Process Dynamics & Control

1,2,3 Elements Control systems

Submitted to : Engr. Tahir Ishfaq

B.Sc Chemical Engineering 8th Semester Session 2009-2013 NFC Institute of Engineering and Fertilizer Research, Faisalabad

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Contents

1,2,3 Element Process Control

1.1 Introduction (Process Control) .......................................................................................................... 3 Elements of a Process Control System ................................................................................................... 3 Process ............................................................................................................................................ 4 Evaluation ....................................................................................................................................... 5 Control ............................................................................................................................................ 5 INDUSTRIAL APPLICATION ............................................................................................................. 5 Feed forward + Feedback Control .......................................................................................................... 8 Ratio Control........................................................................................................................................... 9 Boiler Drum Level Control ................................................................................................................... 10 1. 2. 3. Single Element Drum Level Control ......................................................................................... 11 Two Element Feed water Control.............................................................................................. 14 Three-element Drum Level Control .......................................................................................... 18

Furnace Control system ........................................................................................................................ 27

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1.1 Introduction (Process Control)

The operations that are associated with process control have always existed in nature. Such natural process control can be defined as any operation that regulates some internal physical characteristic that is important to a living organism. Examples of natural regulation in humans include body temperature, blood pressure, and heart rate. Early humans found it necessary to regulate some of their external environmental parameters to maintain life. This regulation could be defined as artificial process control or more simply as process control, as we will refer to it in this book. This type of process control is accomplished by observing a parameter, comparing it to some desired value, and initiating a control action to bring the parameter as close as possible to the desired value. One of the first examples of such control was early mans use of fire to maintain the temperature of his environment. The term automatic process control came into wide use when people learned to adapt automatic regulatory procedures to manufacture products or process material more efficiently. Such procedures are called automatic because no human (manual) intervention is required to regulate them.

Elements of a Process Control System

Figure 1-2 illustrates the essential elements of a process control system. In the system shown, a level transmitter (LT), a level controller (LC), and a control valve (LV) are used to control the liquid level in a process tank. The purpose of this control system is to maintain the liquid level at some prescribed height (H) above the bottom of the tank. It is assumed that the rate of flow into the tank is random. The level transmitter is a device that measures the fluid level in the tank and converts it into a useful measurement signal, which is sent to a level controller. The level controller evaluates the measurement, compares it with a desired set point (SP), and
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produces a series of corrective actions that are sent to the control valve. The valve controls the flow of fluid in the outlet pipe to maintain a level in the tank.

Thus, a process control system consists of four essential elements: process, measurement, evaluation, and control. A block diagram of these elements is shown in Figure 1-3. The diagram also shows the disturbances that enter or affect the process. If there were no upsets to a process, there would be no need for the control system. Figure1-3 also shows the input and output of the process and the set point used for control.

Process
In general, a process consists of an assembly of equipment and material that is related to some manufacturing operation or sequence. In the example presented in Figure 1-2, the process whose liquid level is placed under control includes such components as a tank, the liquid in the tank, the flow of liquid into and out of the tank, and the inlet and outlet piping. Any given process can involve many dynamic variables, and it may be desirable to control all
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of them. In most cases, however, controlling only one variable will be sufficient to control the process to within acceptable limits. One occasionally encounters a multivariable process in which many variables, some interrelated, require regulation. Measurement to control a dynamic variable in a process, you must have information about the entity or variable itself. This information is obtained by measuring the variable. Measurement refers to the conversion of the process variable into an analog or digital signal that can be used by the control system. The device that performs the initial measurement is called a sensor or instrument. Typical measurements are pressure, level, temperature, flow, position, and speed. The result of any measurement is the conversion of a dynamic variable into some proportional information that is required by the other elements in the process control loop or sequence.

Evaluation
In the evaluation step of the process control sequence, the measurement value is examined, compared with the desired value or set point, and the amount of corrective action needed to maintain proper control is determined. A device called a controller performs this evaluation. The controller can be a pneumatic, electronic, or mechanical device mounted in a control panel or on the process equipment. It can also be part of a computer control system, in which case the control function is performed by software.

Control
The control element in a control loop is the device that exerts a direct influence on the process or manufacturing sequence. This final control element accepts an input from the controller and transforms it into some proportional operation that is performed on the process. In most cases, this final control element will be a control valve that adjusts the flow of fluid in a process. Devices such as electrical motors, pumps, and dampers are also used as control elements. INDUSTRIAL APPLICATION 1. Boilers This is a basic diagram of a boiler that shows that a boiler comprises two separate systems. One system is the steam-water system, which is also called the water side of the boiler. In this system water is introduced and, upon receiving heat that is transferred through a solid metal barrier, is heated, converted to steam, and leaves the system in the form of steam.

