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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
Condensate return
T(t)
T
Steam
Ti(t)
Process fluid
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).
Condensate return
T(t)
T
Steam
Ti(t)
Process fluid
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.
Condensate return
T(t)
T
Steam
Ti(t)
Process fluid
How it works?
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.
Condensate return
T(t)
T
Steam
Ti(t)
Process fluid
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:
Fig. 1-2 Heat exchanger control loop
T
Steam
Ti(t)
Process fluid
T(t)
TT
TC
SP
Condensate return
Sensor
Final control element
Transmitter
Controller
(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
(3) Controller compare the signal to the desired value, and decides what to do to maintain the temperature at its desired value.
(4) The controller sends a signal to the final control element to manipulate the steam flow.
Three components of all control systems:
Fig. 1-2 Heat exchanger control loop
(1)Sensor/transmitter( 检测 / 变送 ). The primary and secondary elements.(2) Controller( 控制器 ). The brain of the control system.
(3) Final control element( 执行器 ). A control valve, but not always. (variable-speed pumps, conveyors and electric motors)
T
Steam
Ti(t)
Process fluid
T(t)
TT
TC
SP
Condensate return
Sensor
Final control element
Transmitter
Controller
Three basic operations:
Fig. 1-2 Heat exchanger control loop
(1) Measurement(M). Measuring the variable to be controlled
(2) Decision(D). Based on the measurement, the controller decides what to do to maintain the variable at its desired value.
(3) Action(A). As a controller’s decision, the system must take an action. This is usually accomplished by the final control element.
T
Steam
Ti(t)
Process fluid
T(t)
TT
TC
SP
Condensate return
Sensor
Final control element
Transmitter
Controller
1.2 IMPORTANT TERMS • Controlled variable( 被控变量 )(process variable, measurement). The variable that must be controlled at some desired value.
• Set point( 设定值 ). The desired value of the controlled variable.
Fig. 1-2 Heat exchanger control loop
T
Steam
Ti(t)
Process fluid
T(t)
TT
TC
SP
Condensate return
Sensor
Final control element
Transmitter
Controller
•Controlled object or Process( 被控对象或过程 ). The object that need to be controlled.
• Disturbance ( 干扰 )(upset). Any variable that causes the controlled variable to deviate away from the set point.
• In the heat exchanger, possible disturbances. Inlet process temperature Ti(t), the process flow f(t), The energy content of the steam, ambient condition, process fluid composition and fouling.
T
Steam
Ti(t)
Process fluid
T(t)
TT
TC
SP
Condensate return
Sensor
Final control element
Transmitter
Controller
1.2 IMPORTANT TERMS
Fig. 1-2 Heat exchanger control loop
• Manipulated variable( 操纵变量 ). The variable used to maintain the controlled variable at its desired value.
• 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:
1.2 IMPORTANT TERMS
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.
Two types of control system:
(1) Regulatory control( 定值控制 ): 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.
1.3 TYPES OF CONTROL SYSTEM
(2) Servo control( 随动控制 ): 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.
Points :
(1) Feedback control (closed-loop control)
(2) Feedforward control (open-loop control)
1.4 CONTROL STRATEGIES
(3) Choose a proper control system
反馈控制 ( 闭环控制 )
前馈控制 ( 开环控制 )
• The block diagrams of feedback control
• The characteristics of feedback control
Points:
(1) Feedback control (closed-loop control)
• How it works?
(1) Feedback control (closed-loop control)
1.4 CONTROL STRATEGIES
•How it works?
If the inlet process temperature decreases, thus creating a disturbance, its effect must propagate through the heat exchanger before the outlet temperature decreases. Once the outlet temperature changes, the signal from the transmitter to the controller also changes.
T
Steam
Ti(t)
Process fluid
T(t)
TT
TC
SP
Condensate return
Sensor
Final control element
Transmitter
Controller
Fig. 1-2 Heat exchanger control loop
(1) Feedback control (closed-loop control)
1.4 CONTROL STRATEGIES
•How it works?
It is then that the controller becomes aware that a deviation from set point has occurred and it must compensate for the disturbance by manipulating the steam valve. The controller then signals the valve to increase its opening and thus increase the steam flow.
T
Steam
Ti(t)
Process fluid
T(t)
TT
TC
SP
Condensate return
Sensor
Final control element
Transmitter
Controller
Fig. 1-2 Heat exchanger control loop
The response of feedback control (closed-loop control)
1.4 CONTROL STRATEGIES
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.
