Control

9/12/1999
What This Presentation Covers: Functions of a Control system Basic Controller Terms:
SV PV2 MV
What a controller does. Some examples Control Modes:

MANUAL AUTO CASCADE
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Functions of the XL Control System

Monitor and display plant variables, eg: Flow, temperature, pressure, conductivity, pH, level etc
Alarm the operator to critical conditions. eg: High pH, low flow, high level, pump tripped etc
Control plant variables to Given Set Points, eg: Redox Tank pH, Saturator level, Lime Flow etc
Provide Long Term trending of key variables Control the sequence operation of the plant, eg: DAF plant start-up/shutdown, Lime slaker start-up/shutdown
Basic Controller Terms

A typical XL controller display is shown below
Process Variable (PV) More About Process Variable Set Point (SV) or Set Variable Output (MV) or Manipulated Variable
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Controller Terms - 1. Set Point

On the XL system the Set Point is abbreviated to SV. SV is short for Set Variable The Set Point of a controller is the desired value that the plant process needs to run at. The Controller set point may be: Fixed Adjustable by the operator Automatically adjusted by another controller
The reasons for choosing a set point may be: Environmental (eg pH set points) Safety related To give the best Process Operating Conditions (ie slaker temperature control, pH control, or level control etc)
Controller Terms - 2. Process Variable

On the XL system the Process Variable is abbreviated to PV. The Process Variable of a controller is the variable that is being controlled eg.
pH, Lime Flow, Saturator Level etc
The Process variable is generally measured by a field instrument e.g

Magnetic Flowmeter, Thermocouple, pH probe etc
The Controller will try to keep the Process Variable as close as possible to the Set Point
Controller Terms - 3. Output

On the XL system the Output is abbreviated to MV. MV is short for Manipulated Variable The Output of the controller is automatically varied or manipulated to control the Process Variable as close as possible to the Set Point The output of the controller has a range of 0-100% The output of the controller can go to one of two places depending on the control philosophy: To a control device such as a flow control valve, dosing pump or vibro feeder (typically 4 - 20 mA). Example, by changing its output, the controller can change the position of a valve which will then alter the flow passing through the valve. To the set point of another controller (Cascade Control) Cascade Control will be covered later in this presentation.
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Controller Example 1-Driving a Car

You are the Controller SV
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The Speed limit is the Set Point

60
PV
0 20 40 60 80 100 120 140 160 180
Your Speed is the Process Variable

60
PV
You look at the speedo You decide:Am I going too fast or Am I Going too slow ? You adjust your speed by adjusting the position of the accelerator pedal
0 20 40 60 80 100 120 140 160 180
10

60
PV
Output (MV) to Pedal
You look at the speedo You decide:Am I going too fast or Am I Going too slow ? You adjust your speed by adjusting the position of the accelerator pedal
0 20 40 60 80 100 120 140 160 180
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Controller Example 2-Taking a Shower

SV The Set Point is determined by what temperature you want
You are the Controller
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PV You are the Controller Your senses measure the temperature of the water
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PV You are the Controller You decide:Your senses measure Is the water too hot ? the temperature of the Is the water too cold ? water You adjust the temperature of the water by adjusting the position of the hot and cold water taps
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PV You are the Controller You decide:Your senses measure Is the water too hot ? the temperature of the Is the water too cold ? water You adjust the temperature of the water by adjusting the position of the hot and cold water taps
15
Output (MV) Taps

C H
Closed Loop Control

The two previous controller examples shown, represent what is called closed loop control. Definition Closed loop control is where a measured variable (PV) is compared to its desired value (SV) to produce an output signal (MV) which acts to minimise the difference between the PV and the SV The closed loop (Taking a shower) on slide 15 above, is made up of three parts common to all control systems: a Controller a Feedback signal (You); (Your hands);
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a Final Control Element (the taps).
Closed Loop Control

The controller receives the (PV) signal from the field measuring device (Transmitter). This is called feedback. It compares this feedback signal with the setpoint (SV), and generates an output signal (usually somewhere between 4 and 20 mA) which is sent to the Final Control Element (Usually a valve). The Final Control Element in turn varies the process thereby bringing it to the desired value or setpoint (SV). Therefore, our example represents a closed loop feedback control system. Feedback control systems make up the majority of control systems used in all plants throughout BHP.
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Controller Modes
A controller has 3 basic modes of operation
AUTO CASCADE MANUAL
The Controller mode determines: Where the Set Point (SV) comes from Auto or Cascade How the Controller Output (MV) is set Auto and cascade, or Manual
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Controller Modes
Symbols used in examples
Instrument (LIT= Lev Indicator Transmitter)
LIT 3030
The instrument (Level, flow, pH, conductivity transmitter) lives in the field.
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Controller Modes
LIT 3030
The instrument (Level, flow, pH, conductivity transmitter) lives in the field. Controller (FIC= Flow-Indicator-Controller)
FIC 3061
The square around the controller tells us that the controller lives in the XL Control System.
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Controller Modes
LIT 3030
The instrument (Level, flow, pH, conductivity transmitter) lives in the field. Controller (FIC= Flow-Indicator-Controller)
FIC 3061
The square around the controller tells us that the controller lives in the XL Control System. Final Control Element - Control Valve Although most Final Control Elements are control valves, some may be vibro feeders or variable speed and/or variable stroke pumps.
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Controller Modes Manual

