06-2014 Lup Berumpan Balik
06-2014 Lup Berumpan Balik
Tujuan Pembelajaran
Saat kuselesaikan bab ini, kuingin dapat melakukan
hal-hal berikut.
Kerangka Kuliah
Kerangka Kuliah
Kontroler
Elemen
Kontrol Akhir
Proses
Bab 3-6
SensorTransmitter
Keluaran
Lup Berumpan-balik
KONSEP: Kita telah melihat rincian yang terbatas dalan gambar perpipaan
dan instrumentasi (P&ID). Kita melihat lokasi sensor, variabel yang diukur,
koneksi ke elemen akhir (katup) dan lokasi elemen akhir.
v1
TC
A
v2
Lup Berumpan-balik
REALITANYA: Banyak elemen dalam lup memberpengaruhi keselamatan,
kehandalan, keakuratan, dinamik dan biayanya. Insinyur perlu untuk
memahami rinciannya!
v1
4-20 mA
T
A
v2
4-20 mA
3-15 psi
SENSOR
Sensor: menghasilkan fenomena, mekanik,
listrik, atau sejenisnya yang berhubungan
dengan variabel proses yang diukur.
Trasmiter: mengubah fenomena ini ke dalam
sinyal yang dapat ditransmisikan.
Untuk menggambarkan perilaku
sensor/transmitte (dynamic): Gain of a
sensor/transmitter (rasio antara span keluaran
dan span masukan).
7. Maintenance
8. Konsistensi dengan
lingkungan proses
9. Dynamic
10.Safety
11.Cost
ISSUE
Accuracy - Accuracy is the degree of conformity of the measured value
with the accepted standard or ideal value, which we can take as the true
physical variable. Accuracy is usually reported as a range of maximum
inaccuracy. These ranges should have a significance level, such as 95%
of the measurements will be within the inaccuracy range.
COMMENTS
Accuracy is usually expressed in engineering units
or as a percentage of the sensor range, for example:
Reproducibility
ISSUE
COMMENTS
Range/Span - Most sensors have a limited range over which a process variable can If a chemical reactor typically operates at 300C, the
be measured, defined by the lower and upper range values. Usually, the larger the engineer might select a range of 250-350 C.
range, the poorer the accuracy, and reproducibility. Therefore, engineers select the
smallest range that satisfies the process requirements.
Since the reactor will be started up from ambient
temperature occasionally, an additional sensor should
We select ranges that are easily interpreted by operating personnel, such as 100-200 C, be provided with a range of -50 to 400 C.
but not 100-183 C.
Reliability Reliability is the probability that a device will adequately perform (as
specified) for a period of time under specified operating conditions. Some sensors
are required for safety or product quality, and therefore, they should be very
reliable. Reliability is affected by maintenance and consistency with process
environment. Also, some sensors are protected from contact with corrosive process
environment by a cover or sheath (e.g., a thermowell for a thermocouple), and some
sensors require a sample to be extracted from the process (e.g., a chromatograph).
Linearity - This is the closeness to a straight line of the relationship between the true
process variable and the measurement. Lack of linearity does not necessarily
degrade sensor performance. If the nonlinearity can be modeled and an appropriate
correction applied to the measurement before it is used for monitoring and control,
the effect of the non-linearity can be eliminated. Typical examples of compensating
calculations are the square root applied to the orifice flow sensor and the polynomial
compensation for a thermocouple temperature sensor. The engineer should not
assume that a compensation for non-linearity has been applied, especially when
taking values from a history database, which does not contain details of the
measurement technology.
ISSUE
COMMENTS
On-stream analyzers usually require the
greatest amount of maintenance. The cost
associated with maintenance can be
substantial and should not be overlooked in
the economic analysis.
Consistency with process environment - Most sensors will function properly A float can indicate the interface for a liquid
for specific process conditions. For example, many flow sensors function for level. However, a float is not reliable for a
a single phase, but not for multi-phase fluid flow, whether vapor-liquid or sticky liquid.
slurry. The engineer must observe the limitations for each sensor.
