‘Instrumentation |for OperatorsPILOT SIX— INSTRUMENTATION FOR OPERATORS UNIT THREE— CONTROLLERS AND CONTROL MODES Section 1 Page Controllers .... : 3 ‘Why We TB cee 3 How a Controller Works .......... :4 ‘The Control Loop . 8 System Response : 9 Offect and Oscillation iu ‘Types of Controllers .. Seeeteeervetecs +22 On-Off Controllers. ......ccescosessesee ele Problems with an On-Off Controller . 215 Proportional Controllers . Ww The Throttling Range of the Valve 17 ‘The Throttling Range of the Controller 2 aL How the Proportional Band Affects Control 1 2 Review and Summary . veces BB Section 2 Proportional Controllers with Rate and Reset Action ........-....++ Process Load . Hear tea Feedback Bellows . peenteuetea tee needes How Load Changes Affect Proportional Controllers ‘Automatic Reset How Reset Action Is Measured Rate Action .......0...eseeseeeeeee ‘How the Feedback Bellows Can Affect Rate Action Section 3 Working with Controllers : 58. Introduction ... 7 - 58 Problems with Controller Settings ..... + BS How Control on One Process Affects An * 56 How Reset and Rate Action Affect Control . : 61 Working with the Control Mode ......... +. 6B ‘Who Should Adjust Controllers ... ee a - 65 3717INSTRUMENTATION FOR OPERATORS Unit 3 Controllers and Control Modes Section 1 ControllersUnit Three of Instrumentation for Operators explains the pur- poses and operation of automatic controllers and of control modes used in process control instruments. In Section 1 you will learn how controllers work, the nature of a control loop, and the factors in system response. You will learn about offset and oscillation, on-off controllers and proportional controllers, the throttling range of the valve and of the controller, and how the proportional band affects control. In Section 2 you will learn how changes in process load affect proportional controllers and how changes in process load can be compensated for by use of feedback bellows and by reset and rate action. In Section 3 you will learn how to work with controllers and contro] modes and how to identify controller problems.INSTRUCTIONS ‘This is a programed learning course. Programed learning gives information in a series of steps called frames. Each frame gives some information and asks you to make use of it. Here is how it works. First, cover the response column at the right with a mask. Read this frame and use the information it gives to fill in the blank. A micrometer is an instrument designed to measure in thousandths of an inch, A micrometer is a good tool for measuring very differences in size. Move the mask down to uncover the word at the right of the frame. If you have filled the blank with that word or a word that means the same, you are ready to go ahead to the next frame. ‘The drawing of a micrometer provides information that will help you fill in the next blanks. oBsecT TO BE MEASURED THIMBLE SPINDLE Ris RATCHET CAP Seven major parts are shown in the drawing, but only the_______and the _______ contact the object to be measured. small‘The next frame ealls for a choice. Circle or underline the ap- propriate word. Of the two parts that contact the object, only the (anvil/ spindle) moves. A program is a series of frames that work like the ones you have just done: Read the frame. Use the information to fill in the blanks or make a choice. ‘Move the mask down and cheek the response column, Go on to the next frame. Remember to cover the response column with a mask before you begin each page. spindleSECTION 1 CONTROLLERS ‘Why We Need Controllers 1 Process variables are controlled by opening and clos- gy See ee Let’s say that you want a flow rate of 100 gallons per minute for a process. ‘The control______is set to allow just 100 gallons of liquid per minute into the process. If the flow rate never changes from 100 gallons per minute: ‘A, you don’t need to adjust the control valve. —— B. you have to adjust the control valve con- stantly, ‘Let's say that there is a change in the pressure acting in the liquid which supplies the process. OLD LEVEL When the level in this tank changes, the pressure on the liquid _____. The flow rate to the process: A, stays at 100 gallons per minute. ——B. changes. To maintain the proper flow rate, the control valve must be valves valve changes, or decreases opened, or adjusteda. 10. ue ‘The control valve is adjusted by a controller. ‘The controller: ‘A. can be an operator. —-—B. can be an instrument. ©. can be either an operator or an instru- ment. In a modern installation, the controller is likely to be an (instrument/operator). |. The controller goes into action only when there is a process If there is no process change, the ______ does nothing. If process variables could be held perfectly constant, there would be no need for a controller. Is this likely to happen in a typicsl installation? Yes No How a Controller Works 12, 13. 14. 16. 