introduction for process control systems 过程控制系统概论 shen guo-jiang institute of...
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Introduction forProcess Control Systems
过程控制系统概论
Shen Guo-jiang
Institute of Industrial Control,
Zhejiang University
Contents Origin of Process Control Systems Important Terms and Objective of
Process Control Systems Description of Process Control Systems Types of Control Strategies Course Tasks
Systems and Control Systems
Systems
U
D
Z
Y
Control Systems
examples ?
Inputs
Outputs
Application of control system The military: flight control Mechanical engineering: centrifugal governor
(Watt) Electricity and electronics Process industry (including: petroleum, chemical,
metallurgy, pharmaceutical, environmental protection, etc.)
Economy and management system: CPI levels of control
Other…
Origin of Process Control Systems
Manual Operation: (1) Measure the level by a water
gauge and the eye ( 水位表 );(2) Compare the level to its
desired value in the brain;(3) Based on this comparison,
decide what to do to correct for any deviation ( 偏差 );
(4) Manipulate the outlet valve (输出阀 ) to correct for the deviation.
Purpose: To maintain the level at a desired operating value, when the inlet flow (输入流量) changes.
Limitations with Manual Control
Require the operator to look frequently at the level to take corrective action whenever it deviates from the desired value;
Different operators would make different decisions as to how to move the outlet valve, resulting in inconsistent operation ( 操作的不一致性 );
Require a large number of operators to maintain hundreds of variables in most process plants at a desired value.
Solution ?
Automatic Control SystemSolution: Design a control system to accomplish this control automatically without requiring intervention from the operator.
Three basic components of all control systems:• a sensor / transmitter: the “eye” of the control system, • a controller: the “brain” of the control system,• final control element: often a control valve.
h
hsp
Qi
Qo
LT21
LC21
Feedback Control Process1. Measure the level by a sensor ( 传感器 ) and convert the
output from the sensor to an electric signal by a transmitter ( 变送器 ) ;
2. The controller (控制器 / 调节器) then receives the signal and compares it with the value desired;
3. Depending on this comparison, the controller decides what to do to correct for any deviation;
4. Based on this decision, it sends a signal to the final control element (执行单元) , e. g., a control valve.
h
hsp
Qi
Qo
LT21
LC21
Three basic operationsin every type of control system
Measurement ( 测量, M)Measuring the variable to be controlled is usually done by the combination of sensor and transmitter.
Decision ( 决策, D)Based on the Measurement the controller decides what to do to maintain the variable at its desired value.
Action ( 动作 / 执行, A)As a result of the controller’s decision, the system must then take an action. This is usually accomplished by the final control element. The action taken must come back and affect the measurement.
Important Terms of Automatic Process Control
Controlled Variable (CV, 被控变量 / 受控变量 )The variable that must be maintained or controlled at some desired value.
Setpoint (SP, 设定值 / 给定值 )The desired value of the controlled variable.
Manipulated Variable (MV, 操纵变量 / 操作变量 )The variable used to maintain the controlled variable at its setpoint.
Disturbance (DV, 扰动 / 扰动变量 )Any variable that causes the controlled variable to deviate away from its setpoint.
Objective of Process Control Systems
The objective of an automatic process control system is to adjust the manipulated variable to maintain the controlled variable at its set point in spite of disturbances.
Why automatic control is important:1) Safety. Prevent injury to plant personnel and damage to the process equipment, and protect the environment by minimizing wastes. 2) Product Quality.3) Minimum Cost.
Example 1.1
For the above pressure control system, please describe its CV, SP, MV, DVs, control diagram as well as control objective.
2211 FKFKdt
dPV
PPfKF V 1111
2222 PPfKF V
Variable relations are as follows:
Discuss the solution ?
P
P1
P2Psp Pm
u
f1
f2
F1
F2PC51
PT51
uf 1001
Control Diagram #1 for Example 1.1
Point out its MV, DVs ?
PC51
Psp e(t)
+_
Pm
PT51
Control Valve
P(t)u(t)
222 PPfKV
PPfKV 111
f1
P1
F1
2211 FKFKdt
dPV
P
P2
F2
f2
P
Controlled Process
Control Diagram #2 for Example 1.1
PC51
Psp
+_
Pm
PT51
Control Valve
P(t)u(t) f1
P2
Controlled Process
++
Disturbance Path
(干扰通道)
Control Path(控制通道)
P1
f2
Control Diagram #3 for Example 1.1
PC51
Psp
+_
Pm
PT51
Control Valve
P(t)u(t) F1
Controlled Process
++
Disturbance Path
Control Path
P1, P2, f2
Discuss its correctness
Ex. 1.2: Temperature Control System for a Heat Exchanger
Problem: point out CV, SP, MV, DVs, its block diagram and objective ?