The controller output (MV) is FIXED at a value set by the operator. Example: The DAF Mix tank Lime Flow Controller FIC3061 may be placed in Manual Mode allowing the Lime Flow Control valve to be moved to the position desired by the operator.
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Controller Modes - Manual-Example

DAF Mix Tank Lime Flow Controller
Lime Flow Control Valve
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Controller Modes - Manual-Example

DAF Mix Tank Lime Flow Controller
FIC 3061
Lime Flow Controller
Manually Set Desired Valve Position
0 to 100%
Lime Flow Control Valve Moves to position set by operator
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Controller Modes - Manual-Example DAF Mix Tank Lime Flow Controller

FIC 3061
Lime Flow Manually Set Desired Valve Position
Note:- The link between the controller and the valve is broken. The valve is positioned by the operator
Controller
0 to 100%
Lime Flow Control Valve Moves to position set by operator
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Controller Modes Auto

The controller output (MV) is adjusted AUTOMATICALLY to keep the Process Variable (PV) as close as possible to the Set Point (SV) The Controller Set Point is generally FIXED at some value which is entered by the Operator Example: The DAF Saturator level controller AUTOMATICALLY maintains the correct level by controlling the flow of water to the saturator. It does this by adjusting the position of the flow control valve. The Level Set Point is FIXED by the operator at 892mm
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Controller Modes-Auto-Example
DAF Saturator - Level Control
LIT 3050 Level (in mm) Measured by level transmitter This will be the Process Variable (PV)
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LIT 3050 Level (in mm) Measured by level transmitter This will be the Process Variable (PV)
Flow to Saturator adjusted by Control Valve
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Set Point (SV) in mm entered by the operator SV PV LIC 3050 MV
LIT 3050 Level Measured by level transmitter This will be the Process Variable (PV)
Output (MV) 0-100% sent the control valve
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Set Point (SV) in mm entered by the operator SV PV LIC 3050 MV The controller automatically controls the level in the saturator by adjusting the amount of water flowing to it
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Controller Modes-Auto-Example DAF Saturator - Level Control

1. Remember In AUTO mode the set Point is fixed by the operator
Set Point (SV) in mm entered by the operator SV PV LIC 3050 MV The controller automatically controls the level in the saturator by adjusting the amount of water flowing to the saturator
2. Remember Output (MV) 0-100% In AUTO mode thesent controller More the control its valve automatically adjusts output to try to maintain the PV at the Set Point
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Controller Modes Cascade

