Tuning the parameters of a PID controller

ppt

1. Industrial Automation and Control Technology Management LEVEL V Unit of Competence: Installing process control apparatus and  associated equipment   Industrial Automaon and ControlTechnology ManagementLEVEL V Unit of Competence: Write Specications forIndustrial Electronics and Control Projects                                                                                                                                                                                                           

2. LEARNING OUTCOMES: LO1 :  Prepare process control apparatus and associated equipment LO2: Install  process control apparatus and associated equipment   LO3 :  Complete and report installation activities

3. MODULE CONTENTS:   LO1 :  Prepare process control apparatus  and associated equipment 1.Identification of OH&S procedures 2.Preparing  installation  apparatus 3.Determining  the nature & location of the  work 4.Preparing  process control  apparatus 5.Identifying  tools, equipment and testing  devices

4. 1.Reading  and interpreting drawings  accurately 2.Terminate wiring and tubing at process control apparatus 3.Installing  process control apparatus in  accordance with manufacturers specification 4.Checking  the quality of installed  apparatus   LO3 :  Complete and report  installation activities 1.Following OH&S risk control  measures 2.Preparing  documentation for installation  activities 3.Reporting  the final  result 4.Cleaning  the work area LO2 : Install process control apparatus and  associated equipment

5. OH&S Policies and procedures Occupational health and safety is an aspect of public health program . Creating a healthy workplace and a healthy work force in any occupational environment is the best way to position that occupation to better delivery of service . There are some general points which can be noted : Safety equipment, e.g. goggles, gloves, etc., should be provided and must be used where they are appropriate. Safe working practices are part of any job and you should always learn and adopt them as a natural way of working .   Don’t take shortcuts which compromise your safety, or that of any body else. You should make yourself aware of the procedures used at your place of work to prevent Accidents .   You should know how to isolate electric supplies and how to work safely on electrical circuits.

6. What equipment is covered by the Regulations? Examples of uses of equipment Generally, any equipment which is used by an employee at work  is covered, for example hammers, knives, ladders, drilling machines, power presses, and circular saws, photocopiers, lifting equipment(including lifts), dumper trucks and motor vehicles. which are covered by the Regulations include starting or stopping the equipment, repairing, modifying , maintaining , servicing, cleaning and transporting.   Safety and reliability of control systems Control systems should be designed and  constructed Particular attention should be paid to the following points : a) the  machinery should not start  unexpectedly; b) the parameters of the machinery should not change in an uncontrolled way;

7. Con…. c ). the machinery should not be prevented from stopping if the stop command has already been given ; d ). no moving part of the machinery or piece held by the machinery should fall or be ejected unintentionally ; e ). automatic or manual stopping of the moving parts , whatever they may be, should be unimpeded; f ). Protective devices should remain fully effective or give a stop command; and g ). Safety-related parts of the control system should apply in a coherent way to the whole of an assembly of machinery and partly completed machinery.  

8. Control devices Clearly visible and identifiable and readily distinguish able from one another by their separation , size , shape, colors or feel, and by labeling controls either with words. a). Designed in such a way that controls for starting or stopping are clearly marked; b). Positioned in such a way as to be safely operated without uncertainty or loss of time and without ambiguity ; c). Designed in such a way that the movement of the control device is consistent with its effect; d). Located outside danger zones, except where necessary for certain control devices such as an emergency stop or a teach pendant; e). Positioned in such a way that their operation can not cause additional risk;

9. Starting Machinery should be fitted with a specific start control device. The same requirement applies : a) when restarting the machinery after a stoppage, b) when effecting a significant change in the operating conditions . For machinery functioning in automatic mode, the starting of the machinery, restarting after a stop page , or a change in operating conditions , provided this does not lead to a maybe possible without intervention hazardous situation. Where machinery has several starting control devices and operators can therefore place one another in danger, additional devices should be fitted

10. Stopping Normal stop a ). Machinery should be fitted with a reliable control device allowing the machinery to be brought safely to a complete stop. b ). Each workstation should be fitted with a control device to stop some or all of the functions of the machinery . C ). The machinery’s stop control should have priority over the start controls. D ). Once the machinery or its hazardous functions have stopped, the energy supply to the actuators concerned should be cut off.

