C t l Loop
Control
L
Hardware
H d
The valve is a control engineers best
f i d!
friend!
Georgia Institute of Technology
School of Chemical Engineering
Control Relevant Aspects of
Control Loop Hardware
Necessary for control loop troubleshooting:
To determine if each subsystem (control
computer, actuator system, and sensor system)
is functioning properly
To understand the proper design and operation
of all the components that make-up each of the
subsystems of a control loop
Georgia Institute of Technology
School of Chemical Engineering
Control Diagram of a Typical
Control Loop
Actuator
System
F1
F2
T1
T2
Sensor
System
Controller
TC
T
TT
Georgia Institute of Technology
School of Chemical Engineering
Components and Signals of a
Typical Control Loop
F1
F2
T1
T2
Thermowell
3-15 psig
T
Air
I/P
Operator
Console
Georgia Institute of Technology
4 20 ma
4-20
Tsp
D/A
DCS
Control
Computer
Thermocouple
millivolt signal
A/D
4-20 ma
Transmitter
School of Chemical Engineering
Controllers/Control Computers
Pneumatic controllers
Electronic analog controllers
Supervisory control computers
Distributed Control Systems (DCS)
Fi ldb ttechnology
Fieldbus
h l
Georgia Institute of Technology
School of Chemical Engineering
Pneumatic Controllers - Phase I
Introduced in the 1920
1920ss
Installed in the field next to the valve
Use bellows, baffles, and nozzles with an
air supply to implement PID action.
Provided automatic control and replaced
manual control for many loops
Georgia Institute of Technology
School of Chemical Engineering
Pneumatic Controllers - Phase II
Transmitter type pneumatic controllers
began to replace field mounted controllers
in the late 1930s.
Controller located in control room with
pneumatic transmission from sensors to
control room and back to the valve.
valve
Allowed operators to address a number of
controllers from a centralized control room.
Georgia Institute of Technology
School of Chemical Engineering
Pneumatic Controller Installation
F1
F2
T1
T2
Thermowell
3-15 psig
T
Air
Tsp
Georgia Institute of Technology
Pneumatic
Controller
Th
Thermocouple
l
millivolt signal
3-15 psig
Air
Transmitter
School of Chemical Engineering
Electronic Analog Controllers
Became available in the late 1950
1950ss.
Replaced the pneumatic tubing with wires.
Used resistors, capacitors, and inductors to
implement PID action.
Out sold pneumatic by 1970.
1970
Allowed for advanced PID control: ratio,
feedforward, etc.
Georgia Institute of Technology
School of Chemical Engineering
Analog Controller Installation
F1
F2
T1
T2
Thermowell
3-15 psig
T
Air
I/P
4-20 ma
Th
Thermocouple
l
millivolt signal
Tsp
Georgia Institute of Technology
Electronic
Analog
Controller
4-20 ma
Transmitter
School of Chemical Engineering
Computer Control System
Based upon a mainframe digital computer.
computer
Offered the ability to use data storage and
retrieval, alarm functions, and process
optimization.
First installed on a refineryy in 1959.
Had reliability limitations.
Georgia Institute of Technology
School of Chemical Engineering
Supervisory Control Computer
Video Di
Vid
Display
l
Unit
Al
Alarming
i
Functions
Printer
Supervisory Control Computer
Analog
Control
Subsytem
Interfacing
Hardware
Data Storage
Acquisition
System
...
Georgia Institute of Technology
School of Chemical Engineering
Distributed Control System- DCS
Introduced in the late 1970
1970ss.
Based upon redundant microprocessors for
performing control functions for a part of
the plant. SUPERIOR RELIABILITY
Less expensive
p
per
p loop
p for large
g pplants.
Less expensive to expand.
Facilitates use of advanced control.
Georgia Institute of Technology
School of Chemical Engineering
DCS Architecture
System
Consoles
Host
Computer
Data
Storage
Unit
PLC
Data Highway
(Shared Communication Facilities)
Local
Console
C
l
Local
Control
Unit
Local
Control
Unit
..............
Local
Console
C
l
Process Transmitters and Actuators
Georgia Institute of Technology
School of Chemical Engineering
DCS and Troubleshooting
The data storage and trending capability of
a DCS greatly facilitate troubleshooting
control problems. That is, the sources of
process upsets can many times be tracked
down through the process by trending a
group of process measurements until the
source of the process upset is located.
Georgia Institute of Technology
School of Chemical Engineering
Control Relevant Aspects of a
DCS
The most important control aspect of a DCS
is the cycle time for controller calls. The
shortest cycle times are typically around 0.2
seconds while most loops can be executed
every 0.5 to 1.0 seconds. These cycle times
affect flow control loops and other fast
control loops.
Georgia Institute of Technology
School of Chemical Engineering
Fieldbus Technology
Based upon
p smart valves,, smart sensors and
controllers installed in the field.
Uses data highway to replace wires from sensor to
DCS and to the control valves.
Less expensive installations and better reliability.
Can mix different sources of sensors, transmitters,
and
d controll valves.
l
Now commercially available and should begin to
replace DCSs.
Georgia Institute of Technology
School of Chemical Engineering
Fieldbus Architecture
Plant-Wide Network
Local
Area
Network
Smart
Sensors
.................
