Control Using Two

Manipulated Parameters

©2006Fisher-Rosemount Systems, Inc.

Slide 1- 1
Control Using Two Manipulated Parameters
Introduction
Æ Overview – Typical Examples
Æ Split-Range Control
– Concept, variations in implementation
– Setup in field vs. Splitter Block and IO for each valve.
– Using Splitter Block, Example.
Æ Valve Position Control
– Concept and typical implementation
– Setup of I-only control in implementation
– Impact of mode/status, Example.
Æ Combining Split Range and Valve Position Control
– How to implement in DeltaV
– Example
Æ Summary

©2006Fisher-Rosemount Systems, Inc. Process Control

Slide 1- 2 Introduction – Historic Perspective
Control Using Two Manipulated Parameters
Æ Under specified problem
that has multiple
solutions for unlimited
One(1) Controlled Two(2) Manipulated operation.
Parameter Parameters
Æ Extra degree of freedom
is used to achieve
unique solution that
satisfied specific control
Controller Process objective.
SP
Æ Most common
Unmeasured techniques are: split
Disturbance range, valve position
control.
Æ Combination of these
techniques offer new
capability to address this
class of problems
©2006Fisher-Rosemount Systems, Inc. Process Control
Slide 1- 3 Introduction – Historic Perspective
Split Range – Traditional Implementation
Temperature Example Æ Sequencing of valve accomplished
through calibration of positioner,
selection of actuator (A/O or A/C)
TIC 4-20ma IP Æ Pro – Less expensive installation (1
101 101 pair of wires to field and 1 I/P)
3-15PSI
A/C
Æ Con -Difficult to initially calibrate
TT and continuously improve to get
Cooling 101 best gap and most constant gain.
Process
A/O
Æ Con -Individual valves not
Heating
accessible for trouble shooting loop
and actuator/valve problem.
100
Valve Æ Con – The actuator, pneumatic
Cooling positioner, and I/P performance
Position
(% of Span) Heating shift with time and field conditions
0
3 15 Æ Con – I/P failure disables 2 valves.
IP Output ( PSI ) Replacements in the night may not
have the special settings
©2006Fisher-Rosemount Systems, Inc. Process Control
Slide 1- 4 Introduction – Historic Perspective
 Split Range – Traditional Implementation
pH Example Æ Sequencing of fine and coarse
valve requires pressure switch,
two solenoid valves and
AIC 4-20ma IP associated wiring and tubing
102 102
3-15PSI PS Æ Con – Complex installation
102
Æ Con -Difficult to initially calibrate
and continuously improve to get
A/O pH best gap and most constant gain.
AT
Æ Con -Individual valves not
102
accessible for trouble shooting
A/O Fine Valve Process loop and actuator/valve problem.
Coarse Valve
Æ Con – The switch, actuator,
pneumatic positioner, and I/P
100 performance shift with time and
Valve
Position
Fine Valve field conditions
(% of Span) Coarse Valve
Æ Con – I/P failure disables 2
0 valves. Replacements in the
3 I/P Output ( PSI 1) 5 night may not have the special
©2006Fisher-Rosemount Systems, Inc.
settings Process Control
Slide 1- 5 Introduction – Historic Perspective
 Split Range – DeltaV Implementation
Æ Splitter bock is used
AI PID SPLT AO to implement split
range control.
AO
Æ When using
traditional valves,
split range control
may implemented in
DeltaV Controller
using two(2) current
outputs

PID
Æ Split range control
AI SPLT AO
may be partially or
AO fully assigned to
fieldbus devices.
©2006Fisher-Rosemount Systems, Inc. Process Control
Slide 1- 6 Introduction – Historic Perspective
Split Range Control in DeltaV

©2006Fisher-Rosemount Systems, Inc. Process Control

Slide 1- 7 Introduction – Historic Perspective
Splitter Block Calculation

©2006Fisher-Rosemount Systems, Inc. Process Control

Slide 1- 8 Introduction – Historic Perspective
IN_ARRAY Parameter
Æ The SP range
associated with
each output is
defined by
IN_ARRAY.
Æ SP range of
outputs may be
defined to overlap
SP range Æ The SP upper end
associated of range must be
greater that lower
with OUT1 end of range for
each output

