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Workbook for MPS® PA Compact Workstation
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MPS PA Compact Workstation EN 05/08
Intended use
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
BE.TW.0005
Designation
Courseware
Description
Exercises for process and control engineering
Status
05/2008
Authors
Jürgen Helmich, Stefan Knoblauch, Andreas Wierer (ADIRO)
Translation
Williams Technical Communication Pty Ltd, Brisbane
Graphics
Jürgen Helmich, Stefan Knoblauch (ADIRO)
Layout
Jürgen Helmich (ADIRO)
© Festo Didactic GmbH & Co., 05/2008 Internet: www.festo.com/didactic http://www.festo.com/didactic/de/ProcessAutomation e-mail: [email protected]
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.
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© Festo Didactic • MPS PA Compact Workstation
Contents
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Introduction _______________________________________________________ 7 1.1 Material covered________________________________________________ 8 1.2 Important notes ________________________________________________ 9 1.3 Operator’s responsibilities _______________________________________ 9 1.4 Trainees’ responsibilities ________________________________________ 9 ® 1.5 Hazards associated with operating the MPS PA Compact Workstation _ 10 2 Project planning ___________________________________________________ 11 2.1 PI diagram ____________________________________________________ 12 2.2 Equipment list_________________________________________________ 15 Exercise 2.2 _________________________________________________________ 15 Worksheet 2.2.1 _____________________________________________________ 16 2.3 Project planning – Controlled system _____________________________ 17 Exercise 2.3.1 _______________________________________________________ 18 Exercise 2.3.2 _______________________________________________________ 20 Exercise 2.3.3 _______________________________________________________ 22 3 Analysis __________________________________________________________ 25 3.1 Analysis of the tank ____________________________________________ 26 Exercise 3.1.1 _______________________________________________________ 26 Worksheet 3.1.1_____________________________________________________ 27 3.2 Analysis of a pump _____________________________________________ 28 Exercise 3.2.1 _______________________________________________________ 28 Worksheet 3.2.1 _____________________________________________________ 29 Exercise 3.2.2 _______________________________________________________ 31 Worksheet 3.2.2 _____________________________________________________ 32 Exercise 3.2.3 _______________________________________________________ 33 Worksheet 3.2.3 _____________________________________________________ 34 3.3 Analysis of a proportional valve __________________________________ 35 Exercise 3.3.1 _______________________________________________________ 35 Worksheet 3.3.1 _____________________________________________________ 36 Exercise 3.3.2 _______________________________________________________ 37 Worksheet 3.3.2 _____________________________________________________ 38 3.4 Analyze of a process drive _______________________________________ 39 Exercise 3.4.1 _______________________________________________________ 39 Worksheet 3.4.1 _____________________________________________________ 40 Exercise 3.4.2 _______________________________________________________ 42 Worksheet 3.4.2 _____________________________________________________ 43 Exercise 3.4.3 _______________________________________________________44 Worksheet 3.4.3 _____________________________________________________ 45 3.5 Analysis of a heating element ____________________________________ 46 Exercise 3.5.1 _______________________________________________________ 46 Worksheet 3.5.1 _____________________________________________________ 47 3.6 Analysis of an ultrasound sensor _________________________________ 48 Exercise 3.6.1 _______________________________________________________ 48
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Inhalt
Worksheet 3.6.1 _____________________________________________________ 49 Exercise 3.6.2 _______________________________________________________ 50 Worksheet 3.6.2 _____________________________________________________ 51 3.7 Analysis of a flow meter ________________________________________ 53 Exercise 3.7.1 _______________________________________________________ 53 Worksheet 3.7.1 _____________________________________________________ 54 Exercise 3.7.2 _______________________________________________________ 55 Worksheet 3.7.2 _____________________________________________________ 56 3.8 Analysis of a pressure sensor____________________________________ 59 Exercise 3.8.1 _______________________________________________________ 59 Worksheet 3.8.1 _____________________________________________________ 60 Exercise 3.8.2 _______________________________________________________ 61 Worksheet 3.8.2 _____________________________________________________ 62 3.9 Analysis of a temperature sensor _________________________________ 64 Exercise 3.9.1 _______________________________________________________ 64 Worksheet 3.9.1 _____________________________________________________ 65 Exercise 3.9.2 _______________________________________________________ 66 Worksheet 3.9.2 _____________________________________________________ 67 3.10 System behavior of a container ________________________________ 69 Exercise 3.10.1 ______________________________________________________ 69 Worksheet 3.10______________________________________________________ 70
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Inhalt
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Commissioning ____________________________________________________ 74 4.1 Commissioning a level-controlled system __________________________ 75 Exercise 4.1.1 _______________________________________________________ 76 Worksheet 4.1.1 _____________________________________________________ 77 Exercise 4.1.2 _______________________________________________________ 78 Worksheet 4.1.2 _____________________________________________________ 79 Exercise 4.1.3 _______________________________________________________ 80 Exercise 4.1.4 _______________________________________________________ 81 Worksheet 4.1.3/4.1.4 ________________________________________________ 82 4.2 Commissioning a flow controlled-system___________________________ 83 Exercise 4.2.1 _______________________________________________________ 84 Worksheet 4.2.1 _____________________________________________________ 85 Exercise 4.2.2 _______________________________________________________ 86 Worksheet 4.2.2 _____________________________________________________ 87 Exercise 4.2.3 _______________________________________________________ 88 Worksheet 4.2.3 _____________________________________________________ 89 Exercise 4.2.4 _______________________________________________________ 90 Worksheet 4.2.4 _____________________________________________________ 91 Exercise 4.2.5 _______________________________________________________ 92 Worksheet 4.2.5 _____________________________________________________ 93 4.3 Commissioning a pressure-controlled system_______________________ 94 Exercise 4.3.1 _______________________________________________________ 95 Worksheet 4.3.1 _____________________________________________________ 96 Exercise 4.3.2 _______________________________________________________ 97 Worksheet 4.3.2 _____________________________________________________ 98 Exercise 4.3.3 _______________________________________________________ 99 Worksheet 4.3.3 ____________________________________________________100 Exercise 4.3.4 ______________________________________________________101 Worksheet 4.2.4 ____________________________________________________102 Exercise 4.3.5 ______________________________________________________103 Worksheet 4.3.5 ____________________________________________________104 4.4 Commissioning a temperature-controlled system___________________105 Exercise 4.4.1 ______________________________________________________106 Worksheet 4.4.1 ____________________________________________________107 Exercise 4.4.2 ______________________________________________________108 Worksheet 4.4.2 ____________________________________________________109 Exercise 4.4.3 ______________________________________________________110 Worksheet 4.4.3 ____________________________________________________111 5 Control engineering _______________________________________________113 5.1 Identifying the controlled system ________________________________114 Exercise 5.1.1 ______________________________________________________115 Worksheet 5.1.1 ____________________________________________________116 Worksheet 5.1.2 ____________________________________________________117 5.2 Controller functions ___________________________________________118
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Inhalt
Exercise 5.2.1 ______________________________________________________119 Worksheet 5.2.1 ____________________________________________________120 Exercise 5.2.2 ______________________________________________________121 Worksheet 5.2.2 ____________________________________________________122 Exercise 5.2.3 ______________________________________________________123 Worksheet 5.2.3 ____________________________________________________124 Exercise 5.2.4 ______________________________________________________125 Worksheet 5.2.4 ____________________________________________________126 Exercise 5.2.5 ______________________________________________________127 Worksheet 5.2.5 ____________________________________________________128 Exercise 5.2.6 ______________________________________________________129 Worksheet 5.2.6 ____________________________________________________130 5.3 Controller setting using the Ziegler-Nichols method_________________131 Exercise 5.3.1 ______________________________________________________132 Worksheet 5.3.1 ____________________________________________________133 Exercise 5.3.2 ______________________________________________________134 Exercise 5.3.3 ______________________________________________________135 Worksheet 5.3.2 ____________________________________________________136 5.4 Controller parameterization using the Chien-Hrones-Reswick method__137 Exercise 5.4.1 ______________________________________________________138 Worksheet 5.4.1 ____________________________________________________139 Exercise 5.4.2 ______________________________________________________140 Worksheet 5.4.3 ____________________________________________________141 Worksheet 5.4.3 ____________________________________________________142 Exercise 5.4.3 ______________________________________________________143
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1
Introduction
Festo Didactic’s Learning System for process automation and technology is based on various training prerequisites and vocational requirements. The station Compact ® Workstation of the modular Production System for Process Automation (MPS PA) allows vocational and continuing training that is highly practice-oriented. The hardware comprises industrial components that have been didactically prepared. ®
The courseware – in combination with the Compact Workstation of the MPS PA Compact Workstation – provides a system that is suitable for practice-oriented training of new key competencies: • Social skills • Technical competence • Methodological competence Teamwork, cooperation and organizational skills can be trained at the same time. Real project phases can be trained during the learning projects, including: • • • • • • •
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Planning Assembly Programming Commissioning Operation Maintenance Troubleshooting
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Introduction
1.1 Material covered
Material from the following areas can be covered: • • • • • • • • • • • • • • • • • • • • • • • • • •
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Mechanical engineering Mechanical design of a station Process engineering Reading and creating PI diagrams and documentation. Installation of piping for process components Electrical engineering Correct wiring of electrical components Sensors Correct use of sensors Measurement of non-electrical, process-engineering and control-engineering variables Learning to use and parameterize fieldbus technology such as PROFIBUS Closed-loop control engineering Fundamentals of closed-loop control engineering Expanding measuring chains to closed control loops Analysis of controlled systems P, I, D controls Optimization of a control loop Controlling system (industrial controller) Configuration, parameterization and optimization of an industrial controller Commissioning Commissioning a control loop Commissioning a processing plant Troubleshooting Checking, maintaining and repairing process plants Controlling and monitoring processes with a PC Systematic troubleshooting a processing plant
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© Festo Didactic • MPS PA Compact Workstation
Project planning
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The basic prerequisite for safe handing and fault-free operation of a MPS PA Compact Workstation station is knowledge of the basic safety instructions and regulations.
