Ballard, George

Western Dry Kiln Association

Western Dry Kiln Association. Meeting (44th : 1993 : Reno, Nev.)

Undetermined

ScholarsArchive@OSU

PID VERSUS ON-OFF CONTROL,WHY USE A VALVE POSITIONER?George BallardFoxboro CompanyPortland, ORA discussion of the elements of a process control loop as specificallyrelated to lumber dry kilns must delve into such subjects as PID versus On-Offcontrol, valve characteristics and the use of valve positioners, and various typesof temperature measuring elements employed in the lumber industry.The function of a control loop is to maintain a process output (orproduct) at some desired value, for example, a certain type of wood at aspecified moisture content. The type a control loop historically employed inlumber drying is a feedback loop where, ideally, if we could, we would measurethe moisture content of the wood product and feed that measurement back toa control device. That device would compare the measured moisture content tothe desired moisture content and would produce a controller output to a finaloperator - a valve. The valve would in turn regulate the flow of energy enteringthe kiln which would drive the measured moisture content to the desiredmoisture level.The four components of this loop are, therefore, the measurement, theautomatic controller, the final operator, and lastly the process itself.MEASUREMENTWhile we're most interested in the control of moisture content in lumberdrying, that variable is almost never directly measured and fed back to theautomatic controller. Instead we measure air temperature or differentialtemperature, or wet- and dry-bulb temperatures and those variables becomes thecontrolled variables. In some cases, moisture content is inferentially calculatedand controlled.Early automatic dry kiln controllers employed filled thermal systems tomeasure and control both wet- and dry-bulb temperatures (of the air) within drykilns. Such temperature measuring systems are still in widespread use. Morerecently, thermocouples and resistance temperature detectors (RTD's) are beingemployed, in part due to their inherent electronic characteristics as opposed tothe purely mechanical nature of filled thermal systems.All three types of measuring elements cover a wide range oftemperatures and it can rightly be assumed that any one of the three wouldprovide a measurement that could be used for dry kiln control (See Figure #1).Each has its advantages and disadvantages, however, as this comparison indicates(Figure #2). The practical limits, accuracies, and response figures may varysomewhat from supplier to supplier. These figures are, however, representative.Figure #3 compares the accuracy of a type "J" thermocouple to aplatinum RTD, both measuring a temperature range of 0 to 1000 degrees F. Inthe normal lumber dry kiln operating range, 0 to 300 degrees F, the filledthermal system's accuracy would be approximately ±2.5 degrees, the RTD ±0.75degrees, and the thermocouple ±2.25 degrees.A comparison of response curves (Figure #4) shows that Class II filledthermal systems are quite responsive to changes in temperature as are RTD's.47Small gauge thermocouples also exhibit very rapid response characteristics.Speaking for one controls supplier, platinum RTD's arc recommended forall dry kiln applications and if temperature differential measurement is aconsideration, matched RTD's are required because of their better accuracy.CONTROL MODESShifting our attention to the second element in the control loop, namelythe automatic controller, it's well to keep in mind that the ultimate objective ofthe control system is to dry lumber to some measurable end point in the shortestpossible time without causing damage to the wood.Shinskey's process model on drying was based on the principle that thedryer air temperature is reduced proportionally to the evaporation of moistureas the air passes over the material being dried. It's also accepted that the wet-bulb depression creates a driving force for moisture transfer. The air dry- andwet-bulb temperatures, since they can readily be measured, have therefore beenthe customary controlled variables. The manipulated variable is steam flow, andthe process loads include the wood and air with their associated moisture.Again, looking back on early kiln control, On-Off controllers with On-Offor two-position valves were employed on the steam, spray, and damper operators.On-Off control is the simplest form (or mode) of feedback control, the otherbasic modes being Proportional, Integral, and Derivative (or PID).Figure #5 shows the operation of an On-Off controller and