two man ip control
TRANSCRIPT
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Slide 1- 1Control Using Two Manipulated Parameters
Control Using Two Control Using Two
Manipulated Parameters Manipulated Parameters
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Slide 1- 2
Process Control
Introduction – Historic Perspective
Introduction Introduction Æ Overview – Typical Examples
Æ Split-Range Control
– Concept, variations in implementation
– Setup in field vs. Splitter Block and IO for each valve.
– Using Splitter Block, Example.
Æ Valve Position Control
– Concept and typical implementation
– Setup of I-only control in implementation
– Impact of mode/status, Example.
Æ Combining Split Range and Valve Position Control
– How to implement in DeltaV
– Example
Æ Summary
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Slide 1- 3
Process Control
Introduction – Historic Perspective
Control Using Two Manipulated Parameters Control Using Two Manipulated Parameters Control Using Two Manipulated Parameters Æ Under specified problem
that has multiplesolutions for unlimitedoperation.
Æ Extra degree of freedomis used to achieveunique solution thatsatisfied specific controlobjective.
Æ Most commontechniques are: splitrange, valve positioncontrol.
Æ Combination of thesetechniques offer newcapability to address thisclass of problems
Controller Process
SP
Unmeasured
Disturbance
One(1) Controlled
Parameter
Two(2) Manipulated
Parameters
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Slide 1- 4
Process Control
Introduction – Historic Perspective
Split Range – Traditional Implementation Split Range Split Range – – Traditional Implementation Traditional Implementation Æ Sequencing of valve accomplished
through calibration of positioner,selection of actuator (A/O or A/C)
Æ Pro – Less expensive installation (1pair of wires to field and 1 I/P)
Æ Con -Difficult to initially calibrateand continuously improve to getbest gap and most constant gain.
Æ Con -Individual valves notaccessible for trouble shooting loopand actuator/valve problem.
Æ Con – The actuator, pneumaticpositioner, and I/P performanceshift with time and field conditions
Æ Con – I/P failure disables 2 valves.Replacements in the night may nothave the special settings
IP
101
TT101
TIC
101
Process
Temperature Example
4-20ma
Heating
Cooling
3-15PSI
ValvePosition(% of Span)
IP Output ( PSI )153
0
100
Cooling
Heating
A/C
A/O
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Slide 1- 5
Process Control
Introduction – Historic Perspective
Split Range – Traditional Implementation Split Range Split Range – – Traditional Implementation Traditional Implementation Æ Sequencing of fine and coarse
valve requires pressure switch,two solenoid valves andassociated wiring and tubing
Æ Con – Complex installation
Æ Con -Difficult to initially calibrateand continuously improve to getbest gap and most constant gain.
Æ Con -Individual valves notaccessible for trouble shootingloop and actuator/valve problem.
Æ Con – The switch, actuator,pneumatic positioner, and I/Pperformance shift with time andfield conditions
Æ Con – I/P failure disables 2valves. Replacements in thenight may not have the specialsettings
IP
102
AT102
AIC
102
Process
pH Example
4-20ma
Coarse Valve
Fine Valve
3-15PSI
A/O
pH
ValvePosition(% of Span)
I/P Output ( PSI )1530
100
Fine Valve
Coarse Valve
A/O
PS102
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Slide 1- 6
Process Control
Introduction – Historic Perspective
Split Range – DeltaV Implementation Split Range Split Range – – DeltaV Implementation DeltaV Implementation Æ Splitter bock is used
to implement split
range control.
Æ When using
traditional valves,
split range control
may implemented in
DeltaV Controller
using two(2) current
outputs
Æ
Split range controlmay be partially or
fully assigned to
fieldbus devices.