1.2 Important notes
These operating instructions contain the most important safety instructions for safe operation of a station. In particular, the safety instructions are to be observed by all persons working at the workstation. In addition, local rules and accident-prevention regulations must be observed. The operator is responsible for ensuring that people working at the workstation are limited to:
1.3 Operator’s responsibilities
• Those with a basic knowledge of work safety and accident prevention and who have been instructed in the operation of the station. • Those who have read and understood the safety chapter and warning notices in these operating instructions and have signed to this effect. All persons assigned to working with the workstation are required to carry out the following before starting work:
1.4 Trainees’ responsibilities
• To observe the basic regulations for work safety and accident prevention. • To read and understand the safety chapter and warning notices in these operating instructions and sign to this effect.
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Introduction
1.5 Hazards associated with ® operating the MPS PA Compact Workstation
The workstation has been built in accordance with the state of the art and recognized safety regulations. Nonetheless, operation of the station can result in the danger of injury or death to the user or third parties or damage to the machine or other property. The station is only to be used • For the intended purpose and • When in perfect condition from a safety point of view.
Any faults that could compromise safety must be eliminated immediately!
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Project planning
Project planning of a process plant should include the following documents: • • • • • • • • • • • • • • • • • •
Specifications Process description, associated conditions such as environmental protection Start of scheduling and schedule monitoring Planning of PI diagrams Basic PI diagram Process PI diagram Piping and instrumentation diagram (PI diagram) Function diagrams Design of process plant Environmental protection requirements Specification of all equipment, Instrumentation and Control (EMCS) point list Instrument loop diagram – outline Instrument loop diagram – detailed Wiring and terminal diagrams Assembly plans Installation planning Acquisition Assembly, commissioning and acceptance of the system
The planning of a process-engineering project should be practiced using a PI diagram, an Instrument loop list and an Instrument loop diagram for a controlled system.
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Project planning
2.1 PI diagram
The development of a PI diagram is a significant part of the project work. A PI diagram explains the EMCS functions using measuring points and final control elements. EMCS point designation
LIC 102
The process-related functions in an EMCS plan (Electrical, Instrumentation & Control) are described by EMCS points. The designation indicates the measured variables or other input variables, their processing, the direction of control action, and location. A EMCS point consists of an EMCS circle and is designated by code letters (A-Z) and a code number. The code letters are entered in the upper half of the EMCS circle, the number in the lower half. The sequence of the code letters is based on the following table “EMCS code letters DIN 19227”. Example:
L
I
C
First letter
Supplementary letter
1st following letter
Level
Display
Automatic closed-loop control
The coding system for the EMCS points can be freely selected. Sequential numbering makes sense, as an EMCS points code must only occur once, even if there are several measuring points with the same measured variable. For more information, please see DIN standard 19227 Part 1.
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Project planning
EMCS code letters DIN 19227 Measured variable or other input variable,
“Processing letter
final control element
Letter First letter
Sequence: O,I,R,C,S,Z,A”
Supplementary letter
A
Error message
B C
Automatic closed-loop control
D
Density
E
Electrical variables
F
Flow rate, through put
G
Displacement, length, position
H
Manual input, manual intervention
Difference Sensor function Ratio
Upper limit value(High)
I
Display
J
Measuring point sensing
K
Time
L
Level (including interface applications)
M
Humidity
Lower limit value (Low)
N O
Indicator, Yes/no output
P
Pressure
Q
Material properties, quality variables
R
Radiation variables
Recording
S
Speed, rotational speed, frequency
Switching, sequence and logic control
T
Temperature
Transducer function
U
Composite variables
Composite drive functions
V
Viscosity
Final control element function
W
Weight force, mass
X
Other variables
Integral, sum
Y
Arithmetic function
Z
Emergency intervention, preventive triggering, protective device, safety-related message
+
Upper limit value
/
Intermediate value
-
Lower limit value
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Project planning
Examples for EMCS symbols EMCS symbols DIN 19227 Pipe Pipe with direction of flow Pump, controlled, flange-mounted motor
P101 M
Container, top open B101
Container, closed B303
Valve, manually operated V102
Control valve with actuator V206
Heating element
E401 LIC
EMCS task with process master display
102
Level display automatic closed-loop control
EMCS task with process master display FIC
Flowrate display automatic closed-loop control
201
303
EMCS task with process master display Pressure display automatic closed-loop control
TIC
EMCS task with process master display
401
Temperature display automatic closed-loop control
PIC
Pipe input (output)
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Project planning
An equipment list provides a first indication which controlled system should be used for the measurement and which components are relevant to it.
2.2 Equipment list
Exercise 2.2 Equipment list Name:
Date:
Controlled system: Task: Create an equipment list
Sheet 1 of 2
Task • Draw up an equipment list for the controlled system based on the information given. Consider which of the items of equipment and elements listed in the worksheet you need for setup of the system or controlled system and mark these in the worksheet. • View the individual components and the data sheets and acquaint yourself with the variables used in the system. Resources • Worksheet 2.2.1 Equipment list • Compact Workstation Manual, Chapter “Function and design” • Collection of data sheets
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Project planning
Worksheet 2.2.1 Equipment list Name:
Date:
Controlled system: Task: How to plan a equipment list
Page 2 of 2
• Which components are necessary for the chosen close-loop control system?
Equipment list
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
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Project planning
Draw up a PI diagram, an Instrument loop list and an Instrument loop diagram for a controlled system.
2.3 Project planning – Controlled system
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The MPS PA Compact Workstation comprises the following controlled systems (controls): • • • •
Level Flow rate Pressure Temperature
For use of the individual controlled systems, please use the manual valve settings given in the manual.
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Project planning
Exercise 2.3.1 Project planning for a controlled system – PI diagram Name:
Date:
Controlled system: Task: Draw up a PI diagrams for a controlled system
Sheet 1 of 3
Preparation ®
Read the documentation for the MPS PA Compact Workstation. Task ®
Based on the overall PI diagram of the MPS PA Compact Workstation, draw the PI diagram for the selected controlled system with all components relevant to the controlled system.