an On-Offcontroller with a "Dead Band". Note that in both cases the valve is always eithercompletely open or completely closed and that the measurement cyclesconstantly. The only difference in the operation of these two controllers is thedifference in the frequency and amplitude of the measurement cycle.The principal disadvantage of On-Off control is that its normal conditionis constant cycling. Its principal advantage is that it's low in cost, that is thecontroller and valve are usually inexpensive. On-Off control, in fact, does noteven require a controller as the controller function can be created with contactsand relays or other such devices.Whether or not On-Off control is acceptable depends on the effect ofcycling in the measured variable both on the product and on upsets to otherprocess units. Constant open-to-shut cycling of steam valves, no matter whattheir characteristics, is disruptive to boiler houses and steam headers, not tomention damaging to the valves themselves. Constant cycling of the measuredvariable, namely wet- and dry-bulb temperatures, if large enough, no doubtcontributes to poor quality in the final product. Early On-Off kiln controllersfound acceptance probably due to the fact that most of them possessed a smallamount of dead band and we simply were not doing as good a job of drying aswe are today.On-Off control should only be applied to those situations where threeconditions are present - namely:1. Precise control must not be required because the measurement willconstantly cycle.2. Deadtime in the process must be long enough to prevent excessivevalve wear and upset of other process units, and3. The ratio of dead time to the time constant of the process must besmall so as to prevent too large an amplitude in the measurement cycle.Experience has shown that lumber kilns do not exhibit these conditions48at all times and a degree of proportional action is required for good temperaturecontrol and valve operation. Proportional control, based on the principle thatthe size of the controller response should be proportional to the differencebetween the control point and the measurement value, prevents valve andmeasurement cycling. It is a major improvement over On-Off control becauseof its ability to stabilize the loop. Its main disadvantage is its inevitable offset,but in kilns where loads are fairly constant and the required amount ofproportional control is small, offset is not a problem. The control point can beadjusted until the measurement is at the desired value and thereafter the setpoint is simply a reference point for proportional action.Except in digital control, Integral and Derivative modes of control arerarely if ever used in lumber drying operations. Virtually all modern controllers,digital and otherwise, possess the ability to incorporate PID control into variouscontrol schemes and in many systems the values for P, I, and D areautomatically determined through the use of self-tuning algorithms.FINAL OPERATORSNo controller with whatever control modes will control properly, however,if the valve is sized improperly, leaks, sticks, or is otherwise defective. Theselection of a valve, therefore, with the proper operating characteristics is oneof the most important phases in designing a control loop.Kiln heating and spray control valves must work in concert with theprocess and its piping as well as the steam supply source. The control valve, inorder to provide consistent control, must contribute a certain increment of thetotal system pressure loss. That increment is usually arbitrarily set at from 25to 35% of the total system loss.Most procedures for selecting and sizing control valves begin with inletand outlet pressures, both of which rarely if ever remain constant. Valves areusually selected "later" and are often selected ignoring those factors key tooptimum performance of the process.As already noted, early kiln controllers were usually of the On-Offvariety and On-Off control valves were appropriately employed with thosecontrollers. Cost was and is still of paramount importance to many people andas a result many kilns today are equipped with the less expensive On-Off valveseven when the type of controller and indeed the process itself dictates otherwise.Basically, the control valve (Figure #6) consists of two majorcomponents, the diaphragm operator and the valve subassembly. The actuatorshould position the inner valve positively and quickly for any change in thecontroller output. The valve action, either air-to-open or air-to-close isdetermined by the process.There are two basic categories of control