Introduction

What is an automatic process control? Control in which regulating and switching operations are performed automatically in response to predetermined conditions

Introduction
Why automatic process control is important? Automatic control systems enable us to operate our processes in a safe and profitable manner. Control systems achieve this "safe and profitable" objective by continually measuring process variables such as temperature, pressure, level, flow and concentration and taking actions such as opening valves, slowing down pumps and turning up heaters - all so that the measured process variables are maintained at operator specified set point values

Introduction
Process Control Terminology
Process Variable (PV): What you are trying to control: temperature, pressure, flow, composition, pH, etc. Also called the measurement. Set-Point (SP): The set-point is where you would like the process variable to be. Error (e): Error = SP - PV. In auto mode, the controller uses the error in its calculation to find the output that will get you to the setpoint.

Introduction
Process Control Terminology
Controller Output (CO): Output of the controller. In auto mode the controller calculates the output based on its calculation using the error signal (difference between SP and PV). In manual mode, the user sets the output. Manipulated Variable (MV): Process condition or

variable that can be changed to cause the process variable to change. Disturbance (D): process condition that tends to change the value of the process variable.

Introduction
Components of a Control System
controller seeks to maintain the measured process variable (PV) at set point (SP) in spite of unmeasured disturbances (D). The major components of a control system include a sensor, a controller and a final control element.

Introduction
Components of a Control System
Sensor: Device which is used to measure process variable e.g. flow orifice, Bourdon tube, thermocouple. Controller: Device that keeps process variable at the setpoint. Final control element: Device which directly changes the manipulated variable e.g. control valves, pump, compressor.

Control Architecture
Feedback control Feedforward with feedback control Cascade control Split-range control Ratio control Override control

Feedback Control
Feedback Control Block Diagram
controller error e(t) = (SP-PV) set point, SP +Controller Final Control Element (FCE) Proces s Disturbance, D measured process variable signal, PV controller output signal (CO) manipulated variable (MV) process variable

Measurement Sensor/Transmitter

Feedback Control
Gas pipeline 1

Without control system, flowrate through this line depends on the pressure difference between these 2 gas pipelines.

Gas pipeline 2

Feedback Control
SP

Gas pipeline 1

PV

FC CO

Gas pipeline 2

Feedback Control
When to use feedback control?
Normally feedback control is the first choice when you want to apply automatic control to your system because of its simplicity.

Feedback Control
Advantages of feedback control
Can handle unforeseen disturbances such as frictional and pressure losses. Ensures the desired performance by altering the inputs immediately once deviations are observed regardless of what caused the disturbance. By analyzing the output of a system, unstable processes may be stabilized. Feedback controls do not require detailed knowledge of the system and, in particular, do not require a mathematical model of the process. Feedback controls can be easily duplicated from one system to another.

Feedback Control
Disadvantages of feedback control
Not suitable for system having large dead time. Can only take input from one sensor. The controller responds to the disturbance after its occurrence, so perfect control of the system is theoretically impossible.
Feedback control does not take predictive control action towards the effects of known disturbances.

Cascade Control
Cascade Control Block Diagram
controller error e(t) = (SP-PV) Primary SP +controller error e(t) = (SP-PV) Primary Controller Secondary SP Primary CO +Secondary CO Secondary Controller manipulated variable (MV) Final Control Element (FCE) Secondary Process

Secondary PV

Primary PV Primary Process

Disturbance, D

Disturbance, D

Secondary PV Measurement Sensor/Transmitter

Primary PV

Measurement Sensor/Transmitter

Cascade Control
CO

PI

Header pressure varies as other line valves move, disturbing our feed rate

flow to other users

PV

L Setpoint LC

Exit flow

Cascade Control
CO1 = SP2

Setpoint
FC PV2 PI CO2

Header pressure varies as other line valves move, disturbing our feed rate

flow to other users

PV1

L Setpoint LC

Exit flow

Cascade Control
When to use cascade control?
When a number of various disturbances might be expected in a single control loop. When a fast response is required and it cannot be achieved by using only single control loop.

Cascade Control
Requirements for Cascade Control
The secondary control loop must be faster than the primary control loop. The secondary control loop receives the maximum disturbance. The secondary loop must include the worst expected disturbances. The secondary loop must have a direct influence on the primary loop. Secondary loop must be measured and controllable.

Cascade Control
Advantages of Cascade Control
Better control of the primary variable. Primary variable less affected by disturbances. Faster recovery from disturbances.

Disadvantages of Cascade Control

Cost of measurement of secondary variable. Additional complexity.

