THE INTRODUCTION OF AUTOMATIC PROCESS CONTROL

Xining Ye

GOAL:
Maintaining process variables (temperatures, pressures, flows, compositions, levels) at a desired operating value. Processes are dynamic in nature, and changes are always occurring. The important variables those related to safety, product quality, and production rates will not achieve design conditions.

POINTS:
1.1 PROCESS CONTROL SYSTEM

1.2 IMPORTANT TERMS 1.3 TYPES OF CONTROL SYSTEMS

1.4 CONTROL STRATEGIES 1.5 SUMMARY

1.1 PROCESS CONTROL SYSTEM Manual process control Automatic process control

1.1 PROCESS CONTROL SYSTEM

Steam Process fluid Ti(t) T Condensate return T(t)

Figure 1-1 Heat exchanger

The purpose of this unit: To heat the process fluid from some inlet temperature, Ti(t), up to a desired outlet temperature, T(t).

Steam Process fluid Ti(t) T Condensate return T(t)

Figure 1-1 Heat exchanger

In this process many variables can change, causing the outlet temperature to deviate from its desired value. If this happens, some action must be taken to correct for this deviation.

 Manual process control

(1) Measure the temperature T(t); (2) Compare it to its desired value

(3) Based on this comparison, decide what to do to correct for any deviation. The steam valve can be manipulated to correct for the deviation.
Steam Process fluid Ti(t) T Condensate return T(t)

How it works?
Steam Process fluid Ti(t) T Condensate return T(t)

If the outlet temperature T(t) is above its desired value, the steam valve can be throttled back to cut the steam flow(energy) to the heat exchanger; If the outlet temperature T(t) is below its desired value, the steam valve could be opened more to increase the steam flow to the heat exchanger.

Disadvantages of manual process control

(1) The operator should look at the temperature frequently to take corrective action whenever it deviates its desired value. (2) Different operators would make different decisions as to how to move the steam valve, resulting in inconsistent operation.
(3) This corrective procedure would require a large number of operators.

So, We would like to accomplish this control automatically. Without requiring intervention from the operator.

 Automatic process control:

SP

(1) Measure the outlet temperature of the process stream by a sensor(thermocouple, resistance temperature device, thermisters, etc.) (2) Transmitter transmits the signal to the controller
Process fluid

Controller Final control element

TC

Steam

Transmitter
TT

T(t) Ti(t) (3) Controller compare Sensor the signal to the desired T Condensate value, and decides what return to do to maintain the temperature at its desired Fig. 1-2 Heat exchanger control loop value.

(4) The controller sends a signal to the final control element to manipulate the steam flow.

Three components of all control systems:

SP

(1)Sensor/transmitter( /). The primary and secondary elements. (2) Controller(). The brain of the control system.

Controller Final control element

TC

Steam

Transmitter Process fluid

TT

(3) Final control T(t) Ti(t) Sensor element(). A T Condensate control valve, but not return always. (variablespeed pumps, Fig. 1-2 Heat exchanger control loop conveyors and electric motors)

Three basic operations:

SP

(1) Measurement(M). Measuring the variable to be controlled (2) Decision(D). Based on the measurement, the controller decides what to Process fluid do to maintain the Ti(t) variable at its desired value.

Controller Final control element

TC

Steam

Transmitter
TT

T(t) T Condensate return

Sensor

Fig. 1-2 Heat exchanger control loop (3) Action(A). As a controllers decision, the system must take an action. This is usually accomplished by the final control element.

1.2 IMPORTANT TERMS

Controlled variable()(process variable,
measurement). The variable that must be controlled at some desired value. SP

Controlled object or Process( ). The object that need to be controlled.

Process fluid

Controller Final control element

TC

Steam

Transmitter
TT

Set point(). The desired value of the controlled variable.

Ti(t) T Condensate return

T(t)

Sensor

Fig. 1-2 Heat exchanger control loop

1.2 IMPORTANT TERMS

Manipulated variable(). The variable used to maintain the controlled variable at its desired value. Disturbance ()(upset). Any variable that causes the SP controlled variable to TC deviate away from the set Controller Final control point. element Steam In the heat exchanger, possible disturbances. Transmitter Inlet process temperature TT Process fluid Ti(t), the process flow f(t), T(t) T (t) The energy content of the Sensor T steam, ambient condition, Condensate process fluid composition return and fouling. Fig. 1-2 Heat exchanger control loop
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1.2 IMPORTANT TERMS

NOTE. Disturbances are always occurring in processes, transient conditions are very common. It is because of these disturbances that automatic process control is needed. If there were no disturbances, design operating conditions would prevail, and there would be no necessity of continuously monitoring the process.

With these preceding terms defined, we can say: The objective of an automatic process control system is to adjust the manipulated variable to maintain the controlled variable at its set point in spite of disturbances.

 Why control is important?

(1) Safety: Prevent injury to plant personnel, protect the environment by preventing emission and minimizing waste and prevent damage to the process equipment.

(2) Maintain product quality (composition, purity, color, etc.) on a continuous basis and with minimum cost. (3) Maintain plant production rate at minimum cost.
So, we can say that the reasons for automation of process plants are to provide safety and at same time maintain desired product quality, high plant throughput, and reduce demand on human labor.

1.3 TYPES OF CONTROL SYSTEM

Two types of control system:

(1) Regulatory control(): In some processes the controlled variable deviated from the set point because of disturbances, regulatory control refers to systems designed to compensate for these disturbances.
(2) Servo control(): In some processes, the most important disturbance is the set point itself. That is, the set point may be changed as a function of time. Servo control refers to control systems designed for this purpose. In the process industries, regulatory control is far more common that servo control.

1.4 CONTROL STRATEGIES

Points
(1) Feedback control (closed-loop control) () (2) Feedforward control (open-loop control)

() (3) Choose a proper control system

(1) Feedback control (closed-loop control)

Points:
How it works?
The block diagrams of feedback control

The characteristics of feedback control

1.4 CONTROL STRATEGIES

(1) Feedback control (closed-loop control) How it works?
SP

If the inlet process TC Controller temperature decreases, Final control thus creating a disturbance, element Steam its effect must propagate through the heat exchanger Transmitter TT before the outlet Process fluid temperature decreases. T(t) Sensor Once the outlet temperature T (t) T changes, the signal from Condensate return the transmitter to the controller also changes. Fig. 1-2 Heat exchanger control loop
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1.4 CONTROL STRATEGIES

(1) Feedback control (closed-loop control) How it works?
SP

It is then that the controller TC Controller becomes aware that a Final control deviation from set point has element Steam occurred and it must compensate for the Transmitter TT disturbance by Process fluid manipulating the steam T(t) T (t) Sensor valve. The controller then T signals the valve to Condensate return increase its opening and thus increase the steam Fig. 1-2 Heat exchanger control loop flow.
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1.4 CONTROL STRATEGIES

The response of feedback control (closed-loop control)

This oscillatory response is typical of feedback control and shows that it is essentially a trial and error operation. That is, when the controller notices that the outlet temperature has decreased below the SET POINT, it signals the valve to open. But the opening is more

OUTLET TEMPERATURE

At first the outlet temperature decreases because of the decrease in inlet temperature, but then it increases, even above the set point and continuous to oscillate until it finally stabilizes.

INLET TEMPERATURE

TIME

TIME
CONTROLLER OUTPUT

TIME

Fig.1-3 Response of feedback control

1.4 CONTROL STRATEGIES

Than required. Therefore, the outlet temperature increases above the SET POINT. Noticing this, the controller signals the valve to close again somewhat to bring the temperature back down. This trial and error continued until the temperature reached and stayed at SET POINT.
INLET TEMPERATURE

TIME
OUTLET TEMPERATURE

TIME
CONTROLLER OUTPUT

TIME

Fig.1-3 Response of feedback control

 The block diagrams of feedback control system

Disturbance 1 Disturbance 2

SP Controller Summing junction

Final control element

Process or plant

Sensor/ Transmitter

Output Or Controlled variable

Fig 1-4 Block diagrams of closed-loop control systems

1.4 CONTROL STRATEGIES The characteristics of feedback control

The advantage of feedback control Compensate for all disturbances The result of any disturbance entering the process is to make the controlled variable deviate from the SET POINT. Once the controlled variable deviates from the set point, the controller changes its output to return the controlled variable to SET POINT(its desired value). The feedback control loop does not know, nor does it care, which disturbance enters the process. It only tries to maintain the controlled variable at set point, and in this way compensates for all disturbances. The feedback controller works with minimum knowledge of the process. Actually, the only information it needs is in which direction to move, and how much to move is usually adjusted by trial and error.