11. Operational stop a ) Where , for operational reasons, a stop controls that does not cut off the energy supply to the actuators is required , the stop condition should be monitored and maintained . Emergency stops  Emergency stop controls should be : a).colored red;   and b). positioned in such a way as to be safely  operated with out hesitation or loss of time and without ambiguity . c).be  clearly identifiable , clearly visible and , so that they can be used to stop the hazardous process as quickly as possible, with out creating additional risks

12. Failure of the energy source The fluctuation, interruption and re-establishment after an interruption of the energy source to the machinery should not lead to a dangerous situation (e.g. fails-to-safe). a).The machinery should not start unexpectedly ; b).The parameters of the machinery should not change in an uncontrolled way when such change can lead to hazardous situations; c).The machinery should not be prevented from stopping if the command has already been given; d).No moving part of the machinery, or piece held by the machinery , should fall or be ejected unintentionally; e ).  Automatic or manual stopping of the moving parts , whatever they may be, should be unrestricted ; and f).  The protective devices should remain fully effective  or give a stop command

13. Personal protective equipment (PPE) and OH&S Hazards exist in every workplace in many different forms : sharp edges, falling objects, flying sparks , chemicals , noise and a myriad(numerous) of other potentially dangerous situations. The Occupational Health and Safety Administration (OSHA ) requires that employers protect their employees from work place hazards that can cause injury.

14. In general, employers are responsible for : Performing a "hazard assessment" of the workplace to identify and control physical and health hazards . Identifying and providing appropriate PPE for employees . Training employees in the use and care of the PPE . Maintaining PPE, including replacing worn or damaged PPE . Periodically reviewing, updating and evaluating the effectiveness of the PPE program.  In general, employees should: Properly wear PPE , Attend training sessions on PPE , Care for, clean and maintain PPE, and Inform a supervisor of the need to repair or replace PPE.

15. potential hazards in the following basic hazard categories: Impact, Penetration, Compression (roll-over ), Chemical, Heat/cold, Harmful dust, Light (optical) radiation, and Biologic .

16. Types of eye protection Safety spectacles:- These protective eye glasses have safety frames constructed of metal or plastic and impact-resistant lenses. Side shields are available on some models . Goggles:- These are tight-fitting eye protection that completely cover the eyes , eye sockets and the facial area immediately surrounding the eyes and provide protection  from impact , dust and splashes. Some goggles will fit over corrective lenses . Welding shields:- Constructed of vulcanized fiber or fiberglass and fitted with a filtered lens , welding shields protect eyes from burns caused by infrared or intense radiant light; they also protect both the eyes and face from flying sparks , metal spatter and slag chips produced during welding, brazing , soldering and cutting operations . Laser safety goggles:- These specialty goggles protect against intense concentrations of light produced by lasers. The type of laser safety goggles an employer chooses will depend upon the equipment and operating conditions in the workplace . Face shields:- These transparent sheets of plastic extend from the eyebrows to  below the chin and across the entire width of the employee's head. Some are polarized for glare protection.

17. Head Protection Protecting employees from potential head injuries is a key element of any safety program. In general, protective helmets or hard hats should do the following: Resist penetration by objects. Absorb the shock of a blow. Be water-resistant and slow burning. Foot and Leg Protection Employees who face possible foot or leg injuries from falling or rolling objects or from crushing or penetrating materials should wear protective footwear. Special Purpose Shoes Electrically conductive shoes:-  provide protection against the buildup of static electricity. Employees working in explosive and hazardous locations such as explosives manufacturing facilities Electrical hazard, safety-toe shoes:- are nonconductive and will prevent the wearers feet from completing an electrical circuit to the ground. These shoes can protect against open circuits of up to 600 volts in dry conditions

18. Hand and Arm Protection (Glove) Care of Protective Gloves Protective gloves should be inspected before each use to ensure that they are not torn(worn out), punctured or made ineffective in any way. Body Protection Employees who face possible bodily injury of any kind that cannot be eliminated through engineering, work practice or administrative controls. examples  of workplace hazards that could cause bodily injury :  Temperature extremes;•  Hot splashes from molten metals and other hot liquids;•  Potential impacts from tools, machinery and materials;•  Hazardous chemicals.

