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/ 74
1064WB
Instrumentation
for Operators
UNIT 3:
Controllers and Control Modes -
HOWELL TRAINING Program developed for API by: Howell Tr-sining Company
5201 Lan gfield Road
Houston, Texas 77040
Author: John Erie Vietor
Editor and Program Supervisor: John Ball. Ph.D.
Art: Robert Culp
Content Specialist for API: Oscar Palr-ner, Continental Oil Company
Coordinator of API Content Specialists: L. J. MeALllister, American Oil Company
Chairman, API Training Committee: James W. Porter, Sun Oil Company
Validation provided through
‘the cooperation af: Standard Oil Company of Califorria
Imperial Gil Company, Ltd.
This text has been validated by the Comenittee on Training,
Division of Refining, American Petroleu m Institute, 1968.
PILOT. ip
© Program re 1068
This program may not be reproduced in whale or in part without
‘express permission of Howell Training Compeany. All translation
vights are reserved by the pub Asher. INSTRUMENTATION FOR OPERATORS
UNIT THREE— CONTROLLERS AND CONTROL MODES
Section 1
Controllers .......
‘Why We Need Controllers
How a Controller Works
‘The Control Loop .
System Response 0...
Offset and Oselllstion
‘Types of Controllers «
On-OM Controllers». :
Problems with an On-Of Controller
Proportional Controllers
‘The Throttling Range of the Valve
‘The Throttling Range of the Controller
How the Proportional Band Affects Contrel
Review and Summary
Section 2
Proportional Controllers with Rate and Reset Action
Process Load. oe on
Feedback Bellows
How Load Changes Affect Proportional Controllers
‘Reset Action
‘Automatic Reset
How Reset Action Is Measured
Rate Action
How the Feedback Bellows Can’ Affect Rate Action’
Section 3
‘Working with Controllers
Introduction :
Problems with Controller Settings 1.1...
How Control on One Process Affecia Another Procese
How Reset and Rate Action Affect Control
‘Working with the Control Mode
Who Should Adjust Controllers
2
2
35
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2
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INSTRUMENTATION
FOR OPERATORS
Unit 3
Controllers and Control Modes
Bours
Bentsen, -
Section 1
Controllers ‘Unit Three of Instrumentation for Operators explains the pur-
‘poses and operation of automatic eontrolles and of eontrol
‘modes used in process control instruments.
{In Section 1 you will earn how controllers work, the nature
‘of control loop, and the fectors 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
‘contro
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 feodback bellows and by reset
and rate aetion,
{In Section 8 you will learn how to work with controllers and
control modes and how to identify controller problems. INSTRUCTIONS
‘This is « programed learning course,
Programed lesrning gives information in a series of steps
called frames. Each frame gives some information and asks
you to make uso of it.
Hore 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 fll in the
blank.
A micrometer is an instrument designed to measure in
‘thousandth of an inch,
‘A micrometer is a good tool for measuring very —__
Aifterences in size.
‘Move the mask down to uncover the word at the right of the
frame. If you have fled the blank with that word oF a word
that means the same, you are ready to go ahead to the next
frame.
‘The drawing of micrometer provides information that will
help you fill in the next blanks.
ed
‘at nr
fe aa
FRAME
Seren major parts are shown in the drawing, but only
a ~and the contact the
{Dias to be menorel ‘The next frame calls 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
hhave just done:
‘Read the frame.
Use the information to fill inthe blanks oF make a choles.
‘Move the mask down and eheck the response column.
Go on to the next frame.
‘Remember to cover the response column with a mask before
you begin each page.
‘Notice that the lefthand pages from here on are printed upside down,
‘The program is designed so that you wil go through al the right-hand
pages fist, and then tum the book upside down and go through the other
ages.
spindle SECTION 1
CONTROLLERS
‘Why We Need Controllers
1. Process variables are controlled by opening and clos
ing.
2 Let's say that you want & flow rate of 100 gallons per
‘minute for 2 process.
‘The contral__is set to allow just 100
sallons of liquid per minute into the process.
8, If the flow rate never changes from 100 gallons per
‘minute:
A. you don’t need to adjust the control
Yale,
BB. you have to adjust the control valve con=
tantly.
4. Let's say that there is @ change in the pressure acting
in the liquid which supplies the proces.
VENT,
-|ouo Lever
NEW LEVEL
‘When the Ievel in this tank changes, the pressure on
the liguid
5. ‘The flo rate to the process
A stays at 100 gallons per minute
EB changes.
6. To maintain the proper low rate, the control valve
must be
valves
valve
changes, or decreases
‘opened, or adjusted . Tho control valve is adjusted by a controller.
"The controller:
A. can be an operator.
5 ean be an instrument.
<6 can be either an operator or an instra-
‘ment
8. Ina modem installation, the controller is likely to be
aan (instrument/operator),
9. The controller goes into action only when there is a
process
10, If there is no process change, the does
nothing.
11, If process variables could be held perfectly constant,
‘there would be no need for a controler.
Is this likely to happen in a typical installation?
Yee
No
How a Controller Works
12, ‘The controller is sot to meet the target for the process
‘variable being controlled.
‘The controller must adjuct the.
the process variables on target.
to keer,
18. ‘The target for the controler is calle the set point
Let's say a temperature measurement is on target.
‘The controller (reads/does not read) at the set point.
