1- Control Introduction

Control System Strategies

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for Non Experts ABB

01-04-06 -
 Control
Introduction
Introduction

 Should you give someone who

knows nothing about electronics a
high priced voltmeter and ask
him/her to measure the voltage
across a resistor??
 Yet we do this in process control all
the time!!
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 Control
Introduction

Results:
 Upset “customers”
 Aggravated operators
 High defects
 Product Instability
 Excessive valve wear
 Lost profits
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 Control
Introduction
Introduction

 Process Control Defined

 “…a way of maintaining a process variable at a desired level by
adjusting a device that affects that process variable.”
 Course Content
 The settings and modes of automatic controllers
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 Control
Introduction
Introduction

KI
KP

PB
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 Control
Introduction
Introduction

Process Control: The Early Years

 Large, non-precision valves
 Pneumatic devices
 Forgiving to errors

“The Black Box”

Control
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 Control
Introduction
Introduction

“Black Box" Tuning

Ideal
100 %

Controller
Performance
Potential

Manual
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Time

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 Control
Introduction
Introduction

“Black Box" Tuning

and configuration 100 %
Ideal

Controller
Performance
Auto
Potential

Manual
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Time

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 Control
Introduction
Introduction

“Black Box" Tuning

and configuration 100 %
Ideal

Controller
Performance
Auto
Potential

Manual
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Time

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 Control
Introduction
Introduction

“Black Box" Tuning

and configuration 100 %
Ideal

Optimization
Controller
Performance Potential
Auto
Potential

Manual
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Time

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 Control
Introduction
Introduction

Tuning as Science, Not Art!

Ideal
100 %

Optimization
Potential

Controller
Performance
Auto
Potential

Manual
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Time

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 Control
Introduction
Introduction

Tuning as Science, Not Art!

Ideal
100 %

Optimization
Potential

Controller
Performance
Auto
Potential

Manual
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Time

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 Control
Introduction
Introduction

Tuning as Science, Not Art

Ideal
100 %

Remove
Performance
Controller Gap
Performance
Auto
Potential

Manual
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Time

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 Control
Introduction

Remove
Performance
Gap
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 Control
Introduction
Introduction

Customer Benefits
 High profits
 Less down time
 Product stability
 Improved quality
 Operator confidence
 Customer satisfaction
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 Control
Introduction
Opening the Black Box of Control

Control
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 Control
Introduction
Opening the Black Box of Control
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Quality

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 Control
Introduction
Opening the Black Box of Control

 Process
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Quality

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 Control
Introduction
Opening the Black Box of Control

 Process
 Actuators
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Quality

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 Control
Introduction
Opening the Black Box of Control

 Process
 Actuators
 Transmitter
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Quality

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 Control
Introduction
Opening the Black Box of Control

 Process
 Actuators
 Transmitter
 Filter
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Quality

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 Control
Introduction
Opening the Black Box of Control

 Process
 Actuators
 Transmitter
 Filter
 Controller
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Quality

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 Control
Introduction
Opening the Black Box of Control

 Process
 Actuators
 Transmitter
 Filter
 Controller
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Quality

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 Control
Introduction
Opening the Black Box of Control
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 Control
Introduction
Opening the Black Box of Control

Control Loop
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Optimization

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 Control
Introduction
Tuning

 Can you drive a sports car and

a large industrial truck the
same way?
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 Control
Introduction
Control Loops

Control Loops,
What’s the big deal?
I’ve never been trained,
but I get good results.
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 Control
Introduction
Control Loops

Okay, but how long did

it take you to learn ??
how to get good
results??
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 Control
Introduction
Control Loops

Technical Persons…
 are being asked to wear
several hats.
 have no time for the “school of
hard knocks.”
 Need a reduced learning
curve.

IE
SE

AE
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 Control
Introduction
Control Loops

Learning by trial and error can take years!

Level of Understanding

Years
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2 5
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 Control
Introduction
Control Loops

Learning by trial and error can take years!

Level of Understanding

Years
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2 5
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 Control
Introduction
Control Loops

Reduce the Curve!

Level of Understanding

Days
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2 5
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 Control
Introduction
Control Loops

The Process Control Puzzle

Tu
nin
g

Ga Filter
ins

Pipe Trans-
Size mitter

cess lity
Actuator
Pro Qua
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 Control
Introduction
Control Loops
Off Control
The Pieces of the Puzzle:
Time
 Start with the process
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Process
Control
Valve
ABB
Sensor
 Control
Introduction Control Loops
Off Control
The Pieces of the Puzzle:
Time
 Start with the process
 Add the Controller

Controller
100 Gains
.
80 Open . ..
. . Proportional
60
. .
. .
40 . . Integral
20 Closed
.
0 . ..
. . . . Derivative
. .
. . Setpoint
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Process
Control
Valve
ABB
Sensor
 Control
Introduction
Control Loops
Off Control
The Pieces of the Puzzle:
Time
 Start with the process
 On Control, Well Tuned  Add the Controller
 Adjust the Gains
Controller
100 Gains
.
80 Open . ..
. . Proportional
60
. .
. .
40 . . Integral
20 Closed
.
0 . ..
. . . . Derivative
. .
. . Setpoint
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Process
Control
Valve
ABB
Sensor
 Control
Introduction
Control Loops

Beware!! Off Control

Time

 On Control, Well Tuned

Controller
Gains
 On Control, Poorly Tuned
100
.
80 Open . ..
. . Proportional
60
. .
. .
40 . . Integral
20 Closed
.
0 . ..
. . . . Derivative
. .
. . Setpoint
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Process
Control
Valve
ABB
Sensor
 Control
Introduction
Control Loops: Quality Production

Quality
Production
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 Control
Introduction

Spin-offs of a well-tuned process:

Control Optimization Customer Satisfaction

Process
Repeat Business Automation

Process
Control

Decrease
Less Down Time Troubleshooting
Time
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Value Added Supplier Increased Production

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 Control
Introduction

Where do I
Start?
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 Control
Introduction

Basic Steps for control Loops :

Controller
 Set up actuators and 100
Open .
. ..
Gains
80 . . Proportional
transmitters 60
.
. .
.
40 . . Integral
20
 Set up signal calibration and . .
0
Closed
.
. ..
. . Derivative
. .
Setpoint
filtering . .

 Identify the process

parameters
Process
 Tune the controller based on Control
the process Valve

Sensor
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 Control
Introduction
Start at the Bottom

Configuration Steps:
 Set up actuators and
transmitters
 Set up signal calibration and
filtering

Input Process Output

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 Control
Introduction
Start at the Bottom

Configuration Steps:  Bump Test Methodology

 Set up actuators and
transmitters
 Set up signal calibration and
filtering
 Identify the process
parameters
 First Order Process
 First Order Process Plus
Deadtime
 Integrating Process

Input Process Output

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 Control
Introduction
Start at the Bottom

Configuration Steps:  Control Mode

 Set up actuators and  Proportional
transmitters  Integral
 Set up signal calibration and  Derivative
filtering  Tuning Technique
 Identify the process  Direct Synthesis (no
parameters overshoot)
 Tune the controller based on  Ziegler-Nichols (1/4 wave
the process ratio)

Match
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Controller Process
Characteristics

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