19. Protective clothing comes in a variety of materials, each effective against particular hazards, such as: Paper-like fiber:- used for disposable suit provide protection against dust and splashes.  Treated wool and cotton:- adapts well to changing temperatures, is comfortable, and fire-resistant and protects against dust, abrasions and rough and irritating surfaces. Duck is a closely woven cotton fabric that protects against cuts and braless when handling heavy, sharp or rough materials. Leather  is often used to protect against dry heat and flames. Rubber, rubberized fabrics, neoprene and plastics  protect against certain chemicals and physical hazards.

20. Identifying Materials, Tools, Equipment’s and Testing Devices Instruments are devices which are used to measure attributes of physical systems. The variable measured can include practically any measurable variable related to the physical sciences. These variables commonly include:- pressure, flow, temperature, level, density, viscosity, radiation, current, voltage, inductance, capacitance , frequency, chemical composition, chemical properties, various physical properties, etc.  Instruments can often be viewed in terms of a simple input-output device.

21.   principles of Instrumentation Measurement is the process of determining the amount ,degree or capacity by comparison with the accepted standards of the system units being used. Instrumentation  is a technology of measurement which serves sciences ,engineering, medicine and etc. Instrument  is a device for determining the value or magnitude of a quantity   or variable.   3 phases of instruments  a. Mechanical, b. Electrical and c. Electronic Instruments Electronic instrument  is based on electrical or electronic principles for its measurement functions. The 3 basic functions of instrumentation: Indicating – visualize the process/operation signal processing- manipulates information Recording  – observe and save the measurement reading

22. Mechanical Instruments: These instruments are very reliable for static and stable conditions.

23. Basic Measurement and Control Concepts The basic set of units used on this course is the SI unit system.

24. Process Control Theory: A process  is broadly defined as an operation that uses resources to transform inputs into outputs. It is the resource that provides the energy into the process for the transformation to occur. Process industries include the chemical industry , the oil and gas industry, the food and beverage industry, the pharmaceutical industry, the water treatment industry,  and the power industry. Control  is used to modify the behavior of a system so it behaves in a specific desirable way over time.

25. Process Control Process control  is the act of controlling a final control element to change the manipulated variable to maintain the process variable at a desired Set Point . For example, factors such as the proportion of one ingredient to another , the temperature of the materials , Manufacturers control the production process for three reasons: Reduce variability Increase efficiency Ensure safety

26. Manual and Automatic Control Control operations that involve human action to make an adjustment are called manual control systems. ,Conversely, control operations in which no human intervention is required, such as an automatic valve actuator that responds to a level controller, are called automatic control systems.   Basic Elements of Process Control? Controlling a process requires knowledge of four basic  elements, 1. process  itself, a dynamic behavior that is determined by physical properties; 2. sensor   that measures the process value, measure are temperature, pressure, mass, flow and level. 3. final control element  that changes the manipulated variable, and physical device that receives commands from the controller to manipulate the resource. Typical Final Control Elements used in these processes are valves and pumps . 4. controller   which provides the signal to the final element.  A controller can be a person, a switch, a single loop controller, or DCS / PLC system

27. Closed and Open Control Loops Closed-loop control system   A closed control loop exists where a process variable is measured, compared to a set point, and action is taken to correct any deviation from set point.

