Level 1 Fundamentals Training

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RMT Sales Training - 05 /98 Phase I - Control Fundamental

Contents
Topics: Process Control Terminology Control Principles Basic Control Loop Advance Control Loop Control Algorithm Control System Exercise Slide No: 3 - 10 11 - 18 19 - 23 24 - 31 32 - 46 47 - 54 55 - 59

RMT Training - 05 /98

Level 1 - Control

Process Control Terminology

What is a PROCESS ? Any operation or sequence of operations involving a change in the substance being treated.
Examples: A change of energy state A change of composition A change of dimension hot to cold, liquid to gas a chemical reaction grinding coal

Types of PROCESS VARIABLE:

Pressure Flow Level Temperature Liquid Interface Specific Gravity of liquid Density Mass Conductivity Composition Moles
Level 1 - Control

RMT Training - 05 /98

Process Control Terminology

What is a CLOSED LOOP ? A combination of instruments or functions that are interconnected to measure and control a process variable with feedback. input PROCESS A System with Feedback CONTROLLER
RMT Training - 05 /98

output

FINALCONTROL ELEMENT

MEASUREMENT

Level 1 - Control

Process Control Terminology

What is a TRANSDUCER A device that registers a non-electrical parameter (eg. process variable) and outputs a corresponding useable electrical signal.
Pressure to Capacitance Pressure to Resistance or mV Temperature to Resistance Temperature to mV Capacitance pressure sensor module Piezo-resistive pressure sensor module RTD Thermocouple

Example:

RMT Training - 05 /98

Level 1 - Control

Process Control Terminology

What is a TRANSMITTER

A device that will translate the transducers interpretation of the measured variable into a standard transmission signal.
3 - 15 psi pneumatic signal 4-20 mA dc electrical signal 1-5 V dc electrical signal

RMT Training - 05 /98

Level 1 - Control

Process Control Terminology

ADVANTAGE OF 4-20mA CURRENT SIGNAL Lower installation cost
simple, twisted pair wiring

Better noise immunity

current vs. voltage

Insensitive to wire resistance

current vs. voltage

Better suited for hazardous locations

intrinsic safety

RMT Training - 05 /98

Level 1 - Control

Process Control Terminology

What is a CONTROLLER ? Used to keep a process variable at a desired value (set point).
Closed loop vs. Open loop control

Difference: Open loop control has no feedback

Control Modes

ON/OFF (Binary) Proportional (P) Proportional-plus-Integral (PI) Proportional-plus-Integral-plus-Derivative (PID)

RMT Training - 05 /98

Level 1 - Control

Process Control Terminology

What is a SIGNAL ?
An event that conveys data from one point to another.

What is an INDICATOR ?
An instrument which visually shows the value of the variable.

What is a RECORDER ?
An instrument that makes and displays a continuous graphic, acoustic or magnetic record of a measured variable.

What is a DCS ?
Distributed Control System consisting of functional integrated subsystems. The subsystems are connected by a communication linkage (eg) data bus,data highway.
Level 1 - Control

RMT Training - 05 /98

Process Control Terminology

What is a FINAL CONTROL ELEMENT? The last control element in the process control loop that manipulates the process variable.
Control Valves modulates flow rate operated by actuator Louvers and Dampers operated by pneumatic actuators Variable Speed Drives operated by electronic control signals

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4 - 20 mA
Level 1 - Control

RMT Training - 05 /98

Control Principle

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RMT Training - 05 /98

Level 1 - Control

Control Principle
FEED PROCESS CORRECTING UNIT PRODUCT

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MEASURING UNIT

O/P CONTROLLING
UNIT

PV SP

OPERATOR

Control theory can be encapsulated as the matching of a measured variable (PV) to the plant requirement (SP). A controller implements a Control Algorithm so that an output signal (O/P) activates a correcting unit. The ratio of output signal (O) to input signals (I) is Gain (K). Proportional band 1 % =
K
RMT Training - 05 /98

100 % Gain

I O

x 100%
Level 1 - Control

Control Principle
Process Variable (PV)
the actual measurement of the state of the process

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Set Point (SP)

the desired state of the process variable

Control Algorithm
the predefined response of the controller to PV-SP

Controller Output (O/P)

a signal determined by the control algorithm

Offset
the value of PV-SP when the system is in equilibrium

Direct Acting Controllers

as the value of the measured variable increases, the output of the controller increases.

