Slides Workshop Finn Haugen

University of Muratuwa (UOM) Telemark University College
Sri Lanka Norway
Workshop on Modern Process Control

for Sustainable Process Development:
Process Control
Principles and Technology
17. March 2010
By
Finn Haugen
(Telemark University College)
Norway
In the woods and mountains lives the trolls.
Agenda:
• Why control?
• Feedback control
• Feedforward control
• Sequential control
• Industrial control hardware
• Control structures based on PID control:
• Cascade control
• Ratio control
• Flow smoothing using sluggish level control
• Plantwide control
• Practical demo: Temperature control of an air heater with LabVIEW and PC
• Practical demo: Data logging in the temperature control application
• Practical demo: Control of a pilot biogas reactor at Telemark University
College using LabVIEW (incl. remote operation over the Internet)
Why control?
• Product quality
• Product economy
• Safety
• Environment protection
• Comfort
• Feasibility
• Automation
Agenda:
• Why control?
• Cascade control
• Ratio control
Feedback control
How do you act …
• While you are controlling the temperature of the water in

the shower to make the temperature become equal to the
reference (desired) temperature?
• While you are controlling the speed of your car to hold the
speed at the reference (desired) speed, whether uphill or
downhill?
• While you are controlling the position of your hand as you

try to grab a key to make the position become equal to the
reference (desired) position?
What you do to solve these control problems is probably
this:
You keep on adjusting the control variable (water tab,

throttle, muscle tension) until you observe
that the measurement (observed temperature, speed,
position) is sufficiently close to the reference (desired
temperature, speed, position).
The difference between the reference and the

measurement is denoted the control error.
So, in other words, you keep on adjusting the

control variable until the control error is sufficiently small.
This principle can be denoted ”error-driven control”.
This is also the basic control principle of industrial

computer-based control systems.
Block diagram of a feedback control system
Setpoint
or
In industrial control systems the controller is a
PID controller
(Proportional + Integral + Derivative)
I-term, ui, and therefore t
total control signal, u, ∫ edτ

0
will change (increase) as
long as control error is
different from zero,
t
Kp
causing the error to ui = ∫ edτ
Ti
eventually become zero 0
(in steady-state).
P- and D-term
contributes with speed
in control action.
Example of feedback control: Level control of wood chip tank
Example: Simulation of level control system of wood chip tank
The simulation is run during the presentation.
This and other SimView simulators are available at http://techteach.no.
Another example: Temperature control system of liquid tank
Simulation is run during the presentation.
A feedback control system may become unstable!
Recall the control loop:
Typical causes of reduced stability or instability of a

control loop:
• Increase of loop gain
• Increase of loop dead-time
• Increase of loop time-constants
Let’s try on the chip level control system…

Example: Unstable chip level control system
The time-delay of the transport belt was increased (doubled),
causing instability of the control system.
How to get back stability without increasing speed? Adjust controller parameters!
Agenda:
• Why control?
• Cascade control
• Ratio control
Feedforward control
The purpose of feedforward control:
Faster setpoint tracking
and/or
Faster disturbance compensation
This is achieved by exploiting:

Measurements of disturbances
and
Process knowledge
(in the form of a mathematical model)
Control system with both
feedforward and feedback:
Example: Feedforward control in level control system
How to derive the feedforward controller
(in the example):
(1) Process model: Mass balance:
(2) Solving for the control variable, and

substituting the process variable by its setpoint:
which is the feedforward controller!