Smart
Sensors
Smart Control
Valves and
Controllers
Fieldbus Network
Local
Area
Network
Smart Control
Valves and
Controllers
Fieldbus Network
a
Georgia Institute of Technology
School of Chemical Engineering
Actuator System
Control Valve
Valve body
Valve actuator
I/P converter
Instrument air system
Georgia Institute of Technology
School of Chemical Engineering
Typical Globe Control Valve
Georgia Institute of Technology
School of Chemical Engineering
10
Cross-section of a Globe Valve
Georgia Institute of Technology
School of Chemical Engineering
Balanced vs. Unbalanced Valves
Balanced Plug Valve
Georgia Institute of Technology
Unbalanced Plug Valve
School of Chemical Engineering
11
Valve Characteristics
Georgia Institute of Technology
School of Chemical Engineering
Types of Globe Valves
Quick OpeningOpening used for safety by-pass
by pass
applications where quick opening is desired
Equal Percentage- used for about 90% of
control valve applications since it results in
the most linear install characteristics
Linear- used when a relatively constant
pressure drop is maintained across the valve
Georgia Institute of Technology
School of Chemical Engineering
12
Installed Valve Characteristic
The linearity of the installed valve
characteristics determine the
operating range over which a control
valve can effectively operate.
Outside that range,
range the deadband of
the control valve will increase
significantly.
Georgia Institute of Technology
School of Chemical Engineering
Valve Deadband
It is the maximum change in instrument air
pressure to a valve that does not cause a change in
the flow rate through the valve.
Deadband determines the degree of precision that
a control valve or flow controller can provide.
Deadband is affected by the pressure drop across
the valve
valve, the wear on the valve,
valve and the design of
the valve plug and seat.
Georgia Institute of Technology
School of Chemical Engineering
13
Optional Equipment
Valve Positioner- a controller that adjusts the
instrument air in order to maintain the stem
position at the specified position. Greatly reduces
the deadband of the valve. Positioners are almost
always used on valves serviced by a DCS.
Booster Relay- provides high capacity air flow to
the actuator of a valve. Can significantly
g
y increase
the speed of large valves.
Georgia Institute of Technology
School of Chemical Engineering
Control Relevant Aspects of
Actuator Systems
The key factors are the deadband of the
actuator and the dynamic response as
indicated by the time constant of the valve.
Control valve by itself- deadband 10-25%
and a time constant of 3-15 seconds.
Control
C t l valve
l with
ith a valve
l positioner
iti
or in
i a
flow control loop- deadband 0.1-0.5% and a
time constant of 0.5-2 seconds.
Georgia Institute of Technology
School of Chemical Engineering
14
Sensor Systems
Sensor
temperature sensors
flow sensors
level sensors
pressure sensors
composition analyzers
Transmitter
Georgia Institute of Technology
School of Chemical Engineering
Sensor Terminology
Span
Zero
Accuracy
Repeatability
P
Process
measurementt dynamics
d
i
Calibration
Georgia Institute of Technology
School of Chemical Engineering
15
Span and Zero Example
Consider a case in which the maximum
temperature that is to be measured is 350F
and the minimum temperature is 100F.
Then the zero is 100F and the span is 250F
In addition, if the measured temperature is
k
known
att two
t different
diff
t sensor output
t t levels
l l
(i.e., mas), the span and zero can be
calculated directly.
Georgia Institute of Technology
School of Chemical Engineering
Smart Sensors
Sensors with onboard microprocesssors that
offer a number of diagnostic capabilities.
Smart pH sensors determine when it is
necessary to trigger a wash cycle due to
buildup on the electrode surface.
Smart flow meters????????
Smart thermocouples??????
Georgia Institute of Technology
School of Chemical Engineering
16
Temperature Sensing Systems
Thermocouple and RTDs are most common forms
RTDs
RTD are an order
d off magnitude
it d more precise
i but
b t
are less rugged and cost more than thermocouples.
Typical dynamic response time constant is 6-20
seconds.
Additional thermal resistance on inside or on the
outside of the thermal well can result in an
excessively slow responding temperature
measurement.
Georgia Institute of Technology
School of Chemical Engineering
Pressure Measurements
Usually based on strain gauges
Very fast measurement dynamics
time constant 0
Repeatability less than 0.1%
Georgia Institute of Technology
School of Chemical Engineering
17
Flow Measurements
Orifice plate/DP cell most common approach.
Good repeatability and fast dynamic response.
response
Magnet flow meters and vortex shedding flow
meters are also used in certain situations. They
are more expensive but more reliable and require
less maintenance.
A straight run of pipe before and after the meter is
required for good accuracy for all flow meters.
Georgia Institute of Technology
School of Chemical Engineering
Orifice Plate/DP Cell Flow
Indicator in a Flow Control Loop
FC
Flow Setpoint
FT
Georgia Institute of Technology
School of Chemical Engineering
18
Level Sensors
Usually based on the hydrostatic head in a
vessel measured by the differential pressure.
Has a repeatability of about 1% with a
time constant less than 1 second.
Level measurements based upon
p a float or
x-rays are also used in special situations.
Georgia Institute of Technology
School of Chemical Engineering
Typical Differential Pressure
Level Measurement
Upper Tap
Diaphragm
Vapor
DPT
Liq id
Liquid
Lower Tap
Georgia Institute of Technology
School of Chemical Engineering
19
Analyzer Sensor Systems
GC- most common composition analyzer. Based
on plug flow of a volatile sample through a packed
bed--behaves as deadtime. Deadtime and
repeatability depend on the particular components
being measured.
Radiation absorption- infrared, ultraviolet, and
visible. Can be effective for certain components.
Sampling system can affect dynamics and
reliability of composition measurement.
Georgia Institute of Technology
School of Chemical Engineering
20