Also, a turbine flow meter can be damaged
Some sensors can have direct contact with the process materials, while others by a rapid change in flow rate or liquid
entrained in a vapor stream.
must be protected. Three general categories are given in the following.
Direct contact - Sensors such as orifice plates and level floats have direct
contact with process fluids.
Sheath protection - Sensors such as thermocouples and pressure diaphragms Sensors in direct contact must not be
degraded by the process material.
have a sheath between the process fluid and the sensor element.
Sample extraction - When the process environment is very hostile or the The sheath usually slows the sensor
sensor is delicate and performa complex physiochemical transformation on the response.
Samples must represent the fluid in the
process material, a sample can be extracted.
process.
Naturally, the parts of the sensor that contact the process must be selected
appropriately to resist corrosion or other deleterious effects.
ISSUE
COMMENTS
A greater delay is associated with sensors that
require a sample to be extracted from the
process.
On-stream analyzers usually have the longest
delays, which are caused by the time for
analysis.
Contoh
Akurasi
Termokopel 1,5 K
Orifis 3% dari rentang aliran maksimum
Sensor/transmiter tekanan yang telah dikalibrasi
digunakan untuk mengukur tekanan proses
antara 20 psig dan 50 psig, maka:
Span of the instrument: beda antara harga
tinggi dan rendah; dari contoh berarti spannya
30 psi.
Zero of the instrument: harga range yang
rendah; dari contoh berarti zeronya 20 psig.
F2
F
2
Fmax
M F sinyak keluaran (mA) dan F aliran volumetrik
Gainnya :
dM F
2(16)
KT
Sensor Suhu
Sensor Type
Limits of
Application (C)
Accuracy1,2
type E:
chromel-constantan
-100 to 1000
type J:
iron-constantan
0 to 750
2.2 or 0.75%
type K:
chromel-nickel
0 to 1250
2.2 or 0.75%
type T:
copper-constantan
-160 to 400
RTD
-200 to 650
0.15 + 0.2|T|
Dynamics:
t (s)
Advantages
Disadvantages
Thermocouple
-good reproducibility
-wide range
-minimum span of 40 C
-temperature vs. emf not exactly linear
-drift over time
-low emf corrupted by noise
see note 3
see note 3
-good accuracy
-small span possible
-linearity
-self-heating
-less physically rugged
-self-heating error
-highly nonlinear
-only small span
-less physically rugged
-drift
Thermister
-40 to 150
0.10 C
see note 3
-good accuracy
-little drift
Bimetallic
2%
-low cost
-physically rugged
-local display
Filled system
-200 to 800
1%
1 to 10
Sensor Aliran
Sensor
Rangeabilit
y1
Accuracy2
Dynamics (s)
Advantages
Disadvantages
orifice
3.5:1
-low cost
-extensive industrial practice
venturi
3.5:1
1% of full span
-high cost
-line under 15 cm
flow nozzle
3.5:1
2% full span
elbow meter
3:1
annubar
3:1
0.5-1.5% of full
span
turbine
20:1
0.25% of
measurement
-wide rangeability
-good accuracy
-high cost
-strainer needed, especially for
slurries
-expensive
-high pressure drop
-damaged by flow surge or solids
vortex shedding
10:1
1% of measurement
-wide rangeability
-insensitive to variations in
density, temperature, pressure,
and viscosity
positive
displacement
10:1 or
greater
0.5% of
measurement
-high reangeability
-good accuracy
Sensor Tekanan
Sensor
Limits of
Application
Accuracy
Dynamic
s
bourdon,
"C"
up to 100 MPa
spiral
up to 100 MPa
helical
up to 100 MPa
bellows
typically vacuum to
500 kPa
diaphragm
up to 60 kPa
capacitance/
inductance
Advantages
Disadvantages
-hysteresis
-affected by shock and
vibration
-low cost
-differential pressure
up to 30 kPa
resistive/str
ain gauge
up to 100 MPa
fast
piezoelectric
very fast
-fast dynamics
-sensitive to temperature
changes
Sensor Level
Sensor
float
displacement
differential
pressure
capacitance
Limits of Application
up to 1 m
0.3-3 m
essentially no upper
limit
up to 30 m
Accuracy
-
Dynamics
Advantages
Disadvantages
-good accuracy
-limited range
-cost of external
mounting for high
pressures
-good accuracy
-large range
-applicable to slurries with use of
sealed lines
-assumes constant
density
-sealed lines sensitive
to temperature
-affected by density
variations
Sensor Analyzers
CONTROL
VALVE
6.Precision
2.Range
7.Linearity
3.Failure position
8.Dynamic
4.Gain
9.Konsistensi dengan
lingkungan proses
5.Pressure drop
10.Cost
Valve Body
Valve Body
Advantages
Disadvantages
globe (unbalanced)
-large range
-good shutoff
-unbalanced forces
-high pressure loss
globe (balanced)
-high capacity
-large range
-balanced forces
-poor shutoff
-high pressure loss
ball
-high capacity
-tight shutoff
butterfly
-high capacity
-low pressure loss
-slurry applications
-high torque
-large deadband
-affects flow through limited range (i.e.
0-60%)
-tight shutoff requires special seat material
diaphragm
-slurry applications
-corrosion resistant materials
gate
-tight shutoff
Instrumentation Schematic
of Control Valve
Pemilihan Valve
Pemilihannya tergantung prosesnya,
bahkan proses secara keseluruhan.
Contoh: Proses pemanasan yang baik
adalah menggunakan FC valve; tetapi
kalau fluida yang dipanasi itu berupa
polimer yang kalau pemanasnya mati bisa
terjadi solidasi maka yang aman adalah
menggunakan FO valve.
atau
f = flow
Cv = karakteristik valve VALVE
SIZING
= specific gravity
Cv vp Cv ,max .vp
vp valve position
=% (EQUAL PERCENTAGE)
Cv vp Cv ,max .
vp 1
rangeablity parameter
25, 50, 100 (umumnya 50)
Aliran
Contoh Minyak
Sebuah proses mengalirkan minyak dari tangki penyimpan ke menara
separasi ditunjukkan oleh gambar di atas. Tangki berada kondisi tekanan
atmosfir, dan menara bekerja pada tekanan 25.9 in. Hg (12.7 psia). Aliran
minyak nominalnya 700 gpm, gravitas spesifiknya 0.94 dan tekanan uap
pada suhu yang mengalir 90oF adalah 13.8 psia. Pipanya 8-in. skedul 40
pipa baja komersial. Efisiensi pompanya 75%. Dari korelasi aliran fluida,
jatuh tekanan friksi di pipa adalah 6 psi
1. Lakukan pengukuran (sizing) valve tersebut.
2. Temukan aliran maksimum melalui valve, karakteristik valve terpasang
dan rangeability dari valve (asumsi = 50)
Cv ,max 2 f
2 700
0.94
gpm
607
5
psi
13.0 x10
2
2
2
Gf f
gpm
0.94 700
Total jatuh tekanan bergantung-aliran (tetap):
p0 = pv + pL = 5 + 6 = 11 psi
f max
Cv ,max
1 k L Cv ,max
p0
640
2
Gf
1 13.0 x10 6 640
11
870 gpm
0.94
Jawaban 2: Rangeability
LINEAR
vp 0.05 Cv Cv ,max vp 640 0.05 608
f 0.05
32
1 13.0 x10 6 32
11
109 gpm
0.94
608
1 13.0 x10
rangeability
608 2
11
862 gpm
0.94
f 0.95 862
7.9 19
f 0.05 109
15.6
=%
f 0.95
rangeability
15.6
11
53.2 gpm
0.94
0.05 1
0.95 1
526
11
839 gpm
0.94
f 0.95 839
15.8 34.8
f 0.05 53.2
Rangkuman
dvp
Kv
dm
dCv
dvp
df
dCv
dm
100 %CO
dengan : CO controller output; AO valve, - AC valve
dCv
Cv ,max
(LINEAR)
dvp
dCv
vp-1
ln Cv, max ln Cv
dvp
( %)
pv
df
dCv
Gf
o VARIABEL
1 k L Cv2 Cv 1 k L Cv2
df
dCv
1 k L Cv2
df
1 k L Cv2
dCv
3 / 2
p0
Gf
1 / 2
k L Cv
p0
Gf
pv
f max
1
Kv
Cv ,max
100
Gf
100
Kv
wmax
gpm
%CO
100
pv
1
ln
ln .Cv
f
100
Gf
100
lb/h
(LINEAR)
%CO
gpm
ln
lb/h
w
( %)
%CO
100
%CO
o VARIABEL
Kv
Cv ,max
1 k C
L
100
ln
Cv
Kv
100 1 k L Cv2
2 3 / 2
v
3/ 2
p0
Gf
(LINEAR)
p0
ln
f
Gf
100 1 k L Cv2
( %)
Contoh STEAM
Temukan gain dan posisi valve pada kondisi disain
untuk valve uap air yang mengalir ke reboiler kolom
distilasi dengan laju perpindahan panas disain 15 juta
Btu/h. Uap air dijenuhkan pada 20 psig dan jatuh
tekanannya 5 psi. Asumsikan valvenya berukuran 10in. dengan Cv,max = 1000 dipilih dan tekanan di sekitar
valve tidak bergantung kepada aliran. Aliran
nominalnya 16,130 lb/h, jenis valvenya linear dan =
% dengan parameter rangeabilitasnya 50
Jawaban
Aliran uap air:
w 1.83Cv C f
w1 0.0007TSH
Cv
1.83C f y 0.148 y 3
p1
y 0.148 y 3
1 0.0007TSH
1.63 pv
Cf
p1
LINEAR
1.63 pv 1.63
5
y
0.773
Cf
p1
0.8 34.7
Cv
16,1301 0
w1 0.0007TSH
gpm
450
1.83C f y 0.148 y 3 1.83 0.8 0.773 0.148 0.773 3
psi
Cv
450
vp
0.450
Cv ,max 1000
wmax
w Cv ,max 16,130 1000
lb/h
Kv
358
100 450
100 100 Cv
%CO
=%
vp 1
Cv
450
0.450
Cv ,max 1000
ln
Cv
Cv ,max
ln 0.450
vp
1
1 0.80
ln
ln 50
ln
ln 50
lb/h
Kv
w
16,130 630
100
100
%CO
Contoh MINYAK
Tentukan gain valve pada contoh tersebut!
Tekanannya tidak tetap:
640
11
gpm
2 3 / 2
6
Kv
1 13.0 x10 303
6 .7
100
0.94
%CO
ln 50
700
gpm
Kv
12.5
2
6
100 1 13.0 x10 303
%CO
(LINEAR)
( %)
KONTROLER
Kontroler adalah otak lup kontrol. Ia membuat
keputusan dalam sistem kontrol dengan melakukan:
Aksi Kontroler
Ada 2 jenis aksi kontroler:
Aksi berlawanan (reverse action) atau
turun: bila harga output naik maka
kontroler mengurangi sinyal output (udara
tekan atau arus )-nya.
Aksi searah (direct action) atau naik:
sebaliknya.
Lup Berumpan-balik
Apa yang mempengaruhi respon
terhadap komputer?
Sensor &
transmitter
input dan
konversi A/D
computing
network
konversi
I/P
final
element
Transmisi
elektronik
output
dan D/A
PROSES
Transmisi
elektronik
Transmisi
pneumatik
Lup Berumpan-balik
LATIHAN DI KELAS: Diberikan dinamik berikut ini, sketsakan respon-respon untuk
sebuah step pada stasiun manual (bukan otomatik) terhadap harga yang ditampilkan.
Transmisi
pneumatik
Sensor
Final element,
valve
Konversi sinyal
Proses
Sangat bervariasi
Kalkulasi
kontroler
Lup Berumpan-balik
LATIHAN DI KELAS: Diberikan
dinamik berikut ini, sketsakan
respon-respon untuk sebuah
step pada stasiun manual
(bukan otomatik) terhadap
harga yang ditampilkan.
Apa yang kamu lihat (dari
display) tidak selalu apa yang
terjadi!!
Case A: sistem cepat, sehingga ada
perbedaan dengan display. Case B
lambat, sehingga sesuai dengan
display
Lup Berumpan-balik
Insinyur harus memutuskan apa yang diukur untuk mengendalikan dan katup apa
digunakan untuk menyesuaikan (dan menyediakan peralatan untuk mendukung
keputusan tersebut).
Lup Berumpan-balik
Insinyur harus memutuskan apa yang diukur untuk mengendalikan dan katup apa untuk
menyesuaikan (dan menyediakan peralatan untuk mendukung keputusan tersebut).
CV untuk pengendalian? Gunakan tujuh kategori obyektif pengendalian!
Lup Berumpan-balik
Insinyur harus memutuskan apa yang diukur untuk mengendalikan dan katup apa untuk
menyesuaikan (dan menyediakan peralatan untuk mendukung keputusan tersebut).
MV untuk menyesuaikan?
1.
2.
3.
4.
5.
Lup Berumpan-balik
Insinyur harus memutuskan apa yang diukur untuk mengendalikan dan katup apa untuk
menyesuaikan (dan menyediakan peralatan untuk mendukung keputusan tersebut).
Lup Berumpan-balik
Gambar menunjukkan lup berumpan-balik. Kita akan melihat kalkulasinya pada bab selanjutnya.
Jelaskan, termasuk
konsep umpan-baliknya.
Lup Berumpan-balik
Latihan di kelas untuk lup berumpan-balik: Menggunakan metode yang baru saja
dijelaskan, pilih SATU variabel yang dikendalikan dan SATU variable yang dimanipulasikan
PI
1
AT
1
FT
1
PI
4
TI
1
PI
5
TI
5
TI
2
Feed oil
TI
6
PT
1
TI
3
TI
7
TI
4
TI
8
FT
2
udara
PI
2
PI
3
TI
9
TI
10
FI
3
TI
11
PI
6
Fuel
gas
Lup Berumpan-balik
Musik: Aku tidak dapat mendefinisikan musik yang baik, tapi aku tahu apa yang aku sukai.
Kinerja pengendalian: Kita harus dapat mendefinisikan apa yang kita maui, sehingga kita dapat mendisain peralatan dan kontrol untuk
mencapai sasaran kita.
Controlled Variable
Set point
dimasukkan
oleh orang1.5
1
0.5
10
15
20
25
30
35
40
45
50
Time
Manipulated Variable
1.5
0.5
10
15
20
25
Time
30
35
40
45
50
Lup Berumpan-balik
1.5
Controlled Variable
0.5
0
0
10
15
20
25
Time
Manipulated Variable
2
1.5
0.5
0
0
10
15
20
25
Time
30
35
40
45
50
30
35
40
45
50
Lup Berumpan-balik
2
=
IAE
=
|SP(t)-CV(t)|
dt
IAE =SP
( t ) CV ( t ) dt dtatau ISE SP ( t ) CV ( t ) dt
= IAE
|SP(t)-CV(t)|
1.5
1.5
A
B
0.5
0.5
0
10
5
15
10
20
15
25
Time
Rise time
20
30
25
35
Time
30
40
35
45
40
50
45
50
45
50
1.5
1.5
0.5
0.5
0
10
5
15
10
20
15
25
Time
20
30
25
35
Time
30
40
35
45
40
50
Lup Berumpan-balik
IAE =SP
( t ) CV ( t ) dt dtatau ISE SP ( t ) CV ( t ) dt
= IAE
|SP(t)-CV(t)|
2
0.8
1.5
0.6
0.4
0.2
0.5
0
-0.2
10
15
10
20
15
25
Time
20
30
25
35
Time
30
35
40
45
50
30
35
40
45
50
40
45
50
2
1.5
-0.5
1
-1
0.5
0
-1.5
10
15
10
20
15
25
Time
20
30
25
35
Time
40
45
50
Respon Gangguan
Sering, proses itu dikenai gangguan yang besar dan kecil serta sensor
noise. Ukuran kinerja mengkarakterisasi variabilitasnya.
