Process Control Concepts

Applications and
Terminology
Materials: Mike Sharpe
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Learning Objectives
To Understand Process Control
To Understand What Control System
Implies.
To Understand Basic Terminology.
To Understand Hardware and Devices.
To Understand Pure Control Forms.
PID (ANALOG)
ON/OFF or DISCRETE (DIGITAL)
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Process Control : A Definition
Process control is the regulation or
manipulation of variables that influence the
function of a process.
The goal of process control is to obtain a
product of desired quality and quantity in an
efficient manner.
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The Feedback Control Loop
Process control, both manual and automatic, is
accomplished through the feedback control loop and
instrumentation. The feedback control loop is a
design scheme that continuously corrects or controls
a system.
This is accomplished by measuring a variable and
comparing it to a desired value (setpoint), then
taking corrective action if the two readings differ
outside of allowed variance.
Simply stated, process control involves four steps --
SENSE, COMPARE, COMPUTE, & CORRECT.
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Process is the physical
or chemical change of
matter or conversion of
energy, such as a
change in pressure,
temperature, speed, or
electrical potential.
Process can also be a
series of regularly
occurring steps or
actions intended to
achieve a predetermined
result, such as refining
oil, heat treating metal, or
manufacturing paper.
Each process has any
number of variables
(temperature, flow,
pressure, level, color,
pH, density, etc.) that
can change.
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VARIABLES
To control the process and achieve the
desired results, variables are measured,
controlled, and manipulated.
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Controlled or Process
Variables
The controlled or process variable is
maintained (by process control) at a specified
setpoint value.
This is the variable which the control loop will,
through measurements and field devices,
attempt to keep at a pre-defined level.
This variable could be temperature, flow,
pressure, level, weight, speed, etc.
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Manipulated Variables
There is another variable in the basic process
control model, and that is the manipulated
variable.
Using the example of a forced-air gas
furnace, the manipulated variable is the gas
flow.
The manipulated and process variables are
often the same.
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An Example
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Disturbance
A disturbance is a
temporary,
undesired change
in a variable that
adversely affects
the value of the
controlled variable.
In our example of
the forced-air
heating system,
placing a lamp
near the
thermostat would
produce a
disturbance in the
system by creating
a higher
temperature in the
vicinity of the
thermostat.
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Load changes
A change in a process variable
results in a load change. If, in our
example, a window were opened
on a cold day, the temperature of
the process would change.
The gas valve would remain open
for a longer period of time. Load
changes are typically of longer
duration than disturbances.
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Setpoint and Deviation
Setpoint is the desired value of the controlled or
process variable. There is usually a mechanism for
setting the setpoint, and it can be controlled manually,
automatically, or programmed electronically. In the
example of the forced-air gas heater, the setpoint is the
72 degrees F mark on the thermostat.
Deviation is any departure from the setpoint. A
deviation range may be (and usually is) part of the
design intent of the process, and therefore allowed in
the process control.
For example, furnaces are designed with a setpoint
deviation so that the burner and fan are not triggered
too frequently. In the above example, the allowed
deviation is 70 degrees F to 74 degrees F (plus or
minus 2 degrees F from setpoint). The gas valve will
not open until the air around the thermostat drops to 70
degrees F and will not close until the air has heated to
74 degrees F.
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What Is A Control System ?
Manual Feedback or OPEN LOOPControl.
Completely manual, labor intensive. Accuracy and
efficiency are lacking.
Automatic Feedback or CLOSED LOOPControl.
See Feedforward and Cascade Also.
Automated computerized control, less labor and greater
accuracy and efficiency.
A control system must be capable of:
Measuring (PV) or Input, Comparing or Setpoint,
Computing or Algorithm and Correcting or Output.
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MANUAL FEEDBACK
CONTROL
Operator or Human
Control
In this type of control
scheme, an operator
monitors the process
with gauges and
manually adjust
valves and other
devices to
manipulate or
balance the process.
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Manual Feedback
Loop
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Automatic Feedback Control
Automatic or Computerized Control
In this type of control scheme, a field device such
as a transmitter provides a process Inputto a
controller which in turn compares that value to a
pre-determined Setpoint.
If an Erroris detected, the controller issues a
command or Outputto a Final Control Element
such as a control valve to adjust the process. This
adjustment returns the process to its desired
state.
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Automatic Feedback Loop
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Automatic Feed Forward
Control
Automatic or Computerized Control, A Sub-
function of Feedback Control.
In this type of control scheme, the system
anticipates the effect of disturbances on a
controlled output and compensates for them to
minimize changes in the output.
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Cascade Loop Control
Automatic or Computerized Control, A Sub-
function of Feedback Control.
In this type of control scheme, one loop is nested
inside another to allow the output from one
controller to become the setpoint of the second
controller.
