2006 Fisher-Rosemount Systems, Inc.

Slide 10 - 1
Process Control
Control Using Two Manipulated Input
Control Using Two
Control Using Two
Manipulated Inputs
Manipulated Inputs
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 2
Process Control
Control Using Two Manipulated Input
Control Using Two Manipulated Parameters Control Using Two Manipulated Parameters
Control Using Two Manipulated Parameters
Under specified
problem that has
multiple solutions for
unlimited operation.
Extra degree of
freedom is used to
achieve unique
solution that satisfied
specific control
objective.
Most common
techniques are: split
range, valve position,
and ratio control
Controller Process
SP
One(1) Controlled
Parameter
Two(2) Manipulated
Parameters
FY
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 3
Process Control
Control Using Two Manipulated Input
Basis Split Range Basis
Basis

Split Range
Split Range
In some cases,
two or more
inputs to the
process are used
as one input.
The inputs to the
process are
maintained in a
fixed relationship
as determined by
a splitter station
characterization
and station
setpoint.
FY
111
Process
AT
111
AC
111
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 4
Process Control
Control Using Two Manipulated Input
IP
104A
IP
104B
PT
104
FY
104
PIC
104
Steam Header Example Steam Header Example
Steam Header Example
400# Header
1475# Header
Boiler
Turbo
Generator
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 5
Process Control
Control Using Two Manipulated Input
Valve
Position
(% of Span)
PIC104 Output (% of Span)
100
0
0
100
Valve 104A
Valve 104B
Split Range Output (FY104) - Capacity Split Range Output (FY104)
Split Range Output (FY104)
-
-
Capacity
Capacity
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 6
Process Control
Control Using Two Manipulated Input
Calculating Splitter SP Ranges Calculating Splitter SP Ranges
Calculating Splitter SP Ranges
A 1% change in controller
output to the splitter should
have the same impact on
control parameter when
operating with either valve.
When manipulating the same
or similar material e.g. steam
flow to header, then the range
may be calculated based on
valve rating.
Tests may be performed to
determine impact of each valve
on the controlled parameter.
Example: Steam flow to Header, splitter
interfacing directly to PRVs, no overlap
Valve 1 rating = 50kph
Valve2 rating = 150kph
Desired Splitter Span valve 1 =
100*(50/(150+50)) = 25%
SP range for valve 1 = 0-25%
SP range for valve 2 = 25-100%
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 7
Process Control
Control Using Two Manipulated Input
IP
104A
IP
104B
TT
104
FY
104
TIC
104
COOLER HEATER
Example - Split Range Control Example
Example
-
-
Split Range Control
Split Range Control
Temperature
control using
cooling and
heating
Valves are
sequenced in a
fixed
relationship to
the
temperature
controller
output
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 8
Process Control
Control Using Two Manipulated Input
Valve
Position
(% of Span)
TIC104 Output (% of Span)
100
0
0
100
Cooling (IP104B)
Heating (IP104A)
Split Range Output (FY104) Split Range Output (FY104)
Split Range Output (FY104)
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 9
Process Control
Control Using Two Manipulated Input
Testing Process to Determine
Splitter SP Ranges
Testing Process to Determine
Testing Process to Determine
Splitter SP Ranges
Splitter SP Ranges
With the process at
steady state and AOs
in Auto mode,
determine the
magnitude of change
in the controlled
parameter for a 1
percent change in each
valve.
Calculate the splitter
SP span and range for
each output based on
the observed response
Time
Cooling
Heating
1%
1%
1.1degF 2.2degF
Desired Splitter Span cooling valve =
100*(2.2/(1.1+2.2)) = 66%
SP range for cooling valve = 0-66%
SP range for heating valve = 66-100%
Controlled
Temperature
Example: Temperature controlled using heating
and cooling valves
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 10
Process Control
Control Using Two Manipulated Input
Split Range Control in DeltaV Split Range Control in DeltaV
Split Range Control in DeltaV
Splitter bock is used
to implement split
range control.
Split range control
is most often
implemented using
AO blocks for direct
interface to valves.
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 11
Process Control
Control Using Two Manipulated Input
Splitter Block Calculation Splitter Block Calculation
Splitter Block Calculation
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 12
Process Control
Control Using Two Manipulated Input
SP
0 100
0
100
0
100
0
100
100
100
0
0
OUT_1
OUT_2
LOCK_VAL holds
LOCK_VAL is zero
OUT_ARRAY
0 100 0 100
IN_ARRAY
0 100 0 100
OUT_ARRAY
100 0 0 100
IN_ARRAY
0 40 35 100
OUT_ARRAY
0 100 0 100
IN_ARRAY
0 40 35 100
Splitter Block Splitter Block
Splitter Block
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 13
Process Control
Control Using Two Manipulated Input
IN_ARRAY Parameter IN_ARRAY Parameter
IN_ARRAY Parameter
The SP range
associated with each
output is defined by
IN_ARRAY.
SP range of outputs
may be defined to
overlap
The SP upper end of
range must be greater
that lower end of range
for each output
SP range
associated
with OUT1
SP range
associated
with OUT2
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 14
Process Control
Control Using Two Manipulated Input
OUT_ARRAY Parameter OUT_ARRAY Parameter
OUT_ARRAY Parameter
When SP is outside
defined range, then
the value at the end
of range is used to
determine the output.
LOCKVAL
determines if OUT1
value is held if SP is
greater that the upper
end of range defined
for OUT1.
No restrictions are
placed on the output
range.
OUT1 Range for
associated SP range
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 15
Process Control
Control Using Two Manipulated Input
Example - Neutralizer Example
Example
-
-
Neutralizer
Neutralizer
Neutralizer
Discharge
Reagent
AIC
105
AT
105
IP
105B
FY
105
IP
105A
Coarse
Valve
Fine
Valve
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 16
Process Control
Control Using Two Manipulated Input
Split Range Output Valve Sequencing Split Range Output
Split Range Output

