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Process Control: Designing Process and Control Systems For Dynamic Performance
Process Control: Designing Process and Control Systems For Dynamic Performance
v1
T
Central control room
v2
Digital PID
Sensor
Process
CHAPTER 12: PRACTICAL ISSUES
Accuracy =
Reproducibility =
CHAPTER 12: PRACTICAL ISSUES
A B
C D
CHAPTER 12: PRACTICAL ISSUES
Sensor range - The values over which the sensor can record
the process variable. We need to “cover” expected range, but
typically, the sensor accuracy decreases with increasing
sensor range.
feed
TI
6
PT
1
TI
3
TI
7 TC TI
TI 10
4
product
FT TI
FI
2 8 TI
3
11
fuel
air PI PI PI
2 3 6
CHAPTER 12: PRACTICAL ISSUES
Input - Sensor and Pre-calculations
Analyzer measures the
excess oxygen; PI
• typical value 2%, 1 This sensor for
• range 0 - 10% control needs good
AI PI accuracy within the
1 4 normal operation,
FT e.g., 350 - 450 C
1 TI
PI
1
5
TI
5
TI This monitor
2
should cover
feed the entire range
TI for startup and
6
PT disturbances,
1
Feed flow control needs e.g., 0 - 600 C
TI
accuracy. Maximum 3
range should be about 1.3 TI
TC TI
7
times design value TI 10
4
product
FT TI
FI
2 8 TI
3
11
fuel
air PI PI PI
2 3 6
The pressure is low
here. Do not have
large range.
CHAPTER 12: PRACTICAL ISSUES
Input - Sensor and Pre-calculations
• What is noise?
20 • Why reduce
15
noise using a
filter?
Temperature
10
-5
0 5 10 15 20 25 30 35 40 45 50
Time (min)
CHAPTER 12: PRACTICAL ISSUES
Input - Sensor and Pre-calculations
20
Signal + noise Signal?
15
Temperature
10
5 Noise?
0
-5
0 5 10 15 20 25 30 35 40 45 50
Time (min)
Controllable disturbances
What we call noise tends
to be relatively fast.
Uncontrollable disturbances
[Values are typical for chemical processes, but vary over a wide range]
CHAPTER 12: PRACTICAL ISSUES
Input - Sensor and Pre-calculations
Process Sensor Analog A/D Digital
variable signal filter convert filter
Linearization PID
Without
filter
D(s) Gd(s)
0 5 10 15 20 25 30 35 40 45 50
GS(s)
CVm(s)
With filter
D(s) Gd(s)
0 5 10 15 20 25 30 35 40 45 50
Gf(s) GS(s)
CVf(s) CVm(s)
Phase angle
signal noise
Frequency,
CHAPTER 12: PRACTICAL ISSUES
Input - Sensor and Pre-calculations
Process Sensor Analog A/D Digital
variable signal filter convert filter
Lineariztion PID
1.0
Amplitude
• Perfectly eliminate
ratio the noise
• No dynamics
• Sorry, not possible
0.0
0.0
Phase angle
signal noise
We have only a rough
estimate of
Frequency, this boundary anyway!
CHAPTER 12: PRACTICAL ISSUES
Input - Sensor and Pre-calculations
-1
Not a perfect step, but
10
has the desired trend.
-2
10
-2 -1 0 1 2
10 10 10 10 10
Dimensionless Frequency, (rad/time)
-20
Contributes dynamics to
Phase Angle (degrees)
-100
-2 -1 0 1 2
10 10 10 10 10
Gf(s) GS(s)
CVf(s) CVm(s)
1
t
d CV (t )
MV (t ) ( K sense ) K c E (t )
TI 0 E (t ' )dt 'Td dt I
Ksense Convention A Convention B
+1 Direct acting Increase/increase
-1 Reverse acting Increase/decrease
CHAPTER 12: PRACTICAL ISSUES
Feedback Controller - P, I and D
1
t
d CV (t )
MV (t ) K c E (t )
TI 0 E (t ' )dt 'Td dt I
CV E (t ) 1 t d CV (t )
MV (t ) E (t ' ) CVr
MVr
Kc r
MVr CVr TI
0 CVr dt 'Td dt I
t d CV (t )
MV (t ) 100 E (t ) 1 E (t ' ) CVr
MVr
PB CVr TI
0 CVr dt 'Td dt I
t
d CV (t )
MV (t ) K c E (t ) TR E (t ' )dt 'Td I
0
dt
1
t
d CV (t )
MV (t ) K c E (t )
TI 0 E (t ' )dt 'Td dt I
(t ) T
MVN K c E N E N 1 E N d (CVN 2CVN 1 CVN 2 )
TI t
MVN MVN 1 MVN
MVN MVmax
Anti-reset-windup modification
MVN MVmin
MVN is implemented and stored for use as MVN -1 during the next iteration
CHAPTER 12: PRACTICAL ISSUES
Feedback Controller - P, I and D
TI
6
PT
1
TI
3
TI
7 TC TI
TI 10
4 product
FT TI
8 FI
2 3 TI
11
fuel
air
PI PI PI
2 3 6
CHAPTER 12: PRACTICAL ISSUES
Output processing
feed
situations, we want to 1
v1
T
Central control room
v2
Digital PID
You and a few friends started a company to design a new digital control system.
The company has decided to provide anti-reset-windup using the
“external feedback” method.
Gf(s) GS(s)
CVf(s) CVm(s)
You wonder why the first order filter is used often in process
control. So, you perform the following investigation.
• Determine the transfer function for a 4th order filter, with four
equal time constants.
• Calculate the frequency response for the fourth order filter.
• Identify advantages and disadvantages with respect to a 1st order
filter.
• Decide which is generally best for feedback control.
CHAPTER 12: PRACTICAL ISSUES WORKSHOP 3
Gain Kc (Kc)s PB PB
Integral TI TR TI TR