School of Process, Environmental And Materials Engineering

PEME2010 Laboratory Assignments 2012/13

Student Name Student ID Experiment No. Experiment Title

Nick Marshall 200635726 6 Industrial Process Control

Date of Experiment Date of Submission 18/01/2013

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Abstract
Process control is an essential part of chemical engineering and obviously of extreme importance. Using the PT 326 process trainer and the PC 327 process controller a number of fundamental control types were studied. These were two step control, proportional control, integral and derivate control. It was found that higher power values produce greater deviation and frequency when tow step control is implemented. When using proportional control, higher bandwidths produce greater deviation however reducing the bandwidth to counteract this introduces instabilities. Using greater bandwidths increased the response rate when a step changed occurred and allowed equilibrium to be reached more efficiently. The integral action function eliminated offset but again introduced instability. This instability was decreased by increasing the derivative function.

Contents

Contents
Introduction ................................................................................................................................ 4 Literature Review ....................................................................................................................... 5 Theory ........................................................................................................................................ 7 Methodology .............................................................................................................................. 8 Results ........................................................................................................................................ 9 Discussion ................................................................................................................................ 19 Conclusion ................................................................................................................................ 21 References ................................................................................................................................ 22

1. Introduction
Process control has an extremely important role to play in any chemical engineering operation. The control of factors such as temperature, pressure and flow rate is essential in order to maintain both an efficient and safe process. Of course in todays industr y, the responsibility has since shifted from a human workforce to their more automated counterparts, ensuring more precise control than ever can be implemented. There is a huge array of different control techniques available for use in modern processing plants and this report aims to investigate just a small number of the more simple varieties currently employed.

The investigation consisted of four different experiments each concerning a particular control method or setting. Experiment titles are shown below: Experiment 1 Two Step Control Experiment 2 Continuous Control Experiment 3 Continuous Control, Step Change Experiment 4 Integral and Derivative Controller Actions

The purpose and theory of each experiment is explained in greater detail throughout this report. For this investigation, the PT 326 Feedback Process Trainer and PCS 327 Process Controller are used to simulate a heating process. This unit allows a number of different control configurations to be selected both easily and with great efficiency. Air is drawn into the system by a centrifugal fan and then heated to a pre-set temperature selected by the operator. The control equipment then monitors any variation from this set value and produces a correcting signal if necessary, to either increase or decrease the temperature back to the chosen value. This simple design can be analogous to the process applied within a large furnace in industry.

2. Literature Review

This section contains the relevant background on the process control techniques described within the report.

2.1 Two-Step Control

A two-step control system (otherwise known as on-off) is considered to be the simplest type of control experienced within industry1. A familiar example of two-step control can be found in a typical domestic immersion heater controlled by a thermostat. The water temperature within the boiler is monitored and depending on its value, the power supply is switched on or off in order to heat/cool to the desired level1. This control method is both simple and cheap to install, however, its suitability decreases in situations where more close control is required1. Figure 1, below, shows how the temperature of the water and power vary over time:

Figure 1: Variation of Water Temperature and Power with Time. *Redrawn from 2.

From figure 1 it can be seen that when the temperature rises above the set point, the power is turned off in order to cool the water and vice versa. For the purpose of an immersion heater, this type of control method is perfectly acceptable and performs its role to an appropriate degree of precision.

2.2 Proportional Control Otherwise known as continuous, this control type functions by producing an output signal that is proportional to the deviation between the set point and the measured process value3. The output signal is given by the following equation1:

(Equation 1) Where, J = Output Signal, J0 = Controller output when = 0, kc = Proportional gain (Sensitivity)

From equation 1, it is shown that with proportional control, the greater the magnitude of the error, the larger the corrective force applied. With proportional control the output is related linearly with the input and this will be proven experimentally later in the report3. Another important aspect of proportional control is the proportional bandwidth. The proportional bandwidth is, in simplistic terms, the percentage change of input signal required to change the output from 0% to 100%3. One advantage of proportional control is the relative ease at which a system of this type can be implemented. However as with most things, proportional control has its disadvantages. The main problem encountered using this type of control is the tendency for the system to return to a new equilibrium value rather the set point upon correction1. The difference in the value of this equilibrium and the original set point is referred to as the offset of the system3. It is a quantity that cannot be removed due to underpinning principles of proportional control, particularly the fact that the control action is proportional to the error.

2.3 Integral Control Mode

An integral control system produces an output rate of change that is dependent on the magnitude of the input3. By means of integration, a linear output is produced with a direct relationship to the amplitude of the step change input and integration constant3. Unlike proportional control systems, the integral system can return to exactly the same value as the set point and therefore removes any of the previously described offset1. This control mode is

usually combined with another such as the proportional mode described previously due the slow response time to an error signal.

2.4 Derivative Control Mode

It is often the case that a system is required to respond at a greater/smaller magnitude depending on the external factors influencing any undesired change from the set point. For example, a chemical reactor with changing temperature of 100C / s must produce a signal of greater correctional power than that of a reactor where a change of 1C / s is occurring4. The derivative control mode is designed to respond to the rate of change of error, this is contrary to the proportional and integral modes which are based on what has occurred in the past and present4. Derivative control mode is never used alone but is always combined with another type of control; the simplest of these is proportional-derivative (PD) control. Another benefit of derivative control is the ability to remove any instability introduced by the integral action.

3. Theory
Much of the relevant information and theory can be found in the previous section, this short section contains a few of the key equations governing the three control types discussed previously.

3.1 Integral Equation

Where, Kc is a constant. 5.1 Derivative Equation

(Equation 2)1

(Equation 3)1

Where, KD is a constant. Note: The equation for proportional control is given earlier (Equation 1). 7

4. Methodology

This section contains the appropriate experimental procedures applies during the studies carried out in this report. A brief overview of each experiment is given below.

4.1 Experiment 1

For this experiment the deviation signal was set to channel B on the Oscilloscope and the power supply signal was designated as channel A. The desired temperature was set to 40C. As mentioned earlier, the PCS 327 process controller was used and in this case set to two-step control mode. First the power supply to the heating apparatus (PT 326) was varied and any observations with regards to the oscilloscope were noted (e.g. Amplitude, Frequency). After this had been completed, the power was set to option 1 and the air inlet baffle was instead varied and the same observations were recorded.

4.2 Experiment 2 Instead of two step, this time the process controller was set to the proportional control mode, ensuring that the integral and derivative modes were set to off. The set point was again set to 40C and initially the bandwidth was determined as 100 %. From this point, the bandwidth was decreased in equal sized intervals of 20 (100 %, 80 %, 60 %). The difference between temperature readings was recorded for each bandwidth and any changes to the oscilloscope trace recorded.

4.3 Experiment 3

Here, the internal set value disturbance function is introduced in order to produce a step change. The step change causes a deviation from the set point allowing the systems subsequent response to be observed. This experiment was conducted at bandwidths of 40%, 80% and 120%. Traces of the systems response were drawn using computer software (Note: the set point was fixed at 40C).

4.4 Experiment 4

The same settings as experiment 3 were again used here. Bandwidth was set to 50%. The integral action was then varied between 0.5 and 1 (0.5, 0.75, and 1). Next, the derivative function was switched on and varied between 0.1-0.3. The traces were observed once again and any points of interest noted. All traces discussed in this section can be found in the results section.

5. Results

5.1 Experiment 1

The traces from experiment are shown below:

Note: Channel A = Power Supply Signal, Channel B = Deviation Signal

8 6 4 2 0 -10 -8 -6 -4 -2 -2 -4 -6 -8 Figure 2 Oscilloscope Trace at Power Setting 0.6, Red line = Channel A, Blue line = Channel B 0 V

8 6 4 2 0 -10 -8 -6 -4 -2 -2 -4 -6 -8 0 V

Figure 3 Oscilloscope Trace at Power Setting 0.8, Red line = Channel A, Blue line = Channel B

8 6 4 2 0 V 0 -2 -4 -6 -8 Figure 4 Oscilloscope Trace at Power Setting 1, Red line = Channel A, Blue line = Channel B

-10

-8

-6

-4

-2

Note: All the above traces were performed with the same baffle position (Position 5) and a power setting 1 refers to 100% of the maximum power being supplied to the heater.