valves, namely two-position orOn-Off in which the inner valve opens or closes completely to a response insignal from the controller, and proportioning valves which provide a proportionalresponse to a change in signal from the controller.It is well to note that any proportional valve can be used as an On-Offvalve but the opposite is not true. Some quick opening valves do provide adegree of proportional control but in actual installations are generallyunsatisfactory as proportioning devices.Figure #7 shows the flow versus lift relationship of On-Off, linear, andequal percentage control valves, each at conditions where the pressure dropacross the valve is held constant. An equal percentage valve is so designed that49all openings of the valve will produce equal percentage changes in flow for equalincremental changes in lift or stroke. For example, an equal percentage valvethat will pass 5 GPM at a 20% opening and will pass 7.5 GPM at 30% opening,will pass 11.25 GPM at 40% opening. In other words, each 10% increase willresult in a 50% increase over the previous flow rate. The equal percentage valveprovides wide rangeability and permits the use of constant control settings undervarying pressure drop conditions.Linear valves are so designed that all openings of the valve will produceequal change in flow for equal incremental changes in lift. For example, if at20% of its stroke a linear valve will pass 10 GPM, at 30% it will pass 15 GPM,at 40%, 20 GPM and so forth. The linear valve characteristic provides a fairlywide rangeability, though not as wide as the equal percentage valve, and undermost circumstances will permit use of constant control settings when the pressuredrop across it remains constant.In actual practice, however, a valve has two characteristics. One is thedesign characteristic (just discussed) and the second is the installed characteristic- the latter being the most important. The installed characteristic is therelationship between flow and stroke when the valve is subjected to the pressureconditions of the process. Figure #8 shows the relationships for both linear andequal percentage valves under varying pressure drop conditions. Note that as theratio of minimum operating pressure drop to maximum operating pressure dropbecomes more extreme, the installed characteristic of the equal percentage valvesbecomes more linear, or in other words the valve gain approaches a constant.The linear valve, on the other hand, becomes less linear and its curve isdistorted toward that of an On-Off valve. Consequently, when these conditionsare encountered, an equal percentage valve is usually chosen, explaining itspredominant use over linear valves in industrial applications.A rule of thumb for permissible limits for the installed gain of a valveis that a change in gain larger than 2 or a relative gain smaller than 0.5 shouldbe avoided in the process operating range. If the gain is too high or too low,or if it changes too much in the operating range, process control will becomevery difficult.The question relative to the use of valve positioners is frequently asked.A valve positioner is a device used on or in conjunction with a valve operatorto overcome valve stem friction and accurately position the valve in spite of anyunbalanced forces within the valve body. A positioner may also be used to altervalve characteristics, as for example to give a linear valve the characteristics ofan equal percentage valve or perhaps to alter the valve characteristics inresponse to a non-linearity in the process. It is used to close the loop aroundthe valve actuator or valve motor and it will drive the motor until a mechanicalmeasurement of the valve stem position is balanced against the input signal fromthe controller - in other words the valve is positioned where it's supposed to bein accordance with the signal from the controller.Since a positioner will act to overcome stem friction, it thereby eliminatesor greatly reduces dead band. It has been demonstrated that a positioner forcesthe valve gain closer to unity or at least a constant value which simplifies thecontrol problem. In general it may be stated that a valve positioner will behelpful in every kind of control loop with the possible exception of the controlof flow or liquid pressure.SUMMARY/CONCLUSIONSWhile this short discussion of temperature measurement, control modes,50and control valves has barely touched on these subjects, some generalconclusions and recommendations are suggested.With regard to•temperature measurements in kilns, both wet- and dry-bulb, the use of platinum resistance temperature detectors (sometimes matched),is recommended over both thermocouples and filled thermal systems.In general, the type of control recommended is a form of narrow bandProportional control for purely analog systems with the possible addition ofDerivative to narrow band Proportional in digital system control.Finally, the use of equal percentage valves is recommended for virtuallyall temperature control. As extra insurance against valve sticking and toovercome unforeseen pressure imbalances, the valve may be equipped with apositioner.51rNae/s/W, ,t'72.4,cIaarRA 7-2-4/644.1u.c$s-kNN77.1/E,e4oCou,L.F.E.INILN.NI,2-L4ED 7967e,e44.	 