APPLICATION NOTE

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.

FEED FORWARD COMPENSATION

Conventional feedback pH control is not satisfactory with varying chemical demands. If the influent flow to a pH neutralization tank varies, a closed loop controller cannot anticipate the pending change in chemical demand, due to the increase or decrease in liquid volume. The application requires a flow meter to be installed in the inlet piping of the vessel, which provides a flow (feed forward) signal to the pH controller. The YS170 allows this input to trim the chemical feed, regardless of the output of the feedback pH control. The feed forward input can be characterized in time lag, gain and bias for the specific control requirements.

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

pH Feedback Control with Flow Feedforward Compensation FIGURE 1

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.

DEAD TIME COMPENSATION

Several factors in a pH control system contribute to the inherent dead time. pH electrode measurement response, chemical buffering, mixing time, and equipment dead time are some examples of delays which adversely affect the performance of the pH control loop. When pH deviates from set point, the controller corrects by changing the output to the chemical feeder(s). For a time period, no change in pH is detected. Following this dead time, the pH value begins to change. Control response must be such that over-correction is not done prior to sensing the pH change. Using dead time compensation, the YS170 can remember the output changes and use this information to predict a future pH value. The Smith Predictor is a common form of deadtime compensation. This model monitors any output change and predicts the pH will change in the same but delayed manner. The controller reacts to an anticipated pH value using remembered lag and deadtime. The YS170 has lag (LAG) and deadtime (DED) function modules which can be programmed into a deadtime compensation model. The result of these calculations can be transferred to the input compensation of the PID function block. This allows better pH control by permitting higher gain (PB) and integral action in the PID tuning parameters.

pH Input LAG
Gain

FEED FORWARD PROGRAM

A pH control program which includes feed forward and feedback actions is easy to develop and implement. Control characterization applicable to pH control is discussed later in this technical note. Below is a program flow chart exhibiting both control strategies. Flow Input pH Input

PID Control

DED

Control Output

X LAG

Gain

Deadtime Compensation FIGURE 3

PID Control

SAMPLE & HOLD P+I

As previously discussed, pH control is difficult due to the inherent time lags associated with the process equipment and chemical characteristics of the process liquid. To achieve optimum control, the system should incorporate various ways to compensate for time delays. YS170 has a unique feature installed within the PID control function module. The Sample & Hold function can be activated by installing two time constants during configuration of the controller, the control time (SW) and the sampling time (ST).

+
Bias

+
Control Output

Feedforward Compensation FIGURE 2

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

Sample & Hold PI

OUTPUT

SW

SW

Control Output

Sampling Period (ST)

Figure 4

Input Compensation FIGURE 6

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

NON-LINEAR GAP GAIN

This control action allows the gain or proportional band (PB) of the pH controller to be modified at or near the desired set point. The gain is decreased, compensating for the steep slope of the titration curve. The chemical feed is decreased, allowing for a closer pH control with minimum overshoot at set point. Two constants are configured in the YS170 to use this gap gain feature. The gap width (GW) , or percentage of span around set point, allows the gap gain multiplier is be applied to the PID proportional band setting within this region. The gap gain (GG) is a multiplier of less than 1.0. The product of the GG and reciprocal of proportional band (PB) is the new gain of the controller as pH approaches set point. Figure 8 is a diagram showing the non-linear action of gap gain control.
Gain = 1.0

Low Alarm pH < K?

PPID

PID Control

Control Output

PID Scheduling FIGURE 9

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

Gain < 1.0

OUTPUT

Gap

Non-Linear Gap Gain FIGURE 8

ID Number 03-02