1M. Ifa temperature is not on target, the temperature in-
dicstor does not match the. ——
of the controller.
15, A controller goos into action when:
A. the process is off target.
=F the prooess is on target:
16, When the procoss strays from the set point on any’
process variable, (all/some) controllers affecting that
variable should reset.
Instrument,
change, or upset
controller
valve
set point 17. ‘The drawing represents » simple temperature control
situation,
A MEASURE
B COMPARE
CONTROL
‘The controller is the operator
18, His conse of. {the temperature indicator. touch
19, His_____opens or closes the valve hand
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. compares
21. ‘The controller first receives Information from a
device, and then it to measuring, or sensing;
‘he desived set point. compares
22. If the process measurement and the set point are the
same, the operator:
A. makes an adjustment.
Bi: does nothing. B
2, But if the measurement and the set point are diferent,
Ihe adjusts the control valve
24, Let's say he closes the control valve to cool the process.
How can he tell if the process has cooled?
_—indeates this. touch
5
His sense of — 28,
For every adjustment the controller males, the mens-
luring deviee must feed information back to indicate
‘hat has happened,
In the previous example, the operator gets feedback
Information from his
‘Thoso are the stops 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 difference, the
is moved.
Step 4: Some device gives the controller —_____
information.
Step 5: ‘This feedback “tells” the —__
‘what has happened.
1 the feedback does not mateh the set point on a mod-
fern controller:
A. the controller stops working.
Bi the controller keeps working until the set
point is reached.
Pat an A on the drawing to show where measuring is
belng 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
‘controler 29, This operating situation is slightly diferent from the
previous one.
‘THERMOMETER
‘A MEASURE
B COMPARE a
¢ CONTROL
‘The operator gets 2 measurement and feedback from:
A. his sense of touch.
iO}
,
Ce smuctonnwsann ‘The Control Loop
88, This diagram shows a complete control loop.
CONTROLLER
(ERROR DETECTION MEASUREMENT
COMPARISON)
[MEASUREMENT|
=> _SET PONT
F— error
SIGNAL
VALYE——|
POSITION
CONTROL:
‘A control loop consists of all the elements needed to
EUR the movement of valve.
84, A control loop as shown above:
As cireular and closed.
B. is open-ended,
35. First, the process measuring element sends a signal
to» the controler.
‘The controller is the ______deteetor.
36. At the seme timo, the already-determined —_____
ie fed into the controller (error detector)
87, ‘The error detector makes a __ between
this signal from the process and the set point signal.
8, If there is « difference between the measured signal
and the set point:
A. nothing happens.
=F an error signal is sent to the positioner
of the control valve,
189. The positioner adjusts the __ setting.
40, The eonteol valve changes the process.
Information about this change is pleked up by the
Instrument and fed into the controller.
41, This information is called process ____to
‘the controller.
feedback System Response
42, It takes time for the parts of the control loop to detect
f process change, make a valve adjustment, and get
Drocess feedback,
‘The less time it takes, the (greater/lesser) the eff. seater
5 leney of the control loop.
48, The Instruments should react as fast as itis practical
{for them to react when the ‘anges. process
44. Sometimes there is a time lag in the instruments.
‘Those instruments are operating by (pneumatic/elee-
trical) signals pneumatic
45. The greater the distance the signals must be sent, the
- it takes to receive them. Tonger
46, ‘This means that the instruments will not react imme-
italy to ain process. change
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 far away from
process
48. A change in the control valve position would affect
‘the process (immediately/after some time leg) after some time lag
9 49, Once an adjustment has boen made, i takes time for
the process to change.
15 MINUTES
‘With the amount of heat being applied to the beaker,
‘an increase in temperature from 40°F to 212°F re-
quires 16 minutes.
‘Turning the heat up under thia beaker (will/witl not)
cause it to reach 212°F Instantly.
50, The temperature of the water (changes/does not
change) immedistely with an inerease in heat
‘51, A temperature change in a process
A. will always occur immediately with
‘control valve change.
—B. may take time to occur, no matter how
much the control valve is changed.
52, ‘The time it takes for both the instruments and the
process to change ia called the system response.
‘The aystem response indicates how ——____ th
‘control loop Is moving.
152, Which of the following events occur in a system re-
sponse?
Yee No
Process measurement —
Error detection —
Error signal to control valve =
Control valve adjustment
Process change
Feodhack from process —_
will not
oes not change
fast
Yes
Yes
Yes
Yes
Yes
Yee
sates 3 Offset ond Osc
55. Offset occurs when the provess measurement differs
from the set point
SETPOINT MEASUREMENT
* 8
Instrument (A/B) shows offet B
1¢ instruments ean be used to show process
‘A polnter shows where the set point is on this tempera-
‘ture recorder,
A.
‘time passes.
draws the proctas temperature 96 pen
57. Look at this drawing.
When the process temperature is at the set point, the
pen and the pointer are at the point. same
158, When the pen moves away from the pointer, an
‘has occurred. offset, oF change
u 59. When the process measurement keops bouncing above
and below the set point, the process is oscillating.
SET POINT.
a 8
‘Recorder (A/B) shows an oscillating process. A
60. What is going on in this process, according to these
pressure recorders?
