Advanced Control Technologies

Application Areas for Control

Upstream Midstream Downstream

Geology Production Pipeline

Geophysics Optimization Refining
Drilling Service Distribution

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 Up
str
e
Automated Drilling am

Control Points
Weight on Bit (WOB)
Rate of Penetration
Hook Load
Type of Control
Double cascaded control
Cascaded control is timing critical
Non linear system

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 Up
str
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Directional Drilling am

Control Points
Bump to correct tool-face
Rotate-to-slide on bottom
Dynamic torque rocking
Type of Control
Custom Algorithm
Data trending and feedback
required

Slider is a service Mark of Noble Corporation, Patented

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 Trends in Oil and Gas Technology

Advanced Advanced Distributed Embedded

Measurements Control Intelligence Deployment

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 Real-Time Operating System
Reliability
24 hr operation without crashes
Determinism
Closed-Loop Control Event Response

PID Process Control Discrete Manufacturing

Images courtesy of Schlumberger Limited and Dana Corporation

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Control Algorithms
PID

Basic PID
PID with anti Wind
Gain Scheduling
Cascade Advanced PID
Feed Forward
LQR
Fuzzy Logic Model Based
Model Free Adaptive (MFA)

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Basic PID
Set Point (SP) Desired control point
Output (OP) Controller output
Process Variable (PV) Plant/process output
Error = SP - PV

error OP
SP PV

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Slide combines PID Parameters
Proportional
Drive to setpoint
Error 0, OP 0
Steady-state error
Integral
Eliminate steady state error
OP proportional to error
Derivative
Increase response rate
OP proportional to rate of change of error

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 Advanced PID

Gain Scheduling
Adjusts controller gains with operating conditions
E.g. non-linear system broken into linear regions
with different gains
Switch gains based on operating conditions
error OP
SP PV

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 Advanced PID
Cascade PID: two or more controllers are used
Slave / inner / secondary controller fast
Master / outer / primary controller slow
Benefits:
Faster response
Reduces sensitivity to slave loop disturbances
error

SP PV

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Cascade Control Example
Heat exchanger heats product to a desired temperature:
Temperature controlled by adjusting steam flow based on outlet
temperature.
Steam pressure (and hence flow) fluctuations cause outlet
temperature to vary
Cascade controller, removes effect of variations in steam
pressure

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Tuning Cascade PID

Tune the slave controller first:

Have master loop in manual
Make slave loop fast high gain P or fast PI
Tune the master controller second
Have slave loop in auto
Make master loop relatively slow - consider stability
carefully

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 Model Based

Feed-forward: commonly used to compensate for

a measurable external disturbance before it
affects a controlled variable.
e.g. product feed rate changes

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 Model Based

MIMO: Multiple inputs multiple outputs

Decoupling

(Or) Advanced models including:

Inverse Nyquist Array (INA)
Characteristic Loci
Optimal Control LQR/LQG

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 Demo: Model Free Adaptive Control

MFA system will quickly

adapt to good control
conditions.

When SP is changed,
no oscillation is seen.

PID system continues

to oscillate

Courtesy of Cybosoft: http://www.cybosoft.com/

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 Bearing Centering Control for Timken
Professor Tom Kurfess, Clemson University, Intl Ctr for Automotive Research
LabVIEW Simulation Module, Control Design Toolkit, System Identification
Toolkit, LabVIEW Real-Time and FPGA, NI Motion

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RPI Human Object Transporter
Professor Kevin Craig, Rensselaer Polytechnic Institute (RPI)
LabVIEW Simulation Module, CompactRIO, LabVIEW Real-
Time, LabVIEW PDA
Team of undergrads completed project in 4 months!

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 NI Platform for Control
LabVIEW Development Environment

Control Design Toolkit System ID Toolkit Simulation Module

Simulation Interface PID & Fuzzy Logic Toolkit

State Diagram Toolkit
Toolkit NI Motion Control

LabVIEW Real-Time LabVIEW FPGA LabVIEW Embedded

Targets

PXI cRIO, cFP RIO/DAQ Devices 32-Bit p

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 Application Story
Engineers at Timken had an idea to improve
their bearing centering process

The manufacturing process includes a manual

centering operation using a brass hammer
Drawbacks
High cost (requires an operator)
Low throughput

What type of system is needed?

How would it be implemented?
Would it even work at all?
More on this later
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Back to the Application

Engineers successfully implemented a real-time

centering control system
Measurement resolution of 0.02 m

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LabVIEW Control Design and Simulation
for Rapid Development
 LabVIEW System Identification Toolkit
Identify and validate linear models of
systems from empirical data
Seamless integration with NI I/O
Parametric model estimation (both SISO
and MIMO)
Nonparametric model estimation
Recursive model estimation
Data preprocessing
Model conversion, validation, and
presentation
Closed-loop system identification with
feedback detection
Partially known grey box system
identification

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LabVIEW Control Design Toolkit
Easily create interactive control
design and analysis VIs
Model construction, conversion,
and reduction
Time and frequency response
Dynamic characteristics
Classical control design
- root locus, PID, lead/lag ...
State-space control and estimation
- LQR, LQG, pole placement,
Kalman filter ...

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 LabVIEW Simulation Module
Simulate dynamic systems including controllers and plants
Real-time implementation for rapid control prototyping or hardware-in-the-loop
simulation

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LabVIEW Simulation Module Features
Linear systems continuous and
discrete time
Nonlinear system blocks and lookup
tables
Fixed-step, variable step, and stiff
solvers
Trimming and linearization
Model hierarchy
Integration with Formula node and
MathScript node (through subVI)
Integration with 3D picture control for
system visualization

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