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The other system of a boiler is the fuel-air-flue gas system, which is also called the fire side of the boiler. This system provides the heat that is transferred to the water. The inputs to this system are fuel and the necessary air required to burn the fuel.
STEAM WATER STEAM/WATER SYSTEM BLOWDOWN

FUEL

MIXING OF FUEL & AIR

FURNACE

HEAT TRANSFER SURFACE

FLUE GAS

AIR

ASH

STEAM STEAM

FURNACE

FLUE GAS

FUEL FLAME AIR MUD DRUM WATER CIRCULATES CLOCKWISE

CIRCULATION

GAS BAFFLES

Simple feedback control is shown in the control diagram, With this type of loop, changes in the primary variable feed back to a control function. The control function can be proportional-plus-integral (as shown), proportion-only, proportional-plus-derivative, integral integral-only, or proportional-plus-integral-plus-derivative. In all these cases the controller includes an error detector function, which measures the error between the primary variable and the set point. The controller output is determined by a combustion or summation of the effects of the different control action capabilities that are built into the controller. These are the proportional or gain multiplication of the error magnitude, the difference between the measured amount and the set point, the integral action

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based on incremental time away from set point multiplied by error magnitude, and the derivative or rate of change of the measured variable. A change in the controller output changes the manipulated variable, which through action of the process changes the process output selected as the primary variable This closes the control loop.

PRIMARY VARIABLE XT

K SET POINT

PROCESS

f(x) MANIPULATED VARIABLE

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Feed forward + Feedback Control

In feed forward-plus-feedback control a secondary variable that has a predictable relationship with the manipulated variable is connected. In this case a change in the secondary variable causes the manipulated variable to change in anticipation of a change in the primary variable. This reduces the magnitude of the primary variable change due to the more timely control action that originates from the secondary variable. The feedback portion of the loop contains the set point and can contain any of the controller functions of the basic feedback loop. The feedforward gain is adjustable and may be greater than 1.0.

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Ratio Control
Ratio control consists of a feedback controller whose set point is in direct proportion to an uncontrolled variable. The proportional relationship can be set by the operator of the process, or it can be automatically adjusted by another controller. As shown, the mathematical function is a multiplier. If the ratio is set, the set point of the controlled variable changes in direct proportion to changes in the uncontrolled variable. If the multiplication is changed, the direct proportional relationship or ratio between the controlled and the uncontrolled variables is changed. A careful examination of most boiler control applications will show that the overall control system is an interconnected matrix of the four types of control application.

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Boiler Drum Level Control

The purpose of the drum level controller is to bring the drum up to level at boiler start-up and maintain the level at constant steam load. A dramatic decrease in this level may uncover boiler tubes, allowing them to become overheated and damaged. An increase in this level may interfere with the process of separating moisture from steam within the drum, thus reducing boiler efficiency and carrying moisture into the process or turbine. The functions of this control module can be broken down into the following Operator adjustment of the set point for drum level

Compensation for the shrink & swell effects Automatic control of drum level Manual control of the feed water valve Bump less transfer between auto and manual modes Indication of drum level and steam flow Indication of feed water valve position and feed water flow Absolute/deviation alarms for drum level

The three main options available for drum level control are: 1. Single Element control System 2. Double Element control system
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3. Three element control system

1,2,3 Element Process Control

1. Single Element Drum Level Control

The simplest but least effective form of drum level control is single element control system. Single-element control is the minimum feed water control system and shall be used for the following applications: 1) During start-up or at low-load operation, when flow measurements are generally not accurate. 2) When steam flow rate of change is nominal and feedwater supply pressure is essentially constant. Pressure compensation If the instruments used to measure drum level are sensitive to density variations, then density compensation technologies shall be employed.

