Controller Training
Controller Training
Controller Training
Process Dynamics
Feedback Control
Controller Tuning Procedure
Initial Tuning from Design Data
Process Dynamics
Two Main Types of Processes
Stable Processes
Unstable Processes
Ramp Processes
Exothermic Chemical Reactions
Stable Processes
First Order
Process Heaters
Flash Drums
Flow Controllers
Stable Process
Temperatures
Flows
Process Variable
(Controlled Variable)
Y
X
Controller Output (Manipulated Variable)
Time
STONE & WEBSTER
Kp x 63.2%
Y
X
1%
Kp
Kp (1 - e-1)
Yo
Y
X
Controller Output (Manipulated Variable)
Time
STONE & WEBSTER
y y0 Kp x
(1)
t -
1- e
(2)
IF, Kp 1, x 1, then
a) for t y y0
b) for t y y0 1 - e1 y0 0.632
c) for t y y0 1
STONE & WEBSTER
1st Order
Approximation
Time
dy
SLOPE
Kr
dt
Controller Output
(Manipulated Variable)
Time
dy
C 0
dt
C Constant
y y0 Kr t
(1)
(2)
Dead Time -
OUTFLOW
FLOW
1. CONTROLLER GAIN, K
AFFECTS RATIO OF:
2. RESET TIME, T
AFFECTS TIME FOR LEVEL TO
RETURN TO SETPOINT
HIGH LIMIT
LEVEL
SETPOINT
TIME
PV%
+5
+4
+3
+2
+1
0
(3.5 x 0.632)
3.5%
OP%
3.5
1.75
2.0
1.5min
0.75min
Kp
1.5
0.75
+2
+1
0
2%
0
TIME
STONE & WEBSTER
Feedback Control
Measurement
Setpoint Mechanism
Controller
Final Control Elements
Setpoint
Subtraction
Error
Controller
Calculation
Output
Process
Variable
Process
Measurement
Final Control
Element
Process
STONE & WEBSTER
On/Off Control
On
Off
Gap
PV
Setpoint
Gap
Time
Proportional Control
Effect of Tuning Constant on Control Action
Kc=2.0
Kc=4.0
Kc=6.0
Kc=8.0
Kc=10.0
Process
Variable
Setpoint
Input
Disturbance
+4%
+3%
+2%
+1%
Error
SP
-1%
-2%
+3
+2
+1
OP%
0
-1
Time
E = +2
b)T = 1:
c)T = 2:
d)T = 3:
e)T = 4:
f)T = 5:
g)T = 6:
h)T = 7:
Proportional Control
Error = SP-PV
(% Scale)
Process Variable
Error
PV
Steady State
Offset
Setpoint
Input
Disturbance
OP
Controller Output
Time
Proportional Control
Process
Variable
#2
Process
Variable
#1
Controller
Output
4
Time
8
STONE & WEBSTER
SP
PV #1
Low Kc
PV #1
SP
Average Kc
PV #1
SP
High Kc
Input
Disturbance
PV #3
PV #3
PV #3
SP
Low Kc
SP
Avg Kc
SP
High Kc
Input
Disturbance
0
Question:
4 5
Time
R=
1
TI
R
STONE & WEBSTER
Integral Control
(% Scale)
Error = SP-PV
PV
Input
Disturbance
OP
Time
+4%
+3%
+2%
+1%
ERROR
0
-1%
-2%
+20
+16
+12
+8
OP%
+4
0
0
TIME
Question:
The process variable changes direction at T=3 and begins to return to setpoint. Why does the controller output continue to increase?
Derivative Control
Error = SP-PV
Error = Error - Old Error
( Error) = Error - Old Error
Change in controller output proportional to change of
slope in error.
Derivative control is used to give the controller a slight
kick when the process variable begins to change, or
when it changes direction.
Implementation of derivative control requires in-depth
knowledge. Noisy signals can cause derivative
controllers to become oscillatory.
Details of derivative control are beyond the scope of this
course.
STONE & WEBSTER
1
OP Kc ERROR ERROR
TI
Kc Controller Gain
TI Integral (Reset) Time
PID Control
Integral
Action
Both
Prop.