Agenda:
• Why control?
• Cascade control
• Ratio control
Sequential control
Where is sequential control needed?
In applications where the automation tasks must be
accomplished in a certain sequence.
Tools to design and implement sequential control:

• Sequential Function Charts (SFC)
(which is defined in the IEC 61131-3 about PLC programming
• State Diagrams
(SFCs and State Diagrams are very similar.)
Example of Sequential Function Chart (SFC)
(Used in following simulation.)
An SFC consists of
• Steps (or states)
• Actions
• Transitions
Example: Sequential control of a batch process
Agenda:
• Why control?
• Cascade control
• Ratio control
Industrial control hardware
Typical industrial automation system:
Control devices:
Process Controller
PLC (Programmable Logical Controller)
(ABB ECA600)
(Mitsubishi)
PAC (Programmable Automation Controller)

(National Instruments Compact FieldPoint)
Process Station of a
Distributed Control System (DCS)
(Kongsberg Maritime AIM2000)
Control devices:
PLC
PLC (Mitsubishi FX2N)
Control devices:
PAC
Compact FieldPoint PAC by National Instruments
Control devices:
Process Controller
Process Controller (ABB ECA600)
Agenda:
• Why control?
• Cascade control
• Ratio control
Cascade control
The main purpose of cascade control
(compared to single loop control):
Faster process disturbance compensation
This is achieved by:
Measuring some internal process variable which

is influenced by the disturbance
Cascade control system:
Example: Cascade control of temperature in a vessel
Agenda:
• Why control?
• Cascade control
• Ratio control
Ratio control
Purpose: To maintain a specified ratio of two flows
Equivalent:
FT1 FC1 FT1 FC1
F1 F1
Wild stream Wild stream
Process Process
F2 F2
u u
FT2 FC2 FT2 FFC
K
K F1 = F2SP
MULT FFC
(Flow
Fraction
Controller)
Measured K (specified
F1 ratio)
Agenda:
• Why control?
• Cascade control
• Ratio control
Flow smoothing with sluggish level control
Below is typical configuration.
Control systems specifications:
1. Outflow is as smooth as possible when inflow varies.
Implication: Level control action is sluggish so that the
manipulated outflow (level controller output) is as
smooth as possible.
2. Level does not exceed max or min values at inflow slug.

Implication: Level control action must not be too sluggish.
3. Level should be at setpoint at steady state.

Implication: Level controller must have integral action.
Solution:
PI controller tuned to obtain as sluggish control as possible.
Agenda:
• Why control?
• Cascade control
• Ratio control
Plantwide control
Requirements:
1. Product flow is controlled (to follow a setpoint).
2. Product quality is controlled.
3. Mass balance of liquid and/or gas of each

process vessel (tank, reactor, etc.) is maintained.
4. Temperature in certain process flows and vessels is controlled.

Principal plant with control structure
Example: Nitric acid plant
ST SC
Air
1 1
Feed:
Steam Tail gas
Specified Primary
Amm./Air air Shaft 1
FT FFC ratio O2
2 Compressor
1 Turbine/ Turbine/
K1
Mixer generator generator
Feed: TG1
V3 M1 Reactor TG2
Ammonia
(gas) R1 Steam
NH3 890 oC
Steam
drum
Ammonia D1
(liquid) Process
NH3 Gas N2 and NOx
PT water
1 Water V5 H2O
Tank T1 NO + H2O Gas Absorber
PC
1 A1
FC FT
Cold 3 3
Heater H1
Evaporator water Gas up
Valve E1 Gas
V1 Gas Manual Air with
Liquid down
Liquid control NOx
Condenser C1
Liquid (acid)
LC LT Bleacher
1 1 Feed: QT B1
Secondary P1 1
V2 LT Liq.
air Gas
LT LC NO2 3
O2 2 2
Raw LC
nitric 3
NO2 + H2O
acid
Shaft 1
Compressor HNO3 V4 Gas LT
K2 4
Liquid
(acid) FT FC LC
Final
4 4 4
Condenser C2 nitric
acid
V6 HNO3 V7
Agenda:
• Why control?
• Cascade control
• Ratio control
Demo: Temperature control of air heater
with PC and LabVIEW
Air heater:
NI USB-6008 I/O device
Features of the NI USB-6008 I/O device
• Analog input (AI): 8 inputs with referenced single ended signal coupling, or 4
inputs with differential signal coupling. Voltage ranges: Between ±20V and ±1V.
Max sampling rate is 10000 S/s. 12 bits AD converter.
• Analog output (AO): 2 outputs. Voltage range is 0 - 5V (fixed). Output current is