AI PID SPLT
AO
AO
AI PID SPLT
AO
AO
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Slide 1- 7
Process Control
Introduction – Historic Perspective
Split Range Control in DeltaV Split Range Control in DeltaV Split Range Control in DeltaV
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Slide 1- 8
Process Control
Introduction – Historic Perspective
Splitter Block Calculation Splitter Block Calculation Splitter Block Calculation
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Slide 1- 9
Process Control
Introduction – Historic Perspective
IN_ARRAY Parameter IN_ARRAY Parameter IN_ARRAY Parameter Æ The SP range
associated witheach output isdefined by
IN_ARRAY.Æ SP range of
outputs may bedefined to overlap
Æ The SP upper end
of range must begreater that lower end of range for each output
SP range
associatedwith OUT1
SP range
associated
with OUT2
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Slide 1- 10
Process Control
Introduction – Historic Perspective
OUT_ARRAY Parameter OUT_ARRAY Parameter OUT_ARRAY Parameter Æ When SP is outside
defined range, thenthe value at the end
of range is used todetermine theoutput.
Æ LOCKVALdetermines if OUT1value is held if SP isgreater that theupper end of rangedefined for OUT1.
Æ No restrictions areplaced on the outputrange.
OUT1 Range for associated SP range
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Slide 1- 11
Process Control
Introduction – Historic Perspective
Splitter Block Splitter Block Splitter Block
SP
0 100
0
100
0
100
0
100
100
100
0
0
OUT_1
OUT_2
LOCK_VAL “holds ”
LOCK_VAL “is zero ”
OUT_ARRAY
0 100 0 100
IN_ARRAY
0 100 0 100
OUT_ARRAY
100 0 0 100
IN_ARRAY
0 40 35 100
OUT_ARRAY
0 100 0 100
IN_ARRAY
0 40 35 100HYSTVAL
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Slide 1- 12
Process Control
Introduction – Historic Perspective
AI PID SPLT
AO
AO
IP
103A IP103B TT
103
FY103
TIC
103
COOLERHEATER
TT103 TIC103 FY103 IP103A
IP103B
Slaker – Heating/Cooing Example Slaker Slaker – – Heating/Cooing Example Heating/Cooing Example
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Process Control
Introduction – Historic Perspective
ValvePosition
(% of Span)
TIC103 Output (% of Span)1000
0
100
Cooling (IP103B)
Heating (IP103A)
Split Range Output (FY103) Split Range Output (FY103) Split Range Output (FY103)
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Process Control
Introduction – Historic Perspective
AI PID SPLT
AO
AO
IP104A
IP104B
PT104
FY104
PIC104
PT104PIC104 FY104 IP104A
IP104B
Steam Header Example Steam Header Example Steam Header Example
400# Header
1475# Header Boiler
Turbo
Generator
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Slide 1- 15
Process Control
Introduction – Historic Perspective
ValvePosition
(% of Span)
PIC104 Output (% of Span)1000
0
100
Valve 104A
Valve 104B
Split Range Output (FY104) - Capacity Split Range Output (FY104) Split Range Output (FY104) - - Capacity Capacity
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Process Control
Introduction – Historic Perspective
Calculating Splitter SP Ranges Calculating Splitter SP Ranges Calculating Splitter SP Ranges Æ A 1% change in controller
output to the splitter shouldhave the same impact oncontrol parameter whenoperating with either valve.
Æ When manipulating thesame or similar materiale.g. steam flow to header,
then the range may becalculated based on valverating.
Æ Tests may be performed to
determine impact of eachvalve on the controlledparameter.