16. ‘The controller is set to meet the target for the process variable being controlled. ‘The controller must adjust the —_____ to keep the process variables on target. ‘The target for the controller is called the set point. Let’s say a temperature measurement is on target. ‘The controller (reads/does not read) at the set point. If a temperature is not on target, the temperature in- dicator does not match the of the controller. A controller goes into action when: A. the process is off target. —_B. the process is on target. ‘When the process strays from the set point on any process variable, (all/some) controllers affecting that variable should react. instrument change, or upset controller No valve set point all17. The drawing represents a simple temperature control situation. A MEASURE B COMPARE ¢ CONTROL, The controller is the 18. His sense of ________ is the temperature indicator. 19. His_______opens or closes the valve. 20. His touch gives him information. He already “knows” what the set point should be. To find out whether the process is on target, he what he feels to the set point. 21, The controller first receives information from a ——______ device, and then ____ it to the desired set point. 22, If the process measurement and the set point are the same, the operator : A. makes an adjustment. B. does nothing. 28, But if the measurement and the set point are different, he adjusts the control 24, Let's say he closes the control valve to cool the process. How can he tell if the process has cooled? iis sense of ______indicates this. operator touch hand ‘compares measuring, or sensing; compares valve touch25. For every adjustment the controller makes, the meas- uring device must feed information back to indicate ‘what has happened, In the previous example, the operator gets feedback information from his. 26. These are the steps needed to control a process: ‘Step 1: The process variable is measured. Step 2: The measurement is. to the set point. Step 8: If there is a difference, the. is moved. Step 4: Some device gives the controller information. Step 5: This feedback “tells” the what has happened. 27. If the feedback does not match the set point on a mod- ern controller: A. the controller stops working. ——B. the controller keeps working until the set point is reached, 28, Put an A on the drawing to show where measuring is being done. Put a B to show where comparing is being done. Put a C to show where valve positioning is being done. Put a D to show where feedback is given. touch, or hand compared valve feedback controller29, 30. 31. 32. ‘This operating situation is slightly different from the previous one. THERMOMETER A MEASURE B COMPARE - C CONTROL ‘The operator gets a measurement and feedback from: A. his sense of touch. B. a reading on the thermometer dial. ‘The controller is the ‘The valve is adjusted (by hand/automatically). ‘This is an automatic contro! situation. SET POINT AIR SUPPLY tO} WATER STEAM ‘The process temperature is measured at (A/B/C). At B, the process measurement is ___to the set point. At C, the process is __. operator, or man by hand A ‘compared controlled, or regulatedThe 33, 84, 35. 36. 8T. 40, 41, Control Loop This diagram shows a complete control loop. CONTROLLER (ERROR DETECTION MEASUREMENT ‘COMPARISON ) MEASUREMENT, SET POINT $— error puuaee SIGNAL POSITION CONTROL A control loop consists of all the elements needed to ‘the movement of a valve, A control loop as shown above: ————A. is circular and closed. ——B. is open-ended. First, the process measuring element sends a signal to the controller. The controller is the _____ detector. At the same time, the already-determined —__ is fed into the controller (error detector). The error detector makes a____ between this signal from the process and the set point signal. If there is a difference between the measured signal and the set point: A. nothing happens. ——B. an error signal is sent to the positioner of the control valve. ‘The positioner adjusts the ______setting. The control valve changes the process. Information about this change is picked up by the instrument and fed into the controller. ‘This information is called process ______to the controller. control set point comparison valve measuring feedbackSystem Response 42, It takes time for the parts of the control loop to detect a process change, make a valve adjustment, and get process feedback. ‘The less time it takes, the (greater/lesser) the effi- ciency of the control loop. 43. The instruments should react as fast as it is practical for them to react when the ____ changes. 44, Sometimes there is a time lag in the instruments. JCONTROLLER These instruments are operating by (pneumatic/elec- trical) signals. 45. ‘The greater the distance the signals must be sent, the it takes to receive them. 46, This means that the instruments will not react imme- diately to 2 in process. 47. Sometimes there is a time lag between instrument changes and process changes. PROCESS CONTROL VALVE This control valve is (close to/far away from) the Process. 48, A change in the control valve position would affect the process (immediately /after some time lag) 9 greater Process pneumatic longer change far away from after some time lag49, 60. 51. 58. Once an adjustment has been made, it takes time for the process to change. 