Pump ED 101

Process Control – (Part 1) Smart and Not So Smart Control

Joe Evans, Ph.D http://www.pumped101.com

Even though control technology has become an integral part of many pumping
systems, over half of our readers have not expressed much interest in pump
controls. I think I know why - - today’s controls are not as intuitively
understandable as they used to be. Who wants to read about the advantages of
PID control without a basic understanding of P, I, and D itself. This two part
series will take a brief look at the hierarchy of process control technology and
explain the function of those three, often confusing, letters. Remember, this
column is entitled Pump Ed 101 not 301, so its purpose is to present the basics and,
hopefully, make some of those more advanced control articles a little more
understandable.

Before we start let’s define a term, and the three words it encompasses, that may
lead to some of the confusion surrounding controls. That term is “Process Control
Loop”. Not too long ago we referred to pump control by application - - constant
pressure, pump up, pump down, circulation, etc. But today we tend lump all of these
into the generic term Process Control. A “process” is a systematic series of
actions that result in a desired end product. A simple process example is the
removal of water from a sump. A more complex one could result in the
manufacture of a 1000’ reel of 20 conductor cable. But the key words, systematic
and desired, apply equally to both. A process should be repeatable and provide the
same result each time it is performed. “Control” is the application of direction or
restraint on how that process proceeds. Basically, control supervises the actions
of the process. For example, a sump pump might use simple float switch activation
as a control mechanism. Or, it might go a step further and employ a level sensor
and operate at different speeds in an attempt to keep the sump at some constant
level. A “loop” consists of the set of instructions (digital or analog), from start to
finish, that controls the process. It is called a loop because once the instructions
are completed they will be repeated when the process begins again. Now, there
are many different types of loops and we will discuss several in detail a little later.

A Little History

Is there any rhyme or reason to those schematics that are often found on the
inside of a control panel door? Are they the result of trial and error or is there
some form of logic involved? Well, back in the early 1800’s an English
mathematician named George Boole developed a system of logic known as Boolean
algebra. It uses simple operators such as “if, and, or, & not” that can be combined
to form precise and logical statements that test the “truth” of a series of events.
It is the basis for the design of all control systems regardless of whether they are
composed of simple switches and relays or complex microprocessors. It is also the
basis for several modern day computer programming languages. The schematics
that define the logic of those controllers are simply a graphic representation of
Boolean algebra. Let’s look at a simple example.

Suppose you want your porch light to turn on, for five minutes, each time the
doorbell rings. If “A” is the input from the doorbell and “C” is a timer that
controls the light the Boolean logic would be: “If A Then C”. Translated into
English this statement says that if A is “true” (on) then C is also “true” (on). So,
every time the doorbell rings the light will turn on and remain on until the timer
shuts it off. Now, if you are a tightwad you probably don’t want that light to turn
on during daylight hours, so you add a sensor (B) that provides an input when it is
dark outside. If we add the sensor to our original logic, it becomes: “If A And B
Then C”. This statement says that both A and B must be true if the light is to turn
on. In other words, it has to be dark outside and the doorbell must ring before the
light will turn on. If you change “And” to “Or” the logic would be quite different.
During the day the light will turn on
C
each time the bell rings and, at A
night, it will stay on continuously.
Figure 1 is a schematic
AND C
representation of the different A B
versions of this “ABC” logic. Boolean
algebra is an elegantly simple
A
method of defining the steps C
OR
necessary to control some process. B

Until the 80’s much of the hardware used to implement this logic consisted of
electromagnetic relays. And, relays are still popular today in simpler controllers
because failures are easy to diagnose and they can be replaced as an individual
component. But the transistor has taken over much of this market because of
price, function, and footprint. Today, a couple of chips or integrated circuits (IC)
measuring just a few square inches contain hundreds of transistors and can replace
dozens of relays. The reason the transistor fits in so well is that, like the relay, it
is also a switch. It is part of a family known as semiconductors. Picture it as a
switch with three leads. Under normal circumstances the semiconductor material
will not allow current to flow between leads 1 & 2 but, if a separate current (an
input from a switch or another transistor) is applied to lead 3, the semiconductor
material becomes a conductor and leads 1 & 2 are connected. When these little
switches are integrated into a Programmable Logic Controller (PLC) we end up with
a computerized switching system that can provide a wide range of control
functions. And, if the process requirements change, you can reprogram it to meet
those changing conditions without rewiring the logic section.

