Teknik Kontrol

Mairodi,ST.,MT. Mairodi ST MT

Dosen Semester SKS Buku Referensi Jumlah Peserta Total

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Mairodi, ST.,MT. Genap 3 sks Programmable Logic Controller, Penulis: James A. Rehg dan Glenn J. Sartori ...

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 10 11. 12. 13. 14.

Pengantar Sistem Kontrol Pengantar PLC Field Devices Hardware PLC Driver Interface PLC Mengkonfigurasi PLC Software pemrograman PLC Sistem Bilangan dan Sistem Memory dalam PLC Logika Boolean dalam Pemrograman Instruksi Bit timer dan Counter Instruksi Matematika g p Instruksi Perbandingan/comparison Pengontrolan Variabel Analog Menggunakan PLC
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1. 1 Pengantar Sistem Kontrol

Loop Kontrol
Jenis Pengontrol: Analog dan digital On off On-off dan PID Feedback, Feedforward dan

Cascade Control

Controller

Actuator

Process

Sensor + Transmitter Tujuan Pengontrolan :

Menjaga/mempertahankan nilai besaran pada referensi tertentu Mengatasi gangguan/efek perubahan pada sistem Meningkatkan performansi sistem
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Contoh contoh Contoh-contoh pengontrol yang sering dipakai dalam industri :

Programmable logic controller (PLC) Microcontroller Mi t ll DCS (Distributed Control System) SCADA (Supervisory Control and Data Acquisition) System
DIBAHAS DALAM KULIAH INI

Definition (1) ( )
Process
A series of interrelated actions which transform material It covers all resources that are involved in the process and talks about process inputs (e.g. resources, raw material) and outputs (e.g. finished fi i h d product) d t)
Energies Out Raw Materials Products

Process
Energies Out

Control
To maintain desired conditions in a physical system by adjusting p y y y j g selected variables in the system
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Definition (2) ( )
Process Control
To maintain desired conditions in a physical system by adjusting selected variables in the system in spite of disturbances affecting the system and observation noise

Corrective Action

Process

Knowledge Information

Data

Daylife Example: Driving a Car

Control Objective (Setpoint):
Maintain car in proper lane

Controlled variable:
Location on the road

Brain: Control calculation

Eyes: Sensor

Manipulated variable:
Orientation of the front wheels

Actuator:
Steering wheel

Sensor:
Drivers D i eyes

Controller:
Driver

Disturbance:
Curve in road

Noise:
Rain, fog

Steering wheel: Actuator

Industrial Example #1: Heat Exchanger

Control Objective (Setpoint):
Maintain temperature

Controlled variable:
Outlet temperature of product stream

Manipulated variable:
Steam flow

Product Stream TT

TC

Steam

Actuator:
Control valve on steam line

Sensor:
Thermocouple on product stream

Controller:
Temperature controller

Disturbance:
Changes in the inlet feed temperature

Feed

Condensate

Noise:
Measurement noise

Industrial Example #2: Liquid Level C Control

Control Objective (Setpoint):
Maintain level

Controlled variable:
Fluid level in the tank Fluid

Manipulated variable:
Fluid flow

Actuator:
Control valve on fluid line

Sensor:
Level transmitter on the tank

LC

Controller:
Level controller

Disturbance:
Changes in the inlet feed flow

LT

Noise:
Measurement noise

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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

A t t Actuator
Adjust manipulated variable based on the value of the controller output signal

Process
Physical system to be controlled

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Istilah istilah Istilah-istilah (I)

Control Objective (Setpoint, SP) Controlled Variable (CV) or Process Variable (PV) Measured Process Variable (PVm) Controller Output (CO) Manipulated Variable (MV) Final Control Element (Actuator) Sensor/Transmitter Controller Disturbance Variable (DV) Measurement Noise

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Goal of Process Operation

Safety & Reliability Product Specification Environmental Regulation Operating Constraint Efficiency Maximum profit
24 hours process operation? Hmm I think, to achieve those, we need to continuously monitor & control the process 24 hours a day, 7 days a week!!!