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Feed Forward and Cascade Loops
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PNEUMATIC CONTROLS
Older technology utilizing compressed air for signal
input/output.
With this older technology, pneumatic field devices utilize
compressed air to provide an analog input of 3-15psi to a
control room Boardor to a pneumatic final control
element.
Generally the control room board requires an operator to
monitor the display and take manual action to correct
errors noted by the field device.
Two major problems with pneumatics are accuracy and
response time.
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Pneumatic Control Overview
Still employed in some manufacturing facilities. When pneumatic
devices exists, transducers (I/P and P/I) are employed to convert
signals from impulse or electric (I) to pneumatic (P) and vice
versa to allow the pneumatic devices and the controllers to
communicate.
A pneumatic transmitter in the field would require a P/I to convert
the 3-15psi analog signal to 4-20mA analog signal in order for
the DCS (HPM or PLC) to read it.
A pneumatic final control element such as a control valve would
require an I/P to convert the 4-20mA from the controller to a 3-
15psi signal in order for the valve to respond to the signal.
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Pneumatic Control Overview
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TERMINOLOGY, GENERAL
Continuous Process - A plant process that runs 24 hours a day, 7
days a week such as an oil refinery. The process is continuous
provided there is not a scheduled shutdown.
Batch Process- A plant process which runs a pre-determined
period before stopping such as a food plant. A line will operate to
produce cookie Abefore being shutdown and re-configured to
produce cookie B.
Analog Signal- An input/output signal that is measurable across a
range. (4-20mA,3-15psi or 1-5vdc) These signals are used
primarily for process variable measurement and final control
element manipulation.
Digital Signal- A signal which is defined as On/Off or Yes/No.
These signals are not measurable across a range and are used
primarily for motor Start/Stop, run indication, device position and
alarms.
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Terminology, General
Variable- In a plant process, this would be any measurable or
controllable attribute such as temperature, pressure, flow, level,
weight, volume, etc.
Process Variable (PV)- The variable which is monitored and
maintained at a pre-defined level or setpointby use of the
Control Loop.
Manipulated Variable- The variable that is actually controlled thru
output from the controller to the Final Control Elementin order
to keep the Process Variableat its setpoint.
The Process and Manipulated Variables may be one and the same or
separate.
Control Loop- A design scheme which manages a single or
multiple pieces of equipment in order to manipulate a process.
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Terminology, General
Final Control Element- The device/equipment that is
controlled or managed thru output from the
Controllerin order to manipulate a process.
Input/Output- Also known as I/O, these are the
signals going to or coming from the controller in
order to monitor or control a process.
Input is from the field device to the controller and
output is from the controller to a field device. Always
thought of in terms of the Controller. setpoint- The
target value established for a process.
This is the value at which the Controllerwill
attempt to maintain a given process variable (PV)
thru manipulation of a Final Control Element.
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Terminology, General
Controller- A term used loosely to describe a piece of equipment
that Controlsa process variable or provides Displayat a
console. Commonly referred to as a DCSor PLC.
Error- A term used to define what happens when a Process
Variable (PV) moves outside its setpoint, an Erroris said to
exists.
Cascade Control- A design feature where one control loop is
nested inside another. In this type of Loop, the output from one
controller becomes the setpoint for the second controller.
Ratio Control- A control design where one process is kept at a
definite proportion to another process.
HMI or MMI- Human Machine or Man Machine Interface.
Describes a piece of equipment that allows one to Viewa
process inside the controller. The display console , USor
GUS.
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Terminology, General
Transient Response- Describes how the controller output in a
closed loop system responds.
Underdamped Response- Output reacts too quickly causing
oscillation above and below the setpoint before settling in to a
Steady State
Overdamped Response- Output reacts slowly causing long delays in
the process reaching a Steady State.
Critically Damped Response- Optimum output allowing the process
to reach a Steady Statein the shortest amount of time without
oscillating.
Steady State- Refers to the Process Variable returning to a
normal operating condition after a Transient Response has
occurred.
Steady State Error- Refers to the slight difference between the
actual output value and the desired output after a Transient
Response has occurred.
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Terminology, General
Stability- Ability of a system to attain Steady State control of the
Process Variable (PV) after it has responded to a change.
Sensitivity- Refers to the ratio of the percentage change in output
to the percentage change in input.
The effectiveness of the control system in responding to input
changes. Process Time Lag- Refers to the time it takes a system
to correct itself after a variable has changed. Dead Time- Refers
to the time when a process variable is moving outside setpoint
but the system has not yet sensed the need for correction.
This is dependant on where sensing devices are located and
how sensitive they and the controller are to change.
