Mod - A (Compatibility Mode)
Mod - A (Compatibility Mode)
(EE60034/EE40016)
Introduction
Compression
Expansion E θ = 360°
General Motors, USA ADA, Bangalore
Solid-Gas mixed flow (Coal Mill) Solid-Gas mixed flow with combustion (Sintering)
User PC (1)
User PC (n)
Browser
(Mozilla
http://vlabs.iitkgp.ac.in Firefox,
Internet
explorer)
TCP/IP, CGI.
Web server
(Java,PHP, XML)
6
Introduction
• Science and Technology of Process Control that includes control of
chemical and petrochemical plants, oil refineries, iron and steel plants,
power plants, cement mills, paper mills, pharmaceuticals, food and
beverages, water and wastewater treatment plants, oil and gas fields
etc.
• Automation is viewed as a versatile tool for solving critical problems of
process and production control, plant supervision and management as
well as solving accompanying financial and organizational problems.
8
Aims of Plant Automation
Main flows in an industrial process:
• Material
• Energy
• Information
Expedient Commissioning
SENSORS ACTUATORS
PROCESS
TRANSMITTER TRANSMITTER
SENSORS ACTUATORS
PROCESS
Initial Digital computers were large, slow, expensive and unreliable. Used
only for Supervisory mode.
OPERATOR GUIDANCE MODE SET POINT CONTROL MODE
PLANT PLANT
Early 60’s: Digital computer for process control in chemical industries
(Direct Digital Control, DDC)
Drawbacks
Low fail Safety
SENSORS ACTUATORS
Higher Investment
PLANT
PROCESS
PROCESS
INTERFACE INTERFACE
SENSORS ACTUATORS
PLANT
An Aircraft Cockpit
Air Traffic Control Room17
Electrical Grid Control
CENTRAL COMPUTER
INTERMEDIATE INTERMEDIATE
INTERMEDIATE
COMPUTER 1 COMPUTER 2 COMPUTER 3
μC μC μC μC
μC μC
PLANT
19
Hierarchical Computer System of Company
Remote COMPUTER Commercial Production
Terminals
CENTRE Computers Scheduling Level
Level 4
μC μC μC μC
Direct Control Level
Level 1
Efficiency Analysis
23
4) Monitoring and Command Facilities
a) Screen Partition Message Area
Overview Area
Main display area
Operator Instruction Area
b) Display Organization
c) Standard Displays Plant overview display
Unit of Area Overview
Group Display
Loop Display
Alarm Survey
Trend Display
d) User Defined Display Plant Mimic Diagram
Batch Control Diagram
5) Operating Keyboards and Control Panels
Pushbuttons Switches Binary Indicator Digital Display
24
Communication Links
Data communication between individual system parts.
Plant data has to be exchanged between intelligent monitoring and control
stations, that need a bus or data highway
Due to hierarchical nature of the systems, different types of buses and data
communication networks will be needed.
Foxboro : FOXNET
Siemens: TELEPERM M 25
SOFTWARE
1) Real Time Operating System
2) Communication Software
26
3) Process Oriented Language
4) Application Software
27
5) Knowledge Based Software
AI Programming languages
Fuzzy Logic
28
V001
FROM
PREVIOUS
PROCESS TANK Sequence Control for a
LA Simple Cooling Process
COOLING 01
WATER V002
LA
02
SEQUENCE TABLE 1 2 3 4 5
TA
01
V003 PB01 START BUTTON
√
LA01 HI LIMIT SW
√
LA02 LO LIMIT SW
√ √
TA01 TEMP SW
√
V001 INJECTION VALVE χ
√
V002 COOLING VALVE
√ χ
V003 DISCHARGE VALVE χ √ χ
NEXT THEN
STEP
2 3 4 5 1
Algorithms
Mathematical Expressions and Procedures on which the application software is
based.
u1 y1
u2 y 2 OUTPUTS
INPUTS F(U,P)
u y m
n
p1 p 2 pk
PARAMETERS
30
Closed Loop Control Algorithms
et u t
SPV +- PID SYSTEM yt
det
t
1
u t k c et et dt TD
T I 0 dt
Proportional Gain Reset Time Rate Time
kc
- Integral Gain k cTD - Derivative Gain
TI
Some manufacturers calibrate controllers as proportional band (PB)
Pressure control : 3 to 5s
P 0.5kcu - -
PI 0.45kcu Tu/1.2
PID (Noninteracting) 0.75kcu Tu/1.6 Tu/10
36
iii) Zeigler-Nicholls Tuning based on Process Reaction Curve
u
Y s Ke D s
G s
t U s s 1
y(t) S curve y ss
K = steady state gain =
u
y ss
D Effective process dead time
t
Effective time constant
y(t) S curve
Tangant Method
y ss
D t
D t
Two Point Method
P - -
K D
PI 0.9 -
3.33 D
k D
PID (Noninteracting) 1.5
2.5 D 0.4 D
k D
PID (Interacting) 1.2
2 D 0.5 D
k D
Tuning Rules for Digital Controller
ek uk ut
rk
Co+ntrol Process yt
+
D/A
Algorithm
A/D
Reconstructed signal
y(t) Continuous signal
t
T 2T 3T 4T 5T 6T
References
42