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Tuning and Control Loop Performance, Fourth Edition provides the knowledge to eliminate the misunderstandings, realize the difference between theoretical and industrial application of PID control, address practical difficulties, improve field automation system design, use the latest PID features, and ultimately get the best tuning settings that enables the PID to achieve its full potential. The proportional-integral-derivative (PID) controller is the heart of every control system in the process industry. Given the proper setup and tuning, the PID has proven to have the capability and flexibility needed to meet nearly all of industry’s basic control requirements. However, the information to support the best use of these features has fallen behind the progress of improved functionality. Additionally, there is considerable disagreement on the tuning rules that largely stems from a misunderstanding of how tuning rules have evolved and the lack of recognition of the effect of automation system dynamics and the incredible spectrum of process responses, disturbances, and performance objectives.
Control Performance Management in Industrial Automation provides a coherent and self-contained treatment of a group of methods and applications of burgeoning importance to the detection and solution of problems with control loops that are vital in maintaining product quality, operational safety, and efficiency of material and energy consumption in the process industries. The monograph deals with all aspects of control performance management (CPM), from controller assessment (minimum-variance-control-based and advanced methods), to detection and diagnosis of control loop problems (process non-linearities, oscillations, actuator faults), to the improvement of control performance (maintenance, re-design of loop components, automatic controller re-tuning). It provides a contribution towards the development and application of completely self-contained and automatic methodologies in the field. Moreover, within this work, many CPM tools have been developed that goes far beyond available CPM packages. Control Performance Management in Industrial Automation: · presents a comprehensive review of control performance assessment methods; · develops methods and procedures for the detection and diagnosis of the root-causes of poor performance in complex control loops; · covers important issues that arise when applying these assessment and diagnosis methods; · recommends new approaches and techniques for the optimization of control loop performance based on the results of the control performance stage; and · offers illustrative examples and industrial case studies drawn from – chemicals, building, mining, pulp and paper, mineral and metal processing industries. This book will be of interest to academic and industrial staff working on control systems design, maintenance or optimisation in all process industries.
An instructive reference that will help control researchers and engineers, interested in a variety of industrial processes, to take advantage of a powerful tuning method for the ever-popular PID control paradigm. This monograph presents explicit PID tuning rules for linear control loops regardless of process complexity. It shows the reader how such loops achieve zero steady-position, velocity, and acceleration errors and are thus able to track fast reference signals. The theoretical development takes place in the frequency domain by introducing a general-transfer-function-known process model and by exploiting the principle of the magnitude optimum criterion. It is paralleled by the presentation of real industrial control loops used in electric motor drives. The application of the proposed tuning rules to a large class of processes shows that irrespective of the complexity of the controlled process the shape of the step and frequency response of the control loop exhibits a specific performance. This specific performance, along with the PID explicit solution, formulates the basis for developing an automatic tuning method for the PID controller parameters which is a problem often met in many industry applications—temperature, pH, and humidity control, ratio control in product blending, and boiler-drum level control, for example. The process of the model is considered unknown and controller parameters are tuned automatically such that the aforementioned performance is achieved. The potential both for the explicit tuning rules and the automatic tuning method is demonstrated using several examples for benchmark process models recurring frequently in many industry applications.
Practical Process Control (loop tuning and troubleshooting). This book differs from others on the market in several respects. First, the presentation is totally in the time domain (the word "LaPlace" is nowhere to be found). The focus of the book is actually troubleshooting, not tuning. If a controller is "tunable", the tuning procedure will be straightforward and uneventful. But if a loop is "untunable", difficulties will be experienced, usually early in the tuning effort. The nature of any difficulty provides valuable clues to what is rendering the loop "untunable". For example, if reducing the controller gain leads to increased oscillations, one should look for possible interaction with one or more other loops. Tuning difficulties are always symptoms of other problems; effective troubleshooting involves recognizing the clues, identifying the root cause of the problem, and making corrections. Furthermore, most loops are rendered "untunable" due to some aspect of the steady-state behavior of the process. Consequently, the book focuses more on the relationship of process control to steady-state process characteristics than to dynamic process characteristics. One prerequisite to effective troubleshooting is to "demystify" some of the characteristics of the PID control equations. One unique aspect of this book is that it explains in the time domain all aspects of the PID control equation (including as the difference between the parallel and series forms of the PID, the reset feedback form of the PID equation, reset windup protection, etc.) The book stresses an appropriate P&I (process and instrumentation) diagram as critical to successful tuning. If the P&I is not right, tuning difficulties are inevitable. Developing and analyzing P&I diagrams is a critical aspect of troubleshooting.
