P180 Principles of Control Session Objectives

At the end of the session participants will be able to : Describe the relative response speeds of the control loops for different process parameters (flow, pressure, level, temperature etc.) Apply single control loops in Process Flow Schemes Discuss the use of multiple control loops
The lectured material will be applied in an engineering exercise P180
P180 Control Principles 1

Principles of Control Session Objectives

Principles of Control
Session Topics

Duty of Controllers Single Control Loops Multiple Control Loops Master/Slave Control (Cascade) Ratio Control Split Range Control Override (Selective) Control
P180
Session Topics
P180 Control Principles 2

Principles of Control
Classification of Control Systems
Open Loop Control action independent of output e.g. Toaster, Brewing Coffee, etc.

Closed Loop Control action dependent on output e.g. Furnace, Steam Generator, etc.

P180
Principles of Control

P180 Control Principles

Principles of Process Control

Objectives of Process Control: Increase Productivity Reduce Operating Costs Maintain Quality Maintain Quantity Duty of a Controller: Keep the Process running smoothly (at certain conditions) Compensate for external changes (disturbances, weather, etc.) Control is: Measure Compare Correct P180
Principles of Process Control
P180 Control Principles 4

The Controller

SV PV LT LRC 100 MV

SV: PV: MV:

Set Value (Desired Value ) Measured Value (Actual) Output to Final Element
P180 Control Principles

P180
The Controller

Flow Control (Liquid or Gas)

MV SV

FC
PV

Flow is the Fastest Process Parameter

P180
Flow Control (Liquid or Gas)

P180 Control Principles

Pressure Control (Liquid)

MV SV

PC
PV

Similar response as Flow Control

P180
Pressure Control (Liquid)

P180 Control Principles

Pressure Control (Gas)

SV MV

PC

PV

Slower than Flow or Liquid Pressure

P180 Control Principles

P180
Pressure Control (Gas)

Gas Pressure Control

Flow F

MV SV

PC

PV
F
in

Gas Volume V LC

Fout

P180
Gas Pressure Control

P180 Control Principles

Vapour Pressure Control

to Boilers etc.

PC

Gas LNG
-160 oC

Vapour Pressure Control ~ Temperature Control

P180
Vapor Pressure Control

P180 Control Principles

10

Level Control
Fin

90 % SV = 50 % LC Open

50 %

10 %

50 %

Fout

Closed

P180
Level Control

P180 Control Principles

11

Temperature Control

Furnace Oil T1 Air T2

TC

Fuel

P180
Temperature Control

P180 Control Principles

12

Principles of Control (Multiple Loop Control)

Multi Loop Configurations Master / Slave (Cascade) Ratio Split-Range Selective (or Override)

P180

P180 Control Principles

13

Principles of Control (Multiple Loop Control)

Level Control

C-2 C-1 SV MV PV
LC

P2

P1 F

P180
Level Control

P180 Control Principles

14

Level Control (Master/Slave)

SV
LC C-2 P2

C-1

MV SV
FC

PV

MV

PV
P1 F

P180
Level Control (Master/Slave)

P180 Control Principles

15

Temperature Control (Master/Slave)

Furnace Oil T1 Air T2

TC

Fuel
FC

P180

P180 Control Principles

16

Temperature Control

Ratio Control
Primary Flow (Uncontrolled) FT x1
Ratio Relay

Mixing Coil

QT

X Gain = K K.X1 sv FC X2 Secondary Flow (Controlled) Tank

Chemical Injection Skid

P180
Ratio Control

P180 Control Principles

17

Ratio Control
Fuel Gas
PV FT X MV SV FC PV MV

A/F Ratio 14:1

* 14

Combustion Air

P180

P180 Control Principles

18

Ratio Control

Split-Range Control (1)

Flare Gas Out

Inlet

PC

Export

LC

Liquid Out

P180

P180 Control Principles

19

Split-Range Control (1)

Split-Range Control (1)

Signal to Valves 100% Valve 1 Valve 2

0% 0% 50% 100% Controller Output

P180

P180 Control Principles

20

Split-Range Control (1)

Split-Range Control (2)

0 - 50% PC Gas Out Valve 2 50 - 100%

Gas In Valve 1

PROCESS

Signal to Valves

Valve 1

Signal to Valves

100%

Valve 2

100%

Valve 1

Valve 2

0%

0%

0%

100% 50% Controller Output

P180 Control Principles

0%

100% 50% Controller Output

21

P180

Split-Range Control (2)

Selective or Override Control

SS

FC Gas Feed

PC Gas Processing Plant

Pipeline

P180

P180 Control Principles

22

Selective or Override Control

Compressor Control
Control Systems for Reciprocating Compressors
Bypass (Recycle) Control Inlet Throttling Variable Speed On/Off Control Suction Valve Lifting

Symbol

P180
Compressor Control

P180 Control Principles

23

Reciprocating Compressor Control

PC

SC

P180

P180 Control Principles

24

Reciprocating Compressor Control

Compressor Control
Centrifugal Compressors
Capacity Control
By-Pass Control

Suction Throttling Speed Control Discharge Throttling Symbol

(inefficient) e.g. if Compression Ratio = 8 then Pressures Decreases: Suction 0.1 bar = Discharge 0.8 bar

Inlet Guide Vanes

P180
Compressor Control

P180 Control Principles

25

Compressor Control
PC

Suction Process

Interstage Process Suction Drum

P1

P3 PC P4

P2 SC

Discharge Process 2 Stage

nd

1 Stage

st

1 Stage

st

ASC

2 Stage
ASC

nd

P180

P180 Control Principles

26

Compressor Control