15 MINUTES With the amount of heat being applied to the beaker, an inerease in temperature from 40°F to 212°F re- quires 15 minutes. ‘Turning the heat up under this beaker (will/will not) cause it to reach 212°F instantly. ‘The temperature of the water (changes/does not change) immediately with an increase in heat. A temperature change in a process: A. will always occur immediately with a control valve change. —_B. may take time to occur, no matter how much the control valve is changed. ‘The time it takes for both the instruments and the process to change is called the system response. The system response indicates how control loop is moving. F Which of the following events occur in a system re- sponse? Yes © No Process measurement Error detection Error signal to control valve Control valve adjustment Process change Feedback from process Which of the following occur in the system response? A. Instrument response B, Process response ——. Both A and B 10 will not does not change fost ‘Yes Yes Yes Yes YesOffset and Oscillation 55. Offset occurs when the process measurement differs from the set point. SET POINT MEASUREMENT A B Instrument (A/B) shows offset. B 56. Recording instruments can be used to show process offset. A pointer shows where the set point is on this tempera- ture recorder. A_______.__ draws the process temperature as pen time passes. 57. Look at this drawing. When the process temperature is at the set point, the pen and the pointer are at the ____ point. same 58. When the pen moves away from the pointer, an —has occurred. i offset, or change59. When the process measurement keeps bouncing above and below the set point, the process is oscillating, SET POINT A B Recorder (A/B) shows an oscillating process. 60. What is going on in this process, according to these pressure recorders? ‘The process is at the set point. in ‘There is an offset recorded in: B. ac both B and C. ‘The process is oscillating in. TYPES OF CONTROLLERS ‘On-Off Controllers 61. There are three basic sections to any instrument con- trol system: an instrument to__________ the process; an instrument to_______the set point to this measurement; an instrument to position and adjust the control An on-off controller is one which keeps the control valve either fully open or fully 2 both B and C c ‘measure ‘compare valve closed63. This drawing represents the control loop for a simple on-off controller. ELECTRICAL SET POINT CONTACTS ADJUSTMENT ZZPQINTER BOURDON TUBE: OUTPUT SOLENOID VALVE ‘The process pressure is measured by a. 64. The bourdon tube is connected to a pointer. When the pointer moves back and forth, it opens and closes two _________ contacts. 65. The position of the bourdon tube acts as the (process/ set point) signal. 66. The set point is indicated by the position of one of these electrical. 67. The valve is positioned by a_______ coil. 68. Which of these parts is the error detector? A. Bourdon tube —_B. Pointer and electrical contacts —— 6. Solenoid coil 69. When the bourdon tube senses a prescure change, the pointer 70. When the contacts are closed, current flows to the 71. When this solenoid is energized, it positions the 72. The pointer, by either opening or closing electrical con- tacts, acts like (an on-off switch/an electrical trans- former). 18 bourdon tube electrical process contacts solenoid moves, or changes solenoid valve an on-off switeh78. Let’s say the set point for pressure is 20 PSIG. 74. 1. 76. 17. 8. SET POINT SOLENOID (ON-OFF) INPUT x. ELECTRICAL T= contacts: INPUT TO SENSOR. ‘The electrical contacts (open/close) if the pointer falls below 20 PSIG. ‘This activates the solenoid, whieh in turn the control valve, If pressure rises again, the electrical contacts open, and the control valve is______by the solenoid. ‘The pointer acts as the error detector, but it can only give two error signals: valve , or valve Since these are the only two settings, this kind of con- troller is called an controller. Identify the parts of this on-off control loop. ‘The measuring device is a The controller (error detector) is the Comparing the set point to the measured signal is done by the ‘The valve is positioned by the 4 coil, close opens closed open close on-off bourdon tube Pointer, or contacts pointer, or contacts solenoidProblems with an On-Off Controller 79. The most serious drawback with an on-off controller is that it can position a valve in only different settings. 80. ‘These graphs show process flow. VALVE OPEN VALVE CLOSED 0 5 10 15 20 25 30 MINUTES VALVE CLOSE 0 5 10 15 20 25 30 MINUTES B Graph (A/B) represents flow adjusted by an on-off system. 81. The following indicators show two offset measure- ments. SET POINT VALVE CLOSED An on-off controller changes the valve setting (the same amount/differently) for different process changes. 15 two the same amount83. 85. 86. An on-off controller treats a large offset (the same as/ differently from) a small offset. On-off controllers (are/are not) sensitive to differences in the amount of offset. Even if the amount of offset is tiny, the valve. all the way or _____alll the way. Which graph represents flow rate being controlled by an on-off controller? ~~~ {SET POINT FLow CHANGE TIME—___- A => --\----] SET POINT FLow CHANGE TIME B Graph (A/B). ‘The on-off control loop (is/is not) able to maintain a smooth, even flow rate. 16 the same as are not, opens closes is not87. A graph of flow controlled with an on-off controller Jooks like thi /ALVE OPEN SET POIN VALVE CLOSED. ‘The flow: ——— A. continually bounces above and below the set point. —_.B. is smooth and steady. 