Practical process control for engineers and technicians [electronic resource] / Wolfgang Altmann ; contributing author, David Macdonald.

Cover image for Practical process control for engineers and technicians [electronic resource] / Wolfgang Altmann ; contributing author, David Macdonald.

ISBN:

9781423722755

9780750664004

9780080480251

Title:

Practical process control for engineers and technicians [electronic resource] / Wolfgang Altmann ; contributing author, David Macdonald.

Author:

Altmann, Wolfgang.

Personal Author:

Altmann, Wolfgang.

Publication Information:

Oxford : Newnes, 2005.

Physical Description:

1 online resource (xii, 290 pages) : illustrations.

Series:

Practical professional books from Elsevier

General Note:

Includes index.

Contents:

Process measurement and transducers -- Basic principles of control valves and actuators -- Fundamentals of control systems -- Stability and control modes of closed loops -- Digital control principles -- Real and ideal PID controllers -- Tuning of PID controllers in both open and closed loop control systems -- Controller output modes, operating equations and cascade control -- Concepts and applications of feedforward control -- Combined feedback and feedforward control -- Long process deadtime in closed loop control and the Smith Predictor -- Basic principles of fuzzy logic and neural networks -- Self-tuning intelligent control and statistical process control.

Local Note:

eBooks on EBSCOhost

Subject Term:

Process control.

Production engineering.

Added Author:

Macdonald, Dave, 1942-

Format:

Electronic Resources

Electronic Access:

Click here to view

Publication Date:

2005

Publication Information:

Oxford : Newnes, 2005.

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Shelf Number	Material Type	Copy	Shelf Location	Status
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Summary

This book is aimed at engineers and technicians who need to have a clear, practical understanding of the essentials of process control, loop tuning and how to optimize the operation of their particular plant or process. The reader would typically be involved in the design, implementation and upgrading of industrial control systems. Mathematical theory has been kept to a minimum with the emphasis throughout on practical applications and useful information.This book will enable the reader to:* Specify and design the loop requirements for a plant using PID control* Identify and apply the essential building blocks in automatic control* Apply the procedures for open and closed loop tuning* Tune control loops with significant dead-times* Demonstrate a clear understanding of analog process control and how to tune analog loops* Explain concepts used by major manufacturers who use the most up-to-date technology in the process control field