SP range
associated
with OUT2

©2006Fisher-Rosemount Systems, Inc. Process Control

Slide 1- 9 Introduction – Historic Perspective
OUT_ARRAY Parameter
Æ When SP is outside
defined range, then
the value at the end
of range is used to
determine the
output.
Æ LOCKVAL
determines if OUT1
OUT1 Range for
value is held if SP is
associated SP range
greater that the
upper end of range
defined for OUT1.
Æ No restrictions are
placed on the output
range.

©2006Fisher-Rosemount Systems, Inc. Process Control

Slide 1- 10 Introduction – Historic Perspective
Splitter Block
OUT_1
100
OUT_2 OUT_ARRAY
0 100 0 100
IN_ARRAY
0 100 0 100
0
0 100

100 OUT_ARRAY
100 0 0 100
IN_ARRAY
0 40 35 100

0
0 100
100
LOCK_VAL “holds ” OUT_ARRAY
0 100 0 100
IN_ARRAY
HYSTVAL
LOCK_VAL “is zero ” 0 40 35 100
0
0 100

SP
©2006Fisher-Rosemount Systems, Inc. Process Control
Slide 1- 11 Introduction – Historic Perspective
Slaker – Heating/Cooing Example
AI PID SPLT AO
TIC103 FY103 IP103A
TT103
AO
IP103B

TIC
103
FY
103

IP
103A IP
103B TT
103
HEATER COOLER

©2006Fisher-Rosemount Systems, Inc. Process Control

Slide 1- 12 Introduction – Historic Perspective
Split Range Output (FY103)

100

Valve
Position
(% of Span)
Cooling (IP103B)

Heating (IP103A)

0
0 100
TIC103 Output (% of Span)

©2006Fisher-Rosemount Systems, Inc. Process Control

Slide 1- 13 Introduction – Historic Perspective
Steam Header Example
AI PID SPLT AO
PT104 IP104A
PIC104 FY104
AO
IP104B

1475# Header
Boiler

IP FY PIC
104A 104 104

IP
104B Turbo
PT
104 Generator

©2006Fisher-Rosemount Systems, Inc.

Slide 1- 14
400# Header Process Control
Introduction – Historic Perspective
Split Range Output (FY104) - Capacity

100

Valve
Position
(% of Span)
Valve 104A

Valve 104B

0
0 100
PIC104 Output (% of Span)

©2006Fisher-Rosemount Systems, Inc. Process Control

Slide 1- 15 Introduction – Historic Perspective
Calculating Splitter SP Ranges
Æ A 1% change in controller
output to the splitter should
Example: Steam flow to Header, splitter have the same impact on
interfacing directly to PRV’s, no overlap control parameter when
Valve 1 rating = 50kph operating with either valve.
Valve2 rating = 150kph Æ When manipulating the
same or similar material
e.g. steam flow to header,
Desired Splitter Span valve 1 = then the range may be
100*(50/(150+50)) = 25%
calculated based on valve
rating.
Æ Tests may be performed to
SP range for valve 1 = 0-25% determine impact of each
SP range for valve 2 = 25-100% valve on the controlled
parameter.

©2006Fisher-Rosemount Systems, Inc. Process Control

Slide 1- 16 Introduction – Historic Perspective
Testing Process to Determine
Splitter SP Ranges
Example: Slaker feed temperature controlled Æ With the process
using heating and cooling valves at steady state
Controlled and AO’s in Auto
Temperature
mode, determine
1.1degF 2.2degF the magnitude of
change in the
controlled
Heating 1% parameter for a 1
percent change
Cooling 1% in each valve.
Time Æ Calculate the
splitter SP span
and range for
Desired Splitter Span cooling valve = each output
100*(2.2/(1.1+2.2)) = 66% based on the
observed
SP range for cooling valve = 0-66% response
SP range for heating valve = 66-100%
©2006Fisher-Rosemount Systems, Inc. Process Control
Slide 1- 17 Introduction – Historic Perspective
Example – Split Range