28. An open control loop open control loop  exists where the process variable is not compared, and action is taken not in response to feedback on the condition of the process variable, but is instead taken with out regard to process variable conditions.

29. Grouped by control mechanism function, the three types of controllers are: 1. Discrete controllers 2. Multistep controllers 3. Continuous controllers Discrete Controllers : Discrete controllers are controllers that have only two modes or positions: on  and off  . A common example of a discrete controller is a home hot water heater. Multistep Controllers: Multistep controllers are controllers that have at least one other possible position in addition to on and off. Multistep controllers operate similarly to discrete controllers, but as set point is approached, the multistep controller takes intermediate steps. Controller Algorithms

30. Continuous Controllers Controllers automatically compare the value of the PV to the SP to determine if an error exists. If there is an error, the controller adjusts its output according to the parameters that have been set in the controller. The tuning parameters essentially determine : How much correction should be made? The magnitude of the correction (change in controller output) How long should the correction be applied? The duration  of the adjustment to the controller output How fast should the correction be applied? The speed  at which a correction is made is determined by the derivative mode of the controller.

31.   temperature Sensors: Thermometer – measures absolute temperature (discussed in the previous section) Thermocouple gauge– measures temperature by its affect on two dissimilar metals  A thermocouple is a device that directly converts thermal energy into electrical energy.   Mechanical Sensors: Pressure sensor – measures pressure Barometer – measures atmospheric pressure  Altimeter – measures the altitude of an object above a fixed level Liquid flow sensor – measures liquid flow rate Gas flow sensor – measures velocity, direction, and/or flow rate of a gas  Accelerometer – measures acceleration Electrical Sensors  Ohmmeter – measures resistance Voltmeter – measures voltage Galvanometer – measures current Watt-hour meter – measures the amount of electrical energy supplied to and used by a residence or business.

32. Optical Sensors Light sensors ( photodetectors ) – detects light and electromagnetic energy Photocells ( photoresistor ) – a variable resistor affected by intensity changes in ambient light. Infra-red sensor – detects infra-red radiation

33. Key terms/terminologies Electro acoustic: The interaction between electrical and acoustic phenomena. Electrochemical:  The transfer of electric charge between matter. Electromagnetic:  Objects made magnetic by an electric current. Electromechanical: A mechanical device which is controlled by an electronic device. Electrostatic: Of or related to electric charges at rest or static charges. Optical: Referring to the behavior and properties of light and the interaction of light with matter. Photoelectric : Relates to the electrical effects caused by light.

34. Reading and understanding electrical drawings Electrical drawings can represent anything from a single-line power distribution, to a power or control circuit, and are prepared using various symbols for electrical devices and their interconnections with lines representing conductors or wires used for interconnections. To read and understand electrical drawings, it is necessary to know the following: Symbols used for representing electrical devices Their interconnections, legends, terminology, and abbreviations Sheet numbering and column format for each sheet Wire and terminal numbering (an important aspect in understanding electrical drawings)

35. Basic Electrical Devices Manually actuated push button switches:   A switch used to close or open an electric control circuit. They are primarily used for starting and stopping of operation of machinery

36. Limit switches:   A limit switch is a mechanical device that requires the physical contact of an object with the switch's actuator to make the contact change state (open/closed). As the object or target contacts the operator of the switch, it eventually moves the actuator to the “limit” where the contacts change state. 1. two types of Limit switches a) Lever actuated contacts b) Spring loaded contacts

37. Cont….

38. Pressure switches : is a pneumatic-electric signal converter. Pressure switches are used to sense a change in pressure, and opens or closes an electrical switch when a predetermined pressure is reached.

39. Solenoids Electrically actuated directional control valves form the interface between the two parts of an electro-pneumatic control. 12 V DC, 12V AC, 12V 50/60 Hz, 24V 50/60 Hz, 110/120V 50/60 Hz,220/230V 50/60 Hz.