88. On-off controllers (allow/do not allow) the process to oscillate. 89, The process oscillates because the valve is constantly and 90. An on-off controller (gives/cannot give) steady control of the process. Proportional Controllers The Throttling Range of the Valve 91. On-off controllers cannot give exact control of a process because they react (the same way to/differently for) large and small deviations from the set point. 92. For more exact control, the controller must respond to the process change in proportion to the amount of change. Large changes should cause the controller to make ——______ changes in the valve setting, and small changes should cause _________valve changes. Ww allow opening; closing cannot give the same way to large small98, 95. 96. 97. 100. ‘To make proportional control possible, the valve must have: two settings, -—B. a range of positions between fully opened and fully closed. A proportional controller must be able to send (two different signals/a range of signals) to the control valve. A controller that sends a range of signals to the con- trol valve is called a_______ controller. Here is a valve operated by an air motor. The throt- Wing range of this valve is 8 to 15 PSIG. AIR PRESSURE When the valve is in the position shown in the drawing, the air pressure on the piston is (3 PSIG/more than 3 PSIG). This valve does not open fully until the pressure on the piston reaches_____ PSIG. This valve is open halfway when the pressure on the piston is__.__ PSIG. Three to 15 PSIG is the ______ range of this valve. ‘The controller's signals to the control valve must match the _______________ of the valve. The controller moves the valve proportionally to com- pensate for different rates and amounts of process 18 ‘a range of signals proportional more than 8 PSIG 16 throttling throttling range change, or variation+ 101. This control valve operates through a range of settings. ‘The valve must be shut completely when the liquid level reaches _______ feet. 10 102. Ten feet is (above/below) the set point. above 108. The set point is at 9 feet. FEET vo- SET POINT 9> s-| The valve (permits some flow/does not permit flow) permits some flow when the liquid level is at 9 feet. The valve must now be fully. opened 19105. The drawing shows a proportional control loop. ERROR DETECTOR (CONTROLLER) SET POINT MEASUREMENT RESTRICTION TAY ORIFICE This system sends (pneumatie/electrical) signals. 106. Process flow rate is being measured by a meter. 107. The flow meter sends a pressure signal to the (meas- urement/set point) bellows in the controller. 108. There are two bellows in this controller. One does the process measuring; the other gives the 109. The flapper pivoted between the two bellows acts as the error detector, As long as process pressure and set point pressure stay the same, the error detector (keeps changing /does not change) position. 110. Let’s say pressure in the process decreases. The error detector (moves/does not move). 111. As the flapper moves away from the nozzle, pressure in the pneumatic system connected to the air motor 112. ‘This change in pneumatie pressure acts as the signal. 118. ‘The pneumatic signal operates the air motor. ‘The air motor positions the 20 pneumatic flow measurement set point does not change moves changes, or decreases error valveThe Throttling Range of the Controller 114. 115. 16. ut. 118. The throttling range of a control valve is a range of (pneumatic system pressures/process measurements) . There is a range of process measurements within which the controller must keep the process. ‘This range of process measurements is the throttling range of the (controller/control valve) ‘The throttling range of a controller is sometimes called the proportional band. Which one of these values could represent a propor- tional band? 68 gallons per second —_ 68°F to 88°F ——— 100 PSIG ‘The range of process measurements between the con- trol valve being completely open or closed is called the ______ ef the controller. This pressure gage and controller are regulating proc- ess pressure. Identify the following points. A is the Bis the_____of the C is the ______of the 21 pneumatic system pressures controller 68°F to 88°F throttling range, or proportional band set point throttling range, or Proportional band; controller throttling range; valve119. 120. Set point is found on: proportional controllers only. all controllers. Throttling range is found on: proportional controllers only. on-off controllers only. How the Proportional Band Affects Control 121. Here are the dials of two controllers which have the 122, 123. 