Laboratory assignment 1 (on processes available in process control lab) Title Level Control Loop Objectives: After performing

ng experiments on this process the students are able to know (i)How can you measure a certain level of water in a water tank in industry? (ii)What are the components used in the process and what are the functions of the individual components in the process? (iii)What are the alternative/substitute components can be used for this process? (iv)How to operate the process through DCS/PLC/LOCAL Modes? (v) List of experiments that can be designed to realized the above objectives.

Description of the process: Diagram:-

Components Used: Name of The Components DC 1040 Digital Controller(PID) Specifications Serial No & Makers Name Qua ntity 1 Alternative or Substitute Components PI Controller

i)PV Input:a)Input Sampling Time: 500ms, b)Input Resolution: 14 bit(each) ii)Control Mode:a)Proportional Band(P): 0~200%(On/Off action at P=0), b)Integral Time(I): 0~3600 Sec(PD action at I=0), c)Derivative Time(D): 0~900 Sec(PI action at D=0), c)Cycle Time: 0~150 Sec(4~20mA 0,SSR1,relay10) iii)Output:a)Relay Output: Contact,3A/240V AC b)Voltage Output: Voltage Pulse,20V DC/20mA c)Linear Output: 4~20mA,0~5V,0~10V,1~5V,2~10V d)Motor Control Output: Three Position Step Control(Three Proportional Motor Control) iv)General Specifications:a)Power Consumption:Max 8VA, b)Storage Temperature: -25C~65C

ML7421 A 1032E Electric Linear Valve Actuator

c)Ambient Temparature:0C~50C, d)Ambient Humidity: 50~80%RH(No Condensation) 24V,50/60Hz,12.5VA,Class2,0 or 2V10V DC Selectable,405 LBF 3/4inch Stroke,1.5 MIN NSR

Centrifugal Regenerative Pump Capacitance Type Vertical Level Switch

1,220V,50HZ,0.37KW/0.5HP,Max CUR:2.5A,Power Input: 0.48KW,R Speed 2800rpm,Size 25x25mm,head 20m Power Consumption 10VA(Max),Power Supply 230V AC/110V,AC10%,50Hz/24V DC,Pressure Rating:20Kg/Cm(Max),Relay Contact Rating:5A at 230V AC,Semi Delay:010Sec as standard,Temp.Rating:250C(Max)

1370K04902

Signal Distributor

Water Tank Linear Scale

Power Supply: 230V AC, 45Hz65Hz, Input:1 No.4-20mA DC, Output: 3Nos. 4-20mA DC Capacity: 01200mm Range:75mm800mm

ML 6421A Non-spring Return Electric Linear Valve Actuator, ML 6420 A / ML 7420 A Electric Linear Actuator Regenerative Turbine Pumps, Rotary Pumps Techtrol Magnetic Float Operated Guided Level SwitchFGSI,Techtrol Displacer Type Magnetic Level SwitchDS RF Splitter

10057, Model No. LG 100

1 1

Sump

Ball Valve(Forged) Selector Switch Change over switch SMPS >24V DC Power Supply

1 2 Pole on-off,6Amp 2 Pole 3 position Input: 230V AC Output: 24V DC, 2Amp Kaycee Kaycee Meanwell 1 1 1

Functions/Features of Major Components: a) DC 1040 Digital Controller (PID):- The DC1000 family of microprocessor based controllers combine a high degree of functionality and reliability in four different formats: 1/16 DIN, 1/8 DIN, 3/16 DIN, 1/4 DIN. With a typical accuracy of 0.5% of span, the DC1000 is an ideal controller for regulating temperature and other process variables in a variety of applications including dryers, semiconductor packaging & testing, plastic processing, packaging machinery, painting & coating, and climatic chambers. b) ML7421 A1032E Electric Linear Valve Actuator :(i) Quick and easy installation ii) No separate linkage required. iii) No adjustments required. iv) Accurate valve positioning. v) Low power consumption vi) High close-off ratings. vii) Maintenance free. c) Capacitance Type Vertical Level Switch:- Capacitance Type Level Indicators/Switches are suitably used for monitoring and controlling of liquid levels in tanks or vessels. No moving parts ensure no wear and tear. These level indicators/switches are suitable for wide variety of applications. As media rises and falls in the vessel, the amount of capacitance developed between the sensing probe and the ground (vessel wall or reference probe in case of non-metallic vessels) also rises and falls. This change of capacitance is converted into current signal by the pre amplifier. The pre amplifier output is converted to electric unit. The amplifier, in the electronic unit converts the pre amplifier signal into a proportional voltage which is amplified to drive the induction circuit LED & relay circuit and transmitter circuit. d)Signal Distributor:- The Signal Distributors translate orders received from central control and distribute high power, long duration pulses to the various relays in No.1 Electronic Switching System. e)Water Tank :- i)Bottom Tank: i) Water is supplied from Bottom Tank. ii) The outlet water is going to the Bottom Tank.

iii) When there is overflow in the Top Tank then water is removed in the Bottom Tank. ii) Top Tank: Inlet water is stored in Top Tank. This tank contained that water whose level has to be measured. f)Linear Scale:- with the help of this Linear Scale we can measured the level of the water in the Top Tank. Functioning of The Process: The water is flowing from Bottom Tank through 1inch pipe to Top Tank where level of water is maintained. The water level is measured by Capacitance Type Level Transmitter giving 4-20mA DC output(PV) proportional to water level(0-1200mm).This 4-20mA DC output is fed to the Honeywell make microprocessor based single loop PID Controller(Local Panel)as well as to DCS/PLC panel. The Controller/DCS/PLC compares the PV input with SP and gives the corrective output signal 4-20mA DC which is fed to Honeywell make Electrically Operated Control Valve. There is DCS/PLC changeover switch available on the Local Panel by which control through pressure controller or DCS/PLC can be selected. Controlling the process: Various Control Algorithms:- The DC1000 series of controllers provides several different algorithms: PID or ON/OFF Control Hear/Cool Algorithms with two different PID sets Motor Position Control without slide wire feedback Single Phase Control with/without zero crossover control Three Phase Control with/without zero crossover control

