EMCS Technology Solutions V2

Solutions for Courseware Process Control System
Process Control System EN 02/06
Intended application
This courseware has been developed and manufactured exclusively for vocational and continuing training in process automation and control engineering. The training company and / or trainers have the duty to ensure that trainees observe all safety precautions described in the accompanying manuals and data sheets. Festo Didactic GmbH & Co. and ADIRO Automatisierungstechnik GmbH will not be liable for any damage or injury to trainees, the training company and / or other third parties resulting from use of the equipment for any other purpose than training, unless Festo Didactic GmbH & Co. or ADIRO Automatisierungstechnik GmbH has caused such damage or injury willfully or through negligence.
Order no Designation Description Status Authors Translation Graphics Layout Courseware Exercises for process and control engineering 03/2005 Jrgen Helmich, Stefan Knoblauch, Andreas Wierer (ADIRO) Williams Technical Communication Pty Ltd, Brisbane Jrgen Helmich, Stefan Knoblauch (ADIRO) Jrgen Helmich (ADIRO)
Festo Didactic GmbH & Co., 03/2005 Internet: www.festo.com/didactic http://www.festo.com/didactic/de/ProcessAutomation e-mail: did@festo.com
The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design registration.
Festo Didactic GmbH & Co. Process Control System
Contents
Solutions for process and control engineering _____________________________ 5 Solution for Exercise 2.2 _______________________________________________ 5 Solution for Exercise 2.3.1 ______________________________________________ 9 Solution for Exercise 2.3.2 _____________________________________________ 13 Solution for Exercise 2.3.3 _____________________________________________ 14
Solution for Worksheet 3.1.1 ___________________________________________ 18 Solution for Worksheet 3.2.1 ___________________________________________ 19 Solution for Worksheet 3.2.2 ___________________________________________ 20 Solution for Worksheet 3.2.3 ___________________________________________ 21 Solution for Worksheet 3.3.1 ___________________________________________ 24 Solution for Worksheet 3.3.2 ___________________________________________ 25 Solution for Worksheet 3.4.1 ___________________________________________ 27 Solution for Worksheet 3.4.2 ___________________________________________ 29 Solution for Worksheet 3.4.3 ___________________________________________ 30 Solution for Worksheet 3.5.1 ___________________________________________ 31 Solution for Worksheet 3.6.1 for Siemens BE.SI.0193 ultrasound sensor _______ 32 Solution for Worksheet 3.6.1 for Festo 170710 ultrasound sensor _____________ 33 Solution for Worksheet 3.6.2 ___________________________________________ 34 Solution for Worksheet 3.7.1 ___________________________________________ 36 Solution for Worksheet 3.7.2 ___________________________________________ 37 Solution for Worksheet 3.8.1 ___________________________________________ 38
Contens
Solution for Worksheet 3.8.2 ___________________________________________ 39 Solution for Worksheet 3.8.2 ___________________________________________ 40 Solution for Worksheet 3.9.1 ___________________________________________ 41 Solution for Worksheet3.9.2____________________________________________ 41 Solution for Worksheet 3.10____________________________________________ 42
Contens
Solution for Worksheet 4.1.1 ___________________________________________ 50 Solution for Worksheet 4.1.2 ___________________________________________ 51 Solution for Worksheet 4.1.3 ___________________________________________ 52 Solution for Worksheet 4.2.1 ___________________________________________ 54 Solution for Worksheet 4.2.2 ___________________________________________ 54 Solution for Worksheet 4.2.3 ___________________________________________ 56 Solution for Worksheet 4.2.4___________________________________________ 57 Solution for Worksheet 4.2.5 ___________________________________________ 59 Solution for Worksheet 4.3.1 ___________________________________________ 60 Solution for Worksheet 4.3.2 ___________________________________________ 60 Solution for Worksheet 4.3.3___________________________________________ 62 Solution for Worksheet 4.3.4___________________________________________ 63 Solution for Worksheet 4.3.5___________________________________________ 65
Solution for Worksheet 5.1.1 ___________________________________________ 66 Solution for Worksheet 5.1.1 ___________________________________________ 68 Solution for Worksheet5.1.1____________________________________________ 69 Solution for Worksheet 5.1.1 ___________________________________________ 70 Solution for Worksheet 5.1.1 ___________________________________________ 71 Solution for Worksheet 5.2.6 ___________________________________________ 72 Solution for Worksheet 5.3.1 ___________________________________________ 74
Solutions for Courseware Process Control System
Solution for Exercise 2.2 Which components are necessary for the chosen close-loop control system?
Equipment list for level
Components PLC / controller Tank pressure gauge pump ultrasonic sensor pressure sensor flow rate sensor temperature sensor proportional valve industrial controller proximity switch float switch, overflow float switch for raising level pressure tank SCADA piping and hand valves heating X X X X X X
ADIRO Automatisierungstechnik GmbH Process Control System
Solutions for process and control engineering
Equipment list for flow rate
Components PLC / controller Tank pressure gauge pump ultrasonic sensor pressure sensor flow rate sensor temperature sensor proportional valve industrial controller proximity switch float switch, overflow float switch for raising level pressure tank SCADA piping and hand valves heating X X X X X X
Equipment list for pressure
Components PLC / controller Tank pressure gauge pump ultrasonic sensor pressure sensor flow rate sensor temperature sensor proportional valve industrial controller proximity switch float switch, overflow float switch for raising level pressure tank SCADA piping and hand valves heating X X X X X X X
Equipment list for temperature
Components PLC / controller Tank pressure gauge pump ultrasonic sensor pressure sensor flow rate sensor temperature sensor proportional valve industrial controller proximity switch float switch, overflow float switch for raising level pressure tank SCADA piping and hand valves heating X X X X X X X
Solution for Exercise 2.3.1