Figure Single-element drum level control

This consists of a proportional signal or process variable (PV) coming from the drum level transmitter. This signal is compared to a set point and the difference is a deviation value. This signal is acted upon by the controller which generates corrective action in the form of a proportional output. The output is then passed to the boiler feed water valve, which then adjusts the level of feed water flow into the boiler drum. Only one analogue input and one analogue output required

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Can only be applied to single boiler / single feed pump configurations with relatively stable loads since there is no relationship between drum level and steam- or feed water flow

Possible inadequate control option because of the swell effect

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DRUM LEVEL LT PT f(x) X

1,2,3 Element Process Control

DRUM PRESSURE PRESSURE COMPENSATION

A SET POINT

M/A CONTROL STATION

f(x)

FINAL CONTROL DEVICE

Typical single-drive control system. For simplicity, redundant transmitters have not been shown on this typical control drawing. See Figure 2A for ANSI/ISA-S5.1-1984 format.

SWELL NWL DRUM LEVEL SHRINK

100

% STEAM FLOW

75 STEAM FLOW 50 * 25

* FEEDWATER FLOW

0 0 TIME

* INTERACTION WITH FIRING RATE CONTROL DUE TO IMBALANCE BETWEEN STEAM FLOW AND FEEDWATER FLOW.

By adding a control system instead of a mechanical system which is proportional only better control is achieved. Mechanical systems are proportional only control. By adding integral / reset control effect the level will come back to set point. The swell or shrink results in an increase in level on steam increase. Integral control must be tuned to be slow so the initial rise effect is reduced.

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The standard single element boiler water level control system, with proportional control, gives excellent control on the majority of boiler installations. However, with single element proportional control, the water level must fall for the feed water control valve to open. This means that the water level must be higher at low steaming rates and lower at high steaming rates: a falling level control characteristic. However, where there are very sudden load changes, on some types of water-tube boiler, single element control has its limitations.

2. Two Element Feed water Control

The two-element drum level controller can best be applied to a single drum boiler where the feed water is at a constant pressure. The two elements are made up of the following Level Element: a proportional signal or process variable (PV) coming from the drum level transmitter. This signal is compared to a setpoint and the resultant is a deviation value. This signal is acted upon by the controller which generates corrective action in the form of a proportional value. Steam Flow Element: a mass flow rate signal (corrected for density) is used to control the feedwater flow, giving immediate corrections to feedwater demand in response to load changes. Any imbalance between steam mass flow out and feedwater mass flow into the drum is corrected by the level controller. This imbalance can arise from

Figure 2 Two-element drums level control

Blow down variations due to changes in dissolved solids

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Variations in feed water supply pressure Leaks in the steam circuits

Tighter control of drum level than with only one element

Steam flow acts as feed forward signal to allow faster level adjustments Can best be applied to single boiler / single feedpump configurations with a constant feed water pressure.

Any boiler installation which experiences frequent, sudden changes in load may work better with a two element feedwater control system. This strives to ensure that the quantity of water in the boiler stays constant at all loads, and that during periods of increased, sudden steam demand, the feed water control valve opens. The system works by using the signal from a steam flow meter installed in the steam discharge pipework to increase the level controller set point at high steam loads. The two elements of the signal are: First element - Level signal from the water within the boiler. Second element - Flow signal from the steam flow meter in the boiler steam off-take.

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Two element control steam flow is added. Two-element control is the minimum feed water control for a variable steam flow application. It is not recommended for new applications.
STEAM DRUM PRESSURE PT f(x) X PRESSURE COMPENSATION SET POINT A K LT PRESSURE FLOW TEMPERATURE LEVEL PT f(x) X FT TE f(x) TEMPERATURE AND PRESSURE COMPENSATION

M/A CONTROL STATION

f(x)

FINAL CONTROL DEVICE

Typical single-drive control system. For simplicity, redundant transmitters have not been shown on this typical control drawing. See Figure 3A for ANSI/ISA-S5.1-1984 format.

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This performance is recognized as having the desired pattern of flow and level relationships, and such performance meets the boiler feed water control objectives that have been stated previously, except that of compensating for feed water pressure variation. Tuning such a system for proper action during the shrink and swell period requires the correct balance between the effects of steam flow and drum level. The desired condition is for water flow to hold its flow rate during a load change and change only as the drum level begins to return to its set point. In this manner water inventory is smoothly adjusted to its new desired value. Since the drum level control signal calls for a feed water decrease as the steam flow signal is calling for an increase, the proper gain settings on steam flow and drum level should cause them to offset each other and affect no immediate change in the water flow control valve signal. As the drum level begins to change, the feed water valve control signal is changed to keep the system in continuous balance until steam flow and water flow are again equal and drum level is at the set point. At this point, since steam flow and water flow are equal, there is no driving force to cause further changes in boiler drum water level.

