1. Process Control Priyatmadi 2005 1 Pengantar Pengendalian Proses Priyatmadi Jurusan teknik Elektro FT UGM

2. Process Control Priyatmadi 2005 2 Overall Course Objectives Develop the skills necessary to function as an industrial process control engineer. –Skills Tuning loops Control loop design Control loop troubleshooting Command of the terminology –Fundamental understanding Process dynamics Feedback control

3. Process Control Priyatmadi 2005 3 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

4. Process Control Priyatmadi 2005 4 Process Control Classification Manual Control Automatic Control Feedback Control Feed forward Control Analog Control Digital Control

5. Process Control Priyatmadi 2005 5 Manual Control

6. Process Control Priyatmadi 2005 6 Automatic Control TT TIC I/P 4-20 mA 3-15psi Set point Cold water in hot water out steam in Plant Controller Sensor + - Set point e(t) m(t) c(t)

7. Process Control Priyatmadi 2005 7 Control Diagram of a Typical Control Loop

8. Process Control Priyatmadi 2005 8 Components and Signals of a Typical Control Loop

9. Process Control Priyatmadi 2005 9 Controller Development Pneumatic controllers Electronic analog controllers Supervisory control computers Distributed Control Systems (DCS) Fieldbus technology

10. Process Control Priyatmadi 2005 10 Pneumatic Controllers - Phase I Introduced in the 1920’s 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

11. Process Control Priyatmadi 2005 11 Pneumatic Controllers - Phase II Transmitter type pneumatic controllers began to replace field mounted controllers in the late 1930’s. Controller located in control room with pneumatic transmission from sensors to control room and back to the valve. Allowed operators to address a number of controllers from a centralized control room.

12. Process Control Priyatmadi 2005 12 Pneumatic Controller Installation

13. Process Control Priyatmadi 2005 13 Electronic Analog Controllers Became available in the late 1950’s. Replaced the pneumatic tubing with wires. Used resistors, capacitors, and transistors based amplifiers to implement PID action. Outsold pneumatic controllers by 1970. Allowed for advanced PID control: ratio, feedforward, etc.

14. Process Control Priyatmadi 2005 14 Electronic Controller Installation T F 2 T 2 Thermocouple millivolt signal Transmitter 4-20 ma Electronic Analog Controller 3-15 psig 4-20 ma T sp I/P Air F 1 T 1 Thermowell

15. Process Control Priyatmadi 2005 15 Computer Control System Based upon a mainframe digital computer. Offered the ability to use data storage and retrieval, alarm functions, and process optimization. First installed on a refinery in 1959. Had reliability limitations.

16. Process Control Priyatmadi 2005 16 Supervisory Control Computer

17. Process Control Priyatmadi 2005 17 Distributed Control System- DCS Introduced in the late 1970’s. Based upon redundant microprocessors for performing control functions for a part of the plant. SUPERIOR RELIABILITY Less expensive per loop for large plants. Less expensive to expand. Facilitates the use of advanced control.

18. Process Control Priyatmadi 2005 18 DCS Architecture

19. Process Control Priyatmadi 2005 19 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.

20. Process Control Priyatmadi 2005 20 Control Relevant Aspects of a DCS The most important control aspect of a DCS is the cycle time for controller calls. The shortest cycles 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.

21. Process Control Priyatmadi 2005 21 Fieldbus Technology Based upon 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 (vendors) of sensors, transmitters, and control valves. Now commercially available and should begin to replace DCSs.

22. Process Control Priyatmadi 2005 22 Fieldbus Architecture