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MINING STUDIES AND RESEARCH CENTER (MSRC)

FACULTY OF ENGINEERING – CAIRO UNIVERSITY


NATURAL GAS ENINEERING DIPLOMA

Instrumentation
&
Control
NG505
Part II
Industrial Controllers
Output signal
from Controller
r = Reference
or Set point
Output signal to
E = Error signal control process

Measured representation of the controlled variable

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

b is the measured indication


of the controlled variable

b has practical limitations

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

The range of a temperature sensor is 300K to 440K. Find the error


as percent of span when the set point is 384K and the measured
temperature is 379K

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)

Using the error as percent of span has the


advantage of getting practical evaluation of the
error without knowing what is being measured.

What is the significance of the sign of the error as


percent of span?

5 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering
Controller Terminology

Control parameter range (p)


• Pmin corresponds to umin
• Pmax corresponds to umax
• P and u are linearly related Output signal
u=m*p+q from Controller

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

What is the advantage of using the percentage range of


the controller output?

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

Heater off , temperature drops by 2K/min


Heater on , temperature rises by 4K/min

SP = 323 K
Controller has 8% neutral zone of SP
Controller has 0.5 min lag
Initially the controller is off and ep=0%

Draw the system response

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

L<2m valve 20%


2m<L<3m valve 65%
L>3m valve 100%

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

Tendency of the controlled


variable to settle with no
control operation

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

Notice the importance of the rate

23 MSRC - Natural Gas Engineering Diploma - Instrumentation and control NG505 – Dr. Ahmed Mohamed Kamel – Professor – Electrical Power Engineering

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