Action
Both
Proportional
Action
PV
Controller
Output
Input
Disturbance
Error
OP%
+4%
+3%
+2%
+1%
0
-1%
-2%
20
16
12
8
4
0
-4
SP
Controller Tuning
Define Process Objectives
Minimize Error Between PV and SP
Minimize Movement of Controller Output
Eliminate Swinging
Respond to Upstream Disturbances
Objectives must be Prioritized for each Controller;
no Single Rule Applies for all Situations
PV
(PV x 0.632)
PV
(% Scale)
Output
%
PV %
Kp
OP %
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
Time (Minutes)
(Process Gain)
STONE & WEBSTER
Tuning
Formula
1
R = = Re peats/ Min
TI
STONE & WEBSTER
TC
TC
Slower
Fast
TC
Slowest
PV
20
40
60
80
Time (Minutes)
100
120
STONE & WEBSTER
1)
TC
STONE & WEBSTER
2)
TC
a)
LC
LC
c)
d)
BFW
STM DRUM
PC
LC
LC
Setpoint Change
B) Level Controller
A) Flow Controller
SP
SP
PV
PV
OP
OP
Time
Time
STONE & WEBSTER
1 1
Speed Factor
Kc
1
Kr 2
Speed Factor
<0.5
2) Bring Level Back to Setpoint
TI = 20 min (Average)
TI = 10 min (Fast)
TI = 40 min (Slow)
RESPONSE TEST
SLOPE: LEVEL
LEVEL
MINUTE
CONTROLLER
OUTPUT
PROCESS GAIN: KR =
10
15
20
25
30
LEVEL
MINUTE
CTR . OUTPUT
SLOPE OF OUTFLOW = 2 / 1 = 2
II
FLOW
SLOPE OF OUTFLOW
=2/2=1
INFLOW DISTURBANCE
OUTFLOW
ONE UNIT
OF TIME
I
OUTFLOW
TIME
HIGH LIMIT
ONE UNIT INFLOW
DISTURBANCE
FLOW
60 %
SLOPE OF OUTFLOW AND
CONTROLLER GAIN ( K )
INVERSELY PROPORTIONAL
WITH AVAILABLE VOLUME
OUTFLOW
HIGH LIMIT
ONE UNIT INFLOW
DISTURBANCE
70 %
OUTFLOW
[SETPOINT ASSUMED TO BE 50% IN BOTH CASES]
TIME
26.0 tons / hr
Density = 467 kg / m3
3400 mm ID
9700 mm, T - T
0 tons / hr
2.
3.
4.
5.
7.
8.
9.
Controller Tuning
Pressure Controllers
Pressure Control is a Ramp Process Similar to Level
Control
Pressure Measures Vapor Inventory; Level Measures
Liquid Inventory
In General, Pressure Needs to be Controlled Tightly,
Because Vapor/Liquid Equilibrium is Affected
This is Accomplished by Increasing Controller Gain
1
Kc
Kr
Speed Factor
2 1
Cascade Control
Why Use Cascade Control?
To Reject Measurable Disturbances That Have Faster
Dynamics Than The Primary Controller
EXAMPLE
LC
FC
PI
Cascade Control
CONTROL SYSTEM WHERE OUTPUT OF PRIMARY CONTROLLER
BECOMES SETPOINT OF SECONDARY CONTROLLER
A.)
B.)
PRIMARY
(MASTER)
LC
SECONDARY
(SLAVE)
FC
TC
FC
FUEL
Cascade Control
Requirements
Secondary (inner) loop dynamics must be at least 35 times faster than primary loop.
Sensors and control hardware for the secondary
loop must be installed/maintained.
The PV scale of the secondary loop must have wide
enough range so that the primary loop does not
wind up prematurely.
Multivariable Control
Simultaneous manipulation of multiple
independent variables in order to
control multiple dependent variables.
The primary advantage of multivariable
control is that interactions between
variables are accounted for in the
simultaneous move calculation.
STONE & WEBSTER
TI
FC
FEED
FC
FC
FUEL
AIR
(INDEPENDENT)
MANIPULATED
VARIABLES
(DEPENDENT)
CONTROLED
VARIABLES
FUEL FLOW
AIR FLOW
Variable Interaction
FUEL FLOW
S
CES
PRO
GAIN
PROCESS TEMPERATURE
EXCESS OXYGEN
PROCESS TEMPERATURE
AIR FLOW
EXCESS OXYGEN
Variable Interaction
MULTIVARIABLE GAIN MATRIX
PROCESS
TEMP.
EXCESS
OXYGEN
FUEL FLOW
G11
G12
AIR FLOW
G21
G22
Optimizing System
AI
O2
FC
HOT
FEED
TI
FC
COLD
FEED
FC
FC
FUEL
AIR
(INDEPENDENT)
MANIPULATED
VARIABLES
FUEL FLOW
AIR FLOW
HOT FEED FLOW
COLD FEED FLOW
(DEPENDENT)
CONTROLED
VARIABLES
OUTLET TEMPERATURE
FLUE GAS EXCESS O2
TOTAL FEED
Constrained System
AI
O2
FC
TI
TI
FEED
FC
FC
FUEL
DEGREES OF FREEDOM =
AIR
(INDEPENDENT)
MANIPULATED
VARIABLES
(DEPENDENT)
CONTROLED
VARIABLES
FUEL FLOW
AIR FLOW
Calculation of Multivariable11Solution
G11 X1 + G12 X2 + G1nXn - E1 = 0
G21 X1 + G22 X2 + G2nXn - E2 = 0
Gn1 X1 + Gn2 X2 + GnnXn - En = 0
Flow Controllers
Temperature Controllers
Level Controllers
Pressure Controllers