Chemical Engineering 3P04 Process Control Tutorial # 7 Learning goals

1. Experience with a single-loop controller

2. Answering some questions from PC-Education

An Introductory Experience with Feedback Control

We use many feedback controllers for a typical process Each controller has one measurement and one manipulated variable
PAH

TC-6

PC-1

Vapor product

Feed Methane Ethane (LK) Propane Butane Pentane

T1

T2

T5
LAL LAH

FC-1

T3

LC-1

F2

F3 AC-1 Process fluid Steam L. Key Liquid product

An Introductory Experience with Feedback Control

Lets look at one example feedback loop

v1 4-20 mA A Product composition T

4-20 mA

3-15 psi

control display and computer

v2

Heating medium

An Introductory Experience with Feedback Control

Our first task is to learn about the dynamics. We can apply the process reaction curve experiment.

v1 T A Product composition

3-15 psi

v2

Heating medium

An Introductory Experience with Feedback Control

DYNAMIC SIMULATION, Soop plots deviation variables
l

Mole fraction

Controlled Variable

1.5 1 0.5 0 -0.5

10

20

30

40

50 Time

60

70

80

90

100

minute
1.5

Manipulated Variable

% open

0.5

10

20

30

40

50 Time

60

70

80

90

100

An Introductory Experience with Feedback Control

Observations from the experiment. An increase in valve opening increases the concentration. The process gain is positive.

Time to steady-state is about 25 minutes.

Dead time is about 6 minutes and time constant is about 6 minutes.

The process is stable and overdamped.

The measurement has noise

An Introductory Experience with Feedback Control

The computer has a defined algorithm using the feedback measurement to determine the next value of the manipulated variable

Calculations are done every 1/3 second

The engineer enters the appropriate parameters

v1 T A Product composition

3-15 psi

v2

Heating medium

An Introductory Experience with Feedback Control

S-LOOP plots deviation variables (IAE = 108.3894)

Mole fraction

1.5

Controlled Variable

0.5

Parameter sets the aggressiveness of the controller.

-0.5

10

20

30

40

50 Time

60

70

80

90

minute

KC = 0
(Controller off)

100

Manipulated Variable

0.5

% open

-0.5

-1

10

20

30

40

50 Time

60

70

80

90

100

An Introductory Experience with Feedback Control Mole fraction

S-LOOP plots deviation variables (IAE = 30.8484) 1.2 1

Controlled Variable

0.8 0.6 0.4 0.2 0 -0.2 0 10 20 30 40 50 Time 60 70 80 90

Parameter sets the aggressiveness of the controller.

minute
0.5

KC = 0.3
100

Manipulated Variable

% open

-0.5

-1

-1.5

10

20

30

40

50 Time

60

70

80

90

100

An Introductory Experience with Feedback Control

S-LOOP plots deviation variables (IAE = 17.0748)

Mole fraction

1 0.8

Controlled Variable

0.6 0.4 0.2 0 -0.2 -0.4 0 10 20 30 40 50 Time 60 70 80 90

Parameter sets the aggressiveness of the controller.

0.5

minute

KC = 0.8

100

% open

Manipulated Variable

0 -0.5 -1 -1.5 -2

10

20

30

40

50 Time

60

70

80

90

100

An Introductory Experience with Feedback Control

S-LOOP plots deviation variables (IAE = 21.0976)

Mole fraction

Controlled Variable

0.5

Parameter sets the aggressiveness of the controller.

-0.5

-1

10

20

30

40

50 Time

60

70

80

90

0.5

minute

KC = 1.2

100

Manipulated Variable

0 -0.5 -1 -1.5 -2 -2.5 0 10 20 30 40 50 Time 60 70 80 90 100

% open

An Introductory Experience with Feedback Control

S-LOOP plots deviation variables (IAE = 74.5656)

Mole fraction

Controlled Variable

2 1 0 -1 -2

Parameter sets the aggressiveness of the controller.

10

20

30

40

50 Time

60

70

80

90

minute

KC = 1.8

100

Manipulated Variable

2 0 -2 -4 -6 -8 0 10 20 30 40 50 Time 60 70 80 90 100

% open

An Introductory Experience with Feedback Control

Observations from the samples of feedback performance. Feedback that is too weak takes a long time to compensate a disturbance Feedback that is too strong gives poor behavior and can result in instability Feedback can result in underdamped behavior for a process that is overdamped.

The process dynamics have the dominant effect on control performance.