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Slide 1- 18 Introduction – Historic Perspective
Response to SP Change – Split Range
Output To Large Valve/Small Valve

SP
Small
Valve PID OUT
PV

Large
Valve

©2006Fisher-Rosemount Systems, Inc. Process Control

Slide 1- 19 Introduction – Historic Perspective
 Split Range – Strengths and Weaknesses
Æ Pro - Process operation in simplified since two actuators
are treated as one control manipulated parameter.
Æ Pro – immediate change in target actuator position can be
achieved over the entire operating range independent of
the size of change in the splitter SP
Æ Con – To achieve stable control over the entire operating
range, controller tuning must be established based on the
slower responding manipulated parameter.
Æ Con- Does not take advantage of difference in resolution
of actuator e.g. fine vs. coarse valve.
Æ Valve position control may be used in place of split range
control when there are differences in dynamic response or
resolution in actuators.
©2006Fisher-Rosemount Systems, Inc. Process Control
Slide 1- 20 Introduction – Historic Perspective
Valve Position Control – Traditional
Implementation
pH Example Æ PID control is
implemented using the
actuator with finer
resolution or fastest
AIC impact on controlled
IP
106 parameter
106A
Mode Fine Valve
ZC IP Æ The actuator with
106 106B AT coarse resolution or
Target 106 slower impact on the
I-Only
Valve Process controlled parameter is
Position Controller A/O
Coarse
adjusted by an I-only
Valve
controller to maintain
the long term output of
pH the PID controller at a
given target
Fine Valve
Æ I-Only controller must be
disabled when the PID
Coarse Valve controller is not in an
Time
©2006Fisher-Rosemount Systems, Inc.
Automatic mode.
Process Control
Slide 1- 21 Target Valve Introduction – Historic Perspective
Position
 Valve Position Control – DeltaV
Implementation
Æ I-Only control is
AI PID AO
achieved by
configuration of the PID
I-Only AO
Block STRUCTURE,
GAIN and RESET
parameters.
Æ It is possible to
implement valve
position control in the
Traditional
field devices
DeltaV controller or for
AI PID AO
this function to be
I-Only AO
distributed to fieldbus
devices.
Fieldbus
devices
©2006Fisher-Rosemount Systems, Inc. Process Control
Slide 1- 22 Introduction – Historic Perspective
Valve Position Control in DeltaV
Æ Actuator with fastest
impact or highest
resolution is used to
maintain the
controlled parameter
at setpoint.
Æ The OUT of the PID
used for control is
wired to IN on the
PID block used for I-
Only regulation of
slower responding or
coarse resolution.

PID configured for I-

Only control
©2006Fisher-Rosemount Systems, Inc. Process Control
Slide 1- 23 Introduction – Historic Perspective
Configuring PID for II-Only
-Only Control
Æ The STRUCTURE
parameter should be
configured for “I action
on Error, D action on
PV”
Æ The GAIN should be
set to 1 to allow normal
tuning of RESET (even
though proportional
action is not
implemented.
Æ RESET should be set
significantly slower
than that the product of
the PID gain and reset
time used for control
e.g. 5X slower

©2006Fisher-Rosemount Systems, Inc. Process Control

Slide 1- 24 Introduction – Historic Perspective
Precise Flow Using Big/Small Valve

AI PID AO
FT107 IP107A
FIC107

I-Only AO
ZC107 IP107B

FIC IP
107 107A
FT
107
ZC IP
107 107B

©2006Fisher-Rosemount Systems, Inc. Process Control

Slide 1- 25 Introduction – Historic Perspective
 Example --Boiler
Boiler BTU Demand
AI SUM PID AO
FT109B FY109 IP109A
FIC109
AI I-Only AO
FT109A IP109B
ZC109