"The procese fe at the eat point fg a
‘There {an offset recorded in:
B.
c.
oth B and ©. Doth B and C
‘The process is oscillating in —___. c
TYPES OF CONTROLLERS
On-Off Controllers
1. ‘There are three hasie sections to any instrument con-
‘rol system:
. ‘an instrument to_______the process; measure
fan instrument tothe set point to compare
this measurement;
fan instrument to position and adjust the control
—_— valve
controller is one which keeps the control
ther fully open or fully — dosed
2 668, ‘This drawing representa the control loop for a simple
on-of controler.
ELECTRICAL
SET poINT CONTACTS
ADJUSTHENT
7 fevecrricai Pane
“SUPPLY Zo
eLteis|
PROCESS
pi ‘OUTPUT
SOLENOID =
VALVE
"The process pressure meatured by a ourdon
ea ‘tube
(64, The bourdon tube is connected to a pointer.
‘When the pointer moves back and forth, it opens and
, closes two contacts. electrical
{65. ‘The position of the bourdon tube acts as the (process/
set point) signal. process
66. The set point is indleited by the position of one of
these electrical . contacts
67, The valve is positioned by a. coil. solenold
68, Which of these parts is the error detector?
A. Bourdon tube
'B. Pointer and electrical contacts B
6 Soleneta coi!
69, When the bourdon tube senses a pressure change, the
pointer moves, oF changes
70. When the contacts are closed, current flows to the
a solenoid
p ‘TL, When this solenoid is energized, it positions the
. —_—— valve
"72, The pointer, by ether opening or closing electrical con-
‘tacts, acts like (an on-off switeh/an elect
former) an on-off switeh
Fry 7B, Tat’ say the set point for pressure Is 20 PSIG.
SET POINT
1 ELECTRICAL
CONTACTS
INPUT TO
SENSOR
SOLENOID
ZA oiorr
inpuT Enea mr ourPuT
7
‘The electrical contacts (open/close) if the pointer falls, close
below 20 PSIG.
‘14, This activates the solenoid, which in turn opens
the contral valve,
‘T. If pressure rises again, the electrical contacts open,
/ tnd the control valve is — by the solenoid closed
16. The polnter acts as the error detector, but it cam only
sve two ervor signals: valve, or val open
_a_— close
‘TT. Since these are the onlv two settings, this kind of con-
‘roller is ealled an =
‘78, Identify the parts of this on-off control loop.
: ‘The measuring device is a —— Dbourdon tube
: ‘The controller (error detector) is the —___. pointer, or contacts
Comparing the set point to the measured signal is done
by the = pointer, or contacts
‘The valve is positioned by the ____cofl solenotd
u“ Problems vith on On-Off Controller
‘79, ‘The most serious drawback with an on-off controller
is that it can position a valve in only
Aliferent settings
80, These graphs show procoss flow.
a.
VALVE OPEN
VALVE CLOSED
0 5 10 15 20 25 30
MINUTES
A
YALYE OPEN _
|VALVE CLOSED
0 8 10 is a0 25 30
MINUTES
8
Graph (A/B) represents flow adjusted by an on-off
system,
‘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,
6
two
‘the same amount 82, An on-off controller treats a large offset (the same a8/
ifferently from) a small offset. ‘the same as
88. On-off controllers (are/are not) sensitive to diferences are not
fn the amount of offset.
84, Bven ifthe amount of offset is tiny, the valve —___ ‘opens
all the way or all the way. closes
85, Which graph represents flow rate being controlled by
‘an on-off controller?
ser POINT
: FLow
CHANGE
TIME
SET POINT
FLOW
‘CHANGE
1%e———
B
Graph (A/B). A
86, Tho on-off control loop (is/is not) able to maintain is not
4 smooth, even flow rate.
16
-
| 87. A graph of flow controlled with an on-off controller
Tooks Ike this.
VALVE OPEN
SET POIN'
VALVE CLOSED
‘The fow:
A. continually bounces above and below the
set point,
Bis smooth and stondy.
88. On-off controllers (allow/do not sllow) the process to
cosellate.
89, The process oscillates because the valve is constantly
and
90, An on-off controller (gives/eannot give) steady control
fof the process
Proportional Controllers
The Throttling Ronge of the Valve
91. On-off controllers cannot give exact control of a process
Decause they react (the same way to/differently for)
large and stall 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 eause——____—valve changes.
Ww
opening; closing
the same way to
large
small mt.
95.
96,
97.
98.
100,
‘To make proportional control possible, the valve must
have:
A. two settings.
——B_ a range of positions between fully opened
and folly closed.
A proportional controller must be able to send (two
Gifferent signals/a range of signals) to the control
valve,
A controller that sends a range of signals to the con-
‘rol valve is called a controler.
Here is a valve operated by an air motor. The trot
‘ing range of this valve is 8 to 15 PSIG.
AIR
PRESSURE
INPUT
‘When the valve isin the position shown in the drawing,
tho air pressure on the piston is (8 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 controllers signals tothe control valve must match
the — of the valve.
‘Tho controllar moves the valve proportionally to com-
pensate for different rates and amounts of process
18
range of signals
proportional
‘more than § PSIG
16
°
throttling
throttling range
‘change, oF variation 101, This control valve operates through a range of settings.
i
(ent
10 -|
ser
POINT >| ey
‘The valve must be shut completely when the liquid level
reaches "fet. 10
102, Ten feet is (above/below) the set point, above
103, The set point is at 9 feet.
ner (YY
>» wo~
F ser
POINT 9>|
‘The valve (permits some flow/does not permit flow) permits some flow
when the liguid level is at 9 feet
104, The liquid level has fallen to 8 feet
rer (~
vo—
set
POINT 9
ae
‘The valve must nove be fully opened
19 108.