An Introductory Experience with Feedback Control

Observations from the samples of feedback performance. Even the best behavior is not perfect. The process must be upset before feedback takes action. The valve must be moved to a different steadystate to compensate for a disturbance. We move the disturbance from the important controlled variable to the less important manipulated variable.

S_LOOP parameters for this example

****************************************************************** * S_LOOP: SINGLE LOOP CONTROL SYSTEM ANALYSIS * * MODIFY FEEDBACK PROCESS PARAMETERS, CV(s)/MV(s) = Gp(s) * * * * Kp (taulead(s)+1) exp (- theta(s)) * * Gp(s) = ------------------------------------------------* * (tau1(s)+1) (tau2(s)+1) (tau3^2(s)+2(tau3)xi(s)+1) * * * * * * Measurement noise can be added to the dynamic simulation * * (not the frequency response calculations) by setting kn * * greater than 0. * * * * noise standard deviation ~= 1.4 * kn * ****************************************************************** SELECT THE APPROPRIATE MENU ITEM MODIFY... PRESENT VALUES 1) Process Gain, Kp 1.0000 2) Dead time, theta 5.00 3) Time Constant, taulead (numerator) 0.00 4) Time Constant, tau1 (lag) 2.00 5) Time Constant, tau2 5.00 6) Time Constant, tau3 0.00 7) Damping Coef., xi 1.00 8) measurement noise magnitude, kn 9) Return to main menu Enter the desired selection: 0.05

S_LOOP parameters for this example

****************************************************************** * S_LOOP: SINGLE LOOP CONTROL SYSTEM ANALYSIS * * MODIFY DISTURBANCE PROCESS PARAMETERS, CV(s)/D(s) = Gd(s) * * * * Kd (tauleadd(s)+1) exp (- thetad(s)) * * Gd(s) = ------------------------------------------------------ * * (taud1(s)+1) (taud2(s)+1) (taud3^2(s)+2(taud3)xid(s)+1) * * * ****************************************************************** SELECT THE APPROPRIATE MENU ITEM MODIFY... PRESENT VALUES 1) Disturbance Gain, Kd 1.0000 2) Dead time, thetad 0.00 3) Time Constant, tauleadd(numerator) 0.00 4) Time Constant, taud1 (lag) 2.00 5) Time Constant, taud2 5.00 6) Time Constant, taud3 0.00 7) Damping Coef., xid 1.00 8) Return to main menu Enter the desired selection:

S_LOOP parameters for this example

************************************************************* * S_LOOP: SINGLE LOOP CONTROL SYSTEM ANALYSIS * * MODIFY PID CONTROLLER TUNING CONSTANTS * * /t * * MV(t) = Kc ( E(t) + (1/TI)| E(t) dt - Td (dCV(t)/dt) )* * 0/ * * * * MV(s) = Kc ( E(s) + E(s)/(TI s) - (Td s) CV(s) ) * * * * * * Hints: 1) Set Kc = 0 to turn controller off * * 2) Set TI = 0 to turn integral mode off * * 3) Units * * Kc has units of 1/Kp * * TI and Td have units of theta and tau * ************************************************************* SELECT THE APPROPRIATE MENU ITEM MODIFY... PRESENT VALUES 1) Controller Gain, Kc 1.80 2) Integral Time, TI 7.00 3) Derivative Time, Td 0.00 4) Return to main menu Enter the desired selection:

S_LOOP parameters for this example

************************************************************* * S_LOOP: SINGLE LOOP CONTROL SYSTEM DYNAMIC SIMULATION * * * * Hints: 1) All inputs are steps at 5% of total time * * 2) If Entry 5 is non-zero, PID controller * * is turned off * * 3) Select Time step (delta t) to approximate * * a) for the smallest time constant, * * (delta t) / tau = 0.05 * * b) dead time/ (delta t) = integer * * 4) Usually, (total time) / (time step) < 1000 * * 5) Digital controller exec time integer of * * simulation delta time * ************************************************************* SELECT THE APPROPRIATE MENU ITEM PRESENT VALUES 1) Total simulation time 99.50 2) Time step for simulation 0.200 3) Set point change 4) Disturbance change 5) Process reaction curve MV input 0.00 1.30 0.00

6) Select continuous/digital controller, currently continuous (Controller executed every simulation time step) 7) Execute dynamic simulation 8) Return to main menu Enter the desired selection:

Reinforcing PID Controller Concepts

Lets Perform the following exercises from PC-Education Interactive Learning Modules 8.5 8.9 and 8.13

Tutorial 8.5

(Problems with solutions it doesnt get any better than this!)