Process Control

What does this block diagram mean?

Controller Plant

SP Error OP
PID G(s)

PV
 Control Terms - Three Term Control
Proportional ---- Proportional Band
Integral ---- Integral Time Constant
Derivative ---- Derivative Time Constant

Output ( OP ) = K ( 1 + xdt + dx/dt )

(P I D)

Controller Plant

SP Error OP
PID G(s)

PV
 Loop Response
Under Damped

Setpoint

Critically Damped

Over Damped

Time

Under Damped--Overshoot gives minimum time to setpoint

Critically Damped--No overshoot and stable

Over Damped--No overshoot but excessive time to setpoint

 Loop Tuning

Setpoint x osc

t osc

Time

Rule Of Thumb:

Proportional Band--P = 2* x osc

Integral Time Constant--I = 1.5* t osc
Derivative Time Constant--D = I/5
 Three Term Control

How can I relate this loop response to my

process?

Under Damped

Setpoint

Critically Damped

Over Damped

Time
 Proportional Term Analogy
Speed
(mph)
50
46
Proportional Band
40
Ease off gas pedal

Depress gas pedal

Time

0 mph 40 mph 46 mph

 Integral Term Analogy
Speed
(mph)
50
46
40
Slowly depress gas pedal
to reach 50 mph

Time

46 mph 48mph 50mph

 Derivative Term Analogy
Speed
(mph)
52

50
Proportional Band
48

Time

50 mph 49 mph 50 mph 51 mph 50 mph

 Process Control

How many parameters are controlled in

my Cast Film or Blown Film process?

&

How do they differ from each other in

terms of speed of response?
 Cast Film

G/B
Th

S
Barrel MP Die S
C

P
D D D D D D

D Drive speed control MP Melt pump

T Temperature control P Pressure control
SC Screen changer S Scanning frame
G/B Gravimetrics / Blender Th Thickness control
 Blown Film
D Drive speed control
T Temperature control
SC Screen changer
G/B Gravimetrics / Blender
Th Thickness control
S Scanning frame

C AB Air board
Tr
C Cage
B Bubble diameter sensing
G/B
Tr treater
B B

Barrel S Die S
C

D D D Th D D
T
 Use Of Computer Systems

What benefits can I achieve by using a computer

system on my process?

&
How is my process control equipment connected to a
computer system?
 Computer Supervision - 1

A computer system provides:

One window to view all line information

The ability to modify line parameters
Storage and download of stored recipes
Live trending of data
 Computer Supervision - 2

Additional computer system benefits are:

Generation of batch and shift reports

Statistical Process Control (SPC) trending and data
Historical trend and data information
Networking of data to other departments
 Linking to the Computer - 1

Ideal Industrial
Computer

Temperature Drive Thickness Gravimetric Pressure PLC

Control Control Gauge Blending Control Control

Actual Industrial
Computer

Temperature Drive Thickness Gravimetric Pressure PLC

Control Control Gauge Blending Control Control
 Linking to the Computer - 2

Improved system Industrial

Computer
OEM system

Temperature Thickness Industrial

and Pressure
Gauge Computer
Control

Drive Gravimetric PLC Temperature Control

Control Blending Control Pressure Control
Gravimetrics / Blending
PLC

Drive Scanning
Control Frame
 Digital Communications

My computer has RS232 and the process

equipment has RS232. This is all I need, right?

Wrong!
 RS (EIA) 232, 422 & 485 Analogy
EIA-232:
3 - wire connection ( plus enable links ): Tx, Rx, Common
Point to point ( one to one )
Short distance transmission ( <50ft / 15m )
EIA-422/485:
5-wire connection (422):Tx+, Tx-, Rx+, Rx-, Common
3-wire connection (485):A (Tx+ & Rx+), B (Tx- & Rx-), Common
Multi drop capability: ( 8 for EIA 422 and 32 for EIA 485 )
Long distance transmission ( 4000ft / 1230m )

EIA-232 & EIA-422/485 are analogous to using the air as the transmission
medium for us to communicate. They do not tell us how we communicate.
 EIA-232 / EIA 422 (485) Explained
EIA 232 Noise pulse

Tx Rx
Input signal Recovered signal

EIA 422 (485) Noise pulse

+ +
Tx Rx
Input signal _
Recovered signal
-
Signals
subtracted

Noise pulse
Communications Protocol Analogy

Allo! Hola!

'' Moshi moshi!

Pronti!

Hullo! Hello!