Worksheets • Worksheet 2.3.1 – PI diagram
Resources • • • • •
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Electrical circuit diagram, MPS PA Compact Workstation ® Pipe and instrument PI diagram, MPS PA Compact Workstation ® Data sheets, MPS PA Compact Workstation Workbook “Control of temperature, flow rate and level” , Festo, 170677 Standard DIN ISO EN 10628 “PI diagrams for process plants – general rules” (replaces DIN 28004) • Standard DIN 19227 Part 1 “Graphical symbols and code letters for process control” (ISO3511)
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RI-Fließbild / process flowsheet
Automatisierungstechnik GmbH Limburgstr. 40 D-73734 Esslingen
Arbeitsblatt 2.3.1 / worksheet 2.3.1
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Project planning
Project planning
Exercise 2.3.2 Project planning for a controlled system – Instrument loop list Name:
Date:
Controlled system: Task: Complete an Instrument loop list for a controlled system
Sheet 2 of 3
Task Complete the Instrument loop list for the selected controlled system. Worksheets • Worksheet 2.3.2 – Instrument loop list
Resources • • • •
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Electrical circuit diagram, MPS PA Compact Workstation PI diagram for controlled system from Worksheet 2.3.1 ® Data sheets, MPS PA Compact Workstation Standard DIN 19227 Part 2 “Graphical symbols and code letters for process control” (ISO3511)
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Project planning
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Project planning
Exercise 2.3.3 Project planning for a controlled system – EMCS points plan Name:
Date:
Controlled system: Task: Draw an Instrument loop diagram of a controlled system
Sheet 3 of 3
Task Create the Instrument loop diagram for the selected controlled system.
Worksheets • Worksheet 2.3.3– EMCS points plan
Resources • • • • • •
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Electrical circuit diagram, MPS PA Compact Workstation PI diagram of the controlled system from Worksheet 2.3.1 Instrument loop list from Worksheet 2.3.2 ® Data sheets, MPS PA Compact Workstation Workbook “Control of temperature, flow rate and level” , Festo, 170677 Standard DIN 19227 Part 2 “Graphical symbols and code letters for process control” (ISO3511)
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Project planning
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Project planning
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Analysis
In the exercises, commissioning a system is divided into three areas: • Analysis of the components, sensors and actuators • System behavior • Commissioning of the controlled systems
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The analysis is to cover the function of the actuators and sensors of the MPS PA Compact Workstation. The following questions are to be answered: • • • • •
How does an actuator function? Of what parts does an actuator comprise? What is the characteristic of a sensor? Acquisition of measured values based on practical examples Processing and evaluation of measured values
The following exercises are provided to support training in the area of measurements on actuators and sensors. The following application task offers a good introduction to the topic of measurement technology. The task is to understand the function of a flowrate sensor by recording the characteristic and working with the data sheet.
Instructor’s notes
Target audience and required prior knowledge This task requires basic technical understanding and basic knowledge of electrical engineering. The tasks are designed to provide the trainee with an introduction to various controlled systems. To this end, it makes sense to look at the individual components first.
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Analysis
3.1 Analysis of the tank
Exercise 3.1.1 Volume of the container Name:
Date:
Project name: Task: Calculation of container volume
Sheet 1 of 2
Task • Calculate the volume (capacity) of the tank. • Determine the relationship between the volume (liters) and the container scale (indicated in mm). How much water is in the container if it is filled to a level of 300 mm? What volume is required to achieve a reading of 100 or 1 mm on the scale?
Worksheets • Worksheet 3.1.1 Analysis of the container
Resources • Container data sheet • Workstation manual
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Analysis
Worksheet 3.1.1 Analysis of the container Name:
Date:
Project name: Task: Calculate the volume of the container
Sheet 2 of 2
Calculating the volume of the container
Where:
Container height
h = 300 mm
Container width
w=
Container depth
d=
Find:
Solution:
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Analysis
3.2 Analysis of a pump
Exercise 3.2.1 Analysis of a pump Name:
Date:
Project name: Task: Determining how a pump functions
Sheet 1 of 7
Task • What type of pump is used in the Festo Didactic MPS® PA Compact Workstation? • Count how many other different types of pump there are and name the main differences to different types of pumps. • What are the advantages and disadvantages of the individual pump types? • What are all the things that must be taken into account when using the pump? • Calculate the rated current of the pump. Worksheets • Worksheet 3.2.1 Determine how a pump functions – type, operation, component parts
Resources • Pump data sheet • Station manual
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Analysis
Worksheet 3.2.1 Analysis of a pump Name:
Date:
Project name: Task: Determining how a pump functions – type
Sheet 2 of 7
• What type of pump is it? Name the main differences to different types of pumps.
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Analysis
Analysis of a pump Name:
Date:
Project name: Task: Determining how a pump functions – operation
Sheet 3 of 7
• What must be taken into account when using the pump?
• Calculating the rated current Where: Find: Solution:
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Analysis
Exercise 3.2.2 Analysis of a pump Name:
Date:
Project name: Task: Determining the structure of a pump
Sheet 4 of 7
Task • Name the component parts of the pump. Compare your results with the data sheet.
Exploded view of the pump
Worksheets • Worksheet 3.2.2 Component parts of the pump
Resources • Pump data sheet • Station manual
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Analysis
Worksheet 3.2.2
Analysis of a pump Name:
Date:
Project name: Task: Determining how a pump functions – Components
Sheet 5 of 7
Exploded view of pump
No.
Name of part
1 2 3 4 5 6 7 8 9
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Analysis
Exercise 3.2.3 Analysis of a pump Name:
Date:
Project name: Task: Determining the delivery rate of a pump
Sheet 6 of 7
Task Determine the delivery rate of a pump. • Which components of the MPS® PA Compact Workstation can you use to complete this task? Identify the parts and – if appropriate – do the tasks associated with the parts before undertaking the measurement. • How do you undertake the measurement? Plan the steps. • Calculate the delivery speed of the pump. • Calculate the delivery rate of the pump. • Analyze you measurement and your result compared those of other groups.
Worksheets • Worksheet 3.2.3 Delivery rate
Resources • • • • •
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Collection of data sheets Book of tables Stopwatch FluidLab-PA with EasyPortDA Station manual
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Analysis
Worksheet 3.2.3 Pump Name:
Date:
Project name: Task: Determine the delivery rate of the pump
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Sheet 7 of 7
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Analysis
3.3 Analysis of a proportional valve
Exercise 3.3.1 Analysis of a proportional valve Name:
Date:
Project name: Task: Determine mode of operation of a proportional valve
Sheet 1 of 4
Task Acquaint yourself with the mode of operation of a proportional valve. • What does the term “proportional valve” mean? • What electrical signals do you need to work with a proportional valve?
Worksheets • Worksheet 3.3.1 Analysis of a proportional valve
Resources • Proportional valve data sheet • Station manual
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Analysis
Worksheet 3.3.1 Analysis of a proportional valve Name:
Date:
Project name: Task: Determine mode of operation of a proportional valve
Sheet 2 of 4
• What does the term “proportional valve” mean?
• What electrical signals do you need to use a proportional valve?
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Analysis
Exercise 3.3.2 Analysis of a proportional valve Name:
Date:
Project name: Task: Determining the flow rate of a proportional valve
Sheet 3 of 4
Task • What is the maximum rate at which you can pump the medium used through the proportional valve? Note that other components between the pump and proportional valve may cause flow resistance. On what is this value dependent? • What possibilities are there for adjusting the valve?
Worksheets • Worksheet 3.3.2 Analysis of a proportional valve
Resources • Data sheets • Station manual
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Analysis
Worksheet 3.3.2 Analysis of a proportional valve Name:
Date:
Project name: Task: Determine the flow rate of a proportional valve
Sheet 4 of 4
• What is the maximum rate at which you can pump the medium used through the proportional valve? What does this value depend on?
• What possibilities are there for adjusting the valve?
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Analysis
3.4 Analyze of a process drive Exercise 3.4.1 Analysis of a process drive Name:
Date:
Project name: Task: Determining the mode of operation of a process drive
Sheet 1 of 7
Task Acquaint yourself with the mode of operation of the process drive. • Draw up a parts list for the process drive module. • What electrical signals are used to drive the process drive? • Describe briefly the mode of operation of this module.
Worksheets • Worksheet 3.4.1 Analysis of a process drive
Resources • Data sheets • Station manual
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Analysis
Worksheet 3.4.1 Analysis of a process drive Name:
Date:
Project name: Task: Determining the mode of operation of a process drive
Sheet 2 of 7
• What components is the process drive made up of? Draw up a list of parts
Parts list for process drive module
Item
List of parts, process drive
Type
Quantity
1 2 3 4 5 6 7 8 9 10
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Analysis
Analysis of a process drive Name:
Date:
Project name: Task: Determining the mode of operation of a process drive
Sheet 3 of 7
• What electrical signals do you need to work with the process drive?
• Give a brief description of the module’s mode of operation.
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Analysis
Exercise 3.4.2 Analysis of a process drive Name:
Date:
Project name: Task: Determining the mode of operation a sensor box
Sheet 4 of 7
Task • 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.
