Chemical Engineering 3P04

Process Control
Tutorial # 6
Learning goals

1. Learn basic principles of equipment in a control
loop
2. Build understanding of feedback loop
Loop Elements: Sensor Computer Valve
Why must we transmit these signals?
What is wrong with this picture?
Central control room
controller
Loop Elements: Sensor Computer Valve
Why must we transmit these signals?
Transmitted to/from
Central control room







Displayed locally




Manual valves



Loop Elements: Sensor Computer Valve
Why must we transmit these signals?
Transmitted to/from
Central control room
Safety related or
time critical
Used for control
Important for
quality, reliability,
performance
Trouble shoot and
monitor longer-term
behavior
Displayed locally


Manual valves





Loop Elements: Sensor Computer Valve
Why must we transmit these signals?
Transmitted to/from
Central control room
Safety related or
time critical
Used for control
Important for
quality, reliability,
performance
Trouble shoot and
monitor longer-term
behavior
Displayed locally
Used for local
maintenance/
operation
Not safety or time
critical
Manual valves
Infrequently adjusted
Not safety or time
critical
Central control
room
Loop Transmission: Why learn about it?
We need to understand
the closed-loop
We select equipment to
achieve required
performance
We trouble-shoot
problems
These are our senses
and our handles
?
Central control
room
Class workshop: What are general features that we
seek for the transmission of signals from the
sensor computer and from the computer valve?
Hint: We have lists of features for sensors and for valves already
Loop Transmission: Why learn about it?
Loop Transmission: What features do we seek?
Accuracy and reproducibility
Noise sensitivity
Reliability
Dynamics
Distance
Interoperability
Safety
Diagnostics
Cost
Class Workshop: Explain these
features
Typically much better
than sensors and valves
Dynamics: Transmission delays are in the feedback
loop. Delays in transmission are as bad as delays
in the process.

Good news: Electronic transmission is very fast
compared with other elements in the loop.

Caution: Old transmission systems using air
pressure (pneumatic signals) can be slow for
distance over 50 meters.
Loop Transmission: What features do we seek?
Distance: Process plants can extend over 1000s of
meters. The transmission must be capable of these
distances.

Good news: Electronic transmission via hard wire
has a large enough range.

Caution: Pneumatic signals have limited range.

Note: Telemetry is not now used for process control.
It is used for monitoring remote equipment (wells)
Loop Transmission: What features do we seek?
Interoperability
When you purchase one loop element from a
company, do you want to buy all other elements
from the same company for the life of the plant?
NO!
Standards are recognized so that equipment from
various manufacturers can be used
interchangeably. This was easy for older, analog
technology.
Standards are available for digital technology.
Loop Transmission: What features do we seek?
Loop Transmission: Two typical designs.
Life is exciting during a revolution!
Analog transmission
Continuous electronic signal
Digital transmission
Digital numeric representation
Older technology, but widely
employed and will be in use for
decades
Newer technology, generally used
in new facilities and when
replacing analog technology
Loop Elements: A Typical Analog Loop
I
t
CV CV
T t E
T
E K MV
CV SP E
n i
i
n
n n
d i i
I
n C n
n n n
+
(
(

+ A + =
=

=
=

0
1
) ( 1
Heating medium
fc i/p
Digital controller
Digital number
Thermocouple temperature
sensor, mV signal
transmitter
Analog signal transmission
(4-20 mA)
Digital number
Analog signal transmission
(4-20 mA)
Pneumatic signal
transmission
(3-15 psig)
Valve stem
position
0-100%)
D/A
A/D
Analog to digital
conversion
Digital to analog
conversion
Loop Elements: A Typical Analog Loop
I
t
CV CV
T t E
T
E K MV
CV SP E
n i
i
n
n n
d i i
I
n C n
n n n
+
(
(

+ A + =
=

=
=

0
1
) ( 1
Heating medium
fc i/p
Digital controller
Digital number
Thermocouple temperature
sensor, mV signal
transmitter
Analog signal transmission
(4-20 mA)
Digital number
Analog signal transmission
(4-20 mA)
Pneumatic signal
transmission
(3-15 psig)
Valve stem
position
0-100%)
145 C
7.734 mV
11.2 mA
14.08 mA 11.56 psig
63% open
D/A
A/D
Analog to digital
conversion
Digital to analog
conversion
Loop Elements: All digital transmission
Sensor/transmitter

Special
purpose
controllers:
safety, PLC,
etc.
History,
diagnosis,
optimization,
etc. data storage
and calculations

Digital controllers
(PID, etc.)
Process Process

Operators
consoles
-Processor
at every
sensor and
valve
Loop Elements: Life is exciting during a revolution!
Why have a micro-processor at every sensor and
valve?
Valve







Flow Sensor







Loop Elements: Life is exciting during a revolution!
Why have a micro-processor at every sensor and valve?
Valve







Flow Sensor
Improve accuracy
Correct for density
changes
Diagnose
performance and
warn when
degradation begins
Calibrate quickly
Power supply error
Loop Elements: Life is exciting during a revolution!
Why have a micro-processor at every sensor and valve?
Valve
Diagnose
performance and
warn when
degradation begins
Valve sticking
Air pressure low
Signal not received