10-tit	 ,	 .Q774 	t	 -A I 	 1	 t	 1 .3c.41.4-330 	stet,ado /iio.o71c/lAgies17-a" -Figure 1.	 Temperature ranges for various sensor types.Ai AleADVANTAGES - LOW COST- LONG USEFUL LIFE- SIMPLICITY- NO POWER REQUIRED- HI RELIABILITY- HIGH ACCURACY- HIGH SIGNAL LEVEL- LONG TERM STABILITY- COMPENSATED- NO SPECIAL LEADWIRE- NO COLD JUNCT. REQ'D- WORLDWIDE STANDARD- HIGHER TEMP- MORE RUGGED- M3N CONTACT- SPOT OR AVERAGE- PORTABLE, SELFCOATAINED- TEMP. COMPENS1ITION- TC EXTENSION WIRE- LONG TERM STABILITY- EXPENSIVE- USED ONLY FOR- VERY NON LINE:- EMISSIVITY AFFECTED- REQUIRES OPER;--1FDISADVANTAGES - DIFFICULT TO FEADFRAGILE.LOCAL RESTRICTEDNO RECORD/CONTROLCAPILLARY RESTRICTE:(150 FT., CAN NOT C''T)ISENSOR/REC'R POSITE1RANGE CHANGE LIFFICILTVERY LARGENO MULTIPLEXIN3- MINIMUM SPAN IS 54°FFRAGILEGENERALLY LARGESELF HEATINGHIGHER COSTSPRACTICALMEDIUM	 LIMITS (°F) LINEARITY ACCURACY COSTGLASS STEM	 -200 TO +600 GOOD 0.1 TO 2F LOWTHERMOMETERFILLED	 -320 TO +1400 FAIR/GOOD 0,5 TO 2: MEDSYSTEMRTD	 -330 TO +1200 GOOD 0.3F MEDTHERMO-	 -330 TO 4000 POOR/FAIR 4F MEDCOUPLEPYROMETER	 0 TO 7000 POOR 0.5 TO 2% HIGHFi gure 2.	 Advantages and disadvantages	different temperaturemeasurement methods.o/000'fNr- c 1000 -/-irr orc LeADtviRE	 Ir c f.rreavpo9V wilt(1.	 Hot Junction +.75% x 1000°F	 • +7.5°F 1. RTD Accuracy +0.5% x 1000	 = +5.0°F2.	 TC Wire Cold Junction	 100°F	 . +4.0°F 2. Lead Wire Error +0.1% x 1000	 = +1.0°F3.	 Ext.	 Wire Hot Junction	 100°F	 • +4.0°F4.	 Ext.	 Wire Cold Junction	 72°F	 . +4.0°F5.	 Cold Junction Compensation	 • +2.0°FTotal Max +21.5°F Total Max 46.0"FTotal	 RMS +10.4°F Total	 RMS LI 5.1"FFigure 3.	 Accuracy of thermocouples versus RTDs.I1i11_,-„•_„.--'-.IlI,i-11 --'--,I-Fi r'•I /IT.i-+-[ri;1--r11H!	 I	 i;	 I1	 IIT:4tr ASSE M PLITI-i, Y'I f,iCO 'fi,D,vp'ininj jOtItil ltri; Et Ai13 	 41, t111,! .INIPUEI) iiiii fA, RIEiltnittl71-1610i:70.SlifibrI0INIALi	 -# 1— ZIA'14 1')-M0$	 TRA NISN111009E l,pptitt. Pfl-riidiI-	 ••\III13 1-iE •titT EIf b4rtYA,T :• ••se 'sn-FM /LI l ii riFitiriII' lb F liTPE1	 '-I 1;2;Al iFfslilLNAI !pi -01 Fle, IIA,E 1 E ■;) .p4L i DTID-  kokss,i5r- ite..AW A1,131-/illErplitl_TITANI pTyill 18')iiiiiitsf5..IC1 IAt1	 I Ijiltill lull gung.....1 I	 ,1	 I111011 I	 1 I	 i1t4.1 I iIi■ 	 1	 iI..,	 I1 	 11 !, 1 ! I	 ITIME	 TEMP A 8 D ECONSTANT	 %.SCALE CLASS IIA TYPE 12A BULB218-26W CLASS 38 CLASS IA/0	 0 0 0 0 0 0TO Ot9	 SECS. .(V SECS.II .5	63.2%78 %1.67 SECS.2.5	 SECS.2.0 SECS.3.0 SECS.5.5	 SECS.8.25 SECS. 13.5	 SECS. 18 SECS.Prillrir2	 87	 14, 3.4	 SECS. 4.0 SECS 11.0	 SECS. 18 SECS.' 24 SECS.2.3	 90	 / 3.85 SECS. 4.6 SECS 12.65 SECS. 20.7 SECS. 27.6 SECS.3	 95	 % 5.0 SECS. 6.0 SECS. 16.5	 SECS. 27 SECS. 36 SECS.4	 98	 % 6.7	 SECS. 8.0 SECS. 22.0 SECS. 36 SECS 48 SECSI	 HI 'II	 1 ll'illliT	 'IIII.	 I 1 I I	 t - I II-0	1 0 •	 15	20	 25	 30	35	40	45TIME— SECONDS•	Figure 4.	 Response times for various thermal systems.108I)06lu2CG40UJUJt-2Figure 5.	 On-off control for temperature control of a system.56VALVE ASs'Y DPff/2,9 To4   Figure 6.	 Valve with operator.10090801-70_1-c(601- 5010-u_ 403020aw 10a.01 111111 111111111111111gh fillip. .iiiiiigNinnurmilgiligoiliopolunimil100000110111 minimalNIN 11 1 cidAiiiiii III 1 yrdinriniIlim9P.IsPrailibipim 1 iiiirilinimoolidillil * P -1100111 .- Aimmillimmtelgraillilimil ICAL ONTYP EQUAL PRECENTAGE50:1 VALUENEEDLE VALVEBUTTERFLY TYPE-1-11-1135 I LINEAR CURVE-15(3)-9(9) EC-6(12)a.O.3(15)2	 3 4 5 6 7 8 910 15 20 25 30 40 50 60738090100PERCENT OF MAXIMUM FLOWFigure 7.	 Signal to valve versus flow.A.A Pmin- 0.3 1.0Apr,.0.1	 0.2AOowr0	 0.5	 1.0mB.APmin-0.1Apr0.3IIII05	1.0mFigure 8. Effect of line resistance. A. an equal percentagecharacteristic becomes more linear. B. A linearcharacteristic distorts toward that of a quick-opening valve.1.0f 0.5f 0.559

PID versus on-off control, why use a valve positioner?

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PID versus on-off control, why use a valve positioner?

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