max 5 mA. Maximum sample rate is 150Hz (samples/second). 12 bits DA converter.
• Digital input (DI) and digital output (DO): 12 channels which can be used as
either DI or DO (configured individually). Roughly said: HIGH = 5 V. LOW = 0 V
(TTL).
• Counter: 32 bits. Counting on falling edge.
• On-board voltage sources: 2.5V and 5.0V
• Power: Only via the USB cable.
• Price: 1400 NOK = 170 USD

LabVIEW program
Front panel:
LabVIEW program
Block diagram:
Agenda:
• Why control?
• Cascade control
• Ratio control
LabVIEW program with data logging
of control signal and measurement signal
Front panel (extract):
LabVIEW program with data logging
of control signal and measurement signal
Block diagram (extract):
Agenda:
• Why control?
• Cascade control
• Ratio control
Process & Instrumentation Diagram
H2
H2 Sensor
Sensor Flowmeter
XT
To ventilation
Gas Cooling Device
H2 ppm Sensor
+ Gas/Liquid Separator FQR
Gas Recovery and Pressure

Relief Pipeline
Sample Ports
Feed Tank
Biogas Reactor (Gas)
Gas/Liquid separator Liquid Recovery Pipeline
PR
PR PDR
XC PR
Sieve
Feed Tank
(Apple waste)
Feed Pump
Sample port
Feed Tank
(reactor content)
Circulation Pump Sample
Sample
Sample port
port
port liquid
liquid
liquid
(liquid)
Sample port liquid
Pilot biogas reactor at TUC
Instrumentation
cabinet Fridge
Gas flow
Reactor meter
Hydrogen
Feed pump sensor
Recirculation Gas/liquid
pump separator
Barrel with
apple waste
Gasflow sensor
Hydrogen ppm sensor
PC with LabVIEW for supervision and control
Demo: Remote operation of the reactor with LogMeIn
Demo: Remote operation of the reactor with LogMeIn
Activity for the participants:
Ideas for new application of

process control principles in
your company.
Thanks for your attention
Hope you got some things

to think about ☺

Slides Workshop Finn Haugen

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University of Muratuwa (UOM) Telemark University College

Sri Lanka Norway

Workshop on Modern Process Control

17. March 2010

• While you are controlling the temperature of the water in

• While you are controlling the position of your hand as you

You keep on adjusting the control variable (water tab,

The difference between the reference and the

So, in other words, you keep on adjusting the

This is also the basic control principle of industrial

I-term, ui, and therefore t

total control signal, u, ∫ edτ

Typical causes of reduced stability or instability of a

Let’s try on the chip level control system…

This is achieved by exploiting:

(2) Solving for the control variable, and

which is the feedforward controller!

Tools to design and implement sequential control:

PAC (Programmable Automation Controller)

Faster process disturbance compensation

This is achieved by:

Measuring some internal process variable which

FT1 FC1 FT1 FC1

2. Level does not exceed max or min values at inflow slug.

3. Level should be at setpoint at steady state.

1. Product flow is controlled (to follow a setpoint).

2. Product quality is controlled.

3. Mass balance of liquid and/or gas of each

4. Temperature in certain process flows and vessels is controlled.

• Analog output (AO): 2 outputs. Voltage range is 0 - 5V (fixed). Output current is

• Counter: 32 bits. Counting on falling edge.

• On-board voltage sources: 2.5V and 5.0V

• Power: Only via the USB cable.

• Price: 1400 NOK = 170 USD

Gas Recovery and Pressure

Gas/Liquid separator Liquid Recovery Pipeline

Ideas for new application of

Hope you got some things

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