40. Relays: an electro magnetically actuated switch.

41. Timers: timers are required in control systems to effect time delay between work operations. Temperature switches: automatically senses a change in temperature and opens or closes an electrical switch when a predetermined temperature is reached

42. Proximity sensors: Reed switches are magnetically actuated proximity switches. Reed switches are similar to relays, except a permanent magnet is used instead of a wire coil.

43. direct Control of single acting cylinder

44. Indirect Control of single acting cylinder

45. Design Indirect Control of double acting cylinder (using 5/2 way, double solenoid ) Design Control of double acting cylinder OR logic (Parallel circuit)

46. Terminate wiring and tubing splicing

47. 1. Reading and interpreting drawings accurately

48. Common tube fitting types and names Tube fittings designed to connect a tube to pipe threads are called   connectors. Tube fittings designed to connect one tube to another are called unions

49. Test Equipment For all low voltage electrical installation verification and condition reporting work, electrical contractors and installers should, as a minimum, have the following range of test instruments: Continuity test instrument Insulation resistance test instrument Loop impedance test instrument Residual current device test instrument Earth electrode resistance test instrument Voltage indicating instrument**

50. Check and monitor tools and equipment Managing the Risks of Electrical Work What is electrical work? Electrical work means: Connecting electricity supply wiring to electrical equipment or disconnecting electricity supply wiring from electrical equipment Installing, removing, adding, testing, replacing , repairing, altering or maintaining electrical equipment or an electrical installation.

51. HAZARD ASSESSMENT Certain areas of the building will require different types of cleaning due to differences in the types of hazards. For example, areas requiring differential house keeping attention include: Entryways and lobbies Bathrooms Hallways and corridors Kitchen and cafeteria Offices Warehouse

52. HOUSEKEEPING AREAS—SAFE WORK PRACTICES Supervisors and workers will implement the following safe work practices for housekeeping in all areas of the facility. All Working Surfaces Keep all walking and working surfaces clean, sanitary, and orderly. Keep work surfaces dry. Clean up small spills immediately; report large spills to a supervisor. Ensure that all walking and working surfaces and passage ways are free from protruding nails, splinters, holes, or loose boards.

53. Final Inspection Inspection list shall include at least the following items where applicable: 1.Tray installation; satisfactory testing (where required).  2. Internal draw of piping. 3. Catalyst supports and screens. 4. Internal distributors. 5. Liquid entrainment separators.

54. Visual Inspection Field visual inspection shall ensure that each instrument: has the correct tag number, range, etc.; is in the proper place; is correctly and rigidly installed; is properly earthed where necessary; is suitably protected against adverse environmental conditions.  Attention shall also be paid to the final accessibility of the instrument and the free space necessary for removal or partial disassemble.

55. Recording and notifying document 1.Ensure all devices to be checked out are properly installed and powered. 2.Perform a device Scan operation by right-clicking the interface icon in AMS Device Manager. 3.FOUNDATION field bus devices will appear automatically without a scan operation, 4.Run the AMS Device Manager Tag Naming Utility to transfer the HART device tag to the AMS device tag. 5.For FOUNDATION field bus devices you should name the devices as they appear. 6.AMS Device Manager Audit Trail will automatically document these events, The following steps complete the loop check work process with AMS Device Manager: 7.Verify device configuration with the device specification sheet.

56. Documentation  An essential requirement for an inspection system is to keep up to date, precise and detailed records of all inspection, testing and calibration activities. Blue   leak test  completed.  yellow  pressure test  completed.  orange   cable test completed green  calibration test  completed Red incomplete components are missing Pink calibration fault in temporary use only. white  test failed waiting for further action

57. Procedures of writing report Many project teams utilize the reporting options and tools available in their collaborative project site to track work, identify risks and issues, and keep stakeholders informed about the project. 1.Decide the Objective 2. Understand Your Audience  3. Report Format and Type  4. Gather the Facts and Data  5. Structure the Report Executive Summary Introduction Body 6. Readability 7. Edit

58. THA NK Y OU !!!