Shell Global Solutions

Tuning Workshop
Tuning and Control Schemes
January 2004
Fayez Al-Maleki
Beeby Clive

Level Control Objectives

two categories :
a) buffer capacity
column bottoms/overhead vessel
separator vessel
b) tight
boiler drum level
compressor knock-out vessel

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CP1040

Level Buffer Capacity Control

F in
Operating range

90 %
50 %

90%: valve open

LC

50%: Set value

10%: valve closed

10 %
ATC

F out

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CP1040

Buffer Control Benefits

Maximize the use of available volume in order to smooth the outlet flow
Smaller variations in outlet flow to downstream units
Enables better control downstream

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Cascade Control

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Cascade Control
Cascade Control uses the output of the primary controller to
manipulate the setpoint of the secondary controller as if it
were the final control element.
Reasons for cascade control:
Allow faster secondary controller to handle
disturbances in the secondary loop.
Allow secondary controller to handle non-linear valve
and other final control element problems.
Allow operator to directly control secondary loop during
certain modes of operation (such as start-up).

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Cascade Control

Requirements for cascade control:

Secondary loop process dynamics must be at least four
times as fast as primary loop process dynamics.
Secondary loop must have influence over the primary
loop.
Secondary loop must be measured and controllable.

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Tuning Cascade Loops

Step 1 : Tune slave controller
Put Slave controller in AUTO mode (for closed loop
method) or in MAN mode (for open loop method).
Apply tuning procedure for slave controller.
Step 2 : Tune master
Put Slave controller in CAS mode. Put Master in AUTO
mode (for closed loops tuning) or in MAN mode for
(open loop method).
Apply the tuning procedure for master controller .
Important:
If Slave controller is not doing what the master wants
there is no point of having the master setting the set
point of the slave.
First fix the slave.

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CP1130

Ratio Control

Ratio control is used to ensure that two or more flows are kept at the same
ratio even if the flows are changing.
Applications of ratio control:
Blending two or more flows to produce a mixture with specified
composition.
Blending two or more flows to produce a mixture with specified
physical properties.
Maintaining correct air and fuel mixture to combustion.

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Interacting Control Loops

Hot water

Cold water

FI

Output

TIC

FI

PV

TT

LT

PV

SV

LIC

Output

SV

Valve A

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CP1210

De-coupling Interacting Control Loops

Hot water

Cold water

FI

FI

a+b

+
a

a-b
TIC

PV

TT

LT

PV

SV

LIC

SV

Valve A
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CP1215

Interaction problem :
Both controllers on AUTO
+

Gc of TC
-

SV

PV
Temperature

Hot water valve

Cold water valve

Level
-

PV

Gc of LC

SV
+

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CP1271

Heat exchanger bypass control system

hot oil

FC

TC

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CP1230

De-coupling of interacting bypass control system

FC

TC

b - ab
ab

Total valve opening = b

Valves must have LINEAR characteristic
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CP1240

Interaction in distillation
CONVENTIONAL TUNING OF
QUALITY CONTROLLERS

PROPYLENE
3

2.8

C3

2.6
2.4

C3 in PROPALENE

2.2
2
1.8
1.6

PP splitter

1.4
1.2

1
0.8
0.6
0.4
0.2

C3

C3 in PROPANE

Responses to setpoint changes

PROPANE

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Interaction - Conventional Solutions

1 - Detune both controllers
C3 in PROPALENE

PROPYLENE
F

C3

PP splitter

C3 in PROPANE

2 - Select the more important controller and detune

the other

C3 in PROPALENE

C3

C3 in PROPANE

PROPANE

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Multivariable Control
Response to set point step changes
PROPYLENE
F

C3 in PROPALENE

C3

C3 in PROPANE
F

C3

Multivariable
controller

PROPANE

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Dynamic Multivariable Process Model

Reflux
Flow Setpoint

Gain, Delay
Time const

Top
Quality

Gain, Delay
Time const

Gain, Delay
Time const
Reboiler
Flow Setpoint

Gain, Delay
Time const

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Bottom
Quality

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2x2 Multivariable system

Hot water
Cold water

Hot water

Cold water

Temperature
Multivariable
Process

Level

Temperature

1,1

2,1

1,2

2,2

Level
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CP1260

Control Loops with Interaction

Temperature

Hot water
Cold water

Multivariable
Process

Level
+

Gc of TC

SV

- PV
G

1,1

1,2

2,1

2,2

Gc of LC

Temperature

Level
- PV
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SV
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CP1270

Interaction: Temperature control loop

V 1
t=0
Signal to Hot Water Valve

Constant
Signal to Cold Water Valve

MV 1

t=0

1,1

2,1

1,2

2,2

Temp. transmitter output

MV 2

t=0

Level transmitter output

Notice that level behaves like an integrator so the static gain is infinitive.

G 11 =
G 21 = Tan

MV 1
V 1

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CP1265

Interaction: Level control loop

t=0

t
MV 1

G
Constant
Signal to Hot Water Valve

V 2
t=0

1,1

2,1

1,2

MV 2

G
Signal to Cold Water Valve

t=0

2,2

G 12 =
G 22 =

Temp. transmitter output

Level transmitter output

MV1
V2
Tan

Overall conclusion
Decoupling constants:
G1 =

G2 =

G21
G22

Tan
Tan

G12
G11

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CP1266

Decoupling Interacting Control Loops by means of a static

de-coupler
Controller

Process

hot
valve

PV1

+
-

PV2

TC (c11)

+
+

(G1)

G 2,1

(G2)

G 1,2

LC (c22)

+
+

G 1,1

G 2,2
cold
valve

temp.

+
+

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level

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CP1291

Override Control

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Override Control
Override control is used to take control of an output from one
loop to allow a more important loop to manipulate the output.
The output from two or more controllers are combined in a
high or low selector.
The output from the selector is the highest or lowest
individual controller output.
The selector is shown in the diagram by the < or > symbol

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Split-Range Control
50 -100%

Flare
Liquid + gas in

0 - 50%

Gas Processing

PC
Direct

LC

Liquid out

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CP1020

Split range control (2)

0 - 50%

PC

Gas in

50 -100%
Direct

Gas out

Process

fo

fc
open
fo

fc

close
0

open

50

100%

open
fo

fo

fc

close

fc

close
0
50
100%
Gap between valves

0
50
100%
Overlap between valves
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CP1160

Split-level control
Flare
Liquid + gas in
PC1

Gas Processing
PC2

LC

Liquid out

PC1 setpoint must be higher than PC2 setpoint

Advantage of split level control over split-range
control is that the pressure at which relief to flare
occurs is fixed by PC1 setpoint
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CP1020

Feed Forward Control

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Feed Forward Control

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Feed Forward Control

Feed forward control is a strategy used to
compensate a for disturbances in a system before
they affect the controlled variable .
A feed forward control system measures a
disturbance variable, predicts its effect on the
process, and applies corrective action.

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Feed Forward Control

this system has three major drawbacks:

The model must be exact (including dynamics

and nonlinearities).

All instruments in the loop must be perfectly

calibrated.

Disturbances other than the feedforward

variable are not controlled.

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Feed Forward Control

The feed forward control cancels the effect of

the measured disturbance. Since feedback acts
as the system's watchdog, the process model
need not be exact. In fact, simple gain and
lead-lag elements will usually suffice.

The effect of load changes other than the

measured disturbance will be corrected by the
feedback system.

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Shell Global Solutions

End of The Presentation