106,
107,
108,
109,
110,
m1.
m2,
ua,
‘The drawing shows a proportional control lop.
ERROR DETECTOR
(CONTROLLER)
SET POINT MEASUREMENT
RESTRICTION
ORIFICE
‘This system sends (pneumatic/electrical) signals
Process flow rate is being measured by a
eter.
‘The flow meter sends a pressure signal to the (mess-
uurement/eet point) bellows in the controller.
‘There are two bellows in this controller
One does the process measuring; the other gives the
‘The flapper pivoted between the two bellows acts as
the error detector.
‘As long as process pressure and eet point pressure stay
the same, the error detector (keeps changing/‘loes not
change) position.
Lats say pressure in the process decreases
‘The error detector (moves/does not move)
As the flapper moves away from the nozzle, pressure
in the pneumatic system connected to the air motor
‘This change in pneumatic prossure acts as the —__
signal.
"The pneumatic signal operates the air motor.
‘The air motor positions the
20
pneumatic
tow
‘measurement
set point
dowe nt change
changes, or decreases
valve The Throttling Range of the Controtier
au.
15,
us,
ut,
118,
‘The throttling range of a control valve is a range of
(pneumatic system pressures/procass measurements)
‘There isa range of procass measurements within which
‘the controller must keep the process
‘This ronge of process measurements {s the throttling
range af 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
G8°F to 88°F
100 pst
‘The range of process measurements between the con-
trol valve being completely open or closed is called the
—_—_— ‘of the controler.
‘This pressure gage and controller are regulating proe-
‘oss pressure. Identify the following. points,
Ais the
Bisthe of the
Cis the
BN
pneumatic system pressures
68°F to 88°F
‘throttling range,
‘or proportional band
set point
throttling range, oF
proportional band; controller
throttling range; valve 119. Set point is found on:
proportional controllers only,
al controllers,
120. Throttling range is found on:
proportional controllers only
on-off controllers only.
How the Proportional Band Affects Controt
121. Here are the dials of two controllers which have the
‘same set point.
OPEN CLOSED OPEN, CLOSED
A 8
On controller A, the pressure must inerease to
PSIG to completely close the control valve and decrease
‘t____ PSIG to completely open the control valve.
122. On controller B, pressure must inerease to only
PSIG to completely close the control valve and decrease
‘» only PSIG to completely open the control
valve.
128, It takes a change of 5 PSIG from the set point to com-
pletely open or close the valve on controller A.
I takes a change of only PSIG from the set
ppoint to completely open or close the valve on con-
‘roller B.
124. Controller (A/B) has the wider proportional band.
2
all controllers
proportional controllers only
55
a 125. Let's say process pressure chanyes 4 PSIG.
SET POINT SET POINT
4 PSIG, Psi
i VALVE VALVE VALVE VALVE
OPEN —CLOSED-OPEN. CLOSED
a 8
Controller (A/B) would make the biggest change
the valve setting
126, Controller (A/R) reacts more sensitively to s change
in process pressure
121, There are both advantages and disadvantages to mak-
+ ing 2 controller more sensitive,
One advantage of the more sensitive controller is that
it can Keep the process closer to the
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 (move/less).
129, Let's say that a proportional controller fully opens a
valve for a ehango of 1 PSIG from the eet point
1 psig 5 PSIG
a FULLY OPENS FULLY OPENS
~ VALVE VALVE
A change of 8 PSIG gets (the same/a different) re-
sponse as a change of 1 PSIG,
Ey
st
point
the same 180, If the process constantly changes by more than 1
PSIG, the controler will be treating all the changes
above 1 PSIG (the same differently)
181, Also, within its throttling range, the valve may be
‘moved too far for the process change.
Oren
cLoseD
A 8
Graph (A/B) represents the valve movement of an
‘versensitive proportional controler.
182, ‘The proportional band ean be made s0 narrow that the
controller aets almost ike an
controller.
183. Oversensitive controllers may cause the process to
184. These graphs show valve setting changes during a
roeass change.
VALVE FULLY OPEN
+
Pao
VALVE FULLY CLOSED
A 8
Graph (A/B) represents valve movement made by a
controller with the widest proportional band
Py
the same
ono
cscllate, or eyele 485. The proportional band ean be made so wide that it
‘takes « very large process change to affect the valve
setting
Assume that the controler is adjusted to a very wide
proportional band setting, and the valve setting has
not changed for 10 minutes,
Haas 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 eontroter.
©. 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
‘This 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?
b>]
SET POINT
a 8
Graph (A/B).
Can't tell trom the informa
tion given
change
ensured
‘set point
valve
controler
feedback
change SET POINT
a 8
Graph (A/B).
‘MO. So far, we have discussed two basle types of con-
‘rollers:
——_____controtiers, ana
SS eontrliers.
MI. A throttling range is a feature of.
‘rollers,
ono
proportions!
Proportional Section 2
Proportional Controllers
with Rate and Reset Action SECTION 2
PROPORTIONAL CONTROLLERS WITH RATE
AND RESET ACTION.