1.4 CONTROL STRATEGIES The characteristics of feedback control

The disadvantage of feedback control Can compensate for a disturbance only AFTER the controlled variable has deviated from the set point because of the disturbance.
SP
TC

Controller Final control element

Steam

Transmitter Process fluid Ti(t) T Condensate return

TT

Can not give the controlled variable a timely control (laggard )

T(t)

Sensor

(2) Feedforward control (open-loop control)

Points:
How it works?
The block diagram of feedforward control

The characteristics of feedforward control

 How it works?
The feedforward control is a very common control strategy in the process industries. It is the simplicity that accounts for its popularity.

The objective of feedforward control is to measure the disturbances and compensate for them before the controlled variable deviates from the set point. If applied correctly, the controlled variable deviation would be minimum.

(2) Feedforward control (open-loop control)

Suppose that major disturbance is the inlet temperature Ti(t). To implement feedforward control, this disturbance must first be measured and then a decision made as to manipulate the steam valve to compensate for them.
SP Feedforward controller

Steam
TT

Ti(t) T Condensation retun

T(t)

Fig 1-5 Feedforward control

(2) Feedforward control (open-loop control)

Fig 1-5 shows this control strategy. measure the inlet temperature
SP Feedforward controller

Steam
TT

Feedforward controller makes the decision about how to manipulate the steam valve to maintain the controlled variable at set point.

Ti(t) T Condensation retun

T(t)

Fig 1-5 Feedforward control

 The Block diagrams of Feedforward control

Sensor/ Tranmitter

Process flow Disturbances Output Or Controlled variable

SP Controller

Final control element

Process or plant

Fig 1-6 Block diagrams of feedforward control

 The characteristics of feedforward control The disadvantage of feedforward control

Feedforward control cannot compensate for all disturbances that enter the process

 The characteristics of feedforward control

The disadvantage of feedforward control

SP

In this example, The feedforward control system can compensate only one of disturbances. If any of the other disturbances enter the process, this strategy will not compensate for it, and the result will be a permanent deviation from set point of the controlled variable.

Feedforward controller

Steam
TT

f(t)

Ti(t) T Condensation retun

T(t)

Fig 1-5 Feedforward control

 The characteristics of feedforward control The advantage of feedforward control

SP

It has the characteristic of forward control

So, if we use this strategy correctly, the controlled variable will not deviate set point.

Feedforward controller

Steam
TT

Ti(t) T Condensation retun

T(t)

Fig 1-5 Feedforward control

Some examples: Washing machine

Oven Microwave oven Air conditioner

Feedforward control system

Feedback control system

(3) Choose a proper control system Review:

Feedback control system
Feedforward control system

?:
How to choose a proper control system?

 Proper Control System

Can get the output that a process need
Low cost

 Contrast
Feedforward Control System Feedback Control System

Can not compensate Can compensate all all disturbances disturbances Simple structure Low cost Complex structure High cost

 Choice

An open-loop
system

Simplicity and low cost Trade-off: Complexity and higher cost

Premise: Ensure the requirement of industrial production

A closed-loop system

 Feedforward control with feedback control

In this example, Feedforward control now compensate for the major disturbance; feedback control compensate for all other disturbances.
TC

SP Feedforward controller + +

Steam
TT TT

f(t)

Ti(t) T Condensation retun

T(t)

Fig 1-6 Feedforward control with feedback control

 feedforward control with feedback control

Notice: the three basic operations, M,D,A are still present in this more advanced control strategy. The sensors and transmitters perform the measurement.
TC

SP Feedforward controller + +

Steam
TT TT

f(t)

Ti(t) T Condensation retun

T(t)

Both feedforward and feedback controller make the decision. Fig 1-6 Feedforward control with feedback control The steam valve takes action.

1.5 SUMMARY

The need for automatic process control

The principles of a control system, we can use three letters to describe, M, D and A
Present the basic components of a process control system: sensor/transmitter, controller, and final control element

1.5 SUMMARY

Present two types of control strategies: Feedforward control or feedback control, we also discussed their advantages and disadvantages, Give the principles of choosing the proper control system