LIC 102
PI-diagram for level.
LA+ 101.3
LS102 B102
V101
V112 V102
LS+ 101.2 LS101.1 V105

M
B101
P101
10
PI-diagram for flow rate.
LA+ 101.3
V104
V106
LS+ 101.2 LS101.1 V105 B101
V109
V103
P101
M
FIC 101.1
11
PI-diagram for pressure.
LA+ 101.3
PIC 103
V107 B103 V108 V106
LS+ 101.2 LS101.1 V105 B101
V109
V103
P101
M
12
PI-diagram for temperature.
LA+ 101.3
TIC 104
LS+ 101.2 LS101.1 V105 E104 B101
V109
V103
P101
M
13
Solution for Exercise 2.3.2 EMCS point list for level controlled system.
1 Revision
2 EMCS-point
3 PCS.
4 Component symbol Ultrasonicsensor B101 Transformer
5 EMCS task
6 Place
7 Range
8 Flow rate
9 pressure absolute
10 p
11 t C
12 material value
13 14 Rltg./Ap.Stutz DN R-KL PN D-KL
LIC102
Measure level
4..20mA
1 A1 Controller E/E N1 Relay 1 K1 Applifier A4
transform signal
4...20mA/ 0...10V PI 4..20mA 0...10V digital (0)/ analog (1)
proportional controller
preselect pump
transform signal and power
0...10V
P101
Pump M1
control level
0...24V
0...6 l/min
level controlled system
EMCS point list - solution
14
EMCS point list for flow controlled system.
1 Revision
2 EMCS-point
3 PCS.
4 Component symbol
5 EMCS task
6 Place
7 Range
8 Flow rate
9 pressure absolute
10 p
11 t C
12 material value
FIC101.1
Flow rate sensor B102
Measure flow rate
F 40...1200 Hz 0,3...9,0 l/min
Transformer A2 Controller E/E N1 Relay K1
transform signal
0...1000 Hz/ 0...10 V PI 4..20 mA 0...10 V digital (0)/ analog (1)
pre-select pump
Amplifier A4
0...10 V
P101
Pump M1
Control flow rate
0...24 V
0...6 l/min
flow rate controlled system
15
EMCS point list for pressure controlled system.
1 Revision
2 EMCS-point
3 PCS.
4 Component symbol
5 EMCS task
6 Place
7 Range
8 Flow rate
9 pressure absolute
10 p
11 t C
12 material value
PIC103
Pressure sensor B103 Controller E/E N1 Relay K1
Measure pressure
F 0...400 mbar
PI 4..20 mA 0...10 V digital (0)/ analog (1)
pre-select pump
Amplifier A4
0...10 V
P101
Pump M1
Control flow rate
0...24 V
0...6 l/min
pressure controlled system
16
EMCS point list for temperature controlled system.
1 Revision
2 EMCS-point
3 PCS.
4 Component symbol Temperatur sensor B104 Transformer A3 Controller E/E N1 Relay K_E104
5 EMCS task
6 Place
7 Range
8 Flow rate
9 pressure absolute
10 p
11 t C
12 material value
TIC104
Measure temperature
PT100 80...150 Ohm
-50...+150C
transform signal
0...100 C/ 0...10 V PI 4..20 mA 0...10 V 0/24V / Heating ON/OFF 0 l/min / 6 l/min
Controller, un-steady 2-point control Heating
Control heating
P101
Pump M1
control circulation
0 V / 24 V
Relay K1
pre-select pump
digital (0)/ analog (1)
temperatur controlled system
17
Solution for Exercise 2.3.3
EMCS point plan for level controlled system.
N1
X2.8 PID X2.3 X2.6 X2.2
12
14
6 0...10V U 23 11
K1
22 0...10V
A1
I 4...20 mA 2 4 U
A4
U 0...24 V 14 13
5...300 mm
A2
A1
B102
M1
P101
18
EMCS point plan for flow controlled system.
N1
X2.7 (UE2) X2.3 X2.2 (UA1) X2.6
PID
12
14
5 (Out) U
6 (0V) 0...10V 23
K1
11 22 0...10V
A2
f 0...1000 Hz 2 (IN+) 4 (IN-) 14 U
A4
U 0...24 V 13
40...1200 Hz
A2
A1
B102
M1
P101
19
EMCS point plan for pressure controlled system.
N1
X2.15 (UE3) X2.3 X2.2 (UA1) X2.6
PID
12
14
K1
11 23 22 0...10V U
A4
U 0...24 V 14 13
0...400 mbar
A2
A1
B103
M1
P101
20
EMCS point plan for temperature controlled system.
N1
X2.14 (UE4) X2.3 XMA.2 XMA.11
Out
0V 0...10V U
A3
T 0...100 C 1 2 3
XMA.0 VA
XMA.Q1
1 14
230V PE L N
-50...+150C
B104
T E104
13
21
Solution for Worksheet 3.1.1
The task is to calculate the volume of the container and to establish the relationship between volume and level. To calculate the container volume, refer to the data sheet. Here you will find the internal dimensions of the container. If this data is used to calculate the maximum volume, the result is:
Where:
Container height Container width Container depth
h = 300 mm w = 190 mm d = 175 mm
Find:
Volume at level 300 mm or 100 mm
Solution:
19 0mm 175 mm 300 mm = 9.975.000 mm 3 = 9,975 l 10l
1dm 3 = 1l Volume when scale reads 100 mm a 3.325 l

1mm a 33ml
When the scale reads 300 mm, the volume of medium in the container is 10l.
22
The pump is a normally primed centrifugal pump. This type of pump requires an absolutely tight suction pipe that should always be inclined up away from the pump in order to prevent the formation of air pockets. The pump and suction pipe must be filled with medium. The following points must be taken into account during operation: Before operation, the pump must be filled with medium. The pumps must not run dry but a dry-running period of less than 30 minutes will not damage the pump. The pump must always run in the prescribed direction. The pump is suitable for continuous operation. The medium to be pumped should not contain large particles of contaminant.
1.1.1 Where: Find: Solution:
Calculating the rated current

P = 26W
V = 24V
The rated current of the pump
P =V I
I=
P 26W = = 1.083 A V 24V
23
Exploded drawing of the pump
No. 1 2 3 4 5 6 7 8 9
Part designation Housing, 20 Rotor disk O-ring Screw Motor bracket Washer Shaft Seal Magnet housing
24
To determine the delivery rate of the pump, water is pumped from the lower container to the upper container until the level reads 150 mm on the scale. This allows the average flowrate per unit time (volumetric flow) to be determined. The pump capacity is to be calculated with the aid of the volumetric flow and the delivery head. Procedure 1. 2. 3. 4. 5. 6. 7. 8. 9. Commission the system: fill and vent. Switch on power supply. Close the outlet of the upper container of the level-controlled system. Switch pump ON (with Process Lab, SPS or controller) and start timer. When level of 150 mm on the scale is reached, stop timer. Read off actual scale value (if not exactly 150 mm). Determine and document pumping time and delivery head. Determine average flowrate. Determine pump capacity.
Result
61,5 s
Result of pump speed measurement
135 mm
25
Measured values from diagram: Pumping time t F = 61,5s Delivery head hF = 135mm w = 190mm Container width Container depth l = 175mm
& Calculation of volumetric flow s V :
3 3 & = V = hF w l = 135mm 190mm 175mm = 4488750mm = 72987.8 mm V 61.5s 61.5s t tF s
mm 3 60 mm 3 l & = 4.379.260 = 4.38 V = 72987.8 min min s

The volumetric flow is the volume flowing through the cross-sectional area per unit time. The capacity of the pump can be calculated with the following formula:
& P = V g h with
g = 9.81
m s2
The system comprises a low and a high container and a pump between them. The maximum delivery head hmax is the distance between the inlet port of the pump and the maximum delivery head in the upper container hoB, less the minimum suction height in the lower container huB in relation to the surface of the profile plate. Distance pump inlet maximum delivery head in the upper container:
h oB = 350mm + 145mm 35mm =460mm
Minimum suction height:

huB = 155mm 35mm = 120mm
The maximum delivery head hmax is:

h max = h oB huB = 460mm 120mm = 340mm
The density of water is = 1.00
kg kg = 1000.0 3 3 dm m
26
This results in the following calculation for the capacity of the pump:
& P = V g hmax = 72.99 10 3 P = 243.45 10 3 with N = m 3 kg m m s m3 s 2
m3 kg m 1000 3 9.81 2 0.340m s m s
kg m resulting in the unit s2 Nm P = 243.45 10 3 = 243.45 10 3W s
Explanation of the result No general solution for the capacity of the pump can be given as the value varies from system to system. Component tolerances in the pump, the setting of the motor regulator operating characteristic as well as differences in the piping system (curves, pumping head) can result in different delivery rates.
27
What does the term proportional valve mean? The solenoid valves are closed by a spring at zero current. Any current through the solenoid coil results in a state of equilibrium between the spring and the magnetic force. The strength of the solenoid current or the magnetic force determines the stroke of the armature or degree to which the valve is opened. Ideally, dependency between current and opening of the valve should be linear. In other words, the valve opens and closes to a degree proportional to an analog voltage in the range 0 to 10 V.
What electrical signals do you need to use a proportional valve? The electronics of the proportional valve require a supply voltage of 24 VDC.
The valve is opened or closed with a control voltage of 0 to 10 V.
28
What is the maximum rate at which you can pump the medium used through the proportional valve? The throughput capacity of a control valve is to be determined. The maximum flowrate is calculated from the KV value and the pressure drop across the valve: Where: KVS value data sheet Delivery pressure
KVS = 0.33
m3 h
Proportional valve
p = 0.3bar
l & V = 9.0 min
Pump data sheet
Volume flowrate
Pump data sheet
Find: Maximum flowrate Solution:
p & V = 31.6 KVS with p = 0.3bar and = 1000 & V = 31.6 0.33 0.3 m 3 1000 h kg m3
m3 m3 m3 dm 3 l & V = 0.164 = 164 10 3 = 2.74 10 3 = 2.74 = 2.74 h h min min min
& The flowrate determined with Process Lab: V = 2.3
l min
What possibilities are there for adjusting this valve?
You can set the maximum and the minimum flowrate through the valve via the
Festo Didactic GmbH & Co. PCS
29
electronics with the aid of potentiometers R1 and R2.
30
Equipment list for the process drive module
Item. Process drive equipment list 1 2 3 4 5 6 Ball cock Reducing sleeve Mounting bracket with cheese-head screws Semi-rotary drive Namur solenoid valve Exhaust-air flow control valve with integrated silencer Quick push-pull elbow Solenoid valve Socket with connecting cable Sensor box with connecting cable
Type " SW9/SW11 ALU Sypar
Quantity 1 1 1 1 1 2
7 8 9 10
G1/4
1 1
3-wire 6-wire
1 1
What electrical signals do you need to work with the process drive?
A digital signal for the solenoid valve ( (24V: switch ON, 0V: switch OFF)
Give a brief description of the modules mode of operation..
31
A coil is energized by an electrical signal. This operates the Namur valve magnetically. The semi-rotary drive moves through 90 as the result of the compressed air switched by the valve. This opens or closes the ball cock.
32
What function does the sensor box fulfill? Name the signals you receive from the sensor box and, where appropriate, how you can record these signals. The sensor box delivers three signals 1) a visual signal, red and yellow. Red means Ball clock closed and yellow means Ball cock open.
2) A digital signal to I5 (digital input of the I/O terminal) High means Ball cock closed.
3) A second digital signal to I6 (digital input of the I/O terminal): High means Ball cock open.
33
What type of drive is it? How does it work? It is a semi-rotary drive with a scotch yoke. When the process valve is opened, the pistons move to the end caps. When the process valve is closed, the piston moves toward the shaft. The torque is generated by the scotch yoke. In contrast to rack and pinion drives is not constant throughout the angle of rotation. Benefit: The high breakaway torque of the valve is overcome. The range of motion of the drive is limited to 90 for use with equipment such as ball cocks and butterfly valves.
Function diagram
34
What are all the things you have to take into account when using the heating element?? The heating element may only be switched on if it is entirely immersed in fluid.
Caution!
The heating element is hot!
Calculate the rated current of the heating element. The following values are to be taken from the data sheet: Where: Rated voltage: Heat output at rated voltage:
230V 1000 W
Find:
Rated current of the heating element.
Solution:
i = P = 1000 W 4.35 A 230 V u
35