Some of the Algorithms are discussed below. a) Manual Control:- The control output can be managed manually. If pressing A/M key, the parameter of OUTL comes up in the upper display and a fixed control output is shown in lower display (% value), once the value is changed, the control output is changed and fixed again. b) ON/OFF Control: - The output type must be the relay output (DC10X0XX-1XX-XXXX).Then change Pvalue to 0 in Configuration 1 mode. Until PV reaches SP, the control output is just ON (100%), and then the control output becomes OFF (0%). To prevent the control output from flickering too much frequently, the hysteresis (HYS1 in Operation mode) is to be set. c) PID Control: - PID control is the default control type of this controller. If AT in Operation mode becomes YES, the auto tuning process will start. After the auto tuning is completed, the

controller gets optimum PID values for the control system and starts the operation automatically.(PID values can be set manually in Configuration 1 mode without auto tuning procedure.) Operating Instructions for DCS Control:STEP 1 2 OPERATION Main switch of DCS & computer is on Power on selector switch of DCS is on Power on the computer Open HS Experian software Go to desired control loop by clicking on the corresponding button. 4 no of control loops are therea)Temperature control loop b)Pressure control loop c)Level control loop d)Flow control loop e)Air Flow control loop To control a control loop by DCS first, active the local control system then put the remote/local selector switch at the remote position. Enter into the desired control loop by clicking on the corresponding button. Left click on the word MANUAL Select AUTO by left clicking on the word auto To change the set point value, left click on the existing set point value, a window appears, put there the desired value, and left click on SEND button. To see the trend chart, left click on the desired chart button. To see the historical reply, RESULTS X 1) Power indicating lamp glows. 2) DCS LEDs blink. X Main page opens X

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Control mimic diagram appears A window with auto-manual selection appears. The word MANUAL now changed to AUTO, output value increases. Now the mimic shows the changed Set point value, automatic control starts.

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Screen shows the trend chart consisting of set point & process value.

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click on the button TREND HISTORY.A window reply control panel appears. By clicking any button from 1h to 24h, earlier trend chart, before 1hour to 24hour can be seen. Return to control loop. To change the P, I, D value, click on the current value, a window appears, put the desired value & send. P(gain)-4.723 I(reset)-0.4 D-0.613 To activate the auto tune, click on the word off. a window appears with on-off selection, select on. The selection is made by the selector switch, putting it to position 1. After the completion of the experiment, a)close the HC 900 software, b)Shut down the computer, c)Power off the switch of the DCS panel, d)off the main switch of the computer & DCS , e)put the selector switches of the local panels to the local position OPERATION Main switch of pump & local panel is on. Power on-off switch of the local panel is moved to position 1..

Then the DCS control action changes.

Then auto tune starts working, after 3 cycles DCS defines appropriate PID values, then it returns to the normal mode.

X X Loops will be out of control X X

Operational steps:STEP 1 2 RESULTS Power comes to local panel. 1)power on lamp glows 2)controller LEDs glow

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Main switch of pump starter (green) is pressed. To control with local controller, move selector switch to position 2

Pump is on. Local control loop is in operation.

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Toggle switch inside the panel will remain on position To set a value from 0 to 800 into the controller as a set point, press shift key, when SP value blinks, then press up or key to set the desired value from 0 to 800.After that press set key to enter this value into the memory of the controller. To set PID value, press and hold set key for 5 seconds. Upper display will show P1, lower display will show existing P value. We can change this value same as SP value changing described in step 6. Pressing set key we will get I1 & d1 parameter one by one and these values can be changed by same as P1 value changing. To return to the normal mode, press and hold set key for 5 seconds. To activate Auto Tune, press SET key until At appears at the upper display. Lower display will show no. Press shift key so that lower display will blink. Now change the lower display from no to yes by pressing or key. After completion of the Level

Power to signal distributor. 1) SP value will stop blinking. 2) Automatic control will start.

Controller is ready with P.

Controller is ready with I & D.

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Upper display will show PV value & lower display will show SP value. 1) AT indicator will glow continuously. 2) After getting three cycles auto tune will be completed & AT will glow off.

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Control operation, to turn off the systema) Press the red button of the pump starter. b) Put the power on-off switch to 0 positions. c) Make the Main switch of pump & local panel off.

Pump off. 1) Power indicating lamp off. 2) Controller off. No power to local panel.

Check Points:a) Functional Checking:- Level can be set 0-800mm from the Controller.P,I and D can be available from the controller in configuration mode. Hunting operation can be occurred if the system is not properly tuned. b) Measuring 4-20mA DC signal at level sensor, Controller input and output. c) Accuracy

Dos prior to start the process 1. Ensure the ball valve which is in series with Level Control Valve, is crack opened. Dont. During process is running 1. Switch off the Selector switch prior to completions of process. 2. Change the Remote/Local selector switch position. 3. Configuration of the Local Controller.

List of experiments that can be designed to realized the above objectives: 1. 2. 3. 4. 5. Level measurement using Capacitive level sensor Level control using PID controller Level control using DCS Level control using PLC. Modeling of level loop.