Control Loop Foundation Batch and Continuous Processes

Terry Blevins Principal Technologist Mark Nixon, Manager, Future Architecture

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Control Loop Foundation Short Course

Introduction Background Historic Perspective Measurement Basic Transmitter Types, Limitations Analyzers Examples of On-line Analyzers Final Elements Valves and Variable Speed Drives Field Wiring and Communications Traditional, HART, FF , WirelessHART Control Strategy Documentation Plot Plan, Flow Sheet, P&ID, Loop Diagram Operator Graphics and Metrics Considerations in Display Design Process Characterization Identifying process dynamics and gain Control Objectives Single Loop Control PID basics, selecting PID structure, action Tuning and Loop Performance Manual and automated tuning techniques Multi-loop Control Feedforward, Cascade, Override, Split-range Model Predictive Control Addressing Difficult Dynamics, Interactions Process Modeling Process simulation for Checkout/Training Applications Continuous, Batch, Combustion, Distillation Accessing the book web Site Open Discussions book drawing & Wrap-up

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Control Loop Foundation Short Course

Short Course will provide a summary of key points and examples from Control Loop Foundation All workshops and application examples in the book are based on DeltaV control capability. This book is available at www.isa.org and this week at the ISA booth. The application section is designed to show how control techniques may be combined to address more complex process requirements The book web site may be accessed to perform the workshops and to obtain hands-on experience using application example. Copies of the modules and trends may be downloaded from the web site and imported into a DeltaV system. A new class, Control Loop Foundation Course 9025, Is available through the education department.
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Introduction

Control Loop Foundation address the concepts and terminology that are needed to work in the field of process control. The material is presented in a manner that is independent of the control system manufacturer. Much of the material on the practical aspects of control design and process applications is typically not included in process control classes taught at the university level. The book is written to act as a guide for engineers who are just starting to work in this field. Experienced control engineers will benefit from the application examples on process control design and implementation of multi-loop control strategies.

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Background - Different Construction Techniques

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Wiring Practices

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Plant Organization

Common terms used to describe plant organization are introduced. Plant Area classification by name and area number Units within a process Area

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Lab, Control Room, Lab and Rack Room

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Existing System Electronic and Pneumatic

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Impact of DCS Systems

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Integration of External System/Interface

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Modern DCS Controller

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Impact of Digital Communications

Ethernet Fieldbus Foundation Fieldbus, Profibus Wireless WirelessHART

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Wireless Impact
Wireless Field Devices Relatively simple - Obeys Network Manager Gateway and Access Points Allows control system access to WirelessHART Network Gateways Manages communication bandwidth and routing

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WirelessHART Objectives

Satisfy the end users concerns

Reliable & Secure Fit for Industrial Environments

Keep it simple

As simple as 4-20mA HART Instruments should be Intelligent and easy to use

Use Existing tools

Update DD for Handheld and Asset Management applications Same tools same procedures

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Satisfy the end users concerns

Reliable

Use Mesh for redundant paths (A B) Redundant Gateway to the Host Multiple Network Access Points Coexistence with neighbouring networks
Channel hopping TDMA Low Power

Secure

Device Authentication AES128 Encryption Anti-Jamming Verification at MAC Layer Key Management
Channel Hopping

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Device Types

Wireless Field Devices Relatively simple - Obeys Network Manager All devices are full-function (e.g., must route) Adapters Provide access to existing HART-enabled Field Devices Fully Documented, well defined requirements Gateway and Access Points Allows access to WirelessHART Network from the Process Automation Network Gateways can offer multiple Access Points for increased Bandwidth and Reliability Caches measurement and control values Directly Supports WirelessHART Adapters Seamless access fro existing HART Applications Network Manager Manages communication bandwidth and routing Redundant Network Managers supported Often embedded in Gateway Critical to performance of the network Handheld Supports direct communication to field device For security, one hop only communication All devices compatible with existing DD-enabled Applications

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Impact of Standard on Control

ISA88 Batch terminology IEC 61131 Function blocks, Ladder Logic, Structured Text, Sequential Function Charts. IEC 61804 Function blocks for the process industry,