Reverse Acting Controllers

as the value of the measured variable increases, the output of the controller decreases.

RMT Training - 05 /98

Level 1 - Control

Control Principle
Inherent Regulation A plant possesses inherent regulation when, in the absence of a controller, equilibrium is reestablished after a disturbance.
For example, a tank with constant inflow is in equilibrium. The outflow valve is then opened a little more. The outflow pressure decreases as the tank level falls until inflow again equals outflow. Manipulation of the outflow valve result in different, unique equilibrium states.
RMT Training - 05 /98

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Level 1 - Control

Control Principle
Instrument Symbols
Example Instruments TT Temperature Transmitter I/P Current-to-Pressure Transducer PT Pressure Transmitter P/P Pressure-to-Pressure Transducer

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FIC Flow Indicating Controller TE Temperature Element (Thermocouple, RTD) Instrument Location Local Mounting Panel Front Mounting

Panel Rear, or Rack Mounting

RMT Training - 05 /98

Level 1 - Control

Control Principle
Instrument Symbols
Letter Designations First Letter Measured or Modifier Initiating Variable Analysis User's Choice User's Choice Differential Flow Rate Ratio (Fraction) Current (Electrical) Level Pressure, Vacuum Quantity Integrate, Totalize Radiation Temperature Vibration Succeeding Letters Readout or Output Passive Function Function Alarm Control

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A C D F I L P Q R T V
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Indicate Light Point (Test Connection) Record Transmit Valve, Damper, Louver
Level 1 - Control

Control Principle
Signal Types (ISA)

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Connection to Process, Instrument Supply, or Direct Mechanical Link

Pneumatic Signal

Electric Signal

RMT Training - 05 /98

Level 1 - Control

Control Principle
Controller Types Pneumatic Analog Digital Single Loop Controllers Distributed Control System Fieldbus Control System

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RMT Training - 05 /98

Level 1 - Control

Basic Control Loop

Pressure Control Loop
I/P PIC

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Pressure Loop Issues:

May be a Fast Process Liquid Small Volume May Require Fast Equipment

PT

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Level 1 - Control

Basic Control Loop

Temperature Control Loop Temperature Loop Issues:
Fluid response slowly to change in input heat Requires advanced control strategies Feedforward Control

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Load Disturbance
TIC

Cold Water

I/P TT

Steam

Hot Water
RMT Training - 05 /98 Level 1 - Control

Basic Control Loop

Flow Control Loop Flow Loop Issues:
May be a Very Fast Process Noise in Measurement Signal May Require Filtering May Require Fast-Responding Equipment Typically Requires Temperature Compensation
I/P FIC

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FT

TT

RMT Training - 05 /98

Level 1 - Control

Basic Control Loop

Level Control Loop (Inflow)
I/P LIC

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Level Loop Issues: Control At Inflow or Outflow Non-Self Regulating

LT

RMT Training - 05 /98

Level 1 - Control

Basic Control Loop

Level Control Loop (Outflow)

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LIC

I/P

LT

RMT Training - 05 /98

Level 1 - Control

Advance Control Loop

What is CASCADE CONTROL ?
Consist of one controller (primary, or master) controlling the variable that is to be kept at a constant value, and a second controller (secondary, or slave) controlling another variable that can cause fluctuations in the first variable. The primary controller positions the set point of the secondary, and it, in turn, manipulates the control valve.
Primary controller Secondary controller

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Multi-Variable Control
m
Disturbance Secondary Process Primary Process

r1

FBC

r2

FBC

c1

c2

RMT Training - 05 /98

Level 1 - Control

Advance Control Loop

Example of CASCADE CONTROL
The temperature of the liquid in the vessel is controlled by regulating the steam pressure in the jacket around the vessel.
Temperature transmitter IN Temperature controller