Process Load
1. The Tond 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:
oad surface.
wiz of the engine,
empty track.
2 As long as the truck stays empty and is driven on a
level road st 50 MPH, the load (changes/docs not
ehange).
8. What happens now that the welght of the truck has
increased?
‘Tho speed of the truck unless more
fuel is fed into the engine,
4, Putting more weight on the truck ie the same as in-
creasing the" on the engine, if speed
stays the same.
empty truck
decreases 10,
w,
18,
4
Let's say that we want the truck to move fester.
‘More __ia fed to the engine
Demanding more speed from the truck (inereases/
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 en
As long as the weight moved by the engine stays the
‘same, and the spoed at which the truck i driven on @
level road stays the same, the stays the
‘Sometimes the truck will come to a curve snd must
slow down.
50 MPH 50 MPH.
THROTTLE
ADJUSTMENT,
40.NPH
\
‘The throttle will have to make sn adjustment to change
‘the of the truck
What will happen if we do not adjust the throttl
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 curve changes the
on the engine,
After the truck is returned to 60 MPH, the load on the
tuck has (changed/returned to the same level),
Which of the following ean cause a load change?
‘The weight on the truck is reduced. (Yes/No)
‘The truck must be driven up a hill at the same speed.
(Yes/No)
‘The truck slows down for a eurve, (Yes/No)
Tn the truck, we demand output from the engine,
Do we demand output from an industrial process?
(Yes/No)
By
ful
Increases
Tosa
load
speed
‘returned to the same level
Yee
Yee
Yee
Yes 15, ‘There is a___on each process. load
16, ‘The load on a process acts ike the load on an engine,
500
BARRELS
PER HOUR
‘This process is required to separate 500
Darrels of kerosine per hou.
17. ‘The amount of material and the speed st whieh it mast
bbe produced is the ‘on this process, load
18, Reducing this output to 100 barrels an hous, under
the same conditions, is the same as reducing’ the
load
19, Let's say that the pressure of liquid entering this proc-
css drops. The process must be adjusted to maintain
produetion of 500 barrels an hour.
BARRELS BARRELS
PER HOUR PER HOUR
‘This (ls/ts not) the some as an increase in load, 1s
2» 20, ‘The drawing shows three different valve settings
30 PSIG —— sig
20 PSIG. noe PSIG
10 Psic aoe Psie
‘The pressure pushing liquid through the valves is (the
same/different)
21, For each valve setting there:
are several flow rates
is one ow rate,
22. We want to open a valve so that the flow rate equals
a speeified set polat
‘Under one load condition, how many valve positions
vil give us the desired set point?
Soveral postions
One position
22. Proportional controllers are allyned for one load con
dition.
‘With these controller, there (are soveral valve posi-
tions/is only one valve position) that will give the set
point as long aa the load does not change.
24, Sometimes there isa hill or “curve” in the process, or
slight variations in load, thatthe controller must adjust
for.
‘The controller must move the
25. But, after the adjustment, ifthe load has not changed,
‘the control valve should ‘(move toa new/go back to
the old) set point position.
30
the same
Is one flow rate
One position
fs only one valve position,
valve
eo back to the old 26. Look at the pressure gage in this pneumatic controler.
FLAPPER
i AIR
For each pressure setting in the pneumatic system:
A. there are soveral valve positions.
Bi there is only one valve position. B
27. When this controller is at set point, there is just one
output — ‘sutting to the control valve, pressure
28, Each flapper position produces (one/several) pressure one
setting).
29, Under one load condition, in this controller:
A. there is just one flapper position which A
‘will maintain the procoss at the sot point.
———B. there are several flapper positions which
‘ill maintain the process atthe sot point.
80. 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 ita desired set point, the oatpat
“to the control valve must become bal- pressure
‘anced tothe need of the process, and the flapper
‘must be returned to its set point position.
at Feedback Bellows
82. This pneumatic controller is controlling quid flow.
: ©
It the flow falls below the set polnt, the controller
‘the control valve. opens
8, Does the process change oecur immediately when a
vvalve position changes? (Yes/No) No
84. ‘The controller is normally at diatance from the
process,
When the flow rate changes, does the controller get
‘this feedback information Immediately? (Yes/No) No
85, Are there any time logs betwoen events in the system
response? (Yes/No) Yes
86, Let’s say that flow rate in the process reached the s
point.
‘Would the controller get this information immediately?
(es/No) No
87, The controller cannot find the correct valve position
until it gots "trom the process measure- feedback
‘ment.
88, Since feedback is not immediate, the controller con-
tinues to keep the valve pocition open as if the process
were not at the set point
88, The controller will probably
A. fina the sot point.
overshoot the set point, B
cy 40. This ts what happens when the controler docs not get
immediate feedback.
ERROR DETECTOR
(CONTROLLER)
SET POINT
Flow rate starts to fall, and a steadily deeressing 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, IE does not get process feedback information, the con-
‘roller may eontinue to move the control valve to a fully
position
48, Finally, the controller receives the process feedback,
land the control valve starts to close.
With the lag in process feedback, the control will
probably:
‘A. find the set point positon
B. overshoot the set paint position.
44, With delayed process feodback, this controller acts
more like an controller
‘than a proportional controller.
45. What do we want this controller to do if there
temporary change in load?
