UNIT 1

PROCESS CONTROL PROGRAMMING

The purpose of computer programming is to individualize the functions carried out by a

particular computer system. Making the computer do what is wanted in a particular context-that
is writing the programs that run the hardware has become the leading cost factor in developing
computer systems today, weather for scientific ,business or process control applications.

Programming method for process control computers have tended to lag behind the programming
techniques developed for scientific and business applications. This is because of the smaller
number of applications for any one control computer model, smaller size of the vendor company,
and companys inability to provide the latest in programming techniques for the particular
computer system.

New programs tend to be developed from old programs used previously for similar functions.

Major trend to make all programs as general as possible in order to enhance their use for related
applications to minimize their individuality and reduce the cost of developing the next system.

TYPES OF PROGRAM

It consists of three major parts

The operating system or executive program

The application program
The system support software

Executive program - It consists of all the programs that supervise the overall operations of the
computer system. The functions are as follows
Scheduling and actually starting the execution of the application programs.
Operating all hardware of the system (e.g. allocating main memory to specific functions,
loading programs in to main memory from external bulk memory etc.)
Supervising input output operations.
Servicing the priority interrupt system
Loading analog and digital inputs in to memory.
Controlling outputs to the plant actuators.

Application programs It handle all of the specialized functions required for that particular
installation. The functions are

Conversion of plant input data to engineering units.

Scheduling, optimization and control correction computations.
Operators console, logging and other operator and management presentations.

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System support software are those that programs that help the user to prepare the application
programs. They include the following

Assemblers and compilers that convert programs written in specific assembly language or
a high level language such as FORTRAN in to machine language of the computer.
Editors, linking-loaders and similar packages that allow segments of programs written
separately to be incorporated in to one program in the computer.
Programs that help debug application programs. These programs may not be carried in
the computers memory at all times but may be entered when needed from external
storage (disk or tape).

Features of process control programs

Computer systems used for process control differ from those used for general scientific
and business purposes in that they contain special features that allow operation in a real
time environment.
Process control systems perform time relative operations that are governed by a real
time clock and respond to other externally generated occurrences through an external or
priority interrupt system. The process control program used in the system must allow for
these functions.
The major difference between programming in the process control field and
programming in general scientific and business fields. Because the priority interrupt
capability affects the overall management of the computer system,this function is
included in the executive program of the process control computer.
The other time based and externally simulated functions are included in the application
program of the system.
A second major difference between process control programming and scientific or
business programs is the great dependence on multiprogramming or parallel execution
of functions.

Figure 1 illustrates the operations that are executed by programming in the process
computer system.
The diagram shows the overall system as carried out by a single computer containing all
functions.
The modular system shown in the diagram allows any particular module to be modified
without affecting any of the other modules. This simplifies both the initial programming
effort and required program modifications.
This is possible by the use of data tables indicated in the diagram.
Further advantage of such a program system is that programs developed by others for
any of the modules can be integrated in to the overall program.

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Figure 1

Programming languages for Process Control

The higher level languages are becoming ever more popular for all types of computer
programming, including process control programming.
Assembler languages permit the knowledgeable programmer to take advantage of
programming tricks and the design details of the particular computer to optimize the
operating speed of the system while minimizing the need for memory.
Assembler languages permit more efficient use of the computer.
High level languages for process control can be readily divided in two major branches
General purpose languages
Problem oriented languages

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Fig:2

Fig 2 shows these two branches and their further subdivision in to several different
categories.
Higher level languages have two major advantages over an assembler or any other so
called lower level language .First the same program can be run on any type of computer
for which the corresponding translator program has been written. Second advantage is
that their symbology is usually much more readily interpreted by the average user than
are the assembler or machine languages they replace that is they are more like normal
English or mathematical statements.
A compiler takes the code (program) as written by the programmer and converts it
completely to the machine language of the particular computer. This translation may
include converting the program in to an assembler language as intermediate step.
An interpreter stores the program in the computer in the form developed by the
programmer.
The computer than executes the program a line at a time by interpreting ,or converting
each line to machine language and carrying out the instructions included therein before
going on to the next line.
The programs to be used with an interpreter must be somewhat simpler than programs
to be used with a compiler. When compiling a program, the computer can sense the
complexity of the entire program.

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Compiler languages differ among themselves in terms of their capabilities. Those that
permit complex programs to be readily written in them are called system programming
languages.
Problem oriented languages are those that have been especially developed for a
particular type of application. Process control is an important application type.
Problem oriented languages can be divided in to compiler type languages and fill-in-
the-blanks languages.
Fill-in-the-blanks programs originated with the general process control programming
system (GPCP) by humble oil and refining company.
Compiler type languages are extended versions of the general purpose compiler
languages. A well-known example of this kind of program is AUTRAN (Automatic
utility Translator) and was developed by the Merck, sharp and Dohme Automation
Department.
The fill-in-the-blanks is a largely prewritten, interpreter-type program that offers a
large number of choices in its execution in addition to a well-developed skeleton data
base.
By responding series of questions or a menu displayed on CRT screen ,the system
developer is able to make a proper choice of algorithms for each of the control loops
from the available options.

Recent Developments
During the last decade, the development of computer languages has focused on specific
types of process control tasks, such as batch process control, on the tuning of PID type
control algorithms and on the software for large scale process control systems.
Generic programs became available for the control of batch manufacturing.
DCS software was developed for the design of multivariable control systems.
Other areas of development included programs for relative gain calculations, artificial
intelligence, statistical process control, model based optimization and Fuzzy logic
applications.

ALGORITHMS
An algorithm is the description of the mechanization of a particular equation by the
digital computer. It has also come to mean an equation that has become popular for the
implementation of the particular function on the computer.
In DCS control, the digital computer computes the actual movement of the valve or other
final actuator.

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In supervisory control, the computer computes the required changes in the variables
setpoint, and the final control actuation is left to an analog electronic or pneumatic
controller.

There are two algorithms for programming a three mode PID control loops.

Position Algorithm
Velocity Algorithm

Both differ principally in the place where integration occurs. For position algorithm,
the computer output is the corrected valve position; integration is done in the
computer. For velocity algorithm the computer output is the change that the valve
should undergo between sampling periods; therefore integration must be done by the
final element via a stepping motor, integrating amplifier or other devices.

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