Example: Steam flow to Header, splitter
interfacing directly to PRV’s, no overlap
Valve 1 rating = 50kph
Valve2 rating = 150kph
Desired Splitter Span valve 1 =100*(50/(150+50)) = 25%
SP range for valve 1 = 0-25%
SP range for valve 2 = 25-100%
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Process Control
Introduction – Historic Perspective
Testing Process to Determine
Splitter SP Ranges
Testing Process to Determine Testing Process to Determine
Splitter SP Ranges Splitter SP Ranges Æ With the process
at steady stateand AO’s in Automode, determinethe magnitude of change in thecontrolledparameter for a 1percent change
in each valve.Æ Calculate the
splitter SP spanand range for
each outputbased on theobservedresponse
Time
Cooling
Heating 1%
1%
1.1degF 2.2degF
Desired Splitter Span cooling valve =
100*(2.2/(1.1+2.2)) = 66%
SP range for cooling valve = 0-66%
SP range for heating valve = 66-100%
Controlled
Temperature
Example: Slaker feed temperature controlled
using heating and cooling valves
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Process Control
Introduction – Historic Perspective
Example – Split Range Example Example – – Split Range Split Range
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Process Control
Introduction – Historic Perspective
Response to SP Change – Split Range
Output To Large Valve/Small Valve
Response to SP Change Response to SP Change – – Split Range Split Range
Output To Large Valve/Small Valve Output To Large Valve/Small Valve
SmallValve
LargeValve
PID OUT
SP
PV
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Process Control
Introduction – Historic Perspective
Split Range – Strengths and Weaknesses Split Range Split Range – – Strengths and Weaknesses Strengths and Weaknesses Æ Pro - Process operation in simplified since two actuators
are treated as one control manipulated parameter.
Æ
Pro – immediate change in target actuator position can beachieved over the entire operating range independent of the size of change in the splitter SP
Æ Con – To achieve stable control over the entire operating
range, controller tuning must be established based on theslower responding manipulated parameter.
Æ Con- Does not take advantage of difference in resolutionof actuator e.g. fine vs. coarse valve.
Æ Valve position control may be used in place of split rangecontrol when there are differences in dynamic response or resolution in actuators.
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Process Control
Introduction – Historic Perspective
Valve Position Control – Traditional
Implementation
Valve Position Control Valve Position Control – – Traditional Traditional
Implementation Implementation
IP106A
AT106
AIC106
Process
Æ PID control isimplemented using theactuator with finer resolution or fastest
impact on controlledparameter
Æ The actuator withcoarse resolution or slower impact on the
controlled parameter isadjusted by an I-onlycontroller to maintainthe long term output of the PID controller at agiven target
Æ I-Only controller must bedisabled when the PIDcontroller is not in an
Automatic mode.
pH Example
Fine Valve
A/O
ZC106
IP106B
Coarse
Valve
I-Only
Controller
Mode
Target
Valve
Position
Time
pH
Fine Valve
Coarse Valve
Target Valve
Position
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Process Control
Introduction – Historic Perspective
Valve Position Control in DeltaV Valve Position Control in DeltaV Valve Position Control in DeltaV Æ Actuator with fastest
impact or highestresolution is used to
maintain thecontrolled parameter at setpoint.
Æ The OUT of the PIDused for control is
wired to IN on thePID block used for I-Only regulation of slower responding or coarse resolution.
PID configured for I-
Only control
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Process Control
Introduction – Historic Perspective
Configuring PID for I-Only Control Configuring PID for I Configuring PID for I - - Only Control Only Control Æ The STRUCTURE
parameter should beconfigured for “I actionon Error, D action on
PVӮ The GAIN should be
set to 1 to allow normaltuning of RESET (eventhough proportional
action is notimplemented.
