Pengendalian Proses

Priyatmadi Jurusan teknik Elektro FT UGM

Process Control Priyatmadi 2008

ARITHMETIC VERSUS LOGIC CONTROL

EXAMPLE OF ARITHMETIC CONTROL
PID control, fuzzy control, adaptive control etc

EXAMPLE OF LOGIC CONTROL

Start-stop motor, sequential control, emergency shut down system

COMBINATION OF ANALOG AND LOGIC CONTROL

Process Control Priyatmadi 2008 2

Arithmetic Control
Cold water in steam in 3-15psi Set point
I/P TIC TT

hot water out

4-20 mA Set point + e(t)

4-20 mA m(t) Plant c(t)

Controller

Sensor
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CONTROL ACTION
How to compute m(t) e(t) Controller m(t)

ON-OFF PROPORTIONAL (P) PROPORTIONAL + INTEGRAL (PI) PROPORTIONAL + DIFFERENTIAL (PD) PID + AUCTIONEERING RATIO CONTROL MODERN CONTROL
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Process Control Priyatmadi 2008

ON-OFF CONTROL ACTION

Set point r(t)

e(t)

Controller Sensor

m(t)

Plant

c(t)

c(t)

m(t) = M1 if e(t)>0 m(t) = M2 if e(t)<0

M1 M2 e

Process Control Priyatmadi 2008

ON-OFF CONTROL ACTION WITH GAP

Set point r(t)

e(t)

Controller Sensor

m(t)

Plant

c(t)

c(t)

m(t) = M1 if e(t)>e1 m(t) = M2 if e(t)<e2

M1 e2

e1 M2

Process Control Priyatmadi 2008

Example of ON-OFF action

qi(t)

h(t)

Level sensor qo(t)

Process Control Priyatmadi 2008

example

Process Control Priyatmadi 2008

Proportional Control Action

Set point r(t)

e(t)

m(t) Controller
Sensor

Plant

c(t)

c(t)

m(t)=Kpe(t)
e(t)

m(t)

Process Control Priyatmadi 2008

Integral Control Action

Set point r(t)

e(t)

Controller Sensor

m(t)

Plant

c(t)

c(t)

m(t)=Kie(t)dt
e(t)

m(t)
t

Process Control Priyatmadi 2008

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Derivative Control Action

Set point r(t)

e(t)

Controller Sensor

m(t)

Plant

c(t)

c(t)

m(t)=Kd(de(t)/dt)

e(t)

m(t)
t

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Problem in control
Stability Sensitivity Disturbance rejection Steady state accuracy Transient response Noise
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Process Control Priyatmadi 2008

STABILITY
y A control loop will be stable if at the frequency of oscillation that gives a total phase shift of 3600 around the loop, the gain around the loop is less then 1 Set point r(t)

e(t)

m(t) Controller
Sensor

Plant

c(t)

c(t)

Process Control Priyatmadi 2008

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OUTPUT OF CONTROL SYSTEM WHEN SET POINT IS RISEN Set point r(t)

e(t)

m(t) Controller
Sensor

Plant

c(t)

c(t)

c(t)

UNSTABLE r(t)

[n t
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SENSITIVITY
Sensitivity is a measure of changes in system characteristic due to changes in parameters. Example: Load change Sensor characteristic change Plant characteristic change etc. Controller can be design to be insensitive to one parameter but often it must be sensitive to the others.

Process Control Priyatmadi 2008

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Disturbance rejection
The input to the plant we manipulated is m(t). Plant also receives disturbance input that we do not control. The plant then can be modeled as follow
plant D(t) Gd(s) Gp(t) Gd(t)D(t)
+ +

R(r)

Gc M(t)

C(t)

H Methods to reduce Td(j[) 1. make Gd(s) small 2. increase loop gain by increasing Gc 3. reduced D(s) 4. use feed forward compensation

Process Control Priyatmadi 2008

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Disturbance rejection
Feedforward compensation Feedforward compensation can be applied if the disturbance can be measured.
D(s) Gcd(s)
+

plant Gd(s) Gd(s)D(s)

+

Gc

M(s)

Gp(s)

C(s)

R(s)

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5.5 Steady State Accuracy

c(t)

R(t)
+

E(t)

Gc

M(t)

Gp(t)

C(t)

R(t)

C(t)
[n t

ess

Used integrator to eliminate steady state error but be carefull system can be unstable
c(t)

r(t)

[n t
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Time Response of Control System The typical of unit step response of a system is as c(t) Mpt 1+ d 1.0 0.9 1 d 0.1 Tr
Process Control Priyatmadi 2008

css

Tp

Ts

[nt
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Problem of Noise
Random, meaningless signals can occur in many parts of control loops. These signals, often referred to as noise, can interfere with the intelligence of the signal. For example, heater control the cold water and heated water may not be completely intermixed by the time they reach the thermometer bulb. Slugs of cold water may alternate with hot water to give a rapidly fluctuating, wholly meaningless temperature signal at the bulb. If such a noise bearing signal is allowed to reach the controller, it may result in wild and meaningless corrections to the process, which may cause fluctuating or completely unstable automatic control.
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Problem of Noise
Similar noise problems can occur in connection with most signals, e.g.,
random pulsations in pressure signals, waves in liquid-level signals, turbulence in differential-measured flow signals, and induced currents in circuits (electromagnetic wave, lightning, groundloop, etc)
Process Control Priyatmadi 2008 21

Solutions to Noise Problem

Derivative action produces difficulties where noise exists and, therefore, it should generally not be used in such instances. Filtering or averaging the noise out of the signal. For example, in heater control the source of the thermal noise can be eliminated by better mixing of the hot and cold water in the tank or by using an averaging-type thermometer bulb that measures temperature over a considerable length instead of at one point.
Process Control Priyatmadi 2008 22

Solutions to Noise Problem

Reduction or elimination of the noise at its source, for example
rotary instead of reciprocating pumps to avoid pulsating pressures, larger mixing tanks or surge tanks, stirrers to obtain a uniform signal, longer pipe runs and straightening vanes in flow measurement, shielding of wires against stray voltages Use STP wires.