Flow Sensor
Improve accuracy
Correct for density
changes
Diagnose
performance and
warn when
degradation begins
Calibrate quickly
Power supply error
Loop Elements: Life is exciting during a revolution!
Table 4.3.1 Typical communication for analog and digital transmission.
Loop elements
involved
Traditional, analog Enhanced, digital fieldbus
Sensor to controller Signal representing the
measured value sent to the
controller
To controller
- Measured value
- Diagnostic from sensor

To sensor
- Configuration of sensors (e.g., zero and span
values)

Calculations at sensor
- Filtering measurement
- Linearization
- Correction for process environment (e.g.,
orifice for fluid temperature and pressure) which
can require the use of several sensors
Controller to valve Output of controller
calculation sent to the
valve (i/p converter)
To valve (to the i/p converter)
- Output of controller
- Configuration of valve (max/min openings,
characteristic, etc.)

To controller
- position of stem position of valve
- diagnostic from valve

Calculations at valve
- Modification of relationship between control
signal and stem position to modify characteristic

Note that both
have two-way
communication
Loop Transmission: Two typical designs.
Life is exciting during a revolution!
Analog transmission
Continuous electronic signal
Digital transmission
Digital numeric representation
Older technology, but widely
employed and will be in use for
decades
Newer technology, generally used
in new facilities and when
replacing analog technology
Chemical Engineering 3P04
Process Control
Tutorial # 6
Learning goals

1. Learn basic principles of equipment in a control
loop
2. Build understanding of feedback loop
Lets look at
some examples
from Tutorial #7
FC
Flow Control:
Centrifugal pump with
constant speed (rpm)
Orifice plate sensor
Globe valve
(a)
a) The centrifugal pump increases the pressure of the fluid, i.e., it provides head.
The pump can operate at low or no flow, at least for a short time; the speed of the rotor
does not determine the flow through the pump. Thus, the fluid flow rate is determined by
the driving force (pressure) and the resistances to flow. The pump provides the driving
force and the valve provides an adjustable resistance. Opening the valve increases the
flow rate.

Yes, feedback control is possible. There is a causal relationship between the valve
(resistance) and the flow rate

The orifice plate is a good sensor for clean fluids, and the globe valve is the workhorse
control valve body in the process industries.
FC
Flow Control:
Positive displacement
pump
Orifice plate sensor
Butterfly valve
(b)
b) The positive displacement pump has moving components that define the liquid
flow rate by the speed of rotation or by the linear movement distance and speed.
Therefore the valve resistance does not affect the flow rate, and if the valve is closed too
far could result in damage to the pump.

No, feedback control is not possible in this situation. The operation of the pump
could be adjusted to influence the flow rate; in this case the control valve should be
removed.
FC
Flow Control:
Centrifugal pump with
variable speed driver
Orifice plate sensor

(c)
c) The pressure increase from a centrifugal pump depends
on the rotor speed the fast the rotation, the higher the pressure.
A variable speed motor can be adjusted to achieve the desired
flow rate, which is more energy efficient than adjusting a variable
pressure drop (valve) in the pipe. Increasing the speed increases
the flow rate.

Yes, feedback control is possible.
PC
Flows into the pipe
Flows exiting the pipe
Pressure Control:
Manipulate one exiting
flow
Flexible diaphragm
Globe valve
(h)
h) The pressure in a pipe can be controlled by adjusting one of the
flows. We can prove this by formulating a dynamic material balance.
Naturally, successful control can only be achieved over a range of flows;
when the valve is either fully opened or closed, control is no longer possible.

Yes, feedback control is possible.

A pressure sensor that deflected because of pressure and converted the
deflection to an electronic signal is used in such circumstances. A globe
valve is acceptable here.
PC
Pressure Control:
Manipulate exiting flow
from vessel
Piezoelectric
Globe valve
(i)
i) The pressure in a vessel can be controlled using the exit
(or inlet) flow. The principles are identical to the previous design.

Yes, feedback control is possible.

A piezoelectric sensor generates a small electronic signal when a
pressure is applied; it can be used in this application.
LC
Composition Control in isothermal CSTR
Manipulate the inlet flow
Control C
B

Ball valve
Level maintained constant by LC
AC
C
B

Reaction: A B C
(k)
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
volume / flow
C
o
n
c
e
n
t
r
a
t
i
o
n

o
f

B
CB can be
controlled;
increase the flow
rate to increase
CB
CB cannot be controlled by
adjusting F
CB can be
controlled;
decrease the flow
rate to increase
CB
k) The conversion
(or extent of reaction) depends
on the space time in the reactor.
Clearly, the flow rate affects
the space time.

However, this process is more complex, some might say, Tricky. For
control to be successful, we need to have a controller gain that has a non-
zero gain. The gain can be either positive or negative, but it should not
change sign! What happens in this example? The figure below shows that
the gain changes sign, because of the two reactions. In two regions,
control is possible, but would only function within the region. At the
maximum C
B
point, control is not possible by adjusting the feed flow rate.

While control is possible, great care would have to be employed when
implementing. A different manipulated variable, such as feed
concentration should be investigated.

A ball valve would be an acceptable choice.
LC
AC
C
B