Professional Documents
Culture Documents
Process Control
Principles and Technology
By
Finn Haugen
(Telemark University College)
Norway
In the woods and mountains lives the trolls.
Agenda:
• Why control?
• Feedback control
• Feedforward control
• Sequential control
• Industrial control hardware
• Control structures based on PID control:
• Cascade control
• Ratio control
• Flow smoothing using sluggish level control
• Plantwide control
• Practical demo: Temperature control of an air heater with LabVIEW and PC
• Practical demo: Data logging in the temperature control application
• Practical demo: Control of a pilot biogas reactor at Telemark University
College using LabVIEW (incl. remote operation over the Internet)
Why control?
• Product quality
• Product economy
• Safety
• Environment protection
• Comfort
• Feasibility
• Automation
Agenda:
• Why control?
• Feedback control
• Feedforward control
• Sequential control
• Industrial control hardware
• Control structures based on PID control:
• Cascade control
• Ratio control
• Flow smoothing using sluggish level control
• Plantwide control
• Practical demo: Temperature control of an air heater with LabVIEW and PC
• Practical demo: Data logging in the temperature control application
• Practical demo: Control of a pilot biogas reactor at Telemark University
College using LabVIEW (incl. remote operation over the Internet)
Feedback control
How do you act …
• While you are controlling the speed of your car to hold the
speed at the reference (desired) speed, whether uphill or
downhill?
Setpoint
or
In industrial control systems the controller is a
PID controller
(Proportional + Integral + Derivative)
(in steady-state).
P- and D-term
contributes with speed
in control action.
Example of feedback control: Level control of wood chip tank
Example: Simulation of level control system of wood chip tank
The simulation is run during the presentation.
This and other SimView simulators are available at http://techteach.no.
Another example: Temperature control system of liquid tank
Simulation is run during the presentation.
A feedback control system may become unstable!
Recall the control loop:
How to get back stability without increasing speed? Adjust controller parameters!
Agenda:
• Why control?
• Feedback control
• Feedforward control
• Sequential control
• Industrial control hardware
• Control structures based on PID control:
• Cascade control
• Ratio control
• Flow smoothing using sluggish level control
• Plantwide control
• Practical demo: Temperature control of an air heater with LabVIEW and PC
• Practical demo: Data logging in the temperature control application
• Practical demo: Control of a pilot biogas reactor at Telemark University
College using LabVIEW (incl. remote operation over the Internet)
Feedforward control
The purpose of feedforward control:
Faster setpoint tracking
and/or
Faster disturbance compensation
An SFC consists of
• Steps (or states)
• Actions
• Transitions
Example: Sequential control of a batch process
Simulation is run during the presentation.
Agenda:
• Why control?
• Feedback control
• Feedforward control
• Sequential control
• Industrial control hardware
• Control structures based on PID control:
• Cascade control
• Ratio control
• Flow smoothing using sluggish level control
• Plantwide control
• Practical demo: Temperature control of an air heater with LabVIEW and PC
• Practical demo: Data logging in the temperature control application
• Practical demo: Control of a pilot biogas reactor at Telemark University
College using LabVIEW (incl. remote operation over the Internet)
Industrial control hardware
Typical industrial automation system:
Control devices:
Process Controller
PLC (Programmable Logical Controller)
(ABB ECA600)
(Mitsubishi)
Equivalent:
F1 F1
Wild stream Wild stream
Process Process
F2 F2
u u
FT2 FC2 FT2 FFC
K
K F1 = F2SP
MULT FFC
(Flow
Fraction
Controller)
Measured K (specified
F1 ratio)
Agenda:
• Why control?
• Feedback control
• Feedforward control
• Sequential control
• Industrial control hardware
• Control structures based on PID control:
• Cascade control
• Ratio control
• Flow smoothing using sluggish level control
• Plantwide control
• Practical demo: Temperature control of an air heater with LabVIEW and PC
• Practical demo: Data logging in the temperature control application
• Practical demo: Control of a pilot biogas reactor at Telemark University
College using LabVIEW (incl. remote operation over the Internet)
Flow smoothing with sluggish level control
Below is typical configuration.
Simulation is run during the presentation.
Control systems specifications:
1. Outflow is as smooth as possible when inflow varies.
Implication: Level control action is sluggish so that the
manipulated outflow (level controller output) is as
smooth as possible.
Solution:
PI controller tuned to obtain as sluggish control as possible.
Agenda:
• Why control?
• Feedback control
• Feedforward control
• Sequential control
• Industrial control hardware
• Control structures based on PID control:
• Cascade control
• Ratio control
• Flow smoothing using sluggish level control
• Plantwide control
• Practical demo: Temperature control of an air heater with LabVIEW and PC
• Practical demo: Data logging in the temperature control application
• Practical demo: Control of a pilot biogas reactor at Telemark University
College using LabVIEW (incl. remote operation over the Internet)
Plantwide control
Requirements:
• Analog input (AI): 8 inputs with referenced single ended signal coupling, or 4
inputs with differential signal coupling. Voltage ranges: Between ±20V and ±1V.
Max sampling rate is 10000 S/s. 12 bits AD converter.
• Digital input (DI) and digital output (DO): 12 channels which can be used as
either DI or DO (configured individually). Roughly said: HIGH = 5 V. LOW = 0 V
(TTL).
To ventilation
Gas Cooling Device
H2 ppm Sensor
+ Gas/Liquid Separator FQR
PR
PR PDR
XC PR
Sieve
Feed Tank
(Apple waste)
Feed Pump
Sample port
Feed Tank
(reactor content)
Circulation Pump Sample
Sample
Sample port
port
port liquid
liquid
liquid
(liquid)
Sample port liquid
Pilot biogas reactor at TUC
Instrumentation
cabinet Fridge
Gas flow
Reactor meter
Hydrogen
Feed pump sensor
Recirculation Gas/liquid
pump separator
Barrel with
apple waste
Gasflow sensor
Hydrogen ppm sensor
PC with LabVIEW for supervision and control
Demo: Remote operation of the reactor with LogMeIn
Demo: Remote operation of the reactor with LogMeIn
Activity for the participants: