Before the existence of
Auto controllers…
Manual control
Without automatic controllers, all regulation tasks will have to be
done manually.
An operator has to watch a temperature gauge and adjust a gas
control valve accordingly
For example:
To keep constant the
temperature of water
discharged from an
industrial gas-fired heater,
Manual control
1. Operator has to watch a temperature gauge and adjust a gas
control valve accordingly (Figure 1).
2. If the water temperature becomes too high, the operator has
to close the gas control valve a bit…
3. This setting is enough to bring the temperature back to the
desired value.
4. If the water becomes too cold, he has to open the valve
again.
Introducing Auto controllers…
Automatic control
To relieve our operator from the tedious task of manual control,
we automate the controls
A PID controller is installed.
(Figure2).
The controller has a Set Point
(SP) that the operator can
adjust to the desired
temperature.
Automatic control
1. An actuator (and perhaps a positioner) is installed to
automate the control valve, so that the Controller's Output (CO)
can change the valve's position.
2. In the next step, we'll provide the controller with an indication of
the temperature or Process Variable (PV) by installing a
temperature transmitter.
3. The PV and CO are mostly transmitted via 4 - 20mA signals.
4. PID controller compares the process variable to its set point
and then calculates the difference between the two signals,
also called the Error (E).
5. Based on the error, the controller calculates an output that
positions the control valve. If the temperature is above its set
point, the controller will reduce the valve position and vice versa.
PID controllers
Acronym for Proportional, Integral and Derivative control actions
they perform.
A PID controller attempts to correct
the error between a measured
process variable and a desired
set point by calculating and then
outputting a corrective action that
can adjust the process accordingly
and rapidly, to keep
the error minimal.
PID controller is also called as
3 mode controller .
P, I and D Control Modes
PID controller has proportional, integral and derivative control
modes. These modes each react differently to the error, and also,
the degree of control action is adjustable for each mode.
Proportional Control
The proportional control mode changes the controller output in
proportion to the error (Figure 3).
The adjustable setting here is
called the Controller Gain (Kc),
sometimes also referred to as a
PID controller's P-setting or its
proportional setting.
For example,
Let's consider controlling the water level in the tank in Figure 4 with a
only proportional controller.
As long as the flow out of the tank remains constant, the level
(which is our process variable in this case) will remain at its set
point.
if the operator should increase the
Flow out of the tank,
The tank level will begin to
decrease due to the imbalance
between inflow and outflow.
While the tank level decreases the error increases and our
proportional controller increases the controller
output proportional to this error
Consequently, the valve controlling the flow into the tank opens
wider and more water flows into the tank.
As the level continues to decrease, the valve continues to open
until it gets to a point where the inflow matches the outflow.
At this point the tank level remains constant, P-controller will
keep its output constant and the control valve will hold its
position.
The system now remains at balance with the tank level
remaining below its set point. This residual error is called Offset.
With our P-controller the offset will remain until the operator
manually applies a bias to the controller's output to remove the
offset. It is said that the operator has to manually "Reset" the
controller. Or…we can add Integral action to our controller.
Integral Control
The concept of manual reset as described above led to the
development of automatic reset or Integral Control.
The integral control mode of a controller
produces a long term corrective change in
controller output, driving the error or
offset to zero.
This is given by ;
Most controllers use integral time in minutes as the unit for
integral control, but some others use integral time in seconds,
Integral Gain in Repeats / Minute or Repeats / Second.
A PI controller simply adds together the output of the P and I
modes of the controller. The integral action raises the controller
output far enough to bring the level back to its set point.
Derivative Control
The third control action in a PID controller is derivative.
Derivative control is rarely used in controllers. It is very
sensitive to measurement noise and it makes tuning very difficult
if trial and error methods are applied. Nevertheless, derivative
control can make a control loop respond faster and with less
overshoot.
This is given by ;
Applications best suited for the PID controller
Used in process industry to control slow variables like
Temperature
Ph and other analytical variables
Used in vast majority of automatic process control applications in
industry today.
PID controllers are responsible for regulating flow, temperature,
pressure, level, and a most of other industrial process variables.
Comment
The problem with the PID controller is its complexity.
Although the basic operations of its three actions are
simple enough when taken individually, predicting
just exactly how well they will work together for a particular
application can be difficult.
Images of PIDs of different make.
Auto tuning PIDs
Models are available with
4-20 or 0-20 mA analog
control signal, alarm trip
outputs, and RS-485
communications
Moore industries Corp.
MAC is designed to provide a
closed loop control functions for
strain gauge transducers (e. g.
web tension measurement).
HAEHNE Electronic Meters .
Conclusion
With its proportional, integral and derivative modes, the PID
controller is the most popular method of control by a great
margin. If properly tuned, the three control modes complement
each other in the control effort.
Thank
you.
By
Vijay simha