Solution for Worksheet 3.6.1 for Siemens BE.SI.0193 ultrasound sensor
The sensor characteristic of the ultrasound sensor was recorded with FluidLab-PA. The relationship between the sensor signal and the container level can be derived from the characteristic.
Characteristic of the Siemens ultrasound sensor with FluidLab-PA
Operating range of the Siemens ultrasound sensor, programmed by ADIRO
36
Solution for Worksheet 3.6.1 for Festo 170710 ultrasound sensor
Solution and background Determining the mode of operation of an ultrasound sensor It must be borne in mind that some transducers and PLCs can only read or deliver an analog signal as a voltage signal in the range 0 to 10 V. In this case, signal conversion is required. The analog ultrasound sensor used in this system deliver an analog current signal of 4 to 20 mA based on the distance measured. This can be converted into a voltage signal by means of a load resistor. The description of the sensor indicates that the load resistor RL must be less than 400 . If, for example, RL = 390 , the resulting voltage signal is in the range 2.34 to 7.80 V.
Bildtexte: U Me = Vmeas.
Transducing a signal for example, with the aid of a resistor
37
Recording the characteristic of an ultrasound sensor
Level [mm] 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300
Signal [V] 4.46 5.49 5.5 5.62 6.03 6.43 6.78 7.13 7.52 7.82 8.18 8.51 8.75 8.8 8.82
Bildtexte: Level (mm) 2.00 4.00 etc.
38
Background to the exercise The technical description of analog sensors normally gives the sensors characteristic (graphically, or as an equation with tolerances). If the characteristic is not given, it must be established experimentally. This may also be necessary when operating conditions have an impact on the characteristic. The location of the sensors that is, its attitude and height above the container is of great importance for a level control. The distance measured is between the sensor head and the waters surface and not the actual level.
Bildtexte Ultrasound sensor
Location of the ultrasound sensor
d hB h a
Minimum distance between the sensor and the surface to be measured Measuring range Height of the surface Distance between the surface and the sensor
The characteristic shows that the sensor's signal is only linear in a certain range. When doing later exercises with the ultrasound sensor, it must be ensured that the level in the container is approx. 180 mm and that it remains within the usable range of the sensor.
39
The medium flowing through the flowmeter drives a rotor. The sensor delivers a square-wave signal proportional to the rotational speed of the rotor. This sensor signal can be measured with an oscilloscope. The lower limit of the measuring range is 0.3 l/min. The upper limit of the measuring range is 9.0 l/min. The values are shown in the data sheet.
Measured-value table
Flowrate [l/min] 1 2 3 4 5 6 7 8 9 10
Frequency [Hz] 133 266 400 532 665 798 931 1064 1197 1330
Calculated height after 1 min 30 60 90 120 150 180 210 240 270 300
Measured height after 1 min
Not possible Not possible Not possible Not possible Not possible
Not possible = Insufficient pump capacity
40
1.1.2 K factor:
From data sheet
8000 pulses 0.3 9.0 l
dm
= 8000 pulses
Measuring range:
min
1.1.3
Calculation
For 0.3 l
= 40 1 = 40 Hz min sec For 9.0 l 72000 pulses = 1200 1 = 1200 Hz min min sec min
Flowrate (l/min) Frequency (1/s)
2400 pulses
Durchfluss [l/min]
10 9 8 7 6 5 4 3 2 1
100
200
300
400
500
600
700
800
900
1000 1100 1200 Frequenz [1/s]
41
The analog pressure sensor is a piezoresistive relative pressure sensor with integrated amplifier and built-in temperature compensation in an aluminum housing. The pressure to be measured acts on the piezoresistive element. The resulting signal change is emitted via an integrated amplifier as a voltage at the connector. The maximum output voltage is 10V DC. The output signal can be measured with a voltmeter. The temperature of the medium to be measured must be within a certain range, namely between 25C und 100C. The measuring range is between 0 and 100 mbar or 0 and 400 mbar, depending on the sensor type (see data sheets).
42
10 V 6
U 4
2 0 -1 0 20 40 60 mbar 100
P
Characteristic of the pressure sensor 167224
Pressure [mbar] 0 10 20 30 40 50 60 70 80 90 100
Voltage [V] 0 1 2 3 4 5 6 7 8 9 10
Measured-value table for pressure sensor 167224
43
Characteristic of pressure sensor BE.EL.0600
Increase the voltage at the pump until the desired pressure value is shown on the manometer.
Pressure [mbar] 0 50 100 150 200 250 300 350 400 Voltage [V] 0 1.25 2.5 4.75 5.0 6.25 7.5 8.75 10 Not possible Not possible Not possible Comment
Measured-value table for pressure sensor BE.EL.0600