Æ RESET should be setsignificantly slower than that the product of
the PID gain and resettime used for controle.g. 5X slower
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Process ControlIntroduction – Historic Perspective
AI PIDAO
IP107A
IP
107B
FT107
FIC107
FT107FIC107
IP107A
Precise Flow Using Big/Small Valve Precise Flow Using Big/Small Valve Precise Flow Using Big/Small Valve
ZC107
I-Only AOIP107B
ZC
107
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Process ControlIntroduction – Historic Perspective
Example -Boiler BTU Demand Example Example - - Boiler BTU Demand Boiler BTU Demand
AI PID AOFT109B
FIC109IP109A
ZC109
I-Only AOIP109B
ZC109
FT109A
IP109B
FIC109
FT109B
IP109A
FY109
Low BTU – Waste Fuel
HI BTU Fuel Boiler
BTU Demand
AIFT109A
SUM
FY109
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Process ControlIntroduction – Historic Perspective
Example –Reformer Air Demand Example Example – – Reformer Air Demand Reformer Air Demand
ZC110
AI PID AOFT110
FIC110IP110
ZC110
I-Only AOSC110
FIC110
FT110
SC110
Air
Machine
Secondary
Reformer
Total Air
Demand
IP110
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Process ControlIntroduction – Historic Perspective
Example – Valve Position Control Example Example – – Valve Position Control Valve Position Control
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Process ControlIntroduction – Historic Perspective
Response to SP Change - Valve Position
Control with Large Valve/Small Valve
Response to SP Change Response to SP Change - - Valve Position Valve Position
Control with Large Valve/Small Valve Control with Large Valve/Small Valve Æ Target
position for fine valve is
30%.
Æ When thefine valvesaturates,
thenresponse islimited to bereset of theI-Only
control
Fine Valve
Coarse Valve
SP
PV
Limited
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Process ControlIntroduction – Historic Perspective
Valve Position Control – Strengths and
Weaknesses
Valve Position Control Valve Position Control – – Strengths and Strengths and
Weaknesses Weaknesses Æ Pro – Immediate control response is based on actuator with finest
resolution and/or faster impact on controlled parameter.
Æ Pro – Actuator with coarse resolution or slower impact on controlled
parameter is automatically adjusted to maintain the output of thecontroller output long term at a specified operating point.
Æ Con – The controller output may become limited in response to alarge disturbance or setpoint change. For this case, the dynamic
response becomes limited by the slower tuning of the I-onlycontroller.
Æ The features of split range control and valve position control may becombined to provide immediate response to large changes indemand while retaining the features of valve position control for normal changes.
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Process ControlIntroduction – Historic Perspective
Combining the Best Features of
Split Range and Valve Position Control
Combining the Best Features of Combining the Best Features of
Split Range and Valve Position Control Split Range and Valve Position Control Æ A composite
Block can becreated that
combines thefeatures of splitrange and valveposition control
Æ Support for BKCAL_IN andBKCAL_OUTcan beimplemented to
providebumplesstransfer
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Process ControlIntroduction – Historic Perspective
Composite Algorithm Composite Algorithm Composite Algorithm
Filter
CAS_IN
MODE
SP
x +
x
x
T
ScalingRANGESPAN
NORMAL
OUT_1
OUT_2
BKCAL_OUT
BKCAL_IN1
BKCAL_IN2Balance Calculation
-
-FILTER_TC
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Process ControlIntroduction – Historic Perspective
Composite Implementation Composite Implementation Composite Implementation Æ Parameters that
must be configureare: FILTER_TC,SPAN (of SP),
RANGE (of OUT1), andNORMAL(desired position )
Æ The FILTER_TC
should beconfigured similar to the reset timeof the I-OnlyController that
would be used for valve positioncontrol.
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Process ControlIntroduction – Historic Perspective
Demo – Composite Combining Valve
Position and Split Range Control
Demo Demo – – Composite Combining Valve Composite Combining Valve
Position and Split Range Control Position and Split Range Control
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Process ControlIntroduction – Historic Perspective
Example: Response to SP Change Example: Response to SP Change Example: Response to SP Change Æ For small
changes in SP or load disturbance,the response is
similar to thatprovided byvalve positioncontrol
Æ For largechanges in SP or load disturbance,the immediateresponse is
similar to splitrange control
SP, PV
OUT of
PID
Fine
Valve
Coarse
Valve
Small change Large change
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Process ControlIntroduction – Historic Perspective
Summary Summary Summary Æ Split range control allows fully dynamic
response to major setpoint of load
disturbance changes.Æ Valve position control may be used to takes
advantage of any difference in controlresponse or resolution in the manipulated
parameters.
Æ A composite block has been demonstratedthat combines the best features of split range
and valve position control.