Valve Sequencing
Valve Sequencing
Valve
Position
(% of Span)
AIC105 Output (% of Span)
100
0
0
100
Fine Valve (IP105B)
Coarse Valve (IP105A)
HYSTVAL
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 17
Process Control
Control Using Two Manipulated Input
Split-range Control Workshop Split
Split
-
-
range Control Workshop
range Control Workshop
IP
104A
IP
104B
TT
104
FY
104
TIC
104
COOLER HEATER
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 18
Process Control
Control Using Two Manipulated Input
Split-range Control Workshop Split
Split
-
-
range Control Workshop
range Control Workshop
Step 1. Open the EXAMPLE_G module and go to on-line
operation in Control Studio. Change the mode of the
Splitter block to Auto.
Step 2. Change the splitter SP (setpoint) over the following range
- 0, 25, 50, 75, 100 - and observe the change in the
valves and process outlet temperature.
Step 3. Change the splitter SP (setpoint) to 50 and wait until the
temperature settles to a fixed value.
Step 4. Make a step change in the FEED_TEMP disturbance and
manually adjust the splitter setpoint to get the
OUT_TEMP back to its initial value.
Step 5. Change the splitter mode to Cascade, change the
temperature control setpoint and observe the response.
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 19
Process Control
Control Using Two Manipulated Input
EXAMPLE_G Split Range EXAMPLE_G
EXAMPLE_G

Split Range
Split Range
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 20
Process Control
Control Using Two Manipulated Input
Valve Position Control Valve Position Control
Valve Position Control
IP
106A
AT
106
AIC
106
Process
PID control is
implemented using the
actuator with finer
resolution or fastest
impact on controlled
parameter
The actuator with
coarse resolution or
slower impact on the
controlled parameter is
adjusted by an I-only
controller to maintain the
long term output of the
PID controller at a given
target
pH Example
Fine Valve
A/O
ZC
106
IP
106B
Coarse
Valve
I-Only
Controller
SP=
Target
Valve
Position
Time
pH
Fine Valve
Coarse Valve
Target Valve
Position
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 21
Process Control
Control Using Two Manipulated Input
Example -Boiler BTU Demand Example
Example
-
-
Boiler BTU Demand
Boiler BTU Demand
ZC
109
FT
109A
IP
109B
FIC
109
FT
109B
IP
109A
FY
109
Low BTU Waste Fuel
HI BTU Fuel
Boiler
BTU Demand
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 22
Process Control
Control Using Two Manipulated Input
Example Reformer Air Demand Example
Example

Reformer Air Demand

Reformer Air Demand
ZC
110
FIC
110
FT
110
SC
110
Air
Machine
Secondary
Reformer
Total Air
Demand
IP
110
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 23
Process Control
Control Using Two Manipulated Input
Valve Position Control in DeltaV Valve Position Control in DeltaV
Valve Position Control in DeltaV
The OUT of
the PID used
for control is
wired to IN on
the PID block
used for I-
Only
regulation of
slower
responding or
coarse
resolution.
PID configured for I-
Only control
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 24
Process Control
Control Using Two Manipulated Input
Configuring PID for I-Only Control Configuring PID for I
Configuring PID for I
-
-
Only Control
Only Control
The STRUCTURE
parameter should be
configured for I action
on Error, D action on
PV
The GAIN should be
set to 1 to allow normal
tuning of RESET (even
though proportional
action is not
implemented.
RESET should be set
significantly slower
than that the product of
the PID gain and reset
time used for control
e.g. 5X slower
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 25
Process Control
Control Using Two Manipulated Input
Valve Position Control Workshop Valve Position Control Workshop
Valve Position Control Workshop
ZC
110
FIC
110
FT
110
Small
Valve
Big Valve
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 26
Process Control
Control Using Two Manipulated Input
Valve Position Control Workshop Valve Position Control Workshop
Valve Position Control Workshop
Step 1. Open the EXAMPLE_H module and go to on-line
operation in Control Studio. Change the mode of the flow
controller to Auto.
Step 2. Change the flow control SP (setpoint) over the following
range 40, 50, 60 - and observe the change in the two
outputs.
Why Is the small valve maintained at 50%?
Step 3. Change the SP of the valve position controller and
observe the response.
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 27
Process Control
Control Using Two Manipulated Input
Example H Valve Position Control Example H
Example H