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Measurement

Introduction to devices used for basic measurement

Magnetic flow meter Vortex flow meter Differential pressure for flow measurement Corilois flow meter Absolute and gauge pressure Temperature RTD, thermocouple Level based on pressure/differential pressure Level - Radar

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Device Calibration

Concept of devices calibration and configuration is introduce. Role of hand held devices and EDDL is addressed

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Analyzers

Difference between sampling and situ analyzers is addressed Impact of sampling system on maintenance and measurement delay is highlighted

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Analyzer Example

A couple of common situ analyzers are addressed to show features and options
Flue Gas O2 pH/ORP

Calibration of analyzer and role of sample/hold when used in control is addressed.

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Final Control Element

Basic final control elements are addressed:

Sliding stem valve Rotarty valve Damper drive Variable speed drive Block valve

Advantages and limitations are discussed

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Final Control Element Terminology

Common terms associated with final control elements are defined

Positioner Actuator Valve Body

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Installed Characteristics

Types of valve characteristics and their impact on installed characteristics is addressed

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Field Wiring and Communications

Installation of 2-wire vs 4-wire devices is addressed Common problems are address e.g. need for electric isolation when utilizing a 4-wire device

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Fieldbus Installation

Special requirements for a fieldbus installation are addressed Common terminology is defined:
Multi-drop Power conditioner Terminator

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Control System Documentation

Documentation that is typically generated for a control system installation are addressed. The purpose of each document is explained. Reference provided to ISA-5.4 standard for Instrument Loop Diagrams

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Tag Convention ISA S5.1

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Representation of Signals and Instruments

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Symbols for Field devices and Elements

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Process Symbols

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Symbol Example P&ID Drawing

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Symbol Example(Cont.)

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Symbol Example(Cont.)

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Symbol Example(Cont.)

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Operator Graphics and Metrics

An operator interface design is addressed by Alarm Standard EEMUA 191 Advocates that alarms should be in alarm color. Pipes, pumps, valves, etc. should not be in alarm colors, or any other bright color.

Display Observing Color Usage

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Display Tools

Basic tools for construction a display are discussed

Dynamos, dynamic elements, faceplates, links for creating a display hierarchy

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Performance Metrics

Example used to illustrate how operation metrics may be added to an operator display Benefits of integrating this type of information into the operator interface

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ISA 101 - Human Machine Interfaces for Process Automation Systems

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Center for Operator Performance

http://www.operatorperformance.org/
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Current Members

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Research Programs

Completed
Nature of Expertise Decision Making Exercises Simulator Usage Color Usage/Display Design Alarm Rate & Presentation Impact

Current
Quantify alarm actuation rates that operators can handle Develop & evaluate effectiveness of decision-based operating graphics Develop systematic approach to documenting expertise? of senior operators before they walk out the door Evaluate methods of early detection of off-normal operations Data Mining of Near Miss Process Incidents Human Performance Metrics

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Process Characterization
A plant may be thought of as being made up of a series of processes.
A good understanding of these processes is required to design a control system for the plant.

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Process Definition

Process Specific equipment configuration (in a manufacturing plant) which acts upon inputs to produce outputs.

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Process Terminology

Controlled output (controlled parameter) Process output that is to be maintained at a desired value by adjustment of process input(s). Setpoint Value at which the controlled parameter is to be maintained by the control system. Manipulated input (manipulated parameter) Process input that is adjusted to maintain the controlled parameter at the setpoint. Disturbance input Process input, other than the manipulated input, which affects the controlled parameter. Constraint output (constraint parameter) Process output that must be maintained within an operating range. Constraint limit Value that a constraint parameter must not exceed for proper operation of the process. Other input Process input that has no impact on controlled or constraint outputs. Other output Process output other than controlled or constraint outputs.
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Example Application of Terminology

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Impact of Disturbance Input

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Example Lime Mud Filter Process

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Example Lime Mud Filter ( Cont.)

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Pure Gain Process

When the process output tracks the process input except for a change in signal amplitude, the process is known as a pure gain. The change in signal amplitude is determined by the process gain. For a step change in process input, the process gain is defined as the change in the process output divided by the change in process input

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Example Pure Gain Process

An example of a pure gain process is the jack shaft used in some boiler combustion control systems.

Gain is determine by the length of the lever arms attached to the jack shaft.

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Pure Delay Process

When the process output tracks the process input except for a delay in the output signal, the process is know as a pure delay process.

For a step change in the process input, process deadtime is defined as the time from the input changing until the first affect of the change is seen in the process output.

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Examples Pure Delay Process

Example of pure delay processes are a conveyor belt and a pipeline. Delay is the result of transport time and will vary with the speed of the belt or the flow rate through the pipe.

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First Order Process

When process output immediately begin to respond to a step change in a process input and the rate of change is proportional to its current value and the final value the output will achieve, the process is know as a first order process. The dynamic response is fully captured by identifying the process gain and the process time constant.
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Example First Order Process

An example of a pure lag process is a tank with outlet flow determined by tank level and the outlet flow restriction caused by the orifice. The level will settle at a value which results in an outlet flow that matches the inlet flow.

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First Order Plus Deadtime Process

Most process in industry may be approximated as first order plus deadtime processes. A first order plus deadtime process exhibits the combined characteristics of the lag and delay process.

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Example Steam Heater

An example of a first order plus deadtime process is a steam heater. The process lag is caused by the heating process
The process deadtime is caused by transport delay

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Higher Ordered Systems

The dynamic response of a process is the results of many components working together e.g. I/P, Valve actuator, heat or fluid/gas transport, etc. The net process response of these higher order systems can be approximated as first order plus deadtime.

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Combined Impact of Process Dynamics

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Integrating Process
When a process output changes without bound when the process input is changed by a step, the process is know as a non-self- regulating or integrating process. The rate of change (slope) of the process output is proportional to the change in the process input and is known as the integrating gain.

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Example Integrating Process

An example of a non-self-regulating process is tank level where outlet flow is established by a gear pump. If the inlet flow does not match the outlet flow, then level will continue to change until the tank overflows or runs dry.

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Inverse Response Process

For a few processes, the initial change in the process output to a step change in a process input will be in the opposite direction of the final output change. Processes exhibiting this characteristic are said to have an inverse response.
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Example Inverse Response Process

The level of a vertical thermosiphon reboiler in a distillation column may exhibit an inverse response to a rapid increase in heat input. The size or direction of the change in heat input may determine if an inverse response is obtained.

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Process Linearity

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Example Non-linear Process

Most processes may be approximated as linear over a small operating range. However, over a wide range of operation, processes may exhibit some non-linearity. A common cause of nonlinearity is a change in process gain reflecting the installed characteristics of the final control element i.e. valve acting with the other equipment making up the process, as illustrated in this example.
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Workshop Use of Process Simulation

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Workshop - Process Characterization

Three example processes are include in workshop

First order plus deadtime Integrating Inverse response

Web site is accessed to perform step test. Only a web browser is needed no software to install.

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Control Objective

For the case, production is greatest when the band of variation is reduced to zero and the process parameter is maintained at the value corresponding to maximum production

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Impact of Operating Target

To benefit from improvement in control, the loop must operate at the target that provides maximum production. The plant design conditions may be used as a guide in establishing setpoints for best operation

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Operating at a Limit

For this case, maximum production is obtained by maintaining the process parameter at a limit determined by some plant limitation. How close to the limit you can operate is determined by the quality of the control

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Impact of Reduced Variability

Production improvement is obtained by operating closer to product specification or operating limit.

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Example - Ammonia Plant

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Example - Ammonia Plant (Cont.)

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Example - Ammonia Plant (Cont.)

