Professional Documents
Culture Documents
Copyright © 2002
Douglas J. Cooper
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1. Fundamental Principles of Process Control
Motivation for Automatic Process Control
Safety First:
– people, environment, equipment
The Profit Motive:
– meeting final product specs
– minimizing waste production
– minimizing environmental impact
– minimizing energy use
– maximizing overall production rate
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Douglas J. Cooper
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“Loose” Control Costs Money
Process: Gravity Drained Tank Controller: Manual Mode
4.4
7 0 operatingconstraint
Process: Gravity Drained Tank Controller: Manual Mode
4.2
4.2
6 0
4.0
4.0
5 0
Mor e Pr o f it a bl e O perMora t ioe nPr o f i t a ble O per a t i o n
poorcontrolm eans
3.8
3.8
4 0 largevariability,so
theprocessm ustbe
operatedinaless
3.6
3 0
processvariable profitableregion
It takes more
80
material
100
toTime120(mins)make a 140product160thicker, so greatest
profit is to operate as close to the minimum thickness
constraint as possible without going under
It takes more processing to remove impurities, so greatest
profit is to operate as close to the maximum impurities
constraint as you can without going over
Copyright © 2002
Douglas J. Cooper
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Tight Control = Most Profitable Operation
Process: Gravity Drained Tank Controller: Manual Mode
4.20
7 operatingconstraint
Process: Gravity Drained Tank Controller: Manual Mode
4.2
4.00
6
4.0
tightcontrolperm its
3.80
5
operationn earthe
processvariable
constraint,which
M or e Pr o fi ta bl e Oper aMtioorn e Pr o fi ta bl e Oper a tio n
3.8
4
3.60
m eansm oreprofit
3.6
3
3.40
Copyright © 2002
Douglas J. Cooper
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An introductory example
Copyright © 2002
Douglas J. Cooper
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Consider Heating a House
Thermostat Temperature
controller sensor/transmitter
set point
TC TT
heat loss
(disturbance)
Control
signal
fuel flow
furnace 1. Measurement
valve
2. Computation/
Decision
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3. Action
Douglas J. Cooper
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Automatic Control is
Measurement Computation Action
Error
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Douglas J. Cooper
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Feedback Control Loop Block Diagram:
Components and Variables for home heating
Set Point T
+ Thermostat Fuel Valve Home Heating
TSP - Process
house temperature
Q d
measurement
signal
Tm Temperature T
Sensor/Transmitter
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Douglas J. Cooper
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Terminology
Control Objective
Controlled Process Variable
Measured Variable
Set point
Error
Controller Output
Manipulated Variable
Disturbances
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Douglas J. Cooper
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General Feedback Control Loop Block Diagram
“Actual” controller
Manipulated Controlled
Controller Controller Process Process
error output variable variable
Comparator Disturbance
d(t)
measured variable
(feedback signal)
Measurement
ym(t) Sensor/Transmitter
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Douglas J. Cooper
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Examples
Measurement Sensors:
temperature, pressure, pressure drop, level,
flow density, concentration
Automatic Controllers:
on/off, PID, cascade, feed forward, model-
based Smith predictor, multivariable, sampled
data, parameter scheduled adaptive control
Copyright © 2002
Douglas J. Cooper
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3. Graphical Modeling of Dynamic Process Data
Process Behavior and Controller Tuning
Consider cruise control for a car vs a truck
– how quickly can each accelerate or decelerate
– what is the effect of disturbances (wind, hills, etc.)
Controller (gas flow) manipulations required to maintain set point
velocity in spite of disturbances (wind, hills) are different for a car
and truck because the dynamic behavior of each "process" is
different
Dynamic behavior
how the measured process variable responds over time to changes in
the controller output and disturbance variables
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Douglas J. Cooper
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Understanding Dynamic Process Behavior
To learn about the dynamic behavior of a process, analyze
measured process variable test data
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Douglas J. Cooper
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Modeling Dynamic Process Behavior
The best way to understand process data is through modeling
where:
y(t) is the measured process variable
u(t) is the controller output signal
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Douglas J. Cooper
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FOPDT
When a first order plus dead time (FOPDT) model is fit to
dynamic process data
dy (t )
P y (t ) K P u (t P )
dt
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Douglas J. Cooper
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PID Tuning
Guide
Copyright © 2002
Douglas J. Cooper
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The FOPDT Model is All Important
model parameters (KP, P and P) are used in correlations to compute initial
controller tuning values
size of P indicates the maximum desirable loop sample time (be sure
sample time T 0.1P)
ratio P /P indicates whether MPC (Smith predictor) would show benefit
(useful if P P)
model becomes part of the feed forward, Smith predictor, decoupling and
other model-based controllers
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Douglas J. Cooper
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Step Test
OpenOpen
LoopLoop
Step Step
Test Test
Process:Process:
CustomCustom
Process Process Controller: ManualManual
Controller: Mode Mode
60 60
StepTest
55 55
Process Varia ble
Process Varia ble
50 50
60 60
55 55
Contr olle r Outp ut
Contr olle r Outp ut
50 50
0 0 5 5 10 10 15 15 20 20
Time (miTinms)e (mins)
where u(t) and y(t) represent the total change from initial to final
steady state
A large process gain means the process will show a big response to
each control action
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Douglas J. Cooper
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KP for Gravity Drained Tanks
Gravity Drained Tanks - Open Loop Step Test
Process: Gravity Drained Tank Controller: Manual Mode
3.0
2.8
2.6
2.4 y=(2.88- 1.93) m
Process Varia ble 2.2
2.0
1.8
60
55 u=(60- 50) %
Cont r olle r O utp ut
50
45
8 9 10 11 12 13 14 15 16 17 18
Time (mins)
y 2.88 1.93 m m
KP 0.095
u 60 50% %
manipulated variable
controller output
.