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Safety and Reliability

The control system must provide safe operation
Alarms, safety constraint control, start-up and shutdown

A control system must be able to absorb a variety of disturbances and keep the process in a good operating region
Feed composition upsets, temporary loss of utilities (e.g., (e g steam supply), day to night variation in the supply) process

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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)
Old Controller New Controller N C ll

Imp purity Concen ntration

Imp purity Conce entration

Limit

Limit

Time

Time

Product certification procedures (e g ISO 9000) are (e.g., used to guarantee product quality and place a large emphasis on process control
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Environmental Regulation
Various government laws may specify that the temperatures, concentrations of chemicals, and flow rates of the effluents from a process p 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 lit f t t dt i l k

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Operational Constraint
All real process have constrained inherent to their operation which should be satisfied throughout the operation g p
Examples: Tank should not overflow or go dry g y Distillation column should not be flooded Catalytic reactor temperature should not exceed y p an upper limit since the catalyst will be destroyed

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Efficiency
The operation of a process should be as economical as possible i l ibl in utilization of raw material, energy and capital p

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Maximizing the Profit of a Plant (1)

The operation of a p p process may many y y times involves controlling against constraints Th closer th t you are able t The l that bl to operate to these constraints, the more profit you can make
Example: Maximizing the product production rate usually involving controlling the p y g g process against one or more process constraints

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Maximizing the Profit of a Plant (2)

Constraint control example: A reactor temperature control
At excessively high temperatures the reactor will experience a temperature runaway and explode But the higher the temperature the greater the product yield Therefore better reactor temperature control allows safe operation at a Therefore, higher reactor temperature and thus more profit

New Controller

Improved Performance

Im mpurity Conc centration

Limit

Im mpurity Conc centration

Limit

Time

Time
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The History of Process Control

1960s Pneumatic analog instrumentation, controllers, and computing modules 1970s Electronic analog instrumentation controllers and computing modules instrumentation, controllers,
Direct digital control with special algorithms programmed in main frame computer Supervisory and model predictive control configured in special purpose computers 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 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

1980s Electronic analog instrumentation and digital distributed control systems (DCS) 1990s Smart analog instrumentation, valves, and digital distributed control systems g g y

2000s Field bus based digital smart instrumentation, valves, and control systems

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Common Types of Control Strategy

Manual vs. Automatic Servo vs. Regulator Open-loop vs. Closed-loop Control strategies
Feedback Control Feedforward Control Cascade Control

Single-Input Single-Output (SISO) vs. Multi-Input MultiOutput (MIMO, also known as multivariable)

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Manual vs Automatic vs.

Temperature indicator

Manual
Human has to adjust the MV to obtain the desired value of the PV based on observation and prior experiences i i

Should I adjust the valve or h l should I run?

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?
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Regulator vs Servo vs.

Regulatory control
Follow constant setpoint, overcoming the disturbance

Servo control
Follow the changing setpoint

7.00 AM: 80 C 8.00 AM: 70o C o 9.00 9 00 AM: 60 C C 75.5o C 75.3o C o 75.4 C

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Open loop vs. Closed loop Open-loop vs Closed-loop

DV

Open-loop p p
Process is controlled based on predetermined scenario
Ex.: When food is done in an oven, timers on outdoor lights CO
Decisions

Process

PV

Controller C t ll
SP DV

Closed-loop
The information from sensor is used to adjust the MV to obtain the desired value of the PV
Decisions

CO

Process P

PV

Controller
SP
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Control Strategies (1)

Feedback Control
C Corrective action b ti ti based on process variable (PV) d i bl DV SP

Feedback CO Controller

Process

PV

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

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Control Strategies (2)

Feedforward Control
B Based on th measurement of disturbance (DV) d the t f di t b respond even before any changes occurs in PV feedforward controller can f df d t ll

DV

SP
Advantage

Feedforward CO Controller

Process

PV

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

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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/ Feedback Controller

Process

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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
SP DV1 DV

Outer Feedback Controller

Inner Feedback Controller

CO Inner Process

CO

Outer Process

PV

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Control Strategies (5)

Feedback/Feedforward + Cascade Control
Outer loop
DV

Inner loop
SP

DV1

Outer Feedback Controller C ll

Inner Feedback Controller

CO Inner Process

CO

Outer O ter Process

PV

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SISO vs. MIMO vs

Based on how many PV and MV we have in a process y p

SISO
DV CO
Decisions

MIMO
DVs

PV

Process

Decisions

COs CO

Process

PVs PV

Controller Controller

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Performances of Process Control System y

Closeness to setpoint Short transient to one setpoint to other setpoint 2 Smaller overshoot and less oscillation Smooth and minimum changes of variable 1, 2 manipulation Minimum usage of raw materials and energy 1, 2
1 Regulator 2 Servo

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Istilah istilah Istilah-istilah (II)

Manual control Automatic control Open-loop control Closed-loop control Feedback control Feedforward control f Cascade control
Servo control Regulatory control SISO control MIMO control Transient response Overshoot Oscillation O ill ti

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Ringkasan
Control has to do with adjusting manipulated variables of the process to maintain controlled variables at desired values All control loops have a controller, an actuator, a process, process and a sensor/transmitter Various controller strategies can be realized to achieve d i d process objectives & product hi desired bj ti d t specifications
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