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8 6 4 2 0 -10 -8 -6 -4 -2 -2 -4 -6 -8 Figure 5 Baffle setting 6, Red line = Channel A, Blue line = Channel B 0 V

8 6 4 2 0 -10 -8 -6 -4 -2 -2 -4 -6 -8 Figure 6 Baffle Setting 7, Red line = Channel A, Blue line = Channel B 0 V

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8 6 4 2 0 -10 -8 -6 -4 -2 -2 -4 -6 -8 Figure 7 Baffle Setting 8, Red line = Channel A, Blue line = Channel B 0 V

Note: The power supplied to the heater was 100% (Power setting 1) for figures 5, 6 and 7.

5.2 Experiment 2

7 6 5 Deviation 4 3 2 1 0 0 50 100 150 Proportional Bandwidth % Figure 8 Difference Between Temperature Readings VS. Proportional Bandwidth Series1 Linear (Series1) y = 0.05x + 1 R = 1

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5.3 Experiment 3

4.5 4 3.5 3 2.5 2 1.5 1 0.5 0 -10 -8 -6 -4 -2 0 V

Figure 9 Oscilloscope Trace Before and After Step Change, Bandwidth 40%

6 5 4 3 2 1 0 -10 -8 -6 -4 -2 0 V

Figure 10 Oscilloscope Trace Before and After Step Change, Bandwidth 80%

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6 5 4 3 2 1 0 -10 -8 -6 -4 -2 0 V

Figure 11 Oscilloscope Trace Before and After Step Change, Bandwidth 120%

5.4 Experiment 4

3 2 1 0 -10 -8 -6 -4 -2 -1 -2 -3 -4 Figure 12 Integral Action 0.5, Bandwidth 40% 0

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3 2 1 0 -10 -8 -6 -4 -2 -1 -2 -3 -4 -5 0

Figure 13 Integral Action 0.75, Bandwidth 40%

3 2.5 2 1.5 1 0.5 0 -10 -8 -6 -4 -2 -0.5 -1 -1.5 -2 Figure 14 Integral Action 1, Bandwidth 40% 0

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3 2 1 0 -10 -8 -6 -4 -2 -1 -2 -3 0

Figure 15 Derivative Action 0.1, Integral Action 0.5, Bandwidth 40%

3 2 1 0 -10 -8 -6 -4 -2 -1 -2 -3 -4 -5 Figure 16 Derivative Action 0.1, Integral Action 1, Bandwidth 40% 0

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4 3 2 1 0 -10 -8 -6 -4 -2 -1 -2 -3 -4 0

Figure 17 Derivative Action 0.2, Integral Action 0.5, Bandwidth 40%

4 3 2 1 0 -10 -8 -6 -4 -2 -1 -2 -3 -4 Figure 18 Derivative Action 0.2, Integral Action 1, Bandwidth 40% 0

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3 2 1 0 -10 -8 -6 -4 -2 -1 -2 -3 0

Figure 19 Derivative Action 0.3, Integral Action 0.5, Bandwidth 40%

3 2 1 0 -10 -8 -6 -4 -2 -1 -2 -3 0

Figure 20 Derivative Action 0.3, Integral Action 1, Bandwidth 40%

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6. Discussion

The results from the previous section are discussed here and any explanations to what is observed are given.

