Topic 9 - Proportional Mode and Process Control
Topic 9 - Proportional Mode and Process Control
Proportional Mode
1
Proportional Action
The proportional mode is used to set the basic gain value of the controller. The setting
for the proportional mode may expressed as either:
1) Proportional Gain
2) Proportional Band
PROPORTIONAL GAIN
In electronic controllers, proportional action is typically expressed as proportional gain.
Proportional Gain (Kc) answers the question:
"What is the percentage change of the controller output relative to the percentage
change in controller input?"
PROPORTIONAL BAND
Proportional Band (PB) is another way of representing the same information and
answers this question:
"What percentage of change of the controller input span will cause a 100% change in
controller output?“
Example:
If the set point is suddenly changed 10% with a proportional band setting of 50%, the
output will change as follows:
LIMITS OF PROPORTIONAL ACTION
Example:
If the set point is suddenly changed 10% with a proportional band setting of 50%, the
output will change as follows:
Expressed in Units:
Controller Output Change = (0.2)(12 psi span) = 2.4 psi OR
(0.2)(16 mA span) = 3.2 mA
PROPORTIONAL ACTION – CLOSED LOOP
Loop Gain – Every loop has a critical or natural frequency. This is the frequency at which
cycling may exist. This critical frequency is determined by all of the loop components.
If the loop gain is too high at this frequency, the PV will cycle around the SP; i.e., the
process will become unstable.
Low Gain Example – In the example below, the proportional band is high (gain is low).
The loop is very stable, but an error remains between SP and PV.
PROPORTIONAL ACTION – CLOSED LOOP
High Gain Example– In the example, the proportional band is small resulting in high
gain, which is causing instability. Notice that the process variable is still not on set point.
PROPORTIONAL ACTION – CLOSED LOOP
Advantages – Simple
Disadvantages – Error
Tuning - reduce PB (increase gain) until the process cycles following a disturbance, then
double the PB (reduce gain by 50%).
INTEGRAL MODE
INTEGRAL ACTION
Duration of Error and Integral Mode – Another component of error is the duration of the
error (How long has the error existed?)
The controller output from the integral or reset mode is a function of the duration of the
error.
INTEGRAL MODE
Repeats per Minute – How many times the proportional action is repeated
each minute.
Minutes per Repeat – How many minutes are required for 1 repeat to occur.
INTEGRAL MODE
Slow Reset Example – In this example the loop is stable because the total loop gain is
not too high at the loop critical frequency.
Notice that the process variable does reach set point due to the reset action.
INTEGRAL MODE
Fast Reset Example – In the example the rest is too fast and the PV is cycling around the
SP.
DERIVATIVE MODE
Derivative Mode Basics – Some large and/or slow process do not respond well to small
changes in controller output.
For example, a large liquid level process or a large thermal process (a heat exchanger)
may react very slowly to a small change in controller output.
To improve response, a large initial change in controller output may be applied. This
action is the role of the derivative mode.
The derivative action is initiated whenever there is a change in the rate of change of the
error (the slope of the PV). The magnitude of the derivative action is determined by the
setting of the derivative .
DERIVATIVE MODE
Not every process requires a full PID control strategy. If a small offset has no impact on
the process, then proportional control alone may be sufficient.
PI control is used where no offset can be tolerated, where noise (temporary error
readings that do not reflect the true process variable condition) may be present, and
where excessive dead time (time after a disturbance before control action takes place) is
not a problem.
CONTROLLER ALGORITHMS
In processes where no offset can be tolerated, no noise is present, and where dead time
is an issue, customers can use full PID control.
The table shows common types of control loops and which types of control algorithms
are typically used.
PROCESS CONTROL LOOPS
FEEDBACK CONTROL
A feedback loop measures a process variable and sends the measurements to a
controller for comparison to setpoint. If the process variable is not at setpoint, control
action is taken to return the process variable to setpoint.
PROCESS CONTROL LOOPS
The figure illustrates a feedback loop in which a transmitter measures the temperature
of a fluid and, if necessary, opens or closes a hot steam valve to adjust the fluid’s
temperature.
PROCESS CONTROL LOOPS
Feedback loops are commonly used in the process control industry. The advantage of a
feedback loop is that it directly controls the desired process variable. The disadvantage
to feedback loops is that the process variable must leave setpoint for action to be taken.
EXAMPLES OF SINGLE CONTROL LOOPS
While each application has its own characteristics, some general statements can be
made about pressure, flow, level, and temperature loops.
High-volume systems
(e.g., large natural gas storage
facilities) tend to change more
slowly than low-volume systems
EXAMPLES OF SINGLE CONTROL LOOPS
To compensate for noise, many flow transmitters have a damping function that filters
out noise.
Sometimes, filters are added between the transmitter and the control system.
Because the temperature of the process fluid affects its density, temperature
measurements are often taken with flow measurements and compensation for
temperature is accounted for in the flow calculation.
Typically, a flow sensor, a transmitter, a controller, and a valve or pump are used in
flow control loops
EXAMPLES OF SINGLE CONTROL LOOPS
The speed of changes in a level control loop largely depends on the size and shape of
the process vessel (e.g., larger vessels take longer to fill than smaller ones) and the
flow rate of the input and outflow pipes.
Manufacturers may use one of many different measurement technologies to
determine level, including radar, ultrasonic, float gauge, and pressure measurement.
EXAMPLES OF SINGLE CONTROL LOOPS
MULTIVARIABLE LOOPS
Multivariable loops are control loops in which a primary controller controls one
process variable by sending signals to a controller of a different loop that impacts the
process variable of the primary loop.
For example, the primary process variable may be the temperature of the fluid in a
tank that is heated by a steam jacket (a pressurized steam chamber surrounding the
tank).
MULTI-VARIABLE/ ADVANCED CONTROL LOOPS
MULTIVARIABLE LOOPS
To control the primary variable (temperature), the primary (master) controller signals
the secondary (slave) controller that is controlling steam pressure. The primary
controller will manipulate the setpoint of the secondary controller to maintain the
setpoint temperature of the primary process variable (see figure).
MULTI-VARIABLE/ ADVANCED CONTROL LOOPS
MULTIVARIABLE LOOPS
When tuning a control loop, it is important to take into account the presence of
multivariable loops.
The standard procedure is to tune the secondary loop before tuning the primary loop
because adjustments to the secondary loop impact the primary loop.
Tuning the primary loop will not impact the secondary loop tuning.