Preface	p. xi
1 Introduction	p. 1
1.1 Objectives	p. 1
1.2 Introduction	p. 1
1.3 Basic definitions and terms used in process control	p. 2
1.4 Process modeling	p. 2
1.5 Process dynamics and time constants	p. 5
1.6 Types or modes of operation of process control systems	p. 13
1.7 Closed loop controller and process gain calculations	p. 15
1.8 Proportional, integral and derivative control modes	p. 16
1.9 An introduction to cascade control	p. 16
2 Process measurement and transducers	p. 18
2.1 Objectives	p. 18
2.2 The definition of transducers and sensors	p. 18
2.3 Listing of common measured variables	p. 18
2.4 The common characteristics of transducers	p. 19
2.5 Sensor dynamics	p. 21
2.6 Selection of sensing devices	p. 21
2.7 Temperature sensors	p. 22
2.8 Pressure transmitters	p. 28
2.9 Flow meters	p. 35
2.10 Level transmitters	p. 42
2.11 The spectrum of user models in measuring transducers	p. 44
2.12 Instrumentation and transducer considerations	p. 45
2.13 Selection criteria and considerations	p. 48
2.14 Introduction to the smart transmitter	p. 50
3 Basic principles of control valves and actuators	p. 52
3.1 Objectives	p. 52
3.2 An overview of eight of the most basic types of control valves	p. 52
3.3 Control valve gain, characteristics, distortion and rangeability	p. 67
3.4 Control valve actuators	p. 71
3.5 Control valve positioners	p. 76
3.6 Valve sizing	p. 76
4 Fundamentals of control systems	p. 78
4.1 Objectives	p. 78
4.2 On-off control	p. 78
4.3 Modulating control	p. 79
4.4 Open loop control	p. 79
4.5 Closed loop control	p. 81
4.6 Deadtime processes	p. 84
4.7 Process responses	p. 85
4.8 Dead zone	p. 86
5 Stability and control modes of closed loops	p. 87
5.1 Objectives	p. 87
5.2 The industrial process in practice	p. 87
5.3 Dynamic behavior of the feed heater	p. 88
5.4 Major disturbances of the feed heater	p. 88
5.5 Stability	p. 89
5.6 Proportional control	p. 90
5.7 Integral control	p. 93
5.8 Derivative control	p. 95
5.9 Proportional, integral and derivative modes	p. 98
5.10 I.S.A vs 'Allen Bradley'	p. 98
5.11 P, I and D relationships and related interactions	p. 98
5.12 Applications of process control modes	p. 99
5.13 Typical PID controller outputs	p. 99
6 Digital control principles	p. 100
6.1 Objectives	p. 100
6.2 Digital vs analog: a revision of their definitions	p. 100
6.3 Action in digital control loops	p. 100
6.4 Identifying functions in the frequency domain	p. 101
6.5 The need for digital control	p. 103
6.6 Scanned calculations	p. 105
6.7 Proportional control	p. 105
6.8 Integral control	p. 105
6.9 Derivative control	p. 106
6.10 Lead function as derivative control	p. 106
6.11 Example of incremental form (Siemens S5-100 V)	p. 107
7 Real and ideal PID controllers	p. 108
7.1 Objectives	p. 108
7.2 Comparative descriptions of real and ideal controllers	p. 108
7.3 Description of the ideal or the non-interactive PID controller	p. 108
7.4 Description of the real (Interactive) PID controller	p. 109
7.5 Lead function - derivative control with filter	p. 110
7.6 Derivative action and effects of noise	p. 110
7.7 Example of the KENT K90 controllers PID algorithms	p. 111
8 Tuning of PID controllers in both open and closed loop control systems	p. 112
8.1 Objectives	p. 112
8.2 Objectives of tuning	p. 112
8.3 Reaction curve method (Ziegler-Nichols)	p. 114
8.4 Ziegler-Nichols open loop tuning method (1)	p. 116
8.5 Ziegler-Nichols open loop method (2) using POI	p. 117
8.6 Loop time constant (LTC) method	p. 119
8.7 Hysteresis problems that may be encountered in open loop tuning	p. 120
8.8 Continuous cycling method (Ziegler-Nichols)	p. 120
8.9 Damped cycling tuning method	p. 123
8.10 Tuning for no overshoot on start-up (Pessen)	p. 126
8.11 Tuning for some overshoot on start-up (Pessen)	p. 127
8.12 Summary of important closed loop tuning algorithms	p. 127
8.13 PID equations: dependent and independent gains	p. 127
9 Controller output modes, operating equations and cascade control	p. 131
9.1 Objectives	p. 131
9.2 Controller output	p. 131
9.3 Multiple controller outputs	p. 132
9.4 Saturation and non-saturation of output limits	p. 133
9.5 Cascade control	p. 134
9.6 Initialization of a cascade system	p. 136
9.7 Equations relating to controller configurations	p. 136
9.8 Application notes on the use of equation types	p. 139
9.9 Tuning of a cascade control loop	p. 140
9.10 Cascade control with multiple secondaries	p. 141
10 Concepts and applications of feedforward control	p. 142
10.1 Objectives	p. 142
10.2 Application and definition of feedforward control	p. 142
10.3 Manual feedforward control	p. 143
10.4 Automatic feedforward control	p. 143
10.5 Examples of feedforward controllers	p. 144
10.6 Time matching as feedforward control	p. 144
11 Combined feedback and feedforward control	p. 147
11.1 Objectives	p. 147
11.2 The feedforward concept	p. 147
11.3 The feedback concept	p. 147
11.4 Combining feedback and feedforward control	p. 148
11.5 Feedback-feedforward summer	p. 148
11.6 Initialization of a combined feedback and feedforward control system	p. 149
11.7 Tuning aspects	p. 149
12 Long process deadtime in closed loop control and the Smith Predictor	p. 150
12.1 Objectives	p. 150
12.2 Process deadtime	p. 150
12.3 An example of process deadtime	p. 151
12.4 The Smith Predictor model	p. 152
12.5 The Smith Predictor in theoretical use	p. 153
12.6 The Smith Predictor in reality	p. 153
12.7 An exercise in deadtime compensation	p. 154
13 Basic principles of fuzzy logic and neural networks	p. 155
13.1 Objectives	p. 155
13.2 Introduction to fuzzy logic	p. 155
13.3 What is fuzzy logic?	p. 156
13.4 What does fuzzy logic do?	p. 156
13.5 The rules of fuzzy logic	p. 156
13.6 Fuzzy logic example using five rules and patches	p. 158
13.7 The Achilles heel of fuzzy logic	p. 159
13.8 Neural networks	p. 159
13.9 Neural back propagation networking	p. 161
13.10 Training a neuron network	p. 162
13.11 Conclusions and then the next step	p. 163
14 Self-tuning intelligent control and statistical process control	p. 165
14.1 Objectives	p. 165
14.2 Self-tuning controllers	p. 165
14.3 Gain scheduling controller	p. 166
14.4 Implementation requirements for self-tuning controllers	p. 167
14.5 Statistical process control (SPC)	p. 167
14.6 Two ways to improve a production process	p. 168
14.7 Obtaining the information required for SPC	p. 169
14.8 Calculating control limits	p. 173
14.9 The logic behind control charts	p. 175
Appendix A Some Laplace transform pairs	p. 176
Appendix B Block diagram transformation theorems	p. 179
Appendix C Detail display	p. 181
Appendix D Auxiliary display	p. 185
Appendix E Configuring a tuning exercise in a controller	p. 188
Appendix F Installation of simulation software	p. 190
Appendix G Operation of simulation software	p. 193
Appendix H Configuration	p. 197
Appendix I General syntax of configuration commands	p. 198
Appendix J Configuration commands	p. 199
Appendix K Algorithms	p. 208
Appendix L Background graphics design	p. 223
Appendix M Configuration example	p. 224
Introduction to exercises	p. 229
Exercise 1 Flow control loop - basic example	p. 231
Exercise 2 Proportional (P) control- flow chart	p. 234
Exercise 3 Integral (I) Control - flow control	p. 237
Exercise 4 Proportional and integral (PI) control - flow control	p. 240
Exercise 5 Introduction to derivative (D) control	p. 242
Exercise 6 Practical introduction into stability aspects	p. 246
Exercise 7 Open loop method - tuning exercise	p. 252
Exercise 8 Closed loop method - tuning exercise	p. 256
Exercise 9 Saturation and non-saturation output limits	p. 260
Exercise 10 Ideal derivative action - ideal PID	p. 263
Exercise 11 Cascade control	p. 267
Exercise 12 Cascade control with one primary and two secondaries	p. 271
Exercise 13 Combined feedback and feedforward control	p. 276
Exercise 14 Deadtime compensation in feedback control	p. 279
Exercise 15 Static value alarm	p. 284
Index	p. 286

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Summary

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Table of Contents