6.1 Experiment 1

Initially, when the power supplied to the heater was altered (Figures, 2-4), it can be seen that an increase in power produces a sinusoidal curve of greater amplitude and frequency (Wavelength Decreases). From this one can deduce that the systems supplied with greater power (100%) respond more quickly to a deviation from the set-point than those of which power supply is limited (60% and 80%). The increased amplitude means that a larger deviation in temperature from the set point occurs and this is of course undesirable. A greater power supply results in the heater performing its duty at a much faster rate than when power is limited and this explains the increased amplitude and frequency i.e. a faster rate of heating will therefore result in an increase of time periods in which the power is off and the system is cooling. Looking at figure 4 in particular, the magnitude of the peaks (above set-point) appears to be almost identical to that of the troughs (below set-point) and so the average deviation from the set-point over the time period studied may be considered to be approximately 0 (Peaks and troughs cancel each other out leaving a flat line, the set-point).

Now looking at figures 5-7, it can be seen that as the air inlet baffles are gradually opened, the amplitude and frequency of the oscilloscope trace decreases. This is due to increased airflow to the heater and so a greater volume of air is required to be heated with the same power as before. This results in a slower increase in temperature and a lower maximum deviation which explains the increase in both amplitudes and frequency/wavelength. When the baffles are in their most closed position, the trace is very similar to that of when the power supplied is 100% (figure 4).

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6.2 Experiment 2

From figure 8 it can be seen that at higher proportional bandwidths and greater deviation occurs. The opposite is true for low bandwidths at which the deviation is very small. Also using the equation below, the gain/sensitivity can be calculated:

(Equation 4)

This equation therefore shows that although deviation can be reduced by decreasing bandwidth, however in the process of doing so, sensitivity is also increased to a point where the system becomes extremely unstable.

8.3 Experiment 3 Figures 9-11 show that an increased bandwidth results in a more rapid and stable response to the introduction of a step change. Figure 9 shows that when the step change occurs, the system responds in such a way that it actually over shoots the set-point and further correction is required. This phenomenon results in a slow response to any sudden step change which is usually not adequate in industrial practice. Figure 11 on the other hand shows that at a bandwidth of 120% (the highest of those investigated) the system responds very well to the step change. This is clearly shown in figure 11 by the very small over shot and how quickly the system reaches equilibrium at the set-point.

6.3 Experiment 4

Increasing integral action (figures 12-14) is shown to eliminate the offset at lower bandwidths examined in experiment 2 but this produces greater instability. This produces a number of oscillations post step change. To minimise this, the effect of derivative action was examined at varying levels of integral action (figure 15-16). The addition of derivative action

counteracted the instabilities produced by integral levels, particularly at higher values. As derivative action values are increased instability is reduced, particularly at higher values of

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integral action. Another feature of higher derivative action values is a longer recovery time to steady state

7. Conclusion

Experiment 1, higher power supply and a closed air inlet baffle produce a higher amplitude (Deviation) and frequency. This means that the system responds at a faster rate but also produces a greater deviation from the set point temperature.

Experiment 2, higher proportional bandwidths result in greater deviation. Lower bandwidths reduce the deviation but also introduce more instability to the response. A balance must be struck between an acceptable deviation whilst maintaining good stability.

Experiment 3, increased bandwidth results in a more rapid and stable response, i.e. equilibrium at the set-point is reached much more quickly. Low bandwidths produce an over-shoot of the set point which means a longer response time is experienced.

Experiment 4, increased integral action tends to eliminate off set at lower bandwidth but also increases instability. Derivative action counteracted the instabilities and higher derivative values helped to reduce instability further.

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10. References

1. RICHARDSON, J.F, D G PEACOCK. Chemical Engineering: Chemical and Biochemical Reactors and Process Control. Oxford: Elsevier. 2007.

2. ROMERO, R. Research on Automatic Irrigation Control: State of the Art and Recent Results. Agricultural Water Management, 2012, 114, pp. 59-66. 3. CED ENGINEERING. Instrumentation and Control [Online]. [No Date]. [Accessed: 2 January 2012]. Available From: http://www.cedengineering.com 4. CHAU, P.C. Process Control: A First Course with MATLAB. Cambridge: Cambridge University Press. 2002.

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