Controlled Variable
20
10
-10
-20
100
200
300
400
500
600
700
800
900
1000
Time
Manipulated Variable
20
10
-10
-20
100
200
300
400
500
Time
600
700
800
900
1000
Lup Berumpan-balik
Latihan di kelas: Untuk setiap ukuran kinerja di bawah ini, tentukan harga
yang baiknya, misalnya besar/kecil, positif/negatif, dsb.
Offset
MV overshoot
IAE
Decay ratio
Maximum CV
deviation
Rise time
CV variance
Settling time
MV variance
KINERJA
KONTROLER
Respon Max
Overshoot
Settling time
Rise time
Offset
IAE
Decay Ratio
0,03475 kg/cm2
3,475%
133,25 s
1,2 s
0
30,08 mm2
0,180
0,0375 kg/cm2
3,75%
274,91 s
2,4 s
0
52,21 mm2
0,133
Lup Berumpan-balik
20
Controlled Variable
10
0
-10
-20
0
Manipulated Variable
20
10
0
-10
-20
0
100
200
300
400
500
Time
600
700
800
900
1000
100
200
300
400
500
Time
600
700
800
900
1000
1.5
0.5
-0.5
Controlled Variable
Controlled Variable
20
40
60
80
100
-1
120
Time
2
20
0.5
0
20
40
60
80
100
120
120
80
100
120
0
-1
20
40
60
Time
S-LOOP plots deviation variables (IAE = 24.0376)
1.5
1.5
0.5
Controlled Variable
Controlled Variable
100
20
40
60
80
100
0.5
-0.5
120
Time
20
40
60
80
100
120
80
100
120
Time
1.5
0.5
Manipulated Variable
Manipulated Variable
80
Time
-0.5
60
-0.5
40
Manipulated Variable
Manipulated Variable
Time
1.5
-0.5
20
40
60
Time
80
100
120
0.5
-0.5
20
40
60
Time
Lup Berumpan-balik
Kita dapat menerapkan feedback melalui banyak pendekatan
1.
2.
3.
4.
5.
Heat Exchanger
Exchanger
Respon exchanger terhadap aliran uap air
hanya mempunyai gain 50 C/(kg/s) dan
konstanta waktu 30 detik
Sensor-Transmitter
Sensor-transmitter memiliki range yang
terkalibrasi 50 150 C dan konstanta waktu
10 detik
Control valve
Control valve memiliki kapasitas maksimum
uap air 1.6 kg/s, karakteristik linear, dan
konstanta waktu 3 detik
Heat Exchanger
Exchanger
Gp s
50
C/ kg/s
30 s 1
Sensor-transmitter
100%
1.0 %/C
150 50 C
1. 0
Gm s
%/C
10 s 1
Gain
1.6 (kg/s)
Gainvalve
Control
100%
Gv s
0.016 kg/s / %
0.016
kg/s / %
3s 1
PI
1
AT
1
FT
1
PI
4
TI
1
PI
5
TI
5
TI
2
TI
6
PT
1
TI
3
TI
7
TI
4
TI
8
FT
2
PI
2
PI
3
TI
9
TI
10
FI
3
TI
11
PI
6
PI
1
AT
1
FT
1
PI
4
TI
1
PI
5
TI
5
TI
2
TI
6
PT
1
TI
3
TI
7
TI
4
TI
8
FT
2
PI
2
PI
3
TI
9
TI
10
FI
3
TI
11
PI
6
vS
CA0
Solvent
CA
Pure A
A B
vA
V
TCout
vc
FC
TCin
Tujuan Pembelajaran
Saat kuselesaikan bab ini, kuingin dapat melakukan
hal-hal berikut.
Sumber Pembelajaran
SITE PC-EDUCATION WEB
- Instrumentation Notes
- Interactive Learning Module (Chapter 7)
- Tutorials (Chapter 7)
2.
3.
Jelaskan aksi yang akan kamu ambil jika kamu mengukur sebuah
gangguan dan tidak ingin menunggu koreksi umpan-balik