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
TIME
TIME
TIME
Fig.1-3 Response of feedback control
INLE
T
TE
MP
ER
AT
UR
EO
UT
LET
T
EM
PE
RA
TU
RE
CO
NT
RO
LLE
R
OU
TP
UT
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.
TIME
TIME
TIME
Fig.1-3 Response of feedback control
INLE
T
TE
MP
ER
AT
UR
EO
UT
LET
T
EM
PE
RA
TU
RE
CO
NT
RO
LLE
R
OU
TP
UT
• The block diagrams of feedback control system
Fig 1-4 Block diagrams of closed-loop control systems
Controller Final control
element
Process
or plant
SP Output
Or
Controlled
variable
Sensor/
Transmitter
- Summing
junction
Disturbance 2 Disturbance 1
The advantage of feedback control
1.4 CONTROL STRATEGIES
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.
• The characteristics of feedback control
The disadvantage of feedback control
1.4 CONTROL STRATEGIES
Can compensate for a disturbance only AFTER the controlled variable has deviated from the set point because of the disturbance.
Can not give the controlled variable a timely control (laggard 滞后的 )
• The characteristics of feedback control
T
Steam
Ti(t)
Process fluid
T(t)
TT
TC
SP
Condensate return
Sensor
Final control element
Transmitter
Controller
• The block diagram of feedforward control
• The characteristics of feedforward control
Points:
(2) Feedforward control (open-loop 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.
• How it works?
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.
(2) Feedforward control (open-loop control)
TT
T
Steam
Ti(t)
Feedforward controller
SP
T(t)
Condensation retun
Fig 1-5 Feedforward control
Fig 1-5 shows this control strategy.
(2) Feedforward control (open-loop control)
Fig 1-5 Feedforward control
measure the inlet temperature
Feedforward controller makes the decision about how to manipulate the steam valve to maintain the controlled variable at set point.
TT
T
Steam
Ti(t)
Feedforward controller
SP
T(t)
Condensation retun
• The Block diagrams of Feedforward control
Fig 1-6 Block diagrams of feedforward control
Controller Final control
element
Process
or plant
SP
Process flow
Output
Or
Controlled
variable
Sensor/
Tranmitter
Disturbances
• The characteristics of feedforward control
Feedforward control cannot compensate for all disturbances that enter the process
The disadvantage of feedforward control
• The characteristics of feedforward control
T
Steam
Ti(t) f(t)
Feedforward controller
SP
TT
T(t)
Condensation retun
Fig 1-5 Feedforward control
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.
The disadvantage of feedforward control
• The characteristics of feedforward control
It has the characteristic of forward control
So, if we use this strategy correctly, the controlled variable will not deviate set point.
The advantage of feedforward control
TT
T
Steam
Ti(t)
Feedforward controller
SP
T(t)
Condensation retun
Fig 1-5 Feedforward control
Some examples:
Washing machine
Oven
Microwave oven
Air conditioner
Feedforward control system
Feedback control system
How to choose a proper control system?
? :
• Feedback control system
Review:
• Feedforward control system
(3) Choose a proper control system
• Proper Control System
• Can get the output that a process need
• Low cost
Feedforward Control System
Feedback Control System
Can not compensate all disturbances
Can compensate all disturbances
Simple structure Low cost
Complex structure
High cost
• Contrast
Trade-off:• Simplicity and low cost
• Complexity and higher cost
• ChoiceAn open-loop
system
A closed-loop
system
Premise: Ensure the requirement of industrial production
• Feedforward control with feedback control
T
Steam
Ti(t) f(t)
Feedforward controller
SP
TT
T(t)
Condensation retun
TC
TT
+
+
Fig 1-6 Feedforward control with feedback control
In this example, Feedforward control now compensate for the “major” disturbance; feedback control compensate for all other disturbances.
• feedforward control with feedback control
T
Steam
Ti(t) f(t)
Feedforward controller
SP
TT
T(t)
Condensation retun
TC
TT
+
+
Notice: the three basic operations, M,D,A are still present in this more “advanced” control strategy.
The sensors and transmitters perform the measurement.
Both feedforward and feedback controller make the decision.
The steam valve takes action.
Fig 1-6 Feedforward control with feedback control
• The need for automatic process control
• The principles of a control system, we can use three letters to describe, M, D and A
1.5 SUMMARY
• 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