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YS170 pH Controller
BACKGROUND
pH control has always been a challenge. In process, pH control may be required to insure consistent and quality product. In plant effluent applications, pH control is required to assure any receiving bodies of water are not adversely affected by the relative acidity or alkalinity of the outfall. Input Characterization Non-linear Gap Gain PID Scheduling available for use in a program. Additionally, special control characterizers are available in the PID control function module and can be used for the pH control strategy.
Any of these functions can be used in a pH control strategy. This versatility is necessary due to the varying control characteristics of each pH application.
OVERVIEW
In the past, pH control has been performed by using ON/OFF or PI control, with limited success. In both cases, the controller is unable to compensate for the non-linear characteristics of the solution titration curve. ON/OFF action simply activates a chemical feeder as the pH deviates from set point. This closed loop control cannot determine inherent dead time, chemical buffering or non-linear characteristics. Conventional PI may allow better control due to adjustable gain and integral actions, but still has limitations. Microprocessor-based loop controllers can determine and compensate for lag time, dead time, varying chemical demands and the specific chemical characteristics of the liquid. The YS170 Programmable Loop Controller is a microprocessor-based PID instrument with pre-installed firmware modules which allow optimum pH control. These specific function blocks include: Feed forward Compensation Dead time Compensation Sample and Hold PI
YS170 PROGRAMMING
A YS170 control program can be written using a high level programming language. A process engineer, with little or no programming skills, can readily develop a control strategy to meet his individual pH control requirements. Programming software used with the YS170 is installed in a PC. After developing the control program, it is downloaded to the YS170 pH controller. Any program modifications required later can be easily implemented. Up to 36 pre-defined function modules are
YS170 pH Controller
FIC-1076
LOOP 1
FAIL ALM
PH GPM
300.0
6.80
C A M
PV:
Flow Feedforward
146.9
SV:Set Point
150.0
pH Feedback
MV:
77.7
Acid
Base
0.0
PF OFF
PF
C
S HIFT
O
YOKOGAWA
AT
FT
ID Number 03-02
APPLICATION NOTE
The YS170 PID control module accepts the feed forward signal from an analog input module. The flow input is conditioned using math and time lag modules. The values for these blocks are typically determined during commissioning of the pH control system. Refer to Figure 1 on the prior page depicting a flow meter, pH sensor assembly and transmitter, and YS170 controller installation using a neutralization tank and mixer for agitation of the liquid. The mixer provides the required chemical dispersion. require this instrument configuration for closer control to the desired set point. Figure 3 is a program flow chart showing the Smith Dead time Compensator. As with feed forward compensation, this model is easy to implement in a program and modify in the field as process dynamics change. The lag and dead time constants can be modified accordingly.
pH Input LAG
Gain
PID Control
DED
Control Output
X LAG
Gain
PID Control
+
Bias
+
Control Output
As shown in Figure 2, the feed forward flow input trims or biases the output of the closed loop pH control. Inherent lag times and dead time
ID Number 03-02
APPLICATION NOTE
Using this control action, the output is changed only during the control time and held constant during the remainder of the sampling time. This feature does not require any special programming of the YS170 and can be implemented at any time during or after commissioning of the pH control system. Figure 4 is a diagram of the YS170 control output over time using the Sample & Hold characterization. vertical axis and the ratio on the horizontal. Typically, an S-shaped curve is present. Figure 5 is a titration graph showing a typical curve using a strong acid and base as the reagents. The shape of the curve will vary depending on the chemical composition of the process fluid and the type of reagent used for pH control. Maintaining a pH value near 7 is difficult at best. Prior to the introduction of microprocessor-based control, little could be done to compensate for the steep rise in the titration curve, i.e., little reagent addition results in TIME a large change in pH. Characterizing pH to match the process titration curve is the solution to this problem. YS170 has pre-defined function blocks that can be used to accomplish this task. chart showing the input compensation.
Characterizer GX pH Input Gain PID Control
X
DM
SW
SW
Control Output
Figure 4
PROCESS CHARACTERIZATION
As well as inherent time delays, pH control has another property that is difficult to compensate: non-linear reaction to chemical feed or the titration curve. The titration curve is a relationship of pH to the ratio of reagent to influent flow. This curve is shown in a graph, pH being on the
INPUT COMPENSATION
The YS170 has the ability to develop a characterized pH input to modify the control action of the pH feedback controller. A signal characterizer or function generator (GX) block accepts the pH input and is configured to 14 follow a non-linear 100 13 curve. The input 90 12 is adjusted for 11 80 gain and linked to 10 the input 70 9 compensation 8 60 Small increases in reagent pH (DM) input of the 7 50 flow cause large pH shifts PID function 6 40 module. Using an 5 30 4 input 3 compensation 20 2 permits closer pH 10 1 control over a wider range. 0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 0 Figure 6 is a Ratio of Reagent to Influent Flow programming flow FIGURE 5
The function generator (GX) firmware module is a ten segment line characterizer. The input and the output can be configured for any value between -25.0% and 125.0% of span. This is useful in a pH application to modify the output of the controller as the pH approaches 7 and the steepest portion of the titration curve. Figure 7 is a graph showing the GX function generator
GX Output
GX Input 10 20 30 40 50 60 70 80 90 100
0 to 100% = 0 to 14 pH FIGURE 7
ID Number 03-02
APPLICATION NOTE
compensating for the non-linear shape of the titration curve.
PID SCHEDULING
The YS170 Controller has a firmware module (PPID) which can be used to change PID tuning constants as the pH deviates from set point. Up to eight (8) sets of tuning parameters are available from this block. If the pH deviates more than a predetermined value from set point, the PPID block transfers a new set of PID constants to the PID control function block. This permits more responsive control during an upset condition. The time that the pH may be out of compliance can be minimized. Figure 9 is a program flow chart which includes the PPID function block. In this example, if the pH is less than a low alarm value (K), new tuning constants are installed into the PID block to create a more responsive control output to the chemical feeder(s). This functionality can be written into a program and used at any time. This PPID action may be activated by configuring the controller appropriately. This may be accomplished by using the YS170 programming software or inputting constants to an engineering screen on the front LCD display of the controller. PID scheduling is one of several control charcterizers or function blocks discussed in this application note to provide the user with control options in a pH control application.
pH Input
PPID
PID Control
Control Output
SUMMARY
The YS170 Loop Controller can be implemented in numerous applications throughout a process plant. One of the most challenging is the control of pH. YS170 provides several unique firmware modules to assist in development of a successful pH control strategy.
DEVIATION
OUTPUT
Gap
ID Number 03-02