Cascade mode is similar to AUTO mode. The only difference is that the Controller Set Point varies and is set by the output of another controller. The controller output (MV) is adjusted automatically to keep the Process Variable (PV) as close as possible to the Set Point (SV) Example: The DAF Mix Tank lime flow Controller operates in CASCADE mode. It adjusts the flow of lime to the mix tank by adjusting the position of a control valve. The Lime flow set point is a adjusted by the Mix Tank pH controller
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Controller Modes-Cascade-Example
Mix Tank Lime Flow / pH Control
Lime Flow measured by Mag Flow Meter Mix Tank FT 3061
Lime To Tank Magnetic Flowmeter33
Lime Flow measured by Mag Flow Meter Mix Tank FT 3061
Lime To Tank Lime to Mix tank adjusted by Control Valve Magnetic Flowmeter34
The lime controller operates in CASCADE & controls the lime flow by adjusting the the lime flow control valve Mix Tank
SV FIC 3061 MV Lime Flow (l/m) measured by Mag Flow Meter FT 3061
PV
Where does the Lime Flow Set Point Come From ???
SV FIC 3061 MV Lime Flow (l/m) measured by Mag Flow Meter FT 3061
PV
The Lime Flow Set Point comes from the pH Controller. The pH Controller determines how much lime is required
pHC 3047L MV
Set Point (SV) FIC 3061 MV Lime Flow (l/m) measured by Mag Flow Meter FT 3061
PV
pH is measured and this is the Process pHT Variable(PV) for the 3047B pH Controller SV PV pHC 3047L MV SV The lime controller operates in CASCADE FIC 3061 MV Mix Tank Output (MV) 0-100% sent the control valve PV Lime Flow (l/m) measured by Mag Flow Meter FT 3061 The pH Controller operates in AUTO mode. Its Set Point (SV) is entered by the Operator
pH is measured and Cascade Loops have two controllers:this is the Process pHT Variable(PV) for the 3047B 1. Master Controller (eg pH controller) pH Controller This operates in AUTO mode and adjusts the set point of the Slave Controller SV PV pHC 3047L MV SV FIC 3061 MV Mix Tank Output (MV) 0-100% sent the control valve PV Lime Flow (l/m) measured by Mag Flow Meter FT 3061 The pH Controller operates in AUTO mode. Its Set Point (SV) is entered by the Operator
2. Slave Controller (eg Lime controller) This operated in CASCADEThe mode and lime controller receives its set point from the master operates in CASCADE controller
pH is measured and Cascade Loops have two controllers:this is the Process pHT Variable(PV) for the 3047B 1. Master Controller (eg pH controller) pH Controller This operates in AUTO mode and adjusts the set point of the Slave Controller SV PV pHC 3047L MV The pH Controller operates in AUTO mode. Its Set Point (SV) is entered by the Operator
2. Slave Controller (eg lime controller) This operated in CASCADEThe mode and lime controller receives its set point from the master operates in CASCADE controller
HOW IS THE SET POINT SV FIC CALCULATED Flow (l/m) 3061 PV ???? Lime measured by
MV Mag Flow Meter FT 3061
Mix Tank
Controller Modes-Cascade-Example Set Point Calculation

pHC 3047L
MV
The pH Controller output is ranged 0 to 100 %
SV
FIC 3061
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pHC 3047L
MV
The pH Controller output is ranged 0 to 100 % The Lime Controller set point is ranged 0 to 30 L/min
SV
FIC 3061
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pHC 3047L
MV
The pH Controller output is ranged 0 to 100 % The Lime Controller set point is ranged 0 to 30 L/min
The Lime Flow set point is calculated as follows:-
More
SV Lime Set Point = pH output % X Lime Maximum Range 100 Example:- If pH Output = 10% Lime Set Point = 10% X 100 = 3 L/min 30 L/min
FIC 3061
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Why Use CASCADE CONTROL ???

More
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Why Use Cascade Control

The question is often asked: Why not just have a single AUTO loop ?? Why not just have the output of the pH Controller going straight to the Lime Valve ?? These questions are best answered by looking at the implications of NOT having a CASCADE Loop.
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Let us assume that we do not have CASCADE control on the pH Loop. The pH loop is very slow to respond and thus has to be tuned to have a slow response. What would happen if there were a slight blockage in the lime pipework ??? The lime flow would fall, but there is no CASCADE flow controller, so the pH would slowly fall. The pH controller would then respond by slowly opening the lime valve. The result would be a large drop in pH followed by a slow recovery.
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What does the Cascade flow controller do for us ?? The flow controller will respond immediately to the lime blockage, because it is looking at the measured lime flow and has direct control over the lime flow control valve. By opening the control valve to quickly overcome the blockage only a small drop in pH is registered.
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The need for CASCADE control can be further examined by looking at the Lime Slaker Temperature Control loop This loop originally operated as an AUTO loop with the Temperature controller directly adjusting the Cooling Water Control Valve. It was necessary to convert this loop to a CASCADE flow control loop because the system was repeatedly tripping on Low Cooling Water Flow
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Lime Slaker - Original Control Philosophy

The Lime Flow Set Point comes from the pH Controller. The pH Controller determines how much lime is required Set Point (SV) 50 deg C
Temp Measured by a Thermocouple PV
Cooling Water Flow (l/m) measured by Mag Flow Meter FI 3027
TIC 3026 MV
Lime Slaker
Cooling Water to Slaker adjusted by Control Valve
Magnetic Flowmeter49
Lime Slaker - Original Control Philosophy - Problems

At Start-up TIC3026 would have a preset output of 35% The system had a low flow trip of 7 l/min. Depending on such factors as water pressure, instrument air pressure, the preset output of 35% to the control valve Set Point (SV) 50 deg C may or may not deliver the required 7 l/min The result was that the system frequently tripped on low flow Temp Measured by a Thermocouple PV
Cooling Water Flow (l/m) measured by Mag Flow Meter FI 3027
TIC 3026 MV
Lime Slaker
Lime Slaker - Solution