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Measurement Output Measurement Jacket Pressure transmitter

Pressure controller

OUT

Valve

Steam

SINGLE-LOOP CONTROL
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Cascade Control Loop

Level 1 - Control

Advance Control Loop

Implementing Cascade Control
Steam Header
Cold Water

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RSP

TIC

_
Major Load B: Steam Header Pressure
FT

FC

I/P

TT

Steam Major Load A: Outflow Rate Hot Water (Demand)

Condensate

Load B (Header Pressure) SP RSP

Load A (Demand)

TIC

FC

Steam Flow Process

Temperature Process

FT TT

RMT Training - 05 /98

Level 1 - Control

Advance Control Loop

What is FEED FORWARD CONTROL ?
Applies to a system in which a balance between supply and demand is achieved by measuring both demand potential and demand load and using this data to govern supply. It gives a smoother and stable control than feedback control.

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Multi-Variable Control
Feedwater

Steam

FT FT Flow controller PV O/P LT Boiler Level indicating controller SP Feed forward

SP
RMT Training - 05 /98

Level 1 - Control

Advance Control Loop

Implementing Feedforward Control
Feedforward Equations Summing Junction

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FFD
Feedforward Loop Feedback Loop

FT TIC
Cold Water
I/P

TT
Steam Hot Water
RMT Training - 05 /98 Level 1 - Control

Advance Control Loop

What is RATIO CONTROL ?

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An uncontrolled flow determines a second flow so that a desired ratio is maintained between them. The ratio factor is set by a ratio relay or multiplying unit which would be located between the wild flow transmitter and the flow controller set point. Flow B is controlled in a preset ratio to flow A.

Multi-Variable Control
Controlled flow, B Wild flow, A Ratio Output = A x ratio relay Remote set controller Wild flow, A Controlled flow, B Ratio controller

SP

SP

Output
RMT Training - 05 /98

Output
Level 1 - Control

Advance Control Loop

Example of RATIO CONTROL
Pickling Process
Set

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Acid supply
Measurement

Manual water regulator Water

FT Flow transmitter

FC Magnetic flowmeter
Flow B

Flow A

Control valve

Pickle tank Other Application :

RMT Training - 05 /98

Fuel/air ratio control system on combustion equipment, e.g. boilers.

Level 1 - Control

Advance Control Loop

What is SELECTIVE CONTROL ?
The more important condition between two or more candidates is selected. They are used mainly to provide protection to a piece of equipment which could suffer damage as a result of abnormal operating conditions.

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Multi-Variable Control
Low select O/P PIC PV RS Speed Control O/P Pump
Level 1 - Control

O/P PIC PV

RMT Training - 05 /98

Control Algorithm

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On/Off Multi-step Proportional Integral Derivative

RMT Training - 05 /98

Level 1 - Control

Control Algorithm
On-Off Control
It is a two-position control, merely a switch arranged to be off (or on as required) when the error is positive and on (or off as required) when the error is negative. Ex.. Oven & Alarm control.

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Measured variable

differential

Controller output Time

RMT Training - 05 /98 Level 1 - Control

Control Algorithm
Multi-Step Action
A controller action that may initiate more than two positioning of the control valve with respect to the respective predetermined input values.
8 5 8 0 7 5

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Time

4 3 2 1

Multi-step action
RMT Training - 05 /98

Time
Level 1 - Control

Control Algorithm
Proportional Action (P)
It is the basis for the 3-mode controller. The controller output (O/P) is proportional to the difference between Process Variable (PV) and the Set Point (SP).
Process Load SP PV Controller Output

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Open-loop response of proportional mode

RMT Training - 05 /98 Level 1 - Control

Control Algorithm
Proportional Action (P)
The Algorithm is : - (PV - SP) O/P = + Constant Proportional Band (Constant is normally 50% )
50 O/P % 100

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S - PV Tan = Gain = 100 / Proportional Band

When a disturbance alters the process away from the set-point, the controller acts to restore initial conditions. In equilibrium, offset (PVSP = constant) results.
PV Many controllers have a manual reset. This enables the operators to manipulate the constant term of the algorithm to eliminate offset. Time Recovery time
Offset