124. same set point. OPEN CLOSED OPEN CLOSED On controller A, the pressure must increase to PSIG to completely close the control valve and decrease to... PSIG to completely open the control valve. On controller B, pressure must increase to only PSIG to completely close the control valve and decrease to only _.___ PSIG to completely open the control valve, It takes a change of 5 PSIG from the set point to com- pletely open or close the valve on controller A. It takes a change of only. PSIG from the set point to completely open or close the valve on con- troller B. Controller (A/B) has the wider proportional band. 2 all controllers proportional controllers only 45 BL 49125. Let’s say process pressure changes 4 PSIG. SET POINT SET POINT 4 PSIG VALVE VALVE = VALVE VALVE OPEN CLOSED OPEN CLOSED A B Controller (A/B) would make the biggest change in B the valve setting. 126. Controller (A/B) reacts more sensitively to a change B in process pressure. 127. There are both advantages and disadvantages to mak- ing a controller more sensitive. One advantage of the more sensitive controller is that it ean keep the process closer to the —__ set point 128. But proportional controllers can be too sensitive, Making the proportional band narrower means that for every process change, the controller moves the control valve (more/less) more 129. Let's say that a proportional controller fully opens a valve for a change of 1 PSIG from the set point. 1 PSIG 5 PSIG FULLY OPENS FULLY OPENS VALVE VALVE A change of 5 PSIG gets (the same/a different) re- the same sponse as a change of 1 PSIG. 28180. If the process constantly changes by more than 1 PSIG, the controller will be treating all the changes above 1 PSIG (the same/differently). the same 181. Also, within its throttling range, the valve may be moved too far for the process change, OPEN CLOSED A B Graph (A/B) represents the valve movement of an A oversensitive proportional controller. 132. The proportional band can be made so narrow that the controller acts almost like an controller. on-off 188. Oversensitive controllers may cause the process to oscillate, or eyele 184. These graphs show valve setting changes during a Process change. VALVE FULLY OPEN VALVE FULLY CLOSED A B Graph (A/B) represents valve movement made by a A controller with the widest proportional band. 24185. The proportional band can be made so wide that it takes a very large process change to affect the valve setting. Assume that the controller is adjusted to a very wide proportional band setting, and the valve setting has not changed for 10 minutes. ‘Has the process remained steady during this time? Yes No Can't tell from the information given Review and Summary 186. A controller goes into action only when there is a Process 187. Here is what happens in a control loop: A. The process variable is B. This measurement of process is compared to the in the controller. C. If there is a difference, the controller's output changes, and the control setting is changed. D. The measuring device continues to send process in- formation back to the Thi information is called process E. If the last valve change did not correct the upset, the controller makes a further 188. Which graph shows offset? SET POINT Graph (A/B). Can’t tell from the informa- tion given change measured set point valve controller feedback change139. Which graph shows oscillation? SET POINT ve A Graph (A/B). 140. So far, we have discussed two basic types of con- trollers : —_——-—_-_________ controllers, and controllers, 141. A throttling range is a feature of trollers. _____eon- 26 on-off proportional proportionalSection 2 Proportional Controllers with Rate and Reset ActionSECTION 2 PROPORTIONAL CONTROLLERS WITH RATE AND RESET ACTION Process Load 1. The load on a process is like the load on an engine. ‘This engine is driving an empty truck at 50 MPH. The load on the engine is the: road surface. size of the engine. ———— empty truck. 2. As long as the truck stays empty and is driven on a level road at 50 MPH, the load (changes/does not change). 3. What happens now that the weight of the truck has increased? ‘The speed of the truck unless. more fuel is fed into the engine. 4. Putting more weight on the truck is the same as in- creasing the__________on the engine, if speed stays the same. 27 empty truck does not change decreases: load10. 1. 12. 13. ua. Let's say that we want the truck to move faster. More_____is fed to the engine. Demanding more speed from the truck (incresses/ decreases) the load on the engine. ‘The total weight to be moved and the speed at which it must be moved is the ______on the engine. As long as the weight moved by the engine stays the same, and the speed at which the truck is driven on a evel road stays the same, the _________stays the same. Sometimes the truck will come to a curve and must slow down. 50 MPH 50 MPH THROTTLE ADJUSTMENT, 40 MPH ‘The throttle will have to make an adjustment to change the ___*____ of the truck. ‘What will happen if we do not adjust the throttle again after passing the curve? A. The truck will return to 50 MPH. ———B. The truck will continue going 40 MPH. Even a temporary adjustment for a curve changes the on the engine. After the truck is returned to 50 MPH, the load on the truck has (changed/returned to the same level). Which of the following can cause a load change? ‘The weight on the truck is reduced. (Yes/No) ‘The truck must be driven up 2 hill at the same speed. (Yes/No) The truck slows down for a curve. (Yes/No) In the truck, we demand output from the engine. Do we demand output from an industrial process? (Yes/No) 28 fuel increases load load speed B Toad returned to the same level Yes Yes Yes Yes15. There is a_______on each process. 