The new control system would need to guarantee that the Set Point (SV) low flow trip point was always exceeded 50 deg C This was done by introducing a CASCADE Flow Control loop The Temperature controller would now provide a set point to a new Flow Controller SV The new Flow controller would directly control the Cooling water valve. TIC 3026 PV MV SV Temp Measured by a Thermocouple Output (MV) 0-100% sent the control valve FIC 3027 MV PV Cooling Water Flow (l/m) measured by Mag Flow Meter
Lime Slaker

Set Point (SV) 50 deg C A low Limit is placed on TIC3026 Output. This corresponds to a minimum flow set point of 8 l/min PV
SV TIC 3026 MV SV
Temp Measured by a Thermocouple Output (MV) 0-100% sent the control valve
FIC 3027 MV
PV Cooling Water Flow (l/m) measured by Mag Flow Meter
Lime Slaker

Set Point (SV) 50 deg C A low Limit is placed on TIC3026 Output. This corresponds to a minimum flow set point of 8 l/min PV
SV TIC 3026 MV SV low limit guarantees that the This PVtrip point of low flow FIC 7 l/min is always exceeded. 3027 Lime trips Flow (l/m) The system no longer measured by MV on low flow Output (MV) Mag Flow 0-100% sent Meter the control valve
Temp Measured by a Thermocouple
Lime Slaker
Summary
In this lesson on Process Control Concepts, we have learnt about the following:
The main functions of the XL Control System.
To monitor, alarm, control and trend key plant variables.
The three Basic Control Terms:

PV SV MV Process Variable Set Variable Manipulated Variable
The three main parts of Closed Loop Feedback Control systems:

A Controller, Feedback signal, and Final Control Element.
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Summary
A controller has 3 basic modes of operation
MANUAL AUTO CASCADE MV set by the operator SV fixed and set by the operator, MV adjusted automatically Similar to Auto mode but the SV is varied by another controller (Master Controller)
The Controller mode determines: Where the Set Point (SV) comes from How the Controller Output (MV) is set
You have also seen some examples of why some control modes are used instead of others.
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Assessment
To check your understanding of the course content we would now ask you to complete the short written quiz supplied. This should only take about 15 - 20 minutes, and you may use the presentation to answer the questions. (Open Book) When you have finished, we will go through the answers and correct any mistakes or misunderstandings you may have about the course material Thank you for completing this course.
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9/12/1999

What a controller does. Some examples Control Modes:

Functions of the XL Control System

Basic Controller Terms

Controller Terms - 1. Set Point

Controller Terms - 2. Process Variable

The Process variable is generally measured by a field instrument e.g

Controller Terms - 3. Output

Controller Example 1-Driving a Car

Controller Example 1-Driving a Car

0 20 40 60 80 100 120 140 160 180

Your Speed is the Process Variable

Controller Example 1-Driving a Car

0 20 40 60 80 100 120 140 160 180

Your Speed is the Process Variable

Controller Example 1-Driving a Car

Output (MV) to Pedal

0 20 40 60 80 100 120 140 160 180

Your Speed is the Process Variable

Controller Example 2-Taking a Shower

You are the Controller

Controller Example 2-Taking a Shower

Controller Example 2-Taking a Shower

Controller Example 2-Taking a Shower

Output (MV) Taps

Closed Loop Control

a Final Control Element (the taps).

Closed Loop Control

Controller Modes Manual

Controller Modes - Manual-Example

Lime Flow Control Valve

Controller Modes - Manual-Example

Lime Flow Controller

Manually Set Desired Valve Position

Lime Flow Control Valve Moves to position set by operator

Controller Modes - Manual-Example DAF Mix Tank Lime Flow Controller

Lime Flow Control Valve Moves to position set by operator

Controller Modes Auto

Flow to Saturator adjusted by Control Valve

Output (MV) 0-100% sent the control valve

Flow to Saturator adjusted by Control Valve

Output (MV) 0-100% sent the control valve

Flow to Saturator adjusted by Control Valve

Controller Modes-Auto-Example DAF Saturator - Level Control

Flow to Saturator adjusted by Control Valve

Controller Modes Cascade

Lime Flow measured by Mag Flow Meter Mix Tank FT 3061

Lime To Tank Magnetic Flowmeter33

Lime Flow measured by Mag Flow Meter Mix Tank FT 3061

Output (MV) 0-100% sent the control valve

Output (MV) 0-100% sent the control valve

Output (MV) 0-100% sent the control valve

Output (MV) 0-100% sent the control valve

Controller Modes-Cascade-Example Set Point Calculation

The pH Controller output is ranged 0 to 100 %

Controller Modes-Cascade-Example Set Point Calculation

Controller Modes-Cascade-Example Set Point Calculation

Why Use CASCADE CONTROL ???

Why Use Cascade Control

Why Use Cascade Control

Why Use Cascade Control

Why Use Cascade Control

Lime Slaker - Original Control Philosophy