SP Time

RMT Training - 05 /98

Level 1 - Control

Control Algorithm
Low Proportional Gain: (Closed Loop)
100 90 80 70 60 % 50 40 30 20 10 Output
E0 E1 E2 E3 E4

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SP

PV

0
prop

4 5 Time

RMT Training - 05 /98

Level 1 - Control

Control Algorithm
High Proportional Gain: (Closed Loop)
100 90 PV 80 70 60 % 50 40 30 20 Output 10 SP

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0
higain

4 5 Time

RMT Training - 05 /98

Level 1 - Control

Control Algorithm
Integral Action (I)

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Whilst PV SP, the controller operates to restore equality. As long as the measurement remains at the set point, there is no change in the output due to the integral mode in the controller. The output of the controller changes at a rate proportional to the offset. The integral time gives indication of the strength of this action. It is the time taken for integral action to counter the offset induced by Proportional Action alone.
Set Point RT a{ b{ Time RT = Reset Time min./rpt a=b

% Measurement

Set Point

% Output Time

Open-loop response

Integral mode
RMT Training - 05 /98

Proportional plus Integral mode

Level 1 - Control

Control Algorithm
Integral Action: (Closed Loop)
100 90 80 70 60 PV % 50 40 30 20 10 Proportional Response Proportional Plus Integral Output SP

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4 Time

RMT Training - 05 /98

Level 1 - Control

Control Algorithm
Derivative Action (D)
As the PV changes, the controller resists the change. The controllers output is proportional to the rate at which the difference between the measured and desired value changes. The derivative time is an indication of this action. It is the time that the open-loop P+D response is ahead of the response due to P only.
Set Point DT = Derivative Time (min) DT Proportional only Time

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% Measurement

Set Point

% Output (I/D) Time

Open-loop response

Proportional + Derivative

Derivative mode
RMT Training - 05 /98

Proportional plus Derivative mode

Level 1 - Control

Control Algorithm
PID Action: (Closed Loop)
100 90 80 70 60 % 50 40 30 20 10 PV PID Output SP

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4 5 Time

RMT Training - 05 /98

Level 1 - Control

Control Algorithm
PID Control
% Scale Range

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80 Measurement 60 40 20 Proportional A

Controller Output or Valve Position

Proportional + Integral B Proportional + Integral + Derivative Time - minutes

Open-loop response of three-mode controller

RMT Training - 05 /98 Level 1 - Control

Control Algorithm
P & ID Piping & Instrumentation Drawing
Compressed Air Pipe Converter PID Controller

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I/P
Pneumatic Control Valve

PIC

PT Pressure P
Transmitter Process Vessel

Fluid Pump
RMT Training - 05 /98 Level 1 - Control

Control Algorithm
Controller Selection
Start

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Step change in
valve travel Use PID Can offset be Yes tolerated ? No Yes Is dead time excessive ? No No Is noise present ? Yes Use P+I Use P-only

63.2 % C

Reaction curve
of measured variable

Capacity Dead Time Time (sec)

RMT Training - 05 /98

Level 1 - Control

Control Algorithm
Controller Adjustment
Controlled Variable
Period P-only PID PI

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Time
Control loop Flow Level Temperature Analytical Pressure
RMT Training - 05 /98

Proportional band High (250%) Low Low High Low

Time constant Fast (1 to 15 sec) Capacity dependent Capacity dependent Usually slow Usually fast

Derivative Never Rarely Usually Sometimes Sometimes

Level 1 - Control

Control System
Adaptive Control
An automatic control scheme in which the controller is programmed to evaluate its own effectiveness and modify its own control parameters to respond to dynamic conditions occurring in or to the process which affect the controlled variables.

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Ex)

Digital Controller - Sensors are run to the computers input. - Servomechanisms are connected to the computers output. - Future changes dont require re-wiring. - Changing control functions (P,I, and D) and configurations (between cascade mode and feedforward mode) will be made on the computers program and not necessarily to any hardware.