Worksheets • Worksheet 3.4.2 Analysis of a process drive
Resources • Sensor box data sheet • PCS circuit documentation • Station manual
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Analysis
Worksheet 3.4.2 Analysis of a process drive Name:
Date:
Project name: Task: Explain briefly the mode of operation of the sensor box
Sheet 5 of 7
• 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.
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Analysis
Exercise 3.4.3 Analysis of a process drive Name:
Date:
Project name: Task: Determining the mode of operation a semi-rotary actuator
Sheet 6 of 7
Task • What type of drive is it? • How does it work?
Worksheets • Worksheet 3.4.3 Analysis of a process drive
Resources • Semi-rotary actuator data sheet • Station manual
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Analysis
Worksheet 3.4.3 Analysis of a process drive Name:
Date:
Project name: Task: Determining the mode of operation a semi-rotary actuator
Sheet 7 of 7
• What type of drive is it? • How does it work?
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Analysis
3.5 Analysis of a heating element Exercise 3.5.1 Analysis of a heating element Name:
Date:
Project name: Task: Operation of a heating element
Sheet 1 of 2
Task • What do you have to take into account when using the heating element? • Calculate the rated current of the heating element. • To what temperature may you heat the water in the container?
Resources • Heating element data sheet • Station manual
Worksheets • Worksheet 3.5.1 Heating element
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Analysis
Worksheet 3.5.1 Analysis of a heater element Name:
Date:
Project name: Task: Operation o of a heater element
Sheet 2 of 2
• What are all the things you have to take into account when using the heating element?
• Calculate the rated current of the heater.
Where: Find: Solution:
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Analysis
3.6 Analysis of an ultrasound sensor Exercise 3.6.1 Analysis of an ultrasound sensor Name:
Date:
Project name: Task: Operation of an ultrasound sensor
Sheet 1 of 5
Task • Study the ultrasound sensor data sheet to become acquainted with its mode of operation. Briefly describe the mode of operation in your own words. • What do you need to take into account if you wish to achieve an accurate measurement with an ultrasound sensor? • Measure the output signal of the sensor with a voltmeter. Sketch the measurement setup in the worksheet. Calculate parts need, if required. • How is the sensor signal measured in the system? Give possible reasons why the circuit was designed in this way?
Resources • Ultrasound sensor data sheet • PCS system manual
Worksheets • Worksheet 3.6.1 Ultrasound sensor
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Analysis
Worksheet 3.6.1 Analysis of an ultrasound sensor Name:
Date:
Project name: Task: Operation of an ultrasound sensor
Sheet 2 of 5
• Describe the mode of operation of the ultrasound sensor in your own words. What do you need to take into account if you wish to achieve accurate measurements?
Space for calculations and sketches
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Analysis
Exercise 3.6.2 Analysis of an ultrasound sensor Name:
Date:
Project name: Task: Recording the characteristic of an ultrasound sensor
Sheet 3 of 5
Task • Record the characteristic of the ultrasound sensor. Take a sufficient number of measurements and enter these into a chart. • Evaluate the resulting characteristic. Where is the optimum operating range of the sensor, or to what level must the container be filled for the ultrasound sensor to operate optimally?
Resources • Ultrasound sensor data sheet
Worksheets • Worksheet 3.6.2 Ultrasound sensor
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Analysis
Worksheet 3.6.2 Analysis of an ultrasound sensor Name:
Date:
Project name: Task: Recording the characteristic of an ultrasound sensor
Level [mm]
Sheet 4 of 5
Signal [V]
20 40 60 80 100 120 140 160 180 200 220 240 260 280 300
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Analysis
Ultrasound sensor Name:
Date:
Project name:
Level [mm]
Füllstand [mm]
Task: Recoding the characteristic of the sensor
Sheet 5 of 5
300
250
200
150
100
50
1
52
2
3
4
5
6
7
8
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10 9 Sensorsignal [V] signal [V]
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Analysis
3.7 Analysis of a flow meter Exercise 3.7.1 Analysis of a flow meter Name:
Date:
Project name: Task: Operation of a flow meter
Sheet 1 of 6
Task • How does the flow meter work? What other types of flow meter are there? • How can you measure signals from the sensor? • What is the measuring range of the sensor?
Resources • Flow meter data sheet
Worksheets • Worksheet 3.7.1 Analysis of a flow meter
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Analysis
Worksheet 3.7.1 Analysis of a flow meter Name:
Date:
Project name: Task: Determine the mode of operation of a flow meter
Sheet 2 of 6
• How does the flow meter work? What other types of flow meter are there?
• How can you measure signals from the sensor?
• What flow rates can be measured with the sensor?
Lower limit of measuring range: Upper limit of measuring range:
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Analysis
Exercise 3.7.2 Analysis of a flow meter Name:
Date:
Project name: Task: Recording the characteristic and calculations
Sheet 3 of 6
Task • Based on the data in the data sheet, calculate the minimum and maximum output frequency of the sensor. • Record the characteristic of the flow meter. Take a sufficient number of measurements and enter these into a chart. • Evaluate the resulting characteristic. Compare your result to the characteristic in the data sheet.
Resources • Oscilloscope • Flow meter data sheet
Worksheets • Worksheet 3.7.2 Analysis of a flow meter
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Analysis
Worksheet 3.7.2 Analysis of a flow meter Name:
Date:
Project name: Task: Calculate the output frequency of a flow meter
Sheet 4 of 6
• Calculate the minimum and maximum output frequency of the sensor.
Where: Find: Solution:
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Analysis
Analysis of a flow meter Name:
Date:
Project name: Task: Determine the characteristic of a flow meter
Sheet 5 of 6
Procedure 1. 2.
First calculate the frequency (Hz) for the flow rates. Measure the frequency with the oscilloscope and set the pump voltage to the desired frequency or flow rate. 3. Calculate the flow rate in the upper container that has to be reached within 1 minute for the set pump output. 4. Determine the flow rate for 1 minute experimentally.
Measured-value table
Flow rate [l/min]
Frequency [Hz]
Calculated flow rate after 1 min
Measured flow after 1 min
1 2 3 5 6 7 8 9 10
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Analysis
Analysis of a flow meter Name:
Date:
Project name: Task: Recording the characteristic of a flow meter
Sheet 6 of 6
flow rate [mm]
Durchfluss [l/min]
Diagram
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]
frequency [1/s]
58
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Analysis
3.8 Analysis of a pressure sensor Exercise 3.8.1 Analysis of a pressure sensor Name:
Date:
Project name: Task: Determining the mode of operation of a pressure sensor
Sheet 1 of 5
Task • How does the pressure sensor work? What other types of pressure sensor are there? • How can you measure the signal from the sensor? • What is the measuring range of the sensor?
Resources • Pressure sensor data sheet
Worksheets • Worksheet 3.8.1 Analysis of a pressure sensor
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Analysis
Worksheet 3.8.1 Analysis of a pressure sensor Name:
Date:
Project name: Task: How does a pressure sensor work?
Sheet 2 of 5
• How does a pressure sensor work? What other types of pressure sensor are there?
• How can you measure the signal from the sensor??
• What is the measuring range of the sensor?
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Analysis
Exercise 3.8.2 Analysis of a pressure sensor Name:
Date:
Project name: Task: Recording the characteristic
Sheet 3 of 5
Task • Record the characteristic of the pressure sensor. Take a sufficient number of measurements and enter these into a chart. • Evaluate the resulting characteristic. Compare your result to the characteristic in the data sheet .
Resources • Pressure sensor data sheet
Worksheets • Worksheet 3.8.2 Analysis of a pressure sensor
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Analysis
Worksheet 3.8.2 Analysis of a pressure sensor Name:
Date:
Project name: Task: Determine the mode of operation of a pressure sensor
3.8.1
62
Sheet 4 of 5
Measured-value table
Pressure [mbar]
Voltage [V]
0
0
50
1.25
100
2.5
150
4.75
200
5.0
250
6.25
300
7.5
350
8.75
400
10
Notes
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Analysis
Analysis of a pressure sensor Name:
Date:
Project name: Task: Recording the characteristic
Sheet 5 of 5
voltage [V]
Spannung [V]
3.8.2
Diagram
10 9 8 7 6 5 4 3 2 1
Druck [mbar] pressure [mbar]
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Analysis
3.9 Analysis of a temperature sensor
Exercise 3.9.1 Analysis of a temperature sensor Name:
Date:
Project name: Task: Determining the mode of operation of a temperature sensor
Sheet 1 of 5
Task • The thermal sensor used is a PT100. Explain this designation. What does it mean? • How can you measure the signal from the sensor? • What is the resistance of the sensor at 0°C, and at 100°C? • What is the measuring range of the sensor?
