Instrumentation and Controller Design: Dr. Mudathir A. Fagiri
Instrumentation and Controller Design: Dr. Mudathir A. Fagiri
Instrumentation and
Controller Design
1
Objectives:
1. To teach fundamental Process controller and its
design
2. To educate students the criteria for selection of
suitable transmitters (Sensor/Actuators)
3. To help students in enhancing their knowledge
about different controllers
+
Controller
Controller Actuator
Actuator Process
Process
Sensor
Sensor++
Transmitter
Transmitter
Lecture 1
Introduction to
Process Control
Objectives
Outlines
The importance of process control
Basic concepts of process control
Objectives
Understand what process control is
Know the terms of process control system
Identify the elements of process control system
Understand the importance of process control
Know the type of process control strategies
INTRODUCTION TO PROCESS CONTROL 6
The History of Process Control
1960s Pneumatic analog instrumentation, controllers, and computing modules
1970s Electronic analog instrumentation, controllers, and computing modules
◦ Direct digital control with special algorithms programmed in main frame computer
1980s Electronic analog instrumentation and digital distributed control systems (DCS)
◦ Supervisory and model predictive control configured in special purpose computers
1990s Smart analog instrumentation, valves, and digital distributed control systems
◦ Supervisory and model predictive control configured in special purpose computers
◦ Neural networks, online diagnostics, and expert systems in special purpose computers
◦ Real time optimization using model libraries in special purpose computers
2000s Field bus based digital smart instrumentation, valves, and control systems
◦ Digital bus takes full advantage of smartness and accuracy of instrumentation and valves
◦ Some fast PID controllers such as flow and pressure go to the field transmitter or valve
◦ Model predictive control, neural networks, online diagnostics, and expert systems are
integrated into the graphically configurable field bus based control systems and move to PCs
◦ APC Infrastructure, interface, and engineering costs decrease by an order of magnitude
◦ APC projects use consultants more for front end and commissioning than for whole job
◦ APC software tools are easy enough for the average process and control engineer to use
Energies Out
Process
Energies Out
Data
Knowledge
Information
Driving a Car
Control Objective (Setpoint): Brain:
◦ Maintain car in proper lane Eyes:
Control Sensor
Controlled variable: calculation
◦ Location on the road
Manipulated variable:
◦ Orientation of the front wheels
Actuator:
◦ Steering wheel
Sensor:
◦ Driver’s eyes
Controller:
◦ Driver
Steering wheel:
Disturbance: Actuator
◦ Curve in road
Noise:
◦ Rain, fog
Elements of Process
Control Loop
Sensor
◦ Measure process variable
Transmitter
◦ Convert the measured process variable into standard signal
Controller
◦ Drive actuator by giving an appropriate controller output signal
Actuator
◦ Adjust manipulated variable based on the value of the controller output signal
Process
◦ Physical system to be controlled
Goal of Process
Operation
Safety & Reliability 24 hours process operation?
Hmm… I think, to achieve
Product Specification those, we need to continuously
monitor & control the process
24 hours a day,
Environmental Regulation 7 days a week!!!
Operating Constraint
Efficiency
Maximum profit
Safety and
Reliability
The control system must provide safe operation
◦ Alarms, safety constraint control, start-up and shutdown
Product
Specification
Quality
◦ Products with reduced variability
◦ For many cases, reduced variability products are in high demand and have high value added
(e.g. feedstocks for polymers)
Concentration
Concentration
Limit Limit
Impurity
Impurity
Time Time
Product certification procedures (e.g., ISO 9000) are used to guarantee product quality and place a
large emphasis on process control
Environmental
Regulation
Various government laws may specify that the
temperatures, concentrations of chemicals, and
flow rates of the effluents from a process be within
certain limit
Examples:
◦ Regulations on the amounts of SO2 that a process can eject to the
atmosphere, and on the quality of water returned to a river or a
lake
Constraint
All real process have constrained inherent to their
operation which should be satisfied throughout
the operation
Examples:
◦ Tank should not overflow or go dry
◦ Distillation column should not be flooded
◦ Catalytic reactor temperature should not exceed an upper limit
since the catalyst will be destroyed
Efficienc
y
Concentration
Concentration
Limit Limit
Impurity
Impurity
Time Time
INTRODUCTION TO PROCESS CONTROL 22
Department of Engineering Physics ITB June 2003
Common Types of
Control Strategy
Manual vs. Automatic
Servo vs. Regulator
Open-loop vs. Closed-loop
Control strategies
◦ Feedback Control
◦ Feedforward Control
◦ Cascade Control
Emergency
cooling
Automatic
◦ The computer (or other device) autonomously
controls the process and may report status
back to a operator
Question: Why manual override has to be included in every automatic control systems?