RMT Training - 05 /98

Level 1 - Control

Control System
Supervisory Control
A control strategy where the process control computer performs system control calculations and provides its output to the setpoints inputs of conventional analog controllers. These analog controllers actually control the process actuators, not the main-control computer. S
SP1

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M.I.S

Supervisory Control
SP2

Controller S Controller S

SP3
RMT Training - 05 /98

Controller

Level 1 - Control

Control System
Todays DCS System
Coax

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I/O Rack

Controller Tools for Process Analysis, Diagnostics.

HW and Software Filtering Measurement I/O Rack Controller

Sampled Value Tools for Process Analysis, Diagnostics.

Level 1 - Control

RMT Training - 05 /98

Control System
What is a FIELDBUS ? Definition...
A digital, two-way, multi-drop communication link among intelligent field devices and automation systems. Fieldbus
(Only Digital Signals)

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P T

Control room operator stations

L

Control systems (DCS or PLC)

F

RMT Training - 05 /98

Level 1 - Control

Control System
Fieldbus Control System
Work Systems Gateway Controller H1 H1 H1 H1 H2 Bridge H1 Total of approximately 35,000 devices (due to address limits) . HSE 124 Devices

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32 Devices

H1 - 31.25 Kbit/s HSE - 100 M bit/s (Fast Ethernet)

RMT Training - 05 /98

H1 32 Devices
Level 1 - Control

Control System
Proprietary Bus

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ADVANCED CONTROL

OPTIMIZATION

PID

PID AI AO
4 -20 mA 4 -20 mA 4 -20 mA

AI

DCS

Control in the control room

RMT Training - 05 /98 Level 1 - Control

Control System
Foundation Fieldbus Devices
Delta V

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Built-In Function Blocks

Transmitter
BKCAL_IN OUT IN OUT

Control Anywhere
Valve
FIELDVUE

BKCAL_OUT CAS_IN

AI

PID

AO

Control in the field with fieldbus

RMT Training - 05 /98 Level 1 - Control

Look at how the CONTROL migrate

Central Control Loop
DDC Digital PID PID Analog Analog

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Local Control Loop DCS

Control in the field

FCS

Digital

PID

PID

Loop 1

Loop 2

Loop 1

Loop 2

Loop 1

Loop 2

Control in the device itself

RMT Training - 05 /98 Level 1 - Control

Exercise
Which defined term is closest to the description or encompasses the example given? A. Controller F. Primary element B. Converter G. Signal C. Instrument H. Transducer D. Point of measurement I. Transmitter E. Process 1. Process temperature increases the measurable resistance in a monitored electrical circuit. Pulsed output from a turbine meter. Heat-injected plastic molding.

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[ [ [

] ] ]

2. 3.

RMT Training - 05 /98

Level 1 - Control

Exercise
4. 5. Temperature transmitter. Device which adjusts the measured value of the process to the requirements of the operator. [

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] ] ]

6. 7. 8.

Element, flow transmitter, controller and correcting unit. [ A pipe piece is tapped for a sample fluid. A device changes an industry standard pneumatic signal to an industry standard hydraulic signal. [

RMT Training - 05 /98

Level 1 - Control

Exercise
9. Identify the components indicated by the Arrows.

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RMT Training - 05 /98

Level 1 - Control

Exercise
Which defined term is closest to the description or encompasses the example given. A. B. C. D. E. Cascade control Control algorithm Control valve Feed-forward control Foundation Fieldbus F. G. H. I. Gain Offset Proprietary Bus Smart Device

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10. The predefined response of the controller to PV-SP. 11. The value of PV-SP when the system is in equilibrium. 12. The ratio of controllers output to input. 13. It is a final control element operated by an actuator.

[ [ [ [

] ] ] ]

RMT Training - 05 /98

Level 1 - Control

Exercise
14. Involves master & slave controllers. 15. The output of the loop drives the input. 16. A digital communication based control network with control action in the controller only. 17. A digital communication based control network that allow control in the field. 18. A device that provide both analog & communication signal in its loop wire pair. [ [ [ [ [

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] ] ] ] ]

RMT Training - 05 /98

Level 1 - Control