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Ratio Control
In ratio control, a predetermined ratio is maintained between two or more variables. Each controller has its own measured variable and output to a separate final control element. However, all set points are from a master primary signal that is modified by individual ratio settings A typical application of ratio control is the control of the fuel flow/airflow ratio in a combustion control system
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Process Control Priyatmadi 2008

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Auctioneering Control (Override Control, Limiting Control)

In suction and discharge pressure compressor control, the discharge control valve is normally regulated from the discharge pressure. However, if the suction pressure drops below its set point, control is transferred to the suction pressure controller. This prevents excessive suction on the supply side, from demand exceeding supply, with resultant compressor damage
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Auctioneering Control (Override Control, Limiting Control)

Process Control Priyatmadi 2008

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Modern Control Action

Fuzzy control Optimal control Sliding mode control Adaptive control (Self tuning control)

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Practical control system in Process Industry

The system measures the process, compares it to a set point, and then manipulates the output in the direction which should move the process toward the set point.

 Valves are usually non-linear. That is, the flow through the valve is not the same as the valve position. Several types of valves exist: Linear
Same gain regardless of valve position

Equal Percentage
Low gain when valve is nearly closed High gain when valve is nearly open

Quick Opening
High gain when valve is nearly closed Low gain when valve is nearly open

As we will see later, the gain of the process, including the valve, is very important to the tuning of the loop. If the controller is tuned for one process gain, it may not work for other process gains.

 At low flow, the head loss through the pipes is less, leaving a larger differential pressure across the valve. At high flow, the head loss through the pipe is more, leaving a smaller differential pressure across the valve.

Valves are usually either: Fail Closed, air to open or Fail Open, air to close

The Process Response to the Controller

Process Dynamics: Simple lag

Process Dynamics: Dead time

Measurement of dynamics

Disturbances

The PID algorithm

PROCESS ACTION Defines the relationship between changes in the valve and changes in the measurement. DIRECT : Increase in valve position causes an increase in the measurement. REVERSE :Increase in valve position causes a decrease in the measurement.

The PID algorithm

CONTROLLER ACTION Defines the relationship between changes in the measured variable and changes in the controller output. DIRECT Increase in measured variable causes an increase in the output. REVERSE Increase in measured variable causes a decrease in the output. The controller action must be the opposite of the process action.

Manual Mode

Automatic Mode:

Key concepts
The PID control algorithm does not "know" the correct output to bring the process to the setpoint.
It merely continues to move the output in the direction which should move the process toward the setpoint. The algorithm must have feedback (process measurement) to perform.

The PID algorithm must be "tuned" for the particular process loop. Without such tuning, it will not be able to function.
To be able to tune a PID loop, each of the terms of the PID equation must be understood. The tuning is based on the dynamics of the process response.

PID Tuning Informal methods

decay ration

PID Tuning Informal methods

Minimum overshoot.

PID Tuning Informal methods

Maximum disturbance rejection

PID Tuning Mathematical criteria

IAE - Integral of absolute value of error ISE - Integral of error squared ITAE - Integral of time times absolute value of error ITSE - Integral of time times error squared:

On-line trial tuning

The "by-guess-and-by-golly" method 1. Enter an initial set of tuning constants from experience. A conservative setting would be a gain of 1 or less and a reset of less than 0.1. 2. Put loop in automatic with process "lined out". 3. Make step changes (about 5%) in setpoint. 4. Compare response with diagrams and adjust.

Ziegler Nichols tuning method: open loop reaction rate

Also known as the "reaction curve" method. The process must be "lined out" not changing. With the controller in manual, the output is changed by a small amount. The process is monitored. The following measurements are made from the reaction curve: X % Change of output R %/min. Rate of change at the point of inflection (POI) D min. Time until the intercept of tangent line and original process value

Ziegler Nichols tuning method: open loop reaction rate

Gain Reset Derivative

P PI PID

X/DR 0.9X/DR 1.2X/DR

0.3/D 0.5/D

0.5D

Ziegler Nichols tuning method: closed loop

Place controller into automatic with low gain, no reset or derivative. Gradually increase gain, making small changes in the setpoint, until oscillations start. Adjust gain to make the oscillations continue with a constant amplitude. Note the gain (Ultimate Gain, Gu,) and Period (Ultimate Period, Pu.) The Ultimate Gain, Gu, is the gain at which the oscillations continue with a constant amplitude.

Ziegler Nichols tuning method: closed loop

Gain P PI PID 0.5 GU 0.45 GU 0.6 GU

Reset 1.2/Pu 2/Pu

Derivative Pu/8