This exercise involves examining the temperature sensor. Pt stands for the material out of which the measuring resistor is made.
44
Pt: Platinum, Ni: Nickel. 100 stands for the resistance in Ohms, when the measuring resistor has a temperature of 0C. There are also Pt1000 Sensors. Logically, these have a resistance of 1000 Ohm at a reference temperature of 0C. The temperature coefficient of the sensors is uniform at 3850 ppm/K. That means the internal resistance of the sensor changes by 0.385% for each degree change in temperature. Based on these values, the resistance of the Pt100 at 100C can be calculated as follows: Temperature change from
0C to 100C = 100 K 100 K 0.385% = 38.5% K R100 K = 38.5 R100C = R0C + R100 K = 100 + 38.5 = 138.5
The measuring resistor can be measured with an ohmmeter. Solution for Worksheet3.9.2
R/
/C
Temperature [C] Value []
-100.00 60.25
0.00 100.00
100.00 138.50
200.00 175.84
45
Solution for Worksheet 3.10
What result do you expect? Measurement 1: Inlet valve open, outlet valve closed, pump running
Level [mm] 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 ----0 2 4 6 8 10 12 14 16 18 20 22 24 26
Time [s] 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300
Level [mm] 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56
Time [s]
46
Inflow characteristic with FluidLab-PA - Inlet valve open, outlet valve closed
47
What result to you expect? Measurement 2: Inlet valve open, outlet valve closed, pump not running
Level [mm] 300 290 280 270 260 250 240 230 220 210 200 190 180 170 160 0 5 10 15 20 25 31 38 44 50 56 63 69 75 81
Time [s] 150 140 130 120 110 100 90 80 70 60 50 40 30 20 10
Level [mm] 87 96 104 112 118 130 138 150 162 175 187 200 225 250 -----
Time [s]
48
Outflow characteristic with FluidLab-PA inlet valve open, outlet valve closed
49
What result to you expect? Measurement 3: Inlet valve open, outlet valve open, pump running
Level [mm] 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 ----0 8 19 30 44 60 77 100 131 168 212 280
Time [s] 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300
Level [mm]
Time [s]
50
Inflow characterstic with FluidLab-PA inlet valve open, outlet valve open
51
Bildtexte: Level (mm) 1. Inflow t8s), V2 closed 2. Outflow t(s) 3. Inflow t(s), V2 open
Characteristics for container inflow and outflow
Findings from Measurement 1 The outlet valve V102/V112 is closed. As a result inflow via the inlet valve V101, the increase in the level (h) in the container is steady and linear over time. The greater the inflow, the more quickly the level in the container increases per unit time. If the quantity of water in container B101 were not limited, the amount of water would continue to increase until the container overflowed. There is not self-stabilization here. For this reason, the closed container B102 is an uncompensated controlled system. These uncompensated controlled systems are also termed integral systems (I systems), because the feed quantities add up. The level is thus the sum of all water that flows into the system. The time from empty to full is therefore also called the integration time Ti. Typical integral systems in machine-building are hydraulic cylinders and threaded spindles.
52
Findings from Measurement 2 The hydrostatic pressure in the water column ensures a reduction of flowrate at the outlet. The lower the water column, the lower the hydrostatic pressure and thus the lower the amount of water outflow. This results in a non-linear characteristic. Example: Electrical engineering: discharge of a capacitor Finding from Measurement 3 Controlled systems with compensation are controlled systems whose characteristic reaches equilibrium after a time. In level-controlled systems, the compensation takes the following physical form. When filling with a constant flowrate (inflow), the pressure of the water column at the bottom of the container is proportional to the level. The pressure at the bottom increases with level. This results in an increase in outflow until equilibrium with the inflow is reached. This results in a constant level that is, it no longer increases. This is called a steady-state end value. Outflow flowrate of water = inflow flowrate Controlled systems with equilibrium are also called PT controlled systems: P because the steady-state value is proportional to the input vale T because the steady-state value is only reached after time T If only container (controlled system) is present, the controlled system is called a PT1 = 1st order controlled system. A controlled system of the 0th order would be a pure P system, for example, a lever: the force is transmitted immediately without any delay.
53
Are you using close-loop or open-loop control of the level?