Yee No
Correct for any flow change —
Return to the set point position —_—
Overshoct the set point —
38
Ye
Yes
No 46,
4
ourpur|
48,
49,
0,
5.
ourpur
‘To prevent overshooting, the controller needs feedback
(hetore/after/et the time thet) the process measure-
‘ment ean supply it.
‘The controller feodback bellows ia device that ean
supply feedback to the controller before the process
‘measurement ean.
SET POINT, Iara LMEASUREMENT
TW AUT
SUPPLY
a
FEEDBACK
BELLOWS
ows SUPPLY
LS
‘The feedback bellows is attached to the
‘The measurement bellows and the setpoint bellows are
also attached to the
"The feedback bellows receives its pressure from the
going to the control valve
Any change in the controller's output will
‘the feedhack bellows.
‘Let's say there Is an inereate in the process flow rate.
SET POINT MEASUREMENT
SUPPLY
EEDBACK
BELLOWS,
‘The messuring bellows moves the fapper to the (right/
left) nd (opens/eloses) the flapper noztle,
3
before
‘Mapper
flapper
tout, oF alr
move, or operate, or change
left; closer 52, Pneumatic output pressure __and starta Increases
to close the control valve.
158, Pressure in the feedback bellows also. Increases
454, The bellows expands and moves the flapper to the
(right lett). 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
156, ‘The feedback bellows is “anticipating” the process
change while the valve is changing the process and
before the controller gets the process feedback.
‘Tas, the controller's feedback bellows keeps the con-
troller from moving too for given much, o far
process change.
57. While the focdhack bellows is neting, there (is/ls not) is
an offset between the measurement pen and the set
point.
How Load Changes Affect Proportional Controllers.
58, ‘The eet point on a proportional controller:
A is set for one load condition. A
changes everytime the load changes.
59, Sometimes the losd on a process changes.
A unit may have to inerease its production from 100
‘barrels an hour to 300 barrels en hour with all other
conditions the same.
‘Tis fs an fnerease fn load
60. ‘The original valve position (ean/eannot) handle this cannot
load increase. 61. Steam is being used In this procoss.
‘Tho controler is set to Keep the pressure somewhere
‘around 50 PSIG.
Lets say that there is @ drop In process temperature,
‘causing some of the steam to condense.
STEAM
INPUT =
VALVE
CONTROLLER
ourpur,
‘The pressure (increases/decreasee) decreases
62. To keep the pressure within operating limits, the con-
‘roller must allow "steam Into the proc more
6 than hefore,
68, 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
5, ‘The set point probably (will/will nt) handle the new vill not
load requirement,
66, Here is another situation
‘This controller is maintaining liquid —__. level
36 t
}
\
67. The pressure on the liquid decreases, and the liquid
evaporates at a much hgher rate.
"The controller must____ incoming liquid flow.
68. If the liquid keeps evaporating at a high rate, has the
toad changed? (Yes/No)
69, ‘Here is what happens to a proportional controller de-
signed for one load when the load requirements change.
00 Psi
SET POINT
50 PSIG
0 sic
‘The controller is controling —
‘The set point of this controler ia__PSIG.
10. The process load changes, and a highor flow rate is
needed to keep the process pressure within limits
‘The original valve position (lts/will not Tet) enough
iquid in to Keep to the set point.
TL. Process pressure starts to
"72. As it receives process foodback, the controller starts
to PPP ne control vaive proportionately.
78, Finally, the valve is opened enough to stop the decrease.
finally balanced to the outgoing flow
100 Psi
ORIGINAL LOAD SET POINT
50 PSIG
NEW LOAD
0 Psic
‘The process (is/is not) at the original set point
Now to the pone,
rom the book over, ond goon. &7
Increase
Yee
pressure
50
will not let
decrease
is not 1A, To got this pressure back to the set point, the control
valve must be—— still more. opened
"15. Suppose the pressure in the process measurement be
Jows starts to Increase again in this eontroller.
SET POINT MEASUREMENT
SUPPLY =|
ourPur|
FEEDBACK
BELLOWS surety
‘The flapper will be moved back toward the nozzle, and
the control valve will start to close
6. This (raies/doos not raise) the process pressure to does not raise
‘the original set point,
‘TI. Look at the record on this process pressure recorder.
At A, the procass starts to decrease. pressure
7B, At B, the set point pointer and the pen (are/are not) aro not
‘together.
79, ‘The controller (stops/doos not stop) the decrease stops
38
i 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 it not a problem,
‘The controller shown (can/cannot) work for these
processes.
Other processes need more precise contro, even during
changing Toad eonditions.
‘The controller shown (can/eannot) work for these
rocesses.
Reset Action
8, For more precise control, device is needed to increase
for decrease the output to the control valve beyond the
changes which the proportional controller ean provide.
SET POINT MEASUREMENT
SUPPLY
ourrur|
FEEDBACK
BELLOWS
In this situation, the proportional action is balanced,
Dut a further inereate in flow is needed to got 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 ean open the control
valve, and return the process to the
‘The output air to the control valve changes and moves
‘the control valve to-w new
offset
eammot
open
sot
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) Yes
86, ‘The linkage between the two top bellows ean have
{one position/several positions) when the process is at ‘one position
set point.
87. How can we move the Mapper to a more open position
without changing the set point?