Closed-loop
DV
CO PV
Open-loop Process
Process
◦ Process is controlled based on Decisions
DV
Closed-loop
◦ The information from sensor is used to CO PV
Process
Process
adjust the MV to obtain the desired Decisions
value of the PV
Controller
Controller
SP
INTRODUCTION TO PROCESS CONTROL 26
Department of Engineering Physics ITB June 2003
Control Strategies
(1)
Feedback Control
◦ Corrective action based on process variable (PV)
DV
SP
Feedback CO PV
Feedback Process
Process
Controller
Controller
Advantage
Requires no knowledge of the source or nature of disturbances, and minimal
detailed information about how the process itself works
Disadvantage
Controller takes some corrective actions after some changes occurs in process
variable PV
(2)
Feedforward Control
◦ Based on the measurement of disturbance (DV) feedforward controller can respond even
before any changes occurs in PV DV
Feedforward CO PV
SP Feedforward Process
Process
Controller
Controller
Advantage
Controller takes some corrective actions before the process output is different
from the setpoint theoretically, perfect disturbance rejection is possible!
Disadvantage
◦ Requires process model which can predict the effect of disturbance on PV
◦ If there are some modeling error, feedforward control action will be erroneous (no
corrective action)
◦ Feedforward controller can be quite complex
INTRODUCTION TO PROCESS CONTROL 28
Department of Engineering Physics ITB June 2003
Control Strategies
(3)
Feedback/Feedforward Control
◦ Feedforward controller will adjust CO as soon as the DV is detected
◦ If the feedforward action is not enough due to model error,
measurement error and etc., feedback controller will compensate the
difference
DV
CO PV
SP Feedforward/
Feedforward/ Process
Feedback Process
Feedback
Controller
Controller
Control Strategies
(4)
Cascade Control
◦ The disturbance DV1 arising within the inner loop are corrected by the inner controller
before it can affects the PV of the outer one
Example: Control valve + positioner
Outer loop
Inner loop DV1 DV
SP
Inner CO CO PV
Outer
OuterFeedback
Feedback InnerFeedback
Feedback Inner
Inner Outer
Outer
Controller
Controller Controller
Controller Process
Process Process
Process
SP Outer
OuterFeedback
Feedback Inner CO CO PV
Controller
Controller InnerFeedback
Feedback Inner
Inner Outer
Outer
Controller
Controller Process
Process Process
Process
MIMO
SISO DVs
…
DV
… COs Process PVs
Process
CO PV Decisions …
Process
Process …
Decisions …
Controller
Controller Controller
Controller
The Terms II
Manual control Servo control
Regulatory control
Automatic control
SISO control
Open-loop control
MIMO control
Closed-loop control Transient response
Feedback control Overshoot
Feedforward control Oscillation
Cascade control
Development of a Control
System (1)
1. Open Loop Analysis
◦ What kind of system is considered?
2. Performance Specifications
◦ How is the system required to behave?
◦ The desired performance must be expressed in terms of the different
performance measures that are chosen
◦ Often, depends on the type of control problem to solve
3. Control Configuration
◦ Which signals are used to calculate the control signal?
◦ Depending on the plant the desired performance specifications and
the allowed complexity of the control system
◦ Depending on the type and the number of input signals to the
controller different configurations are recognized
INTRODUCTION TO PROCESS CONTROL 34
Department of Engineering Physics ITB June 2003
Development of a Control
System (2)
4. Control Law
◦ Which algorithm is used to calculate the control signal?
5. Parameter Design (Tuning)
◦ Which are the parameters of the algorithm to calculate the control signal?
6. Evaluation
◦ How will the controlled system behave in theory? simulation!
7. Implementation and Verification
◦ How will the control system be realized?
◦ How does the controlled system behave in practice?
◦ The controller will be implemented and one will verify whether the system
is controlled as expected