PID Control for Industrial Processes presents a clear, multidimensional representation of proportional - integral - derivative (PID) control for both students and specialists working in the area of PID control. It mainly focuses on the theory and application of PID control in industrial processes. It incorporates recent developments in PID control technology in industrial practice. Emphasis has been given to finding the best possible approach to develop a simple and optimal solution for industrial users. This book includes several chapters that cover a broad range of topics and priority has been given to subjects that cover real-world examples and case studies. The book is focused on approaches for controller tuning, i.e., method bases on open-loop plant tests and closed-loop experiments.
Recognising the benefits of improved control, the second edition of Autotuning of PID Controllers provides simple yet effective methods for improving PID controller performance. The practical issues of controller tuning are examined using numerous worked examples and case studies in association with specially written autotuning MATLAB® programs to bridge the gap between conventional tuning practice and novel autotuning methods. The extensively revised second edition covers: • Derivation of analytical expressions for relay feedback responses. • Shapes of relay responses and improved closed-loop control and performance assessment. • Autotuning for handling process nonlinearity in multiple-model-based cases. • The impact of imperfect actuators on controller performance. This book is more than just a monograph, it is an independent learning tool applicable to the work of academic control engineers and of their counterparts in industry looking for more effective process control and automation.
In this in-depth book, the authors address the concepts and terminology that are needed to work in the field of process control. The material is presented in a straightforward manner that is independent of the control system manufacturer. It is assumed that the reader may not have worked in a process plant environment and may be unfamiliar with the field devices and control systems. Much of the material on the practical aspects of control design and process applications is based on the authors personal experience gained in working with process control systems. Thus, the book is written to act as a guide for engineers, managers, technicians, and others that are new to process control or experienced control engineers who are unfamiliar with multi-loop control techniques. After the traditional single-loop and multi-loop techniques that are most often used in industry are covered, a brief introduction to advanced control techniques is provided. Whether the reader of this book is working as a process control engineer, working in a control group or working in an instrument department, the information will set the solid foundation needed to understand and work with existing control systems or to design new control applications. At various points in the chapters on process characterization and control design, the reader has an opportunity to apply what was learned using web-based workshops. The only items required to access these workshops are a high-speed Internet connection and a web browser. Dynamic process simulations are built into the workshops to give the reader a realistic "hands-on" experience. Also, one chapter of the book is dedicated to techniques that may be used to create process simulations using tools that are commonly available within most distributed control systems. At various points in the chapters on process characterization and control design, the reader has an opportunity to apply what was learned using web-based workshops. The only items required to access these workshops are a high-speed Internet connection and a web browser. Dynamic process simulations are built into the workshops to give the reader a realistic "hands-on" experience. Also, one chapter of the book is dedicated to techniques that may be used to create process simulations using tools that are commonly available within most distributed control systems. As control techniques are introduced, simple process examples are used to illustrate how these techniques are applied in industry. The last chapter of the book, on process applications, contains several more complex examples from industry that illustrate how basic control techniques may be combined to meet a variety of application requirements. As control techniques are introduced, simple process examples are used to illustrate how these techniques are applied in industry. The last chapter of the book, on process applications, contains several more complex examples from industry that illustrate how basic control techniques may be combined to meet a variety of application requirements.