Valve Position Control

Valve Position Control
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 28
Process Control
Control Using Two Manipulated Input
Basis Ratio Control Basis
Basis

Ratio Control
Ratio Control
To fully automate a large process, it
is often necessary to provide
coordinated adjustment of multiple
loops.
The technique of ratioing control
loops is an effective way to provide
this coordination.
Ratio station is used to specify ratio
and to calculate setpoint of the
dependent loop.
Ratioing based on the independent
loop setpoint provides a noise free
remote setpoint but will be incorrect
if the independent loop can not
maintain its setpoint
FC
2
FT
2
FC
1
RC
2
Input = SP or PV
of independent
loop
SP
SP= (Ratio * Indep Loop Input )
FT
1
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 29
Process Control
Control Using Two Manipulated Input
Example Reactor Feed Ratio Control Example
Example

Reactor Feed Ratio Control

Reactor Feed Ratio Control
Catalyst flow
must be
maintained in
correct
proportion to
the feed flow for
correct reactor
operation and
final product.
Ratio control
automatically
provides the
correct
proportion of
catalyst to feed.
FC
8
FT
8
RC
9
SC
9 Reactor
Feed
Catalyst
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 30
Process Control
Control Using Two Manipulated Input
Automatic Ratio Adjustment Automatic Ratio Adjustment
Automatic Ratio Adjustment
A process output that
indicates the impact of
the ratio of process
inputs may be
maintained at target by
using feedback to
adjust the ratio target
To the feedback
control, the ratio station
and associated flow
loops are considered to
be part of the process
FC
1
FT
1
FC
1
FT
1
RC
2
AC
1
AT
1
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 31
Process Control
Control Using Two Manipulated Input
Example Slaker Control Example
Example

Slaker Control
Slaker Control
Effective Alkali.
EA, is
maintained at
target though
the adjustment
of lime to green
liquor flow ratio.
As green liquor
feed is
increased, then
lime flow is
automatically
increase in a
proportion to
maintain the
target EA.
Conductivity
FC
7
FT
7
RC
8
SC
8
AC
9
AT
9
Green
Liquor
Lime
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 32
Process Control
Control Using Two Manipulated Input
Ratio Control in DeltaV Ratio Control in DeltaV
Ratio Control in DeltaV
The Ratio block is
used to implement
ratio control.
IN_1 may be a
flow measurement
(wild flow) or
setpoint of another
loop
The true ratio is
calculated base on
IN_1 and IN and
reflected in the
ratio block PV.
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 33
Process Control
Control Using Two Manipulated Input
Ratio Block Function Ratio Block Function
Ratio Block Function
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 34
Process Control
Control Using Two Manipulated Input
Ratio Control Workshop Ratio Control Workshop
Ratio Control Workshop
Static Mixer
AC
1-1
Main Flow
AT
1-1
FC
1-2
FT
1-2
Blend Flow
FC
1-2
FT
1-2
RC
1-2
% Solids
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 35
Process Control
Control Using Two Manipulated Input
Ratio Control Workshop Ratio Control Workshop
Ratio Control Workshop
Step 1. Open the EXAMPLE_I_CNT module and go to on-line operation
in Control Studio. Change the mode of the Ratio block to Auto.
Step 2. Change the Ratio SP (setpoint) over the following range 0.3,
0.5, 0.8 - and observe the change in the blend flow and the
process outlet concentration. Set the Ratio SP to 0.5 percent
and wait for the concentration to settle to a steady value.
Step 3. Make a step change in the FEED and observe the way the ratio
changes the dependent loop. Did the concentration change?
Step 4. Change the ratio block to Cascade mode. Change the setpoint
of the analytical loop to 40% and observe the impact on the ratio
setpoint. Does the measured concentration reach setpoint?
Step 5. Open the EXAMPLE_I_PROC module and examine the process
simulation used in this workshop.
Question: What are the advantages of structuring the process simulation as a
separate module? What are the disadvantages of this approach?
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 36
Process Control
Control Using Two Manipulated Input
EXAMPLE_I_CNT EXAMPLE_I_CNT
EXAMPLE_I_CNT
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 37
Process Control
Control Using Two Manipulated Input
EXAMPLE_I_PROC EXAMPLE_I_PROC
EXAMPLE_I_PROC
2006 Fisher-Rosemount Systems, Inc.
Slide 10 - 38
Process Control
Control Using Two Manipulated Input