SET POINT
MEASUREMENT
ourpur|
FEEDBACK
BELLOWS
A. Move the top of the flapper
'B. Move the bottom of the flapper B
88, To open the valve more when this controller is at set
int, we would move the of the flapper bottom
(toward/away from) the nozzle, away from
0 89. 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
‘2 new valve position
90. Here is» proportional controller that can be reset
anally.
SET POINT. MEASUREMENT
ourpur|
FEEDBACK
BELLOWS
‘Tho bottom of the Aapper has an adjustment screw
on it as Well ne a feedback bellows.
"The serew can move the back and forth.
‘91. Whon there is a load change, and the recorder shows
‘an offset, we can correct this offset by moving the
92. By moving the flapper, the control __post-
tion can be changed (hy/without) changing
int
98. But every time there is a load change and offset, the
‘Mapper setting will have to be —_____ manually.
94, Having an operator reset the controller manually every
time the process load ehanges (Is/is not) practical
a
flapper
knob, or screw, oF Mapper
valve
without
changed, or moved,
or reset
fs not Automatic Reset
95. A proportional controller is a singlesmode controler.
This is « two-mode controller
ssutomatic reset action
proportional and
Ser PONT _._fomppagusarunenent™
SUPPLY.
RELAY!
FEEDBACK
Instead of an adjustment serew, there is a
Dellows connected to the flapper.
96. A control relay has been added to the pneumatic air
faystem to bleed out or add air to the system quickly.
‘The pressure to vim 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 souree a the feedback bellows
B. a different source from the feedback bel-
Towra
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 iden of the feedbeck bellows is to (speed up/slow
down) the movement of the flapper.
100, The resot bellows and the feodback bellows work
(ovith/against) exch other.
e
reset
control valve
valve
slow down
against 101. Let's say that the air lines loading to the reset and
feedback bellows are opened the same amount.
SUPPLY
RELAY
ourpur|
If the reset restrition valve is wide open and the out-
‘put to the eontrol valve changes, the pressure in both
bellows changes at (the same rato/different rates),
102, ‘The bottom position of the Aapper (is/is not) moved
‘when this happens,
102, The apper’s position cannot be changed by the reset
and feodback bellows unless the pressure in these bel-
lows changes at (the same rate/different rates)
104, Look at the controlar now.
SUPPLY
‘The valve to the reset bellows has been partially
ro
the same rato
fs not
diferent rates
closed 105, ‘This mesna that alr will enter and leave the (feedback/
reget) bellows faster and sooner.
106, Daring s process change, the measuring bellows moves
‘the flapper.
‘Then, the ____bellows acts on the flapper.
107. Later, after the feedback bellows has moved and the
‘process has had time to respond, if we are off setpoint,
the bellows goes into action
108, ‘There is still» pressure difference between the bellows
shown in this sketeh,
SET POINT MEASUREMENT
(OUD 0000
SUPPLY
FEEDBACK | RESET
‘As long a there is a pressure difference between the
‘feedback and reset bellows:
A. the bellows will keep moving the flapper.
5 the bellows will stop moving.
109, As Jong as there is a pressure difference between the
{oodback and reeet bellows:
A. the control valve position remains the
——B. the control valve position Keeps moving.
“4
feedback
teedback
reset 1110, This drawing represents process change.
Pon
SET POINT Tmoeasurenen
‘The flow rate of the process increases, and the meas-
turing bellows pushes the flapper toward the nozzle.
Because of proportional action, if there is a big load
change, the procest flow rate’ (is/ia not) decreased is not
fenough when the valve closes, and there ia an offset.
1111, When the fapper first moved, it created 2 pressure
difference between the feedback and reset bellows,
112, The feedback bellows atarts moving the flapper back
‘toward the old position.
SET POINT ao aumysssvrewent™
SUPPLY
RELAY
ourPur|
Later, after process response, the reset bellows starts
‘to fl, and pushes (in the same/in the opposite) di- in the opposite
rection.
118. The measuring bellows starts to return the top of the
linkage to the "pasion. sot point
45 uu.
us.
116,
a.
18,
uy,
120,
1a.
122,
128,
‘The reset bellows keeps moving the flapper until the
pressure in the reset and feedback bellows
While this ts going on, the process is being corrected
runt the prestures in the ———___ bellows and
the Dellows are equa.
‘This happens when the controller gets the procoss back.
to the: —
‘Here is « record of a proportional controllor with reset
action.
NEW CONTROLLER POSITION,
100
Ag cD
ser :
POINT
LOAD CHANGE on
BELLows
a START
‘The process measurement drops at A as the result of
Toad change.
‘The measuring bellows starts opening the control valve
[a
Finally, after the proportional settings havo acted to
stop the process change, the process measurement is
the set point at B.
Ta there a pressure difference between the
reset bellows? (Yes/No)
sdback and
‘Phe process stops decrousing.
Now, the___bellowa starts closing the
flapper more at C.
At D, the process gots back toward the set point.
‘The pressure difference in the reset and feedback bel-
lows now becomes
At this polnt the measurement bellows prassure is
(equal to/different from) the pressure in the set point
bellows
‘The process pen (is/is not) at the desired set point.
"The controller is now set for (the same/a different)
load condition.
46
‘equal, or the same
measurement
set point
set point
below
Yea
equal to
«8 aliferent 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 {s measured in
repeats per minute, or minutes per
4125, Which one of these controller knobs controls the reset
bellows?
oot 75%
00%, 50%
7 3
8 2
° 1
10 0 150%) 0%
MIN. PER REPEAT
a 8
Knob (A/B).