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Other Control Objectives

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Balancing Control Complexity and Benefits

Various techniques may be used to improve the control of a process As the complexity of the control system increases, so does cost for operator training and maintenance

The complexity (cost) of the control system should be balanced with the benefits provided
The benefits of control improvement may be influenced by market conditions i.e. value of product, cost of feedstock, energy cost

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Single Loop Control

In some cases manual control may be appropriate Manual Loader Block may be used to implement manual control

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Manual Control Implementation

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Processing of Analog Input Signal

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Impact of Aliasing

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Setup of Anti-aliasing Filter

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Processing by Analog Input Block

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Filtering Provided by Analog Input Block

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Manual Loader Block

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Analog Output Block

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Analog Output Block - Rate Limiting

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Analog Output Block Increase to Close Option

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Feedback Control

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Proportional Only Control

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Proportional Plus Integral (PI) Control

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Proportional, Integral, Derivative (PID) Control

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PID Structure Selection

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PID Direct/Reverse Selection

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PID Function Block

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PID Form Standard and Series

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Setting PID Form and Structure

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Block Mode Selection of Source of SP and OUT

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Target Modes of Block

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Other Actual Modes of Block

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Duty Cycle Control

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Duty Cycle Control (Cont.)

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Increase-Decrease Control Motor Driven Actuator

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Workshop Feedback Control

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Tuning and Loop Performance Default Setting

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Manual Tuning Technique

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Tools to Automate Tuning

Example base on DeltaV Insight Ondemand Tuning

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Impact of Sticky Valve

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Use of Signal Characterizer to Compensate for Non-linearity

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Characterizer Setup

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Multi-loop Control - Feedforward Control

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Feedforward Control Implementation

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Commissioning Dynamic Compensation

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Workshop Feedforward Control

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Cascade Control

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Example Boiler Steam Temperature

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Cascade Control Implementation

Selecting FRSI_OPT for dynamic reset in primary loop and CONTROL_OPTS for Use PV for BKCAL_OUT in secondary loop can often improve dynamic response.

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Workshop Cascade Control

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Override Control

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Example Override Control

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Override Control Implementation

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Workshop Override Control

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Control Using Two Manipulated Parameters

Three methods Addressed: Split Range Control Valve Position Control Ratio Control

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Split Range Control Implementation

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Split Range Setup

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Example Split Range Control

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Workshop Split Range Control

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Valve Position Control

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Valve Position Control Implementation

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Example Valve Position Control

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Workshop Valve Position Control

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Ratio Control

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Ratio Control Implementation

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Example Ratio Control

In this example the ratio setpoint is adjusted using feedback control based on a downstream analysis of the blended material

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Workshop Ratio Control

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Process Simulation for Ratio Workshop

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Model Predictive Control (MPC)

Operating Within Process Constraint

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MPC May be Layered on Existing Control

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Workshop Model Predict Control

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Process Modeling

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Simulation Diagram

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Simulation Module

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Example Process Simulation Composite

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Workshop Process Modeling

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Application Boiler Drum Level

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Batch Reactor

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Batch Reactor- Processing

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Batch Reactor - Control

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Continuous Reactor

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Continuous Reactor - Control

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Single Fuel Power Boiler

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Power Boiler Combustion Control

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Distillation Column

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Distillation Column Control

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Ammonia Plant H/N Ratio Control

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Ammonia Plant H/N Ratio Control (Cont.)

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Control Loop Foundation Web Site

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Exercise and Process Information

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Workspace Dynamic Simulation/Control

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Chart and Solution Selections

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Summary

Feedback on the book can be provide through the Control Loop Foundation website Questions? Drawing for books

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How to Get More Information

Emerson Education Class

Control Loop Foundation, Course 9025 CEUs: 3.2 This course is for engineers, managers, technicians, and others that are new to process control or need a refresher course. This course includes the practical aspects of control design and process applications that course developers personally learned through years of hands on experience while designing and commissioning process control applications. Overview This 4-1/2 day course covers the concepts and terminology that are needed to understand and work with control systems. Upon completion of this course the student will be able to effectively work with and commission single and multi-loop control strategies. Interactive workshops allow the student to apply what they learn in the class. Prerequisites Windows experience.

Control Loop Foundation - ISA Book

May be purchase through the ISA web site - http://www.isa.org/

Book Web Site

Explore book workshops - http://www.controlloopfoundation.com/
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