Instrumentation
&
Control
NG505
Part II
Industrial Controllers
Output signal
from Controller
r = Reference
or Set point
Output signal to
E = Error signal control process
2 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Controller Terminology
Error Expressed as Percent of Span (ep)
r b
ep 100
bmax bmin
3 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Controller Terminology
Error Expressed as Percent of Span (Examples)
In a standard measured indication range of 4-20mA, calculate the
error as percent of span when the set point is 10.5mA and the
measured indication is 13.7mA
4 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Controller Terminology
Error Expressed as Percent of Span (Notes)
5 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Controller Terminology
Output signal to
control process
u umin
p 100
umax umin
6 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Controller Terminology
Control parameter range (Example)
A controller outputs 4-20mAsignal to control motor
speed from 140 to 600 rpm with linear dependence.
Calculate the current corresponding to 310 rpm and it
percentage value
u=m*p+q
140=m*4+q 600=m*20+q
m = 28.75 units ? and q = 25 units?
310 = 28.75 p + 25
p = 9.91 units?
p = (9.91-4)/16 or (310-140)/(600-140) = 36.9%
7 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Controller Terminology
Control parameter range (Notes)
What is the minimum and maximum values of the
percentage output?
u umin
p 100
umax umin
8 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Types of Controllers
Discontinuous Controllers
On-Off
Multi-Position
Floating (Single and Multi-Speed)
Continuous Controllers
Proportional (P)
Integral (I)
Derivative (D)
PID Controller (Most used in industry)
Others
9 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Discontinuous Controllers
1. On-Off Controller
Two position Mode / BANG BANG
0% ep 0
Controller output p
100% ep 0
10 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Discontinuous Controllers
1. On-Off Controller
• Uses a threshold to trigger
• Dead band lies between the on/off
threshold
• Usually an acceptable error exists
0% e p e p
Controller output p
100% e p e p
Deadband = Neutral zone = differential gap =hysteresis
11 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Discontinuous Controllers
1. On-Off Controller Applications
Best adapted to large-scale systems with relatively slow process
rate
• Room Heating
• Air-Conditioning System
• Liquid Bath Temperature Control
• Level Control in Large Volume Tanks
12 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Discontinuous Controllers
1. On-Off Controller Example
For a temperature control of a water tank
SP = 323 K
Controller has 8% neutral zone of SP
Controller has 0.5 min lag
Initially the controller is off and ep=0%
13 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Discontinuous Controllers
1. On-Off Controller Example Solution
14 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Discontinuous Controllers
1. On-Off Controller Mechanical Implementation
15 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Discontinuous Controllers
2. Multi-Position Controller
0% e p e1
Controller output p 50% e1 e p e2
100% e p e2
16 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Discontinuous Controllers
2. Multi-Position Controller
17 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Discontinuous Controllers
2. Multi-Position Controller Example
18 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Discontinuous Controllers
3. Floating Controller
- Single Speed
dp
KF
dt
p K F t p(0) e p e p
19 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Discontinuous Controllers
3. Floating Controller
- Single Speed
20 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Discontinuous controllers
3. Floating Controller
- Multiple Speeds
dp
K Fi e p e pi
dt
21 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Discontinuous controllers
3. Floating Controller
Suitable for
small lag processes
self regulation processes
22 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Discontinuous controllers
3. Floating Controller
Cycling effect
23 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering