was tuned for, the operator who is not authorized should: Yes No ‘switch to manual control. talk over the problem with the instrument man. eee change control mode settings. pesssoasceeesosons Yes Yes Yes No should not Yes ‘Yes No