16. The load on a process acts like the load on an engine. KEROSINE DISTILLATE 500 BARRELS PER HOUR This process is required to separate barrels of kerosine per hour. 17. The amount of material and the speed at which it must be produced is the _______on this process. 18." Reducing this output to 100 barrels an hour, under the same conditions, is the same as reducing the 19. Let's say that the pressure of liquid entering this proc- ess drops. The process must be adjusted to maintain Production of 500 barrels an hour. 30 PSIG COSI aad 500 BARRELS BARRELS PER HOUR PER HOUR ‘This (is/is not) the same as an increase in load. 29 load load20. ‘The drawing shows three different valve settings. 30 PSIG ar Psig 20 PSIG nee Psi 10 PSIG =e a PSIG ‘The pressure pushing liquid through the valves is (the same/different). 21, For each valve setting there: are several flow rates. is one flow rate. 22, We want to open a valve so that the flow rate equals a specified set, point. Under one load condition, how many valve positions will give us the desired set point? —— Several positions ‘One position 28. Proportional controllers are aligned for one load con- dition. With these controllers, there (are several valve posi- tions/is only one valve position) that will give the set point as long as the load does not change. 24. Sometimes there is a hill or “curve” in the process, or slight variations in load, that the controller must adjust for. ‘The controller must move the 25. But, after the adjustment, if the load has not changed, ‘the control valve should (move to a new/go back to the old) set point position. 80 the same is one flow rate ‘One position is only one valve position valve go back to the old26. Look at the pressure gage in this pneumatic controller. FLAPPER For each pressure setting in the pneumatic system: A. there are several valve positions. B, there is only one valve position. B 27. When this contrdller is at set point, there is just one output setting to the control valve. pressure 28. Each flapper position produces (one/several) pressure one setting (s). 29. Under one load condition, in this controller: ——— A. there is just one flapper position which A will maintain the process at the set point. ——B. there are several flapper positions which ‘will maintain the process at the set point. 30. If the flapper moves, the control valve (moves/does not move). moves 81. To change the control valve the right amount to keep the process stable at its desired set point, the output —_____—to the control valve must become bal- pressure anced to the need of the process, and the —___ flapper ‘must be returned to its set point position. 31Feedback Bellows 82. This pneumatic controller is controlling liquid flow. © If the flow falls below the set point, the controller the control valve. 88. Does the process change occur immediately when a valve position changes? (Yes/No) 34, The controller is normally at a distance from the Process. When the flow rate changes, does the controller get this feedback information immediately? (Yes/No) 85. Are there any time lags between events in the system response? (Yes/No) 86, Let’s say that flow rate in the process reached the set point. ‘Would the controller get this information immediately? (Yes/No) 87. The controller cannot find the correct valve position until it gets ________from the process measure- ment. 88. Since feedback is not immediate, the controller con- ~ tinues to keep the valve position open as if the process were not at the — 89. The controller will probably: A. find the set point. B. overshoot the set point. 32 opens No No Yes feedback set point40. ‘This is what happens when the controller does not get immediate feedback. ERROR DETECTOR (CONTROLLER) ALIGNMEN’ ADJUSTMENT. Flow rate starts to fall, and a steadily decreasing sig- nal is sent into the controller. ‘The control valve starts to 41. The control valve brings the flow rate back to the right rate, but the controller does not get this information immediately. The signal to the controller: A. is still decreasing. B. has started to increase. 42. If it does not get process feedback information, the con- troller may continue to move the control valve to a fully position. 48. Finally, the controller receives the process feedback, and the control valve starts to close. With the lag in process feedback, the control will probably: A. find the set point position. B. overshoot the set point position. With delayed process feedback, this controller acts more like an controller than a proportional controller. 