BTU Demand
FY FIC IP
109 109 109A

FT
109B
HI BTU Fuel Boiler
ZC IP
109 109B
FT
109A
©2006Fisher-Rosemount Systems, Inc.
Slide 1- 26
Low BTU – Waste Fuel Process Control
Introduction – Historic Perspective
 Example ––Reformer
Reformer Air Demand
AI PID AO
FT110 IP110
FIC110

I-Only AO
ZC110 SC110

Total Air
ZC FIC Demand
110 110

IP
SC
110
110
FT Secondary
110 Reformer

Air
Machine
©2006Fisher-Rosemount Systems, Inc. Process Control
Slide 1- 27 Introduction – Historic Perspective
Example – Valve Position Control

©2006Fisher-Rosemount Systems, Inc. Process Control

Slide 1- 28 Introduction – Historic Perspective
Response to SP Change - Valve Position
Control with Large Valve/Small Valve
Æ Target
position for
fine valve is
PV 30%.
SP
Æ When the
fine valve
Coarse Valve
saturates,
Limited then
response is
Fine Valve limited to be
reset of the
I-Only
control

©2006Fisher-Rosemount Systems, Inc. Process Control

Slide 1- 29 Introduction – Historic Perspective
Valve Position Control – Strengths and
Weaknesses
Æ Pro – Immediate control response is based on actuator with finest
resolution and/or faster impact on controlled parameter.
Æ Pro – Actuator with coarse resolution or slower impact on controlled
parameter is automatically adjusted to maintain the output of the
controller output long term at a specified operating point.
Æ Con – The controller output may become limited in response to a
large disturbance or setpoint change. For this case, the dynamic
response becomes limited by the slower tuning of the I-only
controller.
Æ The features of split range control and valve position control may be
combined to provide immediate response to large changes in
demand while retaining the features of valve position control for
normal changes.

©2006Fisher-Rosemount Systems, Inc. Process Control

Slide 1- 30 Introduction – Historic Perspective
Combining the Best Features of
Split Range and Valve Position Control
Æ A composite
Block can be
created that
combines the
features of split
range and valve
position control
Æ Support for
BKCAL_IN and
BKCAL_OUT
can be
implemented to
provide
bumpless
transfer

©2006Fisher-Rosemount Systems, Inc. Process Control

Slide 1- 31 Introduction – Historic Perspective
 Composite Algorithm
NORMAL

SP
CAS_IN x + OUT_1
FILTER_TC -
T Filter
- x
x OUT_2
MODE RANGE Scaling
SPAN
BKCAL_IN1
Balance Calculation BKCAL_OUT
BKCAL_IN2

©2006Fisher-Rosemount Systems, Inc. Process Control

Slide 1- 32 Introduction – Historic Perspective
Composite Implementation
Æ Parameters that
must be configure
are: FILTER_TC,
SPAN (of SP),
RANGE (of
OUT1), and
NORMAL
(desired position )
Æ The FILTER_TC
should be
configured similar
to the reset time
of the I-Only
Controller that
would be used for
valve position
control.

©2006Fisher-Rosemount Systems, Inc. Process Control

Slide 1- 33 Introduction – Historic Perspective
Demo – Composite Combining Valve
Position and Split Range Control

©2006Fisher-Rosemount Systems, Inc. Process Control

Slide 1- 34 Introduction – Historic Perspective
Example: Response to SP Change
Æ For small
changes in SP or
load disturbance,
Small change Large change the response is
similar to that
SP, PV provided by
valve position
OUT of control
PID
Æ For large
Fine changes in SP or
Valve load disturbance,
Coarse the immediate
Valve response is
similar to split
range control

©2006Fisher-Rosemount Systems, Inc. Process Control

Slide 1- 35 Introduction – Historic Perspective
Summary
Æ Split range control allows fully dynamic
response to major setpoint of load
disturbance changes.
Æ Valve position control may be used to takes
advantage of any difference in control
response or resolution in the manipulated
parameters.
Æ A composite block has been demonstrated
that combines the best features of split range
and valve position control.

©2006Fisher-Rosemount Systems, Inc. Process Control

Slide 1- 36 Introduction – Historic Perspective