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BASICS of Process Control

The document discusses various types of process control systems including feedback, feedforward, cascade, ratio, and split control systems. It provides details on common control objectives like safety, environmental protection, and profit. Additionally, it explains the basics of PID controllers and the roles of proportional, integral, and derivative terms.

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Mallikarjun Manjunath
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© Attribution Non-Commercial (BY-NC)
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Download as PPT, PDF, TXT or read online on Scribd
187 views

BASICS of Process Control

The document discusses various types of process control systems including feedback, feedforward, cascade, ratio, and split control systems. It provides details on common control objectives like safety, environmental protection, and profit. Additionally, it explains the basics of PID controllers and the roles of proportional, integral, and derivative terms.

Uploaded by

Mallikarjun Manjunath
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Basics On Process Control and PIDs

Desired Value (SP)

Controller
Control Element

Sensor

Inputs
CAUSE

PROCESS
DISTURBANC ES

Outputs
EFFECT

Seven Control Objectives


SAFETY ENVIRONMENTAL PROTECTION EQUIPMENT PROTECTION SMOOTH OPERATION PRODUCT QUALITY PROFIT MONITORING AND DIAGNOISIS

SAFETY

ENVIRONMENTAL PROTECTION

EQUIPMENT PROTECTION

SMOOTH OPERATION

PRODUCT QUALITY

PROFIT

MONITORING AND DIAGNOISIS

Failing to achieve any of these objectives will lead to operation that will be unprofitable, unsafe or worse

Input Variables
-Manipulated

(or adjustable) Variables

if their values can be adjusted freely by the human operator or a control mechanism
-Disturbances

if their values are not the result of adjustment by an operator or a control system

Output Variables
-Measured

O/P Variables if their values are known by directly measuring them -Unmeasured O/P Variables if they are not or cannot be measured directly

Types Of Controllers
On-Off Controller Proportional Controller Proportional Integral Controller Proportional Derivative Controller Proportional Derivative Integral Controller

On-Off Controller

Proportional Controller
A high proportional gain results in a large change in the output for a given change in the error. In contrast, a small gain results in a small output response to a large input error, and a less responsive (or sensitive) controller. If the proportional gain is too high, the system can become unstable. If the proportional gain is too low, the control action may be too small when responding to system disturbances.

M V(t) = Pout Where


Pout: Proportional output Kp: Proportional Gain, a tuning parameter e: Error = SP PV t: Time or instantaneous time (the present)

Proportional Integral Controller


The integral term (when added to the proportional term) accelerates the movement of the process towards setpoint and eliminates the residual steady-state error that occurs with a proportional only controller. However, since the integral term is responding to accumulated errors from the past, it can cause the present value to overshoot the setpoint value (cross over the setpoint and then create a deviation in the other direction).

M V(t) = Pout + Iout

Where
Iout: Integral output Ki: Integral Gain, a tuning parameter e: Error = SP PV : Time in the past contributing to the integral

Proportional Derivative Controller


The derivative term slows the rate of change of the controller output and this effect is most noticeable close to the controller setpoint. Hence, derivative control is used to reduce the magnitude of the overshoot produced by the integral/proportional component and to improve the combined controller-process stability. However, differentiation of a signal amplifies noise in the signal. Hence, this term in the controller is highly sensitive to noise in the error term. If the noise and the derivative gain are sufficiently large then the process becomes unstable.

M V(t) = Pout + Dout

Where
Dout: Derivative output Kd: Derivative Gain, a tuning parameter e: Error = SP PV t: Time or instantaneous time (the present)

Proportional Derivative Integral Controller


M V(t) = Pout + Dout + Iout

Proportional Gain - Larger Kp typically means faster response since the larger the error, the larger the feedback to compensate. An excessively large proportional gain will lead to process instability. Integral Gain - Larger Ki implies steady state errors are eliminated quicker. The tradeoff is larger overshoot: any negative error integrated during transient response must be integrated away by positive error before we reach steady state. Derivative Gain - Larger Kd decreases overshoot, but slows down transient response and may lead to instability.

Different Types Of Control Systems Feedback Control System


Feedforward Control System Cascade Control System Ratio Control System Split Control System

Feedback Control System


Controller acts after the effect of disturbance has been felt by the system
Advantages: Corrective action occurs regardless of the source and type of disturbances.

Requires little knowledge about the process (For example, a process model is not necessary).
Versatile and robust (Conditions change? May have to re-tune controller).

Disadvantages:
FB control takes no corrective action until a deviation in the controlled variable occurs. FB control is incapable of correcting a deviation from set point at the time of its detection. Theoretically not capable of achieving perfect control. For frequent and severe disturbances, process may not settle out.

Feedforward Control System


Controller acts even before the effect of disturbance has been felt by the system
Advantages: Takes corrective action before the process is upset (cf. FB control.)

Theoretically capable of "perfect control"


Does not affect system stability Disadvantages: Disturbance must be measured (capital, operating costs) Requires more knowledge of the process to be controlled (process model) Ideal controllers that result in "perfect control: may be physically unrealizable. Use practical controllers such as lead-lag units

Comparison
Feedback Control

Feedforward Control

FF Control

Attempts to eliminate the effects of measurable disturbances.


FB Control Corrects for unmeasurable disturbances, modeling errors, etc. (FB trim)

Cascade Control System

Distinguishing features:

-Two FB controllers but only a single control valve (or other -final control element). -Output signal of the "master" controller is the set-point for slave" controller. -Two FB control loops are "nested" with the "slave" (or "secondary") control loop inside the "master" (or "primary") control loop.
Terminology

-slave vs. master -secondary vs. primary -inner vs. outer

Ratio Control System

Split Control System

2 Manipulated Vars.: V1 and V2

1 Controlled Var.: Reactor pressure

While V1 opens, V2 should close

15

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