45. What do we want this controller to do if there is a temporary change in load? Yes No Correet for any flow change Return to the set point position Overshoot the set point 88 || | open open on-off ‘Yes Yes No46. To prevent overshooting, the controller needs feedback (before/after/at the time that) the process measure- ment can supply it. 41. The controller feedback bellows is a device that can supply feedback to the controller before the process measurement can. SET POINT MEASUREMENT (OOH +0000 ouTPuT FEEDBACK BELLOWS SUPPLY ‘The feedback bellows is attached to the 48. The measurement bellows and the set point bellows are also attached to the . 49. The feedback bellows receives its pressure from the ——_____ going to the control valve. 50. Any change in the controller's output will the feedback bellows. 51. Let's say there is an inerease in the process flow rate. SET POINT MEASUREMENT SUPPLY m7. Cees FEEDBACK BELLOWS SUEY ‘The measuring bellows moves the flapper to the (right/ left) and (opens/closes) the flapper nozzle. 34 before flapper flapper output, or air move, or operate, or change left; closes62. Pneumatic output pressure and starts increases to close the control valve. 58, Pressure in the feedback bellows also ____. increases, 54, ‘The bellows expands and moves the flapper to the (right/left). right 55. So the feedback bellows is allowing the flapper to move (in the same direction as/in the opposite direction from) the measurement bellows. in the opposite direction from 56. The feedback bellows is “anticipating” the process change while the valve is changing the process and before the controller gets the process feedback. ‘Thus, the controller's feedback bellows keeps the con- troller from moving too for a given much, or far process change. 57, While the feedback bellows is acting, there (is/is not) is an offset between the measurement pen and the set point, How Load Changes Affect Proportional Controllers 58, The set point on a proportional controlle A. is set for one load condition. A ——— B. changes everytime the load changes. 59. Sometimes the load on a process changes. A unit may have to increase its production from 100 barrels an hour to 300 barrels an hour with all other conditions the same. ‘This is an increase in load 60. ‘The original valve position (can/cannot) handle this cannot oad increase. 3561. Steam is being used in this process. ‘The controller is set to keep the pressure somewhere around 50 PSIG. Let’s say that there is a drop in process temperature, ‘causing some of the steam to condense. STEAM INPUT => 727% VALVE CONTROLLER ‘The pressure (increases/decreases). decreases 62. To keep the pressure within operating limits, the con- troller must allow ____ steam into the proe- more ess than before. 63. Will the steam pressure return to the old level, if some of the steam keeps condensing out? (Yes/No) No 64. The load (has/has not) increased. has 65. The set point probably (will/will not) handle the new will not, load requirement. 66. Here is another situation. This controller is maintaining liquid level 3667. The pressure on the liquid decreases, and the liquid evaporates at a much higher rate. ‘The controller must ___ ineoming liquid flow. 68. If the liquid keeps evaporating at a high rate, has the load changed? (Yes/No) 69. Here is what happens to a proportional controller de- signed for one load when the load requirements change. 100 PSIG SET POINT 50 PSIG 0 PSIG ‘The controller is controlling . ‘The set point of this controller is___ PSIG. 70. ‘The process load changes, and a higher flow rate is needed to keep the process pressure within limits. The original valve position (lets/will not let) enough liquid in to keep to the set point. 71. Process pressure starts to 72. As it receives process feedback, the controller starts to______ the control valve proportionately. 78. Finally, the valve is opened enough to stop the decrease. Incoming flow is finally balanced to the outgoing flow in the process. 100 PSIG ORIGINAL LOAD SET POINT 50 PSIG NEW LOAD 0 PSIG ‘The process (is/is not) at the original set point. aT increase Yes pressure 50 will not let decrease open is not [Now turn the [tum the book74, To get this pressure back to the set point, the control valve must be still more. ‘opened 7. Suppose the pressure in the process measurement bel- lows starts to increase again in this controller. SET POINT MEASUREMENT SUPPLY OUTPUT FEEDBACK BELLOWS SUPPLY ‘The flapper will be moved back toward the nozzle, and the control valve will start to. close 76. This (raises/does not raise) the process pressure to does not raise the original set point. 77. Look at the record on this process pressure recorder. SET POINT ‘At A, the process ___ starts to decrease. pressure 78. At B, the set point pointer and the pen (are/are not) are not together. 79. The controller (stops/does not stop) the decrease. stops 3880. After this change, there is still an_______in the process. 81. In certain processes, the load does not change very much, or a little offset is not a problem. ‘The controller shown (can/eannot) work for these processes. 