Resources • PT100 temperature sensor data sheet
Worksheets • Worksheet 3.9.1 Analysis of a temperature sensor
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Analysis
Worksheet 3.9.1 Analysis of a temperature sensor Name:
Date:
Project name: Task: Determining the mode of operation of a temperature sensor
Sheet 2 of 5
• What does the designation PT100 mean?
• How can you measure the signal from the sensor?
• What is the resistance of the sensor at 0°C, and at 100°C?
• What is the measuring range of the sensor?
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Analysis
Exercise 3.9.2 Analysis of a temperature sensor Name:
Date:
Project name: Task: Recording the characteristic
Sheet 3 of 5
Task • Record the characteristic of the temperature sensor. Take a sufficient number of measurements and enter these into a chart. • Evaluate the resulting characteristic. Compare your result to the characteristic in the data sheet .
Note Before starting, consider the procedure for measurement. As you have to heat the fluid in the container, the measurement is more time-consuming. If you make mistakes during measurement, you will have replace the fluid or wait for it to cool! Caution
For technical and physical reasons, you cannot measure the entire characteristic of the sensor. The maximum temperature in the container must not exceed 60°C. Please observe the safety instructions in the manual for your station/system. Resources • Thermometer
Worksheets • Worksheet 3.9.2 Analysis of a temperature sensor
66
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Analysis
Worksheet 3.9.2 Analysis of a temperature sensor Name:
Date:
Project name: Task: Measuring the temperature sensor signals
Measured-value table
T[°C]
Sheet 4 of 5
R[Ohm]
0 10 20 30 40 50 60 70 80 90 100
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Analysis
Temperature sensor Name:
Date:
Project name: Sheet 5 of 5
R [Ohm]
Task: Recording the characteristic
10
68
20
30
40
50
60
70
80
90
100
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110
120 T[°C]
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Analysis
3.10 System behavior of a container
To complete the task you need either: Level Control Station, Compact System, Compact Workstation or Level Workstation.
Exercise 3.10.1 System behavior of a container Name:
Date:
Project name: Task: Determining the behavior of flow into and out of a container
Sheet 1 of 5
Preparation Fill approx. 10l water into the container. This corresponds to a level of approx. 300mm. Task The behavior of flow into and out of the container is to be determined. • Measure the behavior for the container with the pump switched on, outlet valve closed and inlet valve open. • Measure the behavior for the container with the pump switched off, outlet valve closed and inlet valve open. • Measure the behavior for the container with the pump switched on, outlet valve open and inlet valve open. What result do you expect for each of the measurements? Write down the behavior you expect in the prepared worksheet before starting measurements. Make a sufficient number of measurements and enter these into the prepared coordinate systems. Do not forget to label the axes! Compare the characteristics. What do you notice?
Resources • Stopwatch • Worksheet 3.10.1 System behavior of a container
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Analysis
Worksheet 3.10 System behavior of a container Name:
Date:
Project name: Task: Carry out various measurements that will allow you to describe the flow behavior into and out of the container.
Sheet 2 of 5
• What result to you expect to get? Measurement 1: Inlet valve open, outlet valve closed, pump running
Level [mm]
70
Time [s]
Level [mm]
10
160
20
170
30
180
40
190
50
200
60
210
70
220
80
230
90
240
100
250
110
260
120
270
130
280
140
290
150
300
Time [s]
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Analysis
System behavior of a container Name:
Date:
Project name: Task: Carry out various measurements that will allow you to describe the flow behavior into and out of
Sheet 3 of 5
the container.
• What result do you expect to get? Measurement 2: Inlet valve open, outlet valve closed, pump not running
Level [mm]
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Time [s]
Level [mm]
300
150
290
140
280
130
270
120
260
110
250
100
240
90
230
80
220
70
210
60
200
50
190
40
180
30
170
20
160
10
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Time [s]
71
Analysis
System behavior of a container Name:
Date:
Project name: Task: Carry out various measurements that will allow you to describe the flow behavior into and out of the container.
Sheet 4 of 5
• What result to you expect to get? Measurement 3: Inlet valve open, outlet valve open, pump running.
Level [mm]
72
Time [s]
Level [mm]
10
160
20
170
30
180
40
190
50
200
60
210
70
220
80
230
90
240
100
250
110
260
120
270
130
280
140
290
150
300
Time [s]
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Analysis
System behavior of a container Name:
Date:
Project name: Task: Carry out various measurements that will allow you to describe the flow behavior into and out of
Sheet 5 of 5
the container.
300
200
100
0 0
60
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120
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180
240
300
360
73
4
Commissioning
The following application tasks are designed to help the trainee learn to use the controlled systems and the controllers. A controlled system is to be taken into operation with defined parameters. The behavior of the system is to be observed while it is in operation. Target audience and required prior knowledge This task requires technical understanding. The tasks are designed to give the trainees an introduction to control engineering. The trainees should have a theoretical knowledge of the fundamentals of control engineering. This task is designed to allow the trainee to see theory in a practical example and thus enhance their knowledge. Note
Defined parameters are given for commissioning of the controllers used. The parameters were determined using comparable controlled systems, but part tolerances could result in malfunctioning of the controlled systems used. In this case adjustments have to be made to the parameters.
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Commissioning
4.1 Commissioning a levelcontrolled system
To complete the task you require either: Level-Control System, Compact System, Compact Workstation or Level Workstation.
PI diagram of a level-controlled system – for example, the PCS Level Workstation
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Commissioning
Exercise 4.1.1 Commissioning a level-controlled system Name:
Date:
Project name: Task: Manual operation of a controlled system
Sheet 1 of 7
Task The level of a container is to be kept constant. Preparation Fill approx. 10l water into the lower container. Note
Please note that the entire system must not contain more water than the capacity of one container! Settings and procedure 5. 6.
7.
8.
Deairate the pipe system of the level-controlled system. Set the manual valves so that the medium can flow directly into the upper container. Leave the outlet valve closed so that no water can flow out of the container. Open the outlet valve so that water can flow out of the container. Try to maintain the level at a constant midrange reading by switching the pump ON and OFF (0/24VDC). Use analog control of the pump to improve the result. At what pump voltage is the mean measured value of the controlled system constant?
Are you using closed- or open-loop control to regulate the level? Give reasons for your answer. Worksheets • Worksheet “Commissioning a level-controlled system”
76
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Commissioning
Worksheet 4.1.1 Commissioning a level-controlled system Name:
Date:
Project name: Task: Determining the setpoint
Sheet 2 of 7
• Are you using close-loop or open-loop control of the level?
• Is it possible to maintain a constant level manually?
Pump voltage measured for mean measured value Mean measured value [mm]
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Pump voltage [V]
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Commissioning
Exercise 4.1.2 Commissioning a level-controlled system Name:
Date:
Project name: Task: Determining the operating range and operating point of a controlled system.
Sheet 3 of 7
Purpose of the exercise The purpose of the exercise is to replace a person as a controller by an automatic controller. The actual value is to be measured by a sensor. The pump is to be switched ON and OFF by means of a controller. Task Determine a suitable setpoint (desired level) to be used for commissioning of the controller. Take the operating range of the sensor into account. Enter the value of the sensor into the worksheet supplied when you have reached the desired level. Procedure 1. 2.
Determine the values for the sensor based on the data sheet. What is the reading on the container scale for minimum level? What signal does the ultrasound sensor deliver before and after the transducer (for Level Workstation or Compact Workstation). 3. Switch on the pump to fill the upper container to maximum. What is the reading on the container scale? Measure the sensor signal and the transducer output signal. 4. What measured value is exactly midway between the minimum and maximum levels? Measure the sensor signal and the transducer output signal. Worksheets • Worksheet “Commissioning a level-controlled system”,
78
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Commissioning
Worksheet 4.1.2 Commissioning a controlled system Name:
Date:
Project name: Task: Determining the operating range and operating point of a controlled system
Sheet 4 of 7
Determining the operating range of the level sensor Sensor Level h [mm]
Transducer Output signal I [mA]
Output signal U [V]
Max. measured value
Mean measured value
Min. measured value
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Commissioning
Exercise 4.1.3 Commissioning a level-controlled system Name:
Date:
Project name: Task: Operating a controlled system with set values.