The level is close-loop controlled..
Is it possible to maintain a constant level manually?

It is very difficult to maintain the level accurately.
Pump voltage measured at mean measured value

Mean measured value [mm]
Pump voltage [V]
54
Determining the operating range and operating point of the control

Transducer output signal U [V]
Level h [mm]
Sensor signal I [mA]
Max. measured value
25
Mean measured value
150
Min. measured value
300
10
The mean measured value can be taken as the operating point for the dynamic response of the control. The operating point should always be in the linear part of the sensor characteristic. The relationship between the input variable and the output variable that is the actual value and the manipulated variable is determined for the static response of the control when stationary. The manipulated variable should also be in the linear part of the actuator (pump).
Transient response of a level-controlled system (Compact Workstation) static response
55
A functioning control always comprises at least two elements: a controller and a controlled system. For control tasks it is essential to know which variable in the system is to be controlled. In a level-controlled system, the controlled variable is the level its current status (actual value) is interrogated by a sensor. How does the system respond with the outlet valve closed? The level (actual value) slowly approaches the setpoint. Once the setpoint is reached, the controller ensures that the speed of the pump is reduced as required to maintain the desired level. How does the system respond with the outlet valve open? Opening the outlet valve acts as a disturbance variable. Water is suddenly removed from the container. The level of the container is maintained, however. The pump runs faster (higher RPM) than with the outlet valve closed. Background The controller has the task of controlling the system in such a way that the controlled variable (that is, the level), remains as constant as possible. In the event of a disturbance (sudden removal of water), the controller increases the speed of the pump to pump more water into the container and thus compensate the loss. The controller is informed of a change in level by the signal from the sensor. This signal is termed the actual value.
56
Dynamic response setpoint step-change to operating point with PI controller, outlet valve open
57
It is not possible to maintain a constant flowrate manually.
Solution for Worksheet 4.2.2 Determining the measuring chain of the flow-controlled system with a pump as final control element
Flow-controlled system Pump operating range Flowrate Q [l/min] Signal f [Hz] Flowrate Q [l/min] Flowrate Q [l/min] Sensor
Transducer Signal f [Hz] Flowrate Q [l/min]
MAX
4.3
266
9.0
1200
1000
10.0
7.5
MIN
0.0
0.0
0.4
50
0.0
0.0
0.0
Determining the flowrate characteristic of the pump (light blue = pump voltage, green = flowrate)
58
Mean value of the operating range of the control system with a pump as the final control element
Mean measured value [l/min] Dimensionless value [ 0.0 1.0 ] Pump voltage [V]
2,0
0,35
6,0
Convert the measured value into a dimensionless value in the range [0-0 1.0]. This means that the maximum measurable pressure of 400 mbar would have the value 1.0.
System response for a flow-controlled system with pump at operating point, input voltage jump of 6.0V
59
System response for a setpoint jump of a flow-controlled system with a pump and PI controller
60
Determining the operating range of a flow-controlled system with a proportional valve as final control element
Sensor Transducer
Flow-controlled system Proportional value operating range Signal f [Hz] Flowrate Q [l/min] Output signal f [Hz]
Signal f [Hz]
Flowrate Q [l/min]
Output signal f [Hz]
Signal f [Hz]
MAX
2.3
306
9.0
1200
1000
10.0
7.5
MIN
0.0
0.0
0.4
50
0.0
0.0
0.0
Determining the flowrate characteristic of the proportional valve (light blue = pump voltage, green = flowrate)
61
Mean value of the operating range of the control system with a proportional valve as the final control element
1,2 (153 Hz)
0,15
6,0
System response for a flow-controlled system with proportional valve at operating point, input voltage jump of 5.0 V.
62
System response for a setpoint jump of a flow-controlled system with a proportional valve and a PI controller
63
It is not possible to maintain a constant pressure manually.
Solution for Worksheet 4.3.2 Determining the measuring chain of a pressure-controlled system with a pump as final control element
Pressure-controlled system Pump operating range Pressure p [mbar] Signal U [V] Sensor Measuring range Pressure p [mbar] Signal U [V]
MAX
220
5.45
400
10V
MIN
0.0
0.0
Determining the pressure characteristic of the pump (light blue = pump voltage, green = container pressure)
64
Mean value of the operating range of the pressure-controlled system with a pump as the final control element
110
0.28
8.0
Convert the measured value into a dimensionless value in the range [0-0 1.0]. This means that the maximum measurable pressure of 400 mbar would have the value 1.0.
System response for a pressure-controlled system with pump at operating point, input voltage jump of 8.0 V
65
System response for a pressure-controlled system with pump and PID controller
66
Determining the operating range of the pressure-controlled system with a proportional valve as final control element
Pressure-controlled system Pump operating range Signal [V] Pressure p [mbar] Sensor Measuring range Signal [V] Pressure p [mbar]
MAX
210
5.35
400
10V
MIN
0.0
0.0
Determining the pressure characteristic of the proportional valve (light blue = pump voltage, green = container pressure)
67
Mean value of the operating range of the pressure-controlled system with a proportional valve as the final control element
105
0.26
1.3
System response for pressure-controlled system with proportional valve at operating point, input voltage jump 1.3 V
68
System response for a setpoint jump of a pressure-controlled system with a proportional valve and PID controller
69
The order of the controlled system can be determined from the transient response curve of the controlled system:
Transient responses of systems of different order
Once the order of the controlled system has been established, the time constant T of the controlled system can be determined graphically. For controlled systems of the 1st order, the time constant is determined as follows:
Bildtexte S = output variable When t = T, T = 63%

Determining the time constant
70
Bildtexte: The irrational number e the characteristic value for a steadily decreasing rate of increase calculated? The number e is the final value of the series: Final value Time steps e = 2.71832 (bitte Dezimalpunkt statt komma verwenden) How is the number e, the In the language of mathematics, the time constant is also termed a subtangent. PT1 elements smooth fast-changing signals (high frequencies) but let low frequencies pass. For this reason, they are also known as low-pass filters of the first order. They also generate a phase shift between the input signal and the output signal. The determination of time constants for higher-order controlled systems is described in detail in the workbook Control of temperature, flowrate and level), Chapter 2.3.3, Process analysis and modelling . The controlled system is in steady state after 5T. A controller for the controlled system should always be 8 10 times faster than the time constant to allow correct control.
71
Transient response of the level-controlled system at the operating point The transient response of the level-controlled system is shown as an example. Please note that the same measurement taken on different systems can lead to deviation. Such deviation is caused by component tolerances .The measurement was made using the Compact Workstation level-controlled system and recorded with FluidLab-PA and EasyportDA.
The level-controlled system (with open discharge valve) is a controlled system of the first order.
72
Solution for Worksheet5.1.1
Transient response of the flow-controlled system at the operating point The transient response of the flow-controlled system with a pump as final control element is shown as an example. Please note that the same measurement taken on different systems can lead to deviation. Such deviation is caused by component tolerances. The measurement was made using the Compact Workstation levelcontrolled system and recorded with FluidLab-PA and EasyportDA.
The flow-controlled system is a controlled system of the first order.
73
Transient response of the pressure-controlled system at the operating point The transient response of the pressure-controlled system with pump as final control element is shown as an example. Please note that the same measurement taken on different systems can lead to deviation. Such deviation is caused by component tolerances. The measurement was made using the Compact Workstation levelcontrolled system and recorded with FluidLab-PA and EasyportDA.
The pressure-controlled system is a controlled system of the first order.
74
Transient response of the temperature-controlled system at the operating point The transient response of the temperature-controlled system is shown as an example. Please note that the same measurement taken on different systems can lead to deviation. Such deviation is caused by component tolerances .The measurement was made using the Compact Workstation level-controlled system and recorded with FluidLab-PA and EasyportDA.
Note:
The jump is only shown for a temperature change of 5K compared to the start temperature, then the heater is switched off again.
The temperature-controlled system is a controlled system of the first order.
75
Which controller is suitable for which controlled system?