126. ‘The only purpose of reset action is to get rd of offset
‘and get the process back to the desired
127. A controller with proportional and reset action 18
a tale controller.
Rate Action
128, Which reacts faster?
A. Narrow band proportional controller
8 Wide band proportional controller
129, When there is rapid process change, we would Ike
to have the controler react (faster/slower).
180, For quick response, a (sride/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.
a"
repeat
point
v0.
faster
wide 182, An ideal controller would act Ike @—_____ narrow
‘band proportional controller for fast process changes.
Tt would also act like @______band propor wide
‘ional controller during normal conditions.
188, Some controllers have rate action
‘Rate action increases the effestivenoss of the controller
by letting it act like e band controller narrow
during fast changes and acti ‘band wide
controller during’ normal conditions.
124. A controller with proportional and rate action is a
i controller. two-mode
How the Feedback Bellows Can Affect Rate Action
185, This disgram shows a controller with a restriction
‘valve hooked up to the feedback bellows.
SET POINT MEASUREMENT
SUPPLY
output
FEEDBACK
BELLOWS,
By opening and closing this rar, the fowing emount
‘entering the bellows is increased or air
hovel
126, Let's say we close this valve completely.
‘The feodback bellows receives (none/a litle) of the none
‘pneumatic air
48 187, ‘This means that the bellows (will/eannot) act on the cannot
Aapper.
188, With the restriction valve closed, the controller acts
as if It has no bellows. ‘eodbacke
139, ‘The valve (will/will nt) overshoot the set point. veil
140, ‘The type of proportional band that is oversensitive and
always overshoots the set point If a:
‘A. narrow proportional band. A
B. wide proportional band.
11, When the feedback bellows is turned off, it cannot pre-
vent the controller from overshooting ‘the set point.
With the feedback bellows tured off, the controller
acts like a (narrow /wide) band proportional controller. narrow
142, As a matter of fact, the controller may overshoot the
sot point to far that it moves the control valve com-
pletely open oF completely closed.
"The controller without feedback may act lke an
——— ‘controller, ono
142, Let's say that the restriction valve to the foodback
bellows is opened all the way.
SET POINT, MEASUREMENT
U0
SUPPLY
ourPur|
‘This means that the feedback bellows:
A. fils at the fastest rate. A
5 is at the slowest rate
Ze doesn’t st al
« 4,
445,
6.
output
ut.
us.
9,
180,
When the process changes, the controler’s feedback
Dellows wil resist changes in valve position,
‘The process will have to have a___ process
change for the controller to move the valve any big
amount.
‘This means that when the feodback bellows is fully
open, the controller acts lke a:
A. narrow band controller.
=F wide band controller.
Let's say that we close the restriction valve part way.
SET POINT MEASUREMENT
FEEDBACK
BELLOWS
‘The bellows takes a (longer/shorter) time to fill than
‘when fully opened.
‘This means that during a process change, the feedback
bellows will take to resist the correet-
{ng action of the controller.
For s slow change, even with its restriction valve
partly cloted, 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
(Gril/will not) have as much time to slow down the
output of the controler.
‘Thus, a big change (will/will not) be transmitted to
the control valve
‘This means that the faster the change, the (more/ess)
controller feedback action, and the (bister/smaller)
the correction action transmitted to the control valve.
50
large
longer
veil not
feo 151.
2,
15.
154,
155,
156,
157,
Here is a threemode controller with proportional,
reset, and rate action.
SET POINT MEASUREMENT
OU 20
SUPPLY
FLAPPER
FEEDBACK
RELAY! J RESTRICTION
ourpuT
‘The controler is exactly lke the proportionsl eon-
jon, except that there is a special
fon the feedback bellows
By adjusting the rate restriction we can 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 controler.
During slow process changes, the feedback bellows
Will have time to esteh up to the proportional reset,
fand will work to (speed up/slow down) the controller
action.
So, during fast changes, the feedback bellows does not
set a chance to work, snd the controller acts like
A. narrow band controler.
B, wide band controller.
During slow changes, the feedback bellows has time to
act, and the controller acts like a:
A. narrow band controfler.
=B wide band controfer.
Ordinarily, if a process has Targe 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 of control.
5
behind
low down
B
proportional with rate and
resot action 158,
159,
In the choice between proportional control and propor-
‘ional with reset sction, an important factor is the
ot the load changes that will occur. sie
Another important factor in this choice is the amount
of that ean be tolerated. coffe Section 3
Working with Controllers SECTION 3
WORKING WITH CONTROLLERS
Introduction
1. Lets review some of the facts about control and con-
‘rollers.
CONTROLLER
(ERROR DETECTION
‘COMPARISON )
MEASUREMENT,
ser Pont
$—— error
SIGNAL
MEASUREMENT
vatye—|
POSITION
CONTROL,
A control loop consists of:
fan inatrument 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 {rom the messuring instrament.
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
8, ‘Must the process react immediately to a valve change?
(Yes/No)
Do instruments recelve immediate foodback from a proc-
‘es change? (Yes/No)
4, ‘There are two basic types of controllers: on-off eon-
‘rollers and proportional controllers
"The (on-off/proportional) controller is the simplest in
operation.
oa
controller