Sheet 5 of 7
Task Commission the level-controlled system. Observe the following points: Preparation Acquaint yourself with the operation and parameterization of your controller (industrial controller, PLC or FluidLab-PA). When preparing the controlled system, please observe the notes in Worksheet 4.1.1. 1. 2.
Set the manual valves so that the medium can flow directly into the upper container. Open the outlet valve so that water can flow out of the container.
Parameterization Please set the following parameters for the controller: Parameter
Value
KP
10
TN [s]
5
TV [s]
0
• Start the controller. Worksheets • Worksheet 4.1.3 “Commissioning a level-controlled system”
80
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Commissioning
Exercise 4.1.4 Commissioning a level-controlled system Name:
Date:
Project name: Task: Operating a controlled system with set values
Sheet 6 of 7
Task • How does the system respond? Describe your impressions. • Close valve V112 with the controller running. How does the system respond? Describe your impressions. Worksheets • Worksheet 4.1.3 “Commissioning a level-controlled system”
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Commissioning
Worksheet 4.1.3/4.1.4 Commissioning a level-controlled system Name:
Date:
Project name: Task: Operating a controlled system with set values.
Sheet 7 of 7
• How does the system respond with the outlet valve closed?
How does the system respond with the outlet valve open?
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Commissioning
4.2 Commissioning a flow controlled-system
To complete the task you require either: Flow Control System, Compact System, Compact Workstation or Flow Workstation.
PI diagram for flow controlled-system – for example, PCS Flow Workstation
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Commissioning
Exercise 4.2.1 Commissioning a flow controlled-system Name:
Date:
Project name: Task: Manual operation of a controlled system
Sheet 1 of 10
Task The flow rate in a pipe system is to be kept constant. Preparation Note
Fill approx. 4l water into the (lower) container. Please note that the entire system must not contain more water than the capacity of one container! Settings Set the manual valve so that the medium can flow, for example, via manual valve V104. There should be no flow through other valves and assemblies. Please observe the settings in the manual. Procedure 1. 2.
Switch the pump on. Try to keep the flow rate at a constant 2l/min by switching the pump ON and OFF. 3. Use analog control of the pump to improve the result. At what pump voltage is the flow rate constant at 2l/min? • Are you using open-loop or closed-loop control of the flow? Give reasons for your answer. • Is it possible to achieve a constant flow rate through manual operation? Give reasons for your answer. Worksheets • Worksheet “Commissioning a flow controlled-system”
84
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Commissioning
Worksheet 4.2.1 Commissioning a flow-controlled system, Controlling the flow rate with a pump as final control element Name:
Date:
Project name: Task: Operator as controller
Sheet 2 of 10
• Are you using closed-loop or open-loop control of flow?
• Is it possible to maintain a constant flow rate manually?
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Commissioning
Exercise 4.2.2 Commissioning a flow controlled-system Name:
Date:
Project name: Task: Determining the operating range and operating point of a controlled system.
Sheet 3 of 10
Purpose of the exercise The purpose of the exercise is to replace a person as a controller by an automatic controller. The actual value is to be measured by a sensor. The pump is to be switched ON and OFF by means of a controller. Task Based on the data sheets of the components, develop the measuring chain controlled system – sensor – transducer (if a transducer is present). Determine a suitable setpoint (constant flow rate) for commissioning of the control. Take the operating range of the sensor (actual value) and the pump (final control element) into account. Enter the measured values for the mean flow rate into the worksheet. Calculate the missing values, for example the maximum measurable flow rate of the transducer. Procedure 1.
What is the measured value for minimum flow? What signal does the flow meter deliver before and after the transducer (for Level Workstation or Compact Workstation). 2. Switch the pump on (max.). Measure the output signal of the transducer. 3. What measured value is exactly midway between the minimum and maximum flow rate? Set this as the operating point for the pump voltage. Measure the sensor signal and the output signal of the transducer. 4. What is the pump voltage for a constant flow rate at the operating point? Worksheets Worksheet “Commissioning a flow controlled-system”
86
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Commissioning
Worksheet 4.2.2 Commissioning a flow-controlled system, Controlling the flow rate with a pump as final control element Name:
Date:
Project name: Task: Determining the operating range and operating point of a controlled system.
Sheet 4 of 10
Determining the measuring chain of a flow-controlled system with a pump as final control element Flow control
Sensor
Transducer
Pump operating range Flow rate Q [l/min]
Signal
Flow rate
Output
Input
Output
Flow rate
f [Hz]
Q [l/min]
signal f [Hz]
signal f [Hz]
signal U [V]
Q [l/min]
MAX
MIN
Mean value of the operating range of the control system with a pump as the final control element Mean measured
Dimensionless value
value [l/min]
[ 0.0 – 1.0 ]
Pump voltage [V]
Convert the measured value into a dimensionless value in the range [0-0 – 1.0]. This means that the maximum measurable flow rate of 7.5 l/min would have the value 1.0.
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Commissioning
Exercise 4.2.3 Commissioning a flow controlled-system, Controlling the flowrate with a pump as final control element Name:
Date:
Project name: Task: Operating a controlled system with set values
Sheet 5 of 10
Task Commission the flow controlled-system. Preparation Acquaint yourself with the operation and parameterization of your controller (industrial controller, PLC or FluidLab-PA). When preparing the controlled system, please observe the notes in Worksheet 4.2.1. • Set the manual valves so that the medium can flow directly through manual valve V104. Parameterization Please set the following parameters for the controller: Parameter
Value
KP
1
TN [s]
2
TV [s]
0
• Start the controller. Worksheets Worksheet “Commissioning a flow controlled-system”
88
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Commissioning
Worksheet 4.2.3 Commissioning a flow-controlled system, Controlling the flow rate with a pump as final control element Name:
Date:
Project name: Task: Operating a controlled system with set values
Sheet 6 of 10
• Describe your impressions
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Commissioning
Exercise 4.2.4 Commissioning a flow controlled-system, Controlling the flow rate with a pump as final control element Name:
Date:
Project name: Task: Determining the operating range and operating point of a controlled system.
Sheet 7 of 10
Task For commissioning of the flow controlled-system, determine the operating range of the proportional valve and a suitable operating point. Enter the mean flow rate of the proportional valve into the worksheet. Preparation Set the proportional valve to minimum maximum flow rate. You will find instructions for adjustment in the data sheet for the proportional valve . Procedure 1.
Switch the pump on and activate the proportional valve (Workstation). ® For MPS PA Compact Workstations with Bürkert or Siemens industrial controllers switch the “PUMP” and “VALVE” switches ON. 2. Increase the output voltage for proportional valve V106. 3. What is the reading for the minimum flow rate through proportional valve V106? What signal does the flow meter deliver before and after the transducer? 4. Switch the pump ON (max.). Measure the sensor signal and the output signal of the transducer. 5. What measurement is exactly midway between minimum and maximum flow rate? Set this as the operating point for the pump voltage. Measure the sensor signal and the output signal of the transducer. 6. What is the pump voltage for constant flow rate at the operating point? Worksheets • Worksheet “Commissioning a flow controlled-system”
90
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Commissioning
Worksheet 4.2.4 Commissioning a flow-controlled system, Controlling the flow rate with a pump as final control element Name:
Date:
Project name: Task: Determining the operating range and operating point of a controlled system.
Sheet 8 of 10
Determining the operating range of a flow-controlled system with a proportional valve as final control element Flow control Proportional value operating range
Sensor
Signal f [Hz]
Flow rate Q [l/min]
Flow rate Q [l/min]
Transducer
Output signal f [Hz]
Input signal f [Hz]
Output signal U [V]
Flow rate Q [l/min]
MAX
MIN
Mean value of the operating range of the control system with a proportional valve as the final control element Mean measured
Dimensionless value
value [l/min]
[ 0.0 – 1.0 ]
Pump voltage [V]
Convert the measured value into a dimensionless value in the range [0-0 – 1.0]. This means that the maximum measurable flow rate of 7.5 l/min would have the value 1.0.