Permanent control deviation P Temperature Simple controlled systems with unsophisticated requirements Pressure Mostly unusable PD Simple controlled systems with unsophisticated requirements Mostly unusable Well suited. Also I controllers for controlled systems with large delay time Flow Unsuitable Unsuitable Usable, but I controller alone often better Level In the case of short dead time Transport Unsuitable because of dead time Unsuitable Usable, but I controller alone often better Has little advantage over PI Suitable Suitable Very suitable Suitable Suitable if controlled variable does not pulsate too much No permanent control deviation PI Suitable PID Very suitable
Selection of controller types for the most important controlled variables
76
Controlled system P Unsuitable because of dead time PD Unsuitable
Controller type PI Usable, but I controller normally sufficient PID Has little advantage over PI
Pure dead time
1st order with short dead time 2nd order with short dead time
Suitable if control deviation acceptable Control deviation normally too large for required Xp
Suitable if control deviation acceptable Control deviation normally too large for required Xp
Well suited
Suitable
Worse than PID
Well suited
Higher order Without compensation with delay time
Unsuitable Suitable
Unsuitable Suitable
Worse than PID Suitable
Well suited Very suitable
77
Procedure used in the Ziegler-Nichols method
Configure the controller as a P controller
Vary the amplification factor Kr until the controlled system approaches the limit of stability. (Until it just starts to oscillate.)
Read the periodic time of an oscillation.
Use the Ziegler-Nichols table to calculate the necessary parameters for the controller.
78

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Solutions for Courseware Process Control System

Process Control System EN 02/06

Festo Didactic GmbH & Co. Process Control System

Festo Didactic GmbH & Co. Process Control System

Festo Didactic GmbH & Co. Process Control System

Solutions for Courseware Process Control System

Equipment list for level

ADIRO Automatisierungstechnik GmbH Process Control System

Solutions for process and control engineering

Equipment list for flow rate

ADIRO Automatisierungstechnik GmbH Process Control System

Solutions for process and control engineering

Equipment list for pressure

ADIRO Automatisierungstechnik GmbH Process Control System

Solutions for process and control engineering

Equipment list for temperature

ADIRO Automatisierungstechnik GmbH Process Control System

Solutions for process and control engineering

Solution for Exercise 2.3.1

PI-diagram for level.

LS+ 101.2 LS101.1 V105

ADIRO Automatisierungstechnik GmbH Process Control System

Solutions for process and control engineering

PI-diagram for flow rate.

LS+ 101.2 LS101.1 V105 B101

ADIRO Automatisierungstechnik GmbH Process Control System

Solutions for process and control engineering

PI-diagram for pressure.

V107 B103 V108 V106

LS+ 101.2 LS101.1 V105 B101

ADIRO Automatisierungstechnik GmbH Process Control System

Solutions for process and control engineering

PI-diagram for temperature.

LS+ 101.2 LS101.1 V105 E104 B101

ADIRO Automatisierungstechnik GmbH Process Control System

Solutions for process and control engineering

4 Component symbol Ultrasonicsensor B101 Transformer

13 14 Rltg./Ap.Stutz DN R-KL PN D-KL

1 A1 Controller E/E N1 Relay 1 K1 Applifier A4

4...20mA/ 0...10V PI 4..20mA 0...10V digital (0)/ analog (1)

transform signal and power

level controlled system

EMCS point list - solution

ADIRO Automatisierungstechnik GmbH Process Control System

Solutions for process and control engineering

EMCS point list for flow controlled system.

13 14 Rltg./Ap.Stutz DN R-KL PN D-KL

Flow rate sensor B102

Measure flow rate

F 40...1200 Hz 0,3...9,0 l/min

Transformer A2 Controller E/E N1 Relay K1

0...1000 Hz/ 0...10 V PI 4..20 mA 0...10 V digital (0)/ analog (1)

transform signal and power

Control flow rate

flow rate controlled system

EMCS point list - solution

ADIRO Automatisierungstechnik GmbH Process Control System

Solutions for process and control engineering

EMCS point list for pressure controlled system.

13 14 Rltg./Ap.Stutz DN R-KL PN D-KL

Pressure sensor B103 Controller E/E N1 Relay K1

PI 4..20 mA 0...10 V digital (0)/ analog (1)

transform signal and power