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HARDWARE, CONTROLLERS
PLC (Programmable Logic Controller)- Originally developed to
provide an automated replacement for the ON/OFF Relays used
in manufacturing. This was a Digital controller that was capable
of starting and stopping (ON/OFF) processes but had no
measuring capabilities (Analog).
Because of this limitation, the PLC was used primarily for Batch,
not Continuous Processes. Other limitations were, it had no
MMI/HMI capability, could not run other applications, could not
store historical data and could not provide trending.
Modern PLCs do have Analog capabilities for measuring but are
still suffer from the other limitations noted above. Modern PLCs
are still used primarily for Batch Processing and do not have the
capacity for data processing the DCS has!
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Hardware, Controllers
DCS (Distributed Control System)- The DCS was developed to
provide manufacturing processes with a total control system.
This system allowed for not only Digital (ON/OFF) but also
Analog (Measurable Across a Range) control.
The DCS gives the plant operators total control of all processes,
not just Batch. This new system also provided a means for
Viewingthe system through the Console or HMI/MMI.
This system is easily programmable from the console and also
allows for running business applications, historical data
gathering, trending and networking with other plant or company
locations through the plant communications system.
The latest Honeywell DCS is known as TPS or TOTAL PLANT
SOLUTIONS. The TPS is comprised of several individual pieces
of hardware which can be reviewed at the Honeywell Intra-net
Site.
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Hardware, Field Devices
ANALOG INPUT (EXAMPLES)
Transmitters -Temperature, Flow, Pressure and Level
Speed Sensors
Thermocouples (T/C)
RTDs
Valve Position Transmitters
Transducers (P/I)- Pneumatic to Impulse Converters
ANALOG OUTPUT (EXAMPLES)
Valve Positioners
Transducers (I/P)- Impulse to Pneumatic Converters
Speed Controller
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Hardware, Field Devices
DIGITAL INPUT (EXAMPLES)
Valve Position Switch
Level Switch
Switches in General
Interposing Relays (Voltage Step-up or Step-down Devices)
Motor Run Status
DIGITAL OUTPUT (EXAMPLES)
Solenoid Valves
Relays
Motor Starters
Alarms
Indication Lights
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PROGRAMMING, PID
PID is an acronym for PROPORTIONAL, INTEGRAL and
DERIVATIVE. These are forms of Pure Control which could also
be called forms of Analog Control.
PID is used when simple ON/OFF or Digital Control will not
suffice because a RANGE is required in the Final Control
Element.
These are DCS (Controller) programming types used individually
or combined to achieve the desired Process Control. When
combined, they are known as Composite.
THE FOLLOWING EXAMPLES ARE NOT INTENDED TO
EXPLAIN TO THE STUDENT HOW TO PROGRAM, BUT
RATHER TO FAMILIARIZE THE STUDENT WITH THE TERMS.
THE MECHANICS OF PROGRAMMING ARE COVERED IN
THE TPS COURSES WHICH ARE COVERED ELSEWHERE.
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(P)roportional Control
Gain
A form of control where the Final Control Element
such as a control valve will stroke open or closed
in some proportion to the change in Error.
(Deviation of Process Variable from setpoint).
The movement of this valve (OUTPUT) is fixed to a
percentage of change in the Process Variable (PV).
This type control does not respond well to long term or
steady state changes in the process.
Expressed Mathematically As:
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(I)ntegral Control
Proportional plus Reset
A form of control where the Final Control Element such as a
control valve will assume a new stable position while the
process variable returns to the setpoint. Stable position
means whatever position is necessary for the process to
return to setpoint.
The movement of this valve (Output) is in response to not only
the size of the error but also the length of time of the error.
The Final Control Element will settle (Reset) at a new position
required to return the process variable to setpoint.
Expressed Mathematically As:
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(D)erivative Control
Rate
A form of control where the Final Control Element
such as a control valve will open or close
additionally provided the error continues to change
(Up or Down).
The output to adjust the valve continues only while the
error continues to change. When the error stabilizes (even
if outside the setpoint) this type control stops.
This type control is generally not used alone but integrated
with Proportional or Proportional and Integral.
Expressed Mathematically As:
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Programming, ON/OFF
A form of control where the output is intended to
either turn on or turn off a Final Control Element such
as a pump. With this form, there is no range for the
position of the Final Control Element, only ON/OFF or
OPEN/CLOSED. Also known as a Digital Signal.
The output from the controller is simply a signal to a
device to start or stop and does not provide any type
of Measurable (Range) output.
Used primarily for solenoid valves (open/close),
pumps and motors (start/stop), relays (interposing),
alarms, indication lights and safety shutdown
systems.
The input from digital devices would be for position
or run indication such as valve positions, level
switches and motor run status.
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End
This is the end of this introduction to Process
Control Concepts.