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Commissioning
Exercise 4.2.5 Commissioning a flow controlled-system, Controlling the flow rate with a proportional valve as final control element Name:
Date:
Project name: Task: Operating a controlled system with set values
Sheet 9 of 10
Task Commission the flow controlled-system with the proportional valve as the final control element. Set the proportional valve (see notes in the data sheet). Preparation Acquaint yourself with the operation and parameterization of your controller (industrial controller, PLC or FluidLab-PA). When preparing the controlled system, please observe the notes in Worksheet 4.3.1. • Set the manual valves so that the medium can flow directly through proportional valve V106. Parameterization Please set the following parameters for the controller: Parameter
Value
KP
2
TN [s]
1
TV [s]
0
• Start the controller. Worksheets • Worksheet 4.2.5 “Commissioning a flow controlled-system”
92
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Commissioning
Worksheet 4.2.5 Commissioning a flow-controlled system, Controlling the flow rate with a proportional valve as final control element Name:
Date:
Project name: Task: Operating a controlled system with set values
Sheet 10 of 10
• Describe your impressions
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Commissioning
4.3 Commissioning a pressurecontrolled system
To complete the task you need either: pressure-controlled system, Compact System, Compact Workstation or Pressure Workstation.
PI diagram for the pressure-controlled system – for example: PCS Pressure Workstation
94
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Commissioning
Exercise 4.3.1 Commissioning a pressure-controlled system Name:
Date:
Project name: Task: Manual operation of a controlled system
Sheet 1 of 10
Task Commission the pressure-controlled system. The pressure level in the pressure reservoir is to be kept constant at a certain value. Preparation • Fill approx. 5l of water into the lower container. • Close all manual valves. • Set the manual valves so that the medium can be pumped directly into the pressure reservoir. • Pump the water into the pressure reservoir and carefully open pressure relief valve V107 until the pressure reservoir is half-filled with air and half-filled with water. Close pressure relief valve V107. The pressure relief valve is NEVER to be opened during measurements or normal operation! Please note that the entire system must not contain more water than the capacity of one container!
Note
Procedure Try to maintain a constant pressure in the pressure reservoir by switching the pump ON and OFF. Task • Are you using open-loop or closed-loop control of the pressure? Give reasons for your answer. • Is it at all possible to maintain a constant pressure by manual operation? Give reasons for your answer. Worksheets • Worksheet 4.3.1 “Commissioning a pressure-controlled system”
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Commissioning
Worksheet 4.3.1 Commissioning a pressure-controlled system, Controlling the pressure with a pump as final control element Name:
Date:
Project name: Task: Operator as controller
Sheet 2 of 10
• Are you using open-loop or closed-loop control of the pressure?
• Is it possible to maintain constant pressure manually?
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Exercise 4.3.2 Commissioning a pressure-controlled system Name:
Date:
Project name: Task: Determining the operating range and operating point of a controlled system
Sheet 3 of 10
Purpose of the exercise The purpose of the exercise is to replace a person as a controller by an automatic controller. The actual value is to be measured by a sensor. The pump is to be switched ON and OFF by means of a controller. Task Based on the data sheets of the components, develop the measuring chain controlled system – sensor – transducer (if a transducer is present). Determine a suitable setpoint (constant pressure in the container) for commissioning of the control. Take the operating range of the sensor (actual value) and the pump (final control element) into account. Enter the measured values for the mean reservoir pressure into the worksheet. Calculate the missing values. Procedure 1.
What is the measured value for minimum pressure? What signal does the pressure sensor deliver? 2. Switch the pump ON (max.). Measure the sensor signal. What is the maximum pressure the sensor can read? 3. What measured value is exactly midway between the minimum and maximum levels? Set the operating point for the pump voltage to this value. Measure the sensor signal. 4. What is the pump voltage for a constant pressure close to the operating point? Worksheets • Worksheet “Commissioning a pressure-controlled system”
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Commissioning
Worksheet 4.3.2 Commissioning a pressure-controlled system, Controlling the pressure with a pump as final control element Name:
Date:
Project name: Task: Determining the operating range and operating point of a controlled system
Sheet 4 of 10
Determining the measuring chain of a pressure-controlled system with a pump as final control element Pressure control
Sensor
Pump operating range
Measuring range
Pressure
Signal
Pressure
Output signal
p [mbar]
U [V]
p [mbar]
U [V]
MAX
MIN
Mean value of the operating range of the pressure-controlled system with a pump as the final control element
Mean measured value
Dimensionless value
Pump voltage
[l/min]
[ 0.0 – 1.0 ]
[V]
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.
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Exercise 4.3.3 Commissioning a pressure-controlled system Name:
Date:
Project name: Task: Operating a controlled system with set values
Sheet 5 of 10
Task Commission the pressure-controlled system with set values for the control parameters. Preparation Acquaint yourself with the operation and parameterization of your controller (industrial controller, PLC or FluidLab-PA). When setting up the controlled system, please observe the notes in Worksheet 4.3.1. Parameterization A functioning control system comprises a controlled system and a controlling unit (controller). This requires various parameters. Please set the following parameters for the controller: Parameter
Value
KP
1,0
TN [s]
2,0
TV [s]
0,1
• Start the controller. • How does the system respond? Describe your impressions on the worksheet provided. Worksheets • Worksheet “Commissioning a pressure-controlled system”, IBN_P_AB04_3
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Commissioning
Worksheet 4.3.3 Commissioning a pressure-controlled system, Controlling the pressure with a pump as final control element Name:
Date:
Project name: Task: Operating a controlled system with set values
Sheet 6 of 10
• Describe your impressions
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Exercise 4.3.4 Commissioning a pressure-controlled system Name:
Date:
Project name: Task: Determining the operating range and operating point of a controlled system.
Sheet 7 of 10
Task Determine the working range and a suitable operating point for a proportional valve for commissioning of a pressure-controlled system. Enter the measured value for the mean operating pressure that can be controlled with the proportional valve into the worksheet. Preparation Set the proportional valve to minimum / maximum flow rate. (This is not a typographical error!). You will find instructions on adjustment in the data sheet for the proportional valve. Procedure 1.
Switch the pump ON and activate the proportional valve. ® For MPS PA Compact Workstations with Bürkert or Siemens industrial controllers switch the “PUMP” and “VALVE” switches ON. 2. What is the measured value for the minimum pressure through proportional valve V106? What signal does the pressure sensor deliver? 3. Increase the output voltage for proportional valve V106 to maximum. Measure the sensor signal and the output signal of the transducer. 4. What measurement is exactly midway between minimum and maximum flow rate? Set this as the operating point for the pump voltage. Measure the sensor signal and the output signal of the transducer. 5. What is the pump voltage for system pressure at the operating point? Worksheets • Worksheet “Commissioning a pressure-controlled system”, IBN_P_AB04_3
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Commissioning
Worksheet 4.2.4 Commissioning a pressure-controlled system, Controlling the pressure with a proportional valve as final control element Name:
Date:
Project name: Task: Determining the operating range and operating point of a controlled system
Sheet 8 of 10
Determining the operating range of the pressure-controlled system with a proportional valve as final control element Pressure control Pump operating range Pressure p [mbar]
Signal U [V]
Sensor Measuring range Pressure p [mbar]
Output signal [V]
MAX
MIN
Mean value of the operating range of the pressure-controlled system with a proportional valve as the final control element Mean measured value [l/min]
Dimensionless value [ 0.0 – 1.0 ]
Pump voltage [V]
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.
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Exercise 4.3.5 Commissioning a pressure-controlled system Name:
Date:
Project name: Task: Operating a controlled system with set values
Sheet 9 of 10
Task Commission the pressure-controlled system with proportional valve with set values for the control parameters . Preparation Acquaint yourself with the operation and parameterization of your controller (industrial controller, PLC or FluidLab-PA). When preparing the controlled system, please observe the notes in Worksheet 4.3.1. Parameterization A functioning control system comprises a controlled system and a controlling unit (controller). This requires various parameters. Please set the following parameters for the controller: Parameter
Value
KP
3.0
TN [s]
8.0
TV [s]
2.0
• Open manual valve V109 (see PI diagram) between the pressure reservoir and the supply tank a minimum amount to achieve a constant “system load” and start the controller. • How does the system respond? Describe your impressions in the worksheet provided. Worksheets • Worksheet “Commissioning a pressure-controlled system”
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Commissioning
Worksheet 4.3.5 Commissioning a pressure-controlled system, Controlling the pressure with a proportional valve as final control element Name:
Date:
Project name: Task: Operating a controlled system with set values
Sheet 10 of 10
• Describe your impressions
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4.4 Commissioning a temperature-controlled system
To complete the task you need either: Temperature-Control System, Compact System, Compact Workstation or Temperature Workstation.