measured
process variable level sensor
& controller
disturbance
variable
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Douglas J. Cooper
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Non-Interacting Gravity Drained Tanks
TANK 1
dh1 h1
A V1 ( t )
I.C.: t=0 h1 = h1s
dt R1
TANK 2
dh 2 h2 h1
A VP ( t )
I.C.: t=0 h2 = h2s
dt R2 R1
Copyright © 2002
Douglas J. Cooper
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Overall Time Constant From Step Test Data
OpenOpen
LoopLoop
Step Test
Step Test
Process:Process:
Custom Custom
Process Process Controller: ManualManual
Controller: Mode Mode
60 60
StepTest
55 55
60 60
55 55
Cont r olle r Out p ut
Contr olle r Outp ut
50 50
0 0 5 5 10 10 15 15 20 20
Time (miTinms)e (mins)
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Douglas J. Cooper
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P for Gravity Drained Tanks
1) Locate where the measured process variable first shows a clear initial response to the step change – call this time tYstart
From plot, tYstart = 9.6 min
2.2
2.0
1.8
60
55
Contr olle r O utp ut
50
45
8 9 10 11 12 13 14 15 16 17 18
Time (mins)
tYstart
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Douglas J. Cooper
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P for Gravity Drained Tanks
2) Locate where the measured process variable reaches y63.2, or
where y(t) reaches 63.2% of its total final change
2.2
2.0
1.8
60
55
Cont r olle r Outp ut
50
45
8 9 10 11 12 13 14 15 16 17 18
Time (mins)
tYstart t63.2
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Douglas J. Cooper
All Rights Reserved
P for Gravity Drained Tanks
Gravity Drained Tanks - Open Loop Step Test
Process: Gravity Drained Tank Controller: Manual Mode
3.0
2.8
y63.2 =2.53m
2.6
2.4 y =0.95m
Process Varia ble 2.2
2.0
1.8
60
55
Cont r olle r Outp ut
50
45
8 9 10 11 12 13 14 15 16 17 18
Time (mins)
tYstart t63.2
2.2
2.0
1.8
60
55
P =1.6minutes
Contr olle r Outp ut
50
45
8 9 10 11 12 13 14 15 16 17 18
Time (mins)
tYstart t63.2
Copyright © 2002
Douglas J. Cooper
All Rights Reserved
Apparent Dead Time From Step Test Data
P is the time from when the controller output step is made until
when the measured process variable first responds
Apparent dead time, P, is the sum of these effects:
– transportation lag, or the time it takes for material to travel
from one point to another
– sample or instrument lag, or the time it takes to collect analyze
or process a measured variable sample
– higher order processes naturally appear slow to respond
Notes:
– Dead time must be positive and have units of time
– Tight control in increasingly difficult as P 0.7P
– For important loops, work to avoid unnecessary dead time
Copyright © 2002
Douglas J. Cooper
All Rights Reserved
P for Gravity Drained Tanks
Gravity Drained Tanks - Open Loop Step Test
Process: Gravity Drained Tank Controller: Manual Mode
3.0
2.8
2.6
2.4
Process Varia ble 2.2
2.0
1.8
60
55
Contr olle r Outp ut
50
P =0.4minutes
45
8 9 10 11 12 13 14 15 16 17 18
tUstep Time (mins)
tYstart
P = tYstart tUstep
= 9.6 min 9.2 min
= 0.4 min
Copyright © 2002
Douglas J. Cooper
All Rights Reserved
Workshop 1:
Exploring Dynamics of Gravity Drained Tanks
Copyright © 2002
Douglas J. Cooper
All Rights Reserved
Processes Have Time-Varying Behaviors
The predictions of a FOPDT model are constant over time
But real processes change every day because
– surfaces foul or corrode
– mechanical elements like seals or bearings wear
– feedstock quality varies and catalyst activity drifts
– environmental conditions like heat and humidity change
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Douglas J. Cooper
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Processes Have Nonlinear Behaviors
The predictions of a FOPDT model are constant as operating level changes
The response of a real process varies with operating level
Example Nonlinear Behavior
Process: Custom Process Controller: Manual Mode
80
responseshapeisdifferent
C
70 at different operatinglevels
60
Process Varia ble
B
50
A
70
65
60
Contr olle r Outp ut
55 eventhoughcontroller
50 output stepsarethesame
2 4 6 8 10 12 14 16 18 20
Time (time units)
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Douglas J. Cooper
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Gravity Drained Tanks is Nonlinear
Nonlinear Behavior of Gravity Drained Tanks
Model: First Order Plus Dead Time (FOPDT) File Name: TEST.DAT
7
6 nonlinearprocess
5
4 variableresponse
Measure d Level (m )
3
2 constant param eter
1 FO PD Tm odel
90
80
70
60
Cont r o l e r Out p ut ( % )
50
equal u’s
40
0 5 10 15 20 25 30 35 40 45
Time
Gain (K) = 0.075, Time Constant (T1) = 1.15, Dead Time (TD) = 0.53 SSE: 206.0