Steam
Tsp
Tm
T
RV
RF , Ti
u(t)
Condensate
Process Fluid
TC22
TT22
Block Diagram for Heat Exchanger
Tsp
+_
Tm
++ T(t)RV (t)
RF (t), Ti (t)Disturbance
Path
TT22
Steam Valve
Control Path
TC22
Heat Exchanger
u(t)
General Feedback Control Systems
CV: temperature, pressure, flow, level, composition(成份含量 ) and property(属性 ) of process fluid ;
ysp u(t)
+_
ym(t)
++ y(t)MV
DVs Disturbance
Path
Sensor & Transmitter
Final Control Element
Control Path
Controller
Controlled Plant
General Control Systems
Controller: Hardware & Software
Control Strategies / Algorithms
(控制策略与算法 )
ysp u(t)
+_
ym(t)
++ y(t)MV
DVs Disturbance
Path
Sensor & Transmitter
Final Control Element
Control Path
Controller
Controlled Plant
Hardware of Controllers Analog control instruments (DDZ-II, III) Digital control instruments ( 数字控制器 ) Programmable logic controllers ( 可编程逻
辑控制器, PLC) Distributed control systems (集散控制系
统或称分布式控制系统, DCS ) Fieldbus control system (现场总线控制系
统, FCS ) Ethernet for Process Automation ( 过程自
动化以太网, EPA)
Types of Control Systems Regulatory Control (“定值控制”或“调节
控制”) and Servo Control (”伺服控制”或“跟踪控制”)Examples : continuous processes and batch processes or flight control.
Feedforward Control (前馈控制) and Feedback Control (反馈控制)Examples : temperature control system in a heat exchanger.
Feedforward Control & Feedback Control
T
RV
RF
Tsp
Tm
u(t)
Ti
Feedforward Controller
Condensate
Process Fluid
Steam
TT22
FT31
TT32
RFm Tim
Compare the advantages and disadvantages of both strategies.
Steam
Tsp
Tm
T
RV
RF , Ti
u(t)
Condensate
Process Fluid
TC22
TT22
Feedforward Feedback Control
T
RV
Tm
u(t)
Steam
Condensate
Process Fluid
Feedforward ControllerTsp
TC22
TT22
RF Ti
FT31
TT32
RFm Tim
Types of Control Systems Switch Control (开关量控制) and
Continuous Control (连续量控制)Examples: air conditioner control
Continuous-Time Control (连续时间控制) and Discrete-Time Control (离散时间控制 , 也称“采样控制” , Digital Control, “ 数字控制”)Examples: control systems based on computers or analog instruments
Types of Control Systems (cont.)
Multi-input-multi-output Control ( MIMO,多输入多输出控制 , or “ 多变量控制” ), Single-input-single-output Control ( SISO, 单输入单输出控制) and Multi-loop Control (多回路控制)Examples: distillation column control
Linear Control (线性控制) and Nonlinear Control (非线性控制)Examples: pH control
Multi-loop Control for Distillation
LC
TC
LC
FC
FC
DistillationColumn
SteamResidue
ProcesssFluid
Product
Basic Process Control Strategies
Single-loop PID ( 单回路 PID 控制 ) Cascade Control ( 串级控制 ) Ratio Control ( 比值控制 ) Override or Selective Control ( 超驰或选
择控制) etc.
Features: PID based, simple, no model needed, easy tuning, and for SISO systems.
Advanced Process Control ( 先进控制, APC) Strategies
Feedforward Control ( 前馈控制 ) Dead-time Compensation ( 纯滞后补偿 ) Decoupling ( 解耦 ), Predictive Control ( 预测控制) Adaptive Control ( 自适应控制 ), etc.
Features: Model based, complicated, computer needed, and most for MIMO or SISO systems with long dead-time.
Primary Task of the Course
To analyze, design and implement the control strategies or controller for continuous controlled processes
ysp u(t)
+_
ym(t)
++ y(t)MV
DVs Disturbance
Path
Sensor & Transmitter
Final Control Element
Control Path
Controller
Controlled Plant
Techniques Correlative to Process Control Engineering
Process Control Engineering
Control Theory
Optimization
Chemical Engineering
Measuremental & Control Instruments
Computer & Networks
System Simulation
Next Lecture
Defined the types of processes: self-regulating and non-self-regulating processes, single- and multi-capacitance processes ;
Discussed the modeling from process dynamics;
Discussed process characteristic parameters K, T,τ, and their obtaining methods from process data.