82. Other processes need more precise control, even during changing load conditions. ‘The controller shown (can/eannot) work for these Processes. Reset Action 88. For more precise control, a device is needed to increase or decrease the output to the control valve beyond the changes which the proportional controller can provide. SET POINT MEASUREMENT Aeeeeea eae eee SUPPLY ar ouTPUT FEEDBACK B faa SUPPLY In this situation, the proportional action is balanced, but a further increase in flow is needed to get the proc- ess back to the set point. ‘The flapper must be moved to (open/close) the nozzle. 84. By opening the nozzle more, we can open the control valve, and return the process to the ‘The output air to the control valve changes and moves the control valve to a new 39 offset cannot open set point position85. Here is the controller when the pressure in the set point bellows is equal to the pressure in the measure- ment bellows. NOZZLE FLAPPER| BOTTOM Do the measurement and set point bellows always re- turn to this position when the process is at set point? (Yes/No) 86. The linkage between the two top bellows can have (one position /several positions) when the process is at set point. 87. How can we move the flapper to a more open position without changing the set point? SET POINT 0 See ee eeeereeereere eee ooo. SUPPLY MEASUREMENT ouTPUT A. Move the top of the flapper ——.B. Move the bottom of the flapper 88. To open the valve more when this controller is at set point, we would move the of the flapper (toward/away from) the nozzle. 40 Yes one position bottom, away from89. ouTPUT 91. 92, 93, 94, Changing the controller’s output and the valve position to keep the process at set point during a load change is called reset. In the situation shown above, which of these actions is reset? ——A. Moving the top of the flapper when the process changes. ——_B. Moving the bottom of the flapper to get a new valve position. Here is a proportional controller that can be reset manually, SET POINT MEASUREMENT SUPPLY FEEDBACK BELLOWS SUPPLY The bottom of the flapper has an adjustment screw on it as well as a feedback bellows. ‘The screw can move the ________ back and forth. When there is @ load change, and the recorder shows an offset, we can correct this offset by moving the By moving the flapper, the control___*__posi- tion can be changed (by/without) changing the set point. But every time there is a load change and offset, the flapper setting will have to be _____ manually. Having an operator reset the controller manually every time the process load changes (is/is not) practical. a1 flapper Amob, or serew, or flapper valve without changed, or moved, or reset, is notAutomatic Reset 95. A proportional controller is a single-mode controller. This is a two-mode controller with proportional and automatic reset action. SET POINT __ MEASUREMENT =m ‘ SUPPLY ielceeah FEEDBACK | RESET ourpuT Instead of an adjustment serew, there is a bellows connected to the flapper. 96. A control relay has been added to the pneumatic air system to bleed out or add air to the system quickly. ‘The pressure to run the reset bellows comes from the output air going from the control relay to the 97. Pressure to operate the reset bellows comes from: A. the same source as the feedback bellow: B. a different souree from the feedback bel lows. 98. The reset bellows has a restriction ______in the air line to it. 99. The idea of the reset bellows is to push the flapper to a new position. ‘The idea of the feedback bellows is to (speed up/slow down) the movement of the flapper. 100. The reset bellows and the feedback bellows work (with/against) each other. 42 reset control valve valve slow down101. Let’s say that the air lines leading to the reset and feedback bellows are opened the seme amount. SET POINT Din LMEASUREMENT. SUPPLY RELAY OUTPUT If the reset restriction valve is wide open and the out- put to the control valve changes, the pressure in both bellows changes at (the same rate/different rates). the same rate 102. The bottom position of the flapper (is/is not) moved is not when this happens. 108. The flapper's position cannot be changed by the reset and feedback bellows unless the pressure in these bel- lows changes at (the same rate/different rates). different rates 104. Look at the controller now. SET POINT — uae SUREMENT SUPPLY FEEDBACK | RESET ‘The valve to the reset bellows has been partially —: closed 43105. 106. 107. 108. 109. ‘This means that air will enter and leave the (feedback/ reset) bellows faster and sooner. During a process change, the measuring bellows moves the flapper. ‘Then, the ____ bellows acts on the flapper. Later, after the feedback bellows has moved and the process has had time to respond, if we are off set point, the ___ellows goes into action. ‘There is still a pressure difference between the bellows shown in this sketch. SET POINT —— in SUPPLY MEASUREMENT ‘As Jong as there is a pressure difference between the feedback and reset bellows: ———A. the bellows will keep moving the flapper. ———B. the bellows will stop moving. ‘As long as there is a pressure difference between the feedback and reset bellows: ———A. the control valve position remains the same. —--B. the control valve position keeps moving. 44 feedback feedback reset