Feedforward with Feedback Control

Feedforward with Feedback Control Block Diagram
Disturbance, D Disturbance Sensor/Transmitter Disturbance Process

Feedforward Computation Element

controller error e(t) = (SP-PV)

set point, SP +-

controller output signal (CO) Controller + +

CO feedforward Final Control Element

manipulated variable

process variable
+

Process

measured process variable signal, PV Measurement Sensor/Transmitter

Feedforward with Feedback Control

Steam to header

PV1

LC

L setpoint

F setpoint

Steam Drum
FC

CO

BFW from header

2-Element Cascade Control

Feedforward with Feedback Control

FT Steam to header

LY PV1

LC

L setpoint

FC

CO
BFW from header

Steam Drum

3-Element Control

Feedforward with Feedback Control

When to use feedforward control?
Concern is focused on one specific disturbance that is responsible for repeated, costly disruptions to stable operation. Reject disturbance(s) before it disturbs / disrupts the system. There is no practical secondary process variable which can be established.

Feedforward with Feedback Control

Requirements for feedforward control?
Disturbances must be measured. A mathematical model of process is required.

Feedforward with Feedback Control

Advantages of feedforward control
Corrective action taken BEFORE PV deviates from setpoint.

Disadvantages of feedforward control

Cost of measurement of disturbance. Additional complexity.

Not suitable for a system which has a number of disturbances.

Split-Range Control
Split-Range Control Loop Block Diagram
manipulated variable 1 controller error e(t) = (SP-PV) set point, SP controller output signal (CO) Controller CO 1 Final Control Element 1 (FCE1) Process Final Control Element 2 (FCE2) manipulated variable 2 process variable

+-

Splitter

CO 2

measured process variable signal, PV Measurement Sensor/Transmitter

Split-Range Control

50-100% 100% 0-50% B A

PC

Gas to flare Gas to compressor % valve opening 0% 0% Controller Output % opening valve A % opening valve B 100%

Split-Range Control

50-100% 100% 0-50% B A

PC

Gas to flare Gas from header % valve opening 0% 0% Controller Output % opening valve A % opening valve B 100%

Split-Range Control
When to use split-range control Split-range control is used in situations where more than one manipulated variable is required.

Split-Range Control
Advantages of split-range control
Can control over the wide range Can handle more than one disturbances at the same time.

Disadvantages of split-range control

Additional cost for final control element. Difficulty in controller tuning.

Ratio Control
Ratio Control Block Diagram
Measurement Sensor/Transmitter measured process variable signal, PV2 Ratio controller error e(t) = (SP-PV) set point, SP controller output signal (CO) Final Control Element 1 (FCE1) manipulated variable process variable

+-

Controller

Process

measured process variable signal, PV1

Measurement Sensor/Transmitter

Ratio Control

PV 1

FT

Product 2
RY SP PV 2 FC FT CO

Mixed ratio Storage Tank

Product 1

Ratio Control
When to use ratio control The ratio control architecture is used to maintain the flow rate of one stream in a process at a defined or specified proportion relative to that of another.

Ratio Control
Requirement for ratio control A ratio controller architecture requires that the signal from each flow sensor/transmitter change linearly with flow rate.
50 MMSCFD Fluid flowrate 0 MMSCFD 4 mA Transmitter Signal 20 mA

Override Control
Override Control Block Diagram
controller error e(t) = (SP-PV) set point, SP2 +Controller selected CO manipulated variable (MV) Final Control Element (FCE) process variable controller output signal (CO2)

Selector

Process

controller error e(t) = (SP-PV) set point, SP1 +-

controller output signal (CO1)

Disturbance, D

Controller

measured process variable signal, PV

Measurement Sensor/Transmitter

Override Control

>
FC PC

TC

Fuel gas Fired Heater

Heated process fluid

Override Control
When to use override control
When there is a constraint in operation or equipment.

Advanced Control
> R <

O2 FC Y FT <

>
PC Max. PC Min. TC

Fuel gas from header

Y FC

Heated process fluid Fired Heater

FT

Air Blower

Cross Limiting Control for Fired Heater

Summary
Control Architecture Feedback Philosophy Control adjusts error after it occurs Advantages - simple to design - no process model needed Disadvantages - correct error after it has already occurred. - usually takes input from one sensor - accurate process model is needed. - accurate measurement is needed. - increase complexity to the control system - additional costs required. - flow sensor/transmitter has to change linearly with the flowrate. - add complexity to the process control - tuning model is difficult due to multiple setpoints and parameters. - make system unstable due to integral action. External feedback is needed.

Feedforward

Control corrects error before it occurs.

- correct possible error before it occurs. - Ideally can produce a perfect control where there is never offset.

Ratio

Control connects two flows to maintain a constant ratio. Controller output from one control is a setpoint of the other control loop.

- generate defined ratio for given two streams. - simple model - responds quickly to high frequency changes - incorporate multiple sensor reading together. - prevent operation or equipment from operating over its constraints.

Cascade

Override Control action from one controller takes priority

Split-range

One controller adjusts more than one manipulated variables.

-can control over the wide range -can handle many disturbances

-make controller tuning more difficult.