Smart and Not So Smart Control

The typical residential sprinkler system is controlled by a simple timer that turns
the system on at some preset time and then turns it off at some other preset
time. And, it doesn’t matter if it is raining cats and dogs - - it will turn on and off
based on the timer settings. In the process environment, this control scheme is
known as “open loop” control. The key characteristic of open loop control is that
the controller has no clue what is going on within the system. It simply follows its
instructions, to the letter, regardless of its surroundings. Open loop control works
well as long as the event it controls is repetitive and no damage could result from
its action. If our sprinkler activates during a rainstorm, the water is wasted but
no damage occurs.
Figure 2 is a graphic AC SPRINKLER SPRINKLER
representation of this POWER TIMER VALVE

control loop.

It is a bit different when it comes to your home heating system. Although open
loop control could be used, the results would be less than satisfactory. You would
experience periods when it is too warm and others when it is too cold as the heater
would start and stop based on a simple timing cycle. A better control method
would provide some “feedback” to the heater based on the desired temperature
and the actual measured temperature at any point in time. The system could then
make its own decision as to when it should start and how long it should operate. In
the typical home heating system this is accomplished with a thermostat. When the
temperature drops below a certain predetermined level, the thermostat starts the
heating system and runs it at its full capacity until the temperature rises to some
preset, maximum. The thermostat then stops the heating system and waits to
begin another cycle. This is a simple example of “closed loop” control. More
specifically, it is known as “on/off, closed loop control” as the heater is either fully
on or fully off and there are no intermediate settings. The key characteristic of
the closed loop controller is that it receives some form of feedback as to what is
going on within the system and can
therefore make smarter decisions. CONTROL HEATER
Figure 3 is graphic representation
of this closed loop example. THERMOSTAT

Smarter Control – The P in PID

Now, suppose, for a moment, that our home heating example does not use an on/off
thermostat but, instead, uses one that can transmit the actual measured
temperature in the room back to the heating system controller. Let’s also suppose
that the heating system can vary its output based upon the temperature reading it
receives from the thermostat. As the temperature in the room approaches its
“set point” the heater would not necessarily turn off but, instead, reduce its
output and attempt to keep the room at the desired temperature. If the
temperature drops, it would increase its output and if the temperature increases it
would either reduce its output further or shut off completely. Furthermore, these
changes in output would be in “proportion” to the change in temperature. A small
change in temperature results in a small change in output while larger changes in
temperature would lead to proportionally larger changes in heat output.

The example above is one of “proportional, closed loop” control and is the “P” in
“PID”. In the pumping environment proportional control is seen daily. Constant
speed, multi-pump booster systems use pressure switches to start or stop
additional pumps based upon changes in system pressure. Sewage lift stations use
level switches to accomplish the same mission based on changes in the liquid level.
I like to refer to these applications as “fixed, proportional control” as there is a
limited number of “proportions” (pump combinations) available to the control loop.
Proportional control works best in systems where the feedback measurement
changes slowly. In the booster system example above, feedback (pressure) can
change quickly so we will often employ a fairly large pressure differential and
maybe even delay timers to keep lag pumps from cycling on or off too quickly.

But, unlike the constant speed booster, today’s variable speed (dynamic) systems
rely on a microprocessor or PLC to execute the Boolean logic necessary to control a
pump’s pressure. A computer program, or algorithm, monitors pressure and makes
its own decisions about changes in pump speed. But, when conditions change quickly
in a dynamic system, proportional control, alone, doesn’t always do a good job.

Next month we will take a look at how the I & D of PID can help proportional
control do a better job in applications where feedback changes quickly.
Joe Evans is the western regional manager for Hydromatic Engineered Waste
Water Systems, a division of Pentair Water, 740 East 9th Street Ashland, OH
44805. He can be reached at [email protected], or via his website at
www.pumped101.com. If there are topics that you would like to see discussed
in future columns, drop him an email.