0% found this document useful (0 votes)
276 views74 pages

16-Instrumentation For Operators-Unit 3 PDF

Uploaded by

Ahmad 77
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
0% found this document useful (0 votes)
276 views74 pages

16-Instrumentation For Operators-Unit 3 PDF

Uploaded by

Ahmad 77
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
You are on page 1/ 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 fa 2 a a 8 . 5 53 6 61 vag iad a 2 eyalol- 6 / OL GX9) the so) 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

You might also like