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While the system shown will achieve all of the desired control objectives under the conditions specified, it has a serious drawback if the feedwater control valve pressure differential and thus the control valve flow characteristic are not always the same. This figure demonstrates how the performance is seriously degraded by variations in feedwater pressure. Such feedwater pressure variations change the relationship between steam flow and feedwater flow. Boiler drum level is then forced to develop an offset from set point in order to bring the steam flow and feed water flow into balance. Under conditions of unpredictable or variable feedwater pressure, three-element feedwater control is necessary if the desired results are to be achieved. Three-element control shall be used for variable steam flow applications. Redundancy is not shown to 3. Three-element Drum Level Control

The three-elements are made up of the following Level Element , Steam Flow Element & Feedwater Flow element Feedwater responds rapidly to variations in feedwater demand, either from the

Steam flow rate feedforward signal Feedwater pressure or flow fluctuations

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Three-element drum level control

The three-element drum level control is ideally suited where a boilerplant consists of multiple boilers and multiple feedwater pumps or where the feedwater has variations in pressure or flow.

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Figure 3 Three-element drum level control The three-elements are made up of the following: Level Element and Steam Flow Element: corrects for unmeasured disturbances within the system such as: Boiler blowdown Boiler and superheater tube leaks Feedwater Flow Element: responds rapidly to variations in feedwater demand, either from t Steam flow rate feedforward signal Feedwater pressure or flow fluctuations In order to achieve optimum control, both steam and feedwater flow values should be corrected for density. The three-element system provides tighter control for drum level with fluctuating steam load. Ideal where a system suffers from fluctuating feedwater pressure or flow. More sophisticated level of control required Additional input for feedwater flow required

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The measurements of the output process variables furnish the information to the control system. Process Dynamics & Control Page 22

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P&ID and control schemes will be developed.. For the energy input requirement, a firing rate

demand signal must be developed. The firing rate demand creates the separate demands for the mass of fuel and combustion air. The overall system must be applied and coordinated in a manner to minimize the effect of these interactions. The interactions can be greatly affected by the control system design.

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a, b are typical characteristics c, d are after damper and fuel valve linearization. Cam linkage is used for fuel valve. Positioner cam may be used for air flow. Fuel valves and air dampers tend to have different flow characteristics. Typical characteristics are shown in the previous slide.. If the master regulator were to move each to the 50% position, then air flow for approximately 75% capacity would be provided while fuel for 25% capacity was being supplied. By making the flow characteristics linear, they can then be aligned.

Reactor/column heat integration with auxiliary reboiler in parallel and Q controller.

Figure deteriorates as the auxiliary reboiler provides less and less heat to the column. The reason is that uncontrolled variations in the steam pressure of the waste heat boiler affect the heat supplied to the column. When these variations are of the same order of magnitude as the

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total heat supplied by the auxiliary reboiler, the latter cannot compensate properly for the variations. Part of the problem in this parallel arrangement is that the disturbances propagate into the column before the auxiliary reboiler has a chance to react. We can improve on this situation by providing a total heat controller. The principle of total heat control is simple. We measure the combined heat input from all heat sources. This becomes the input to the socalled Q controller that manipulates the utility valve. The total heat demand is adjusted by changing the Q controller's setpoint. See Fig. 2

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Furnace Control system

1,2,3 Element Process Control

Figure furnace control system is a simplified sketch of a fired reboiler used to heat the fluid in the bottom of a distillation column. A typical use of this process is in the petrochemical field where crude oil is refined by the heating and partially vaporizing the raw oil. Starting at the distillation column in the upper left corner, we can see that the fluid in the lower portion of the distillation column (called the bottoms) circulates through the reboiler by convection. The temperature of the bottoms is measured at the fluids outlet from the reboiler. This temperature is used to control the amount of heat supplied to the process. A signal corresponding to the measured temperature is sent to the fuel feed controller. The controller, in turn, regulates the fuel flow to the reboilers burner by adjusting the fuel control valve. The burner safety control is a device that signals a shutoff of fuel flow to the reboiler for any of the following reasons:

decrease in the level of fluid in the distillation column, stopping the flow of fluid. loss of burner flame.
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low fuel line pressure.

1,2,3 Element Process Control

The fuel flow is actually stopped by two solenoid valves connected in series with the input fuel line. The solenoids close whenever electrical power to the system is lost. Finally, there is a reboiler damper controller. This is a manually operated controller that allows the operator to adjust the position of the damper for maximum burner efficiency.

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