PI diagram for a temperature-controlled system – for example, PCS Temperature Workstation
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Commissioning
Exercise 4.4.1 Commissioning a temperature-controlled system Name:
Date:
Project name: Task: Manual operation of a controlled system
Sheet 1 of 6
Preparation Fill approx. 5l water into the (lower) container for temperature-controlled system. Note
Please note that the entire system must not contain more medium than the capacity of one container! Settings Fill the lower container so that the heating element is completely submerged. The higher the level in the container, the longer it will take to heat the medium. Task Measure the current temperature of the medium. Add 5K. Attempt to reach and maintain this temperature by switching the heater ON and OFF. For safety reasons, the heater is limited to a maximum temperature of 60°C. • Are you using open-loop or closed-loop control? Give reasons for your answer. Worksheets • Worksheet “Commissioning a temperature-controlled system”
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Commissioning
Worksheet 4.4.1 Commissioning a temperature-controlled system Name:
Date:
Project name: Task: Manual operation of a controlled system
Sheet 2 of 6
• Are you using open-loop or closed-loop control of temperature?
• Is it possible to maintain a constant temperature manually?
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Commissioning
Exercise 4.4.2 Commissioning a temperature-controlled system Name:
Date:
Project name: Task: Determining the operating range and operating point of a controlled system
Sheet 3 of 6
Purpose of the exercise The purpose of the exercise is to replace a person as a controller by an automatic controller. The actual value is to be measured by a sensor. The heater is to be switched ON and OFF by means of a controller. Task Determine the signal delivered by your temperature sensor when submerged in the heated medium (Worksheet 4.4.1). Measure the resistance of the temperature sensor. Calculate the temperature from this. Worksheets • Worksheet “Commissioning a temperature-controlled system”
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Commissioning
Worksheet 4.4.2 Commissioning a temperature-controlled system Name:
Date:
Project name: Task: Determining the operating range and operating point of a controlled system
Sheet 4 of 6
Determining the measuring chain of the temperature-controlled system with a heater as the final control element Temperature control Heater operating range Temperature t [°C]
MAX
60
MIN
20
Sensor Measuring range
Resistance R [Ω Ω]
Temperature t [°C]
Transducer
Resistance R [Ω Ω]
Input resistance R [Ω Ω]
Output signal U [V]
Temperature t [°C]
Mean value of the operating range of the temperature-controlled system with a heater as the final control element Mean measured value
Dimensionless value
t [°C]
[0.0 - 1.0]
Convert the measured value into a dimensionless value in the range [0-0 – 1.0]. This means that the maximum measurable temperature of 100 °C would have the value 1.0.
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Commissioning
Exercise 4.4.3 Commissioning a temperature-controlled system Name:
Date:
Project name: Task: Operating a controlled system with set values
Sheet 5 of 6
Task Commission the temperature-controlled system with heater. Parameterization Please parameterize your controller with the following values: FluidLab-PA Parameter
Switching hysteresis
2-point controller
0.05
Bürkert
Sipart DR19
Parameter
industrial PID controller
industrial PID controller
KP
4.0
TN
2500
TV
0.0
• Use the pump to circulate the medium during normal operation. Start the controller. • How does the system respond? Describe your impressions. Worksheets • Worksheet “Commissioning a temperature-controlled system”, IBN_T_AB04_4
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Worksheet 4.4.3 Commissioning a temperature-controlled system Name:
Date:
Project name: Task: Operating a controlled system with set values
Sheet 6 of 6
• Describe your impressions
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5
Control engineering
Machines and systems often require variables such as pressure, temperature, flow rate or level to be controlled to a predetermined value. Also, these values should not change in the event of faults. This type of task is undertaken by a controller. Closed-loop control engineering covers all problems associated with this task. The variable to be controlled is measured, converted and supplied to the automatic controller as an electrical signal. The controller then compares this value (or value curve) with the preset value. The corrective action to be taken in the system is then derived. Finally, a suitable point for corrective action to influence the controlled variable must be determined, for example, the heater’s regulator. Here, the response of the system is important. Closed-loop control
Standard DIN 19226 applies: Closed-loop control is a process whereby one variable, namely the variable to be controlled (controlled variable) is continuously monitored, compared with another variable, namely the reference variable, and – depending on the outcome of this comparison – influenced in such a manner as to bring about adaptation to the reference variable despite any disturbance variables. This feedback results in a closed action loop.
The control technician is responsible for: • • • • • • • • •
Identification of the controlled system Definition of the controlled variable Determination of measuring point Determination of disturbance variables Selection of the final control elements Determining whether a controller will result in worthwhile benefit Selection of suitable controller(s) Installation of controller(s) in compliance with regulations Commissioning, parameterization and optimization
These topics are covered in greater detail in the following exercises, which are designed to give trainees an introduction to control engineering. Trainees should have a basic theoretical knowledge of control engineering.
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Control engineering
5.1 Identifying the controlled system
The time response of a controlled system must be known for optimum controller selection. This allows conclusions to be drawn regarding the dynamic response of the controlled system and the controller settings to be determined. The time response of a controlled system is determined by recording a transient response of the system. For systems with delay, such as where there is energy storage, the time constant of the controlled system is determined by applying a tangent or, in the case of multiple delays, an inflectional tangent.
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Control engineering
Exercise 5.1.1 Identification of a controlled system Name:
Date:
Controlled system: Task: Determining the time response of a controlled system
Sheet 1 of 3
Task Determine the transient response of the controlled system at the operating point. The operating point is determined in Chapter 4, Commissioning. • What type of system is it or of which order is it? Sketch the curve in Worksheet 5.1.1. • Determine the order by drawing a tangent to the curve and comparing the curve in Worksheet 5.1.1. • Graphically determine the time constant of the controlled system in Worksheet 5.1.2.
Resources • Work book, Control of Temperature, Flow rate and Level, 170677 Worksheets • Worksheet 5.1.1 “Determining the order” • Worksheet 5.1.2 “Determining the time constant”
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Control engineering
Worksheet 5.1.1 Identification of a controlled system Name:
Date:
Controlled system: Task: Determining the order of a controlled system
Sheet 2 of 3
• What type of system is it or of which order is it? Sketch the curve: process value / actual value
time • Determine the order by drawing a tangent to the curve and comparing the curve:
process value / actual value order
order
time
Order:
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Control engineering
Worksheet 5.1.2 Identification of a controlled system Name:
Date:
Controlled system: Task: Determining the time constant of a controlled system
Sheet 3 of 3
• Determine the time constant of the controlled system.
Procedure 1. 2. 3.
Apply an (origin) tangent to the curve. Draw the “maximum value” as a horizontal line at the maximum actual value. Draw a perpendicular as a vertical line (90° to the maximum value) at the intersection of “maximum value” and “tangent”. 4. Draw a horizontal line at the intersection of the curve and the perpendicular. The actual value at this point should be 63% of the "maximum value". 5. Read off on the time scale how long the system needs to reach 63%. This is the time constant.
S = output variable when t = T, T = 63%
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Control engineering
5.2 Controller functions
The following theoretical exercises allow trainees to consolidate their knowledge of control engineering. The purpose of the exercise is to give the trainee the opportunity to see how a real controlled system responds to various controllers and why it is necessary to find a suitable controller and to parameterize it correctly. Target audience and required prior knowledge This exercise requires technical understanding. Basic knowledge of control engineering is absolutely essential. This exercise is for control technicians and trainees who have to make use of basic control engineering.
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Control engineering
Exercise 5.2.1 Mode of operation of a P controller Name:
Date:
Controlled system: Task: Determining the mode of operation of a controlled system with a P controller
Sheet 1 of 12
Task • Try to control the controlled system with a P controller. Set each of the amplification factors given in the table in turn. • Record the transient response. • Describe your result. How does the system respond? Parameter list
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Parameter
Value
KP
2
KP
5
KP
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Control engineering
Worksheet 5.2.1 Mode of operation of a P controller Name:
Date:
Project name: Task: Determining the mode of operation of a controlled system with P controller
Sheet 2 of 12
• How does the system respond to control by a P controller?
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Control engineering
Exercise 5.2.2 Mode of operation of a I controller Name:
Date:
Controlled system: Task: Determining the mode of operation of a controlled system with an I controller
Sheet 3 of 12
Task • Try to control the controlled system with an I controller. Set the parameters shown in the table. • Describe your result. How does the system respond? Parameter list
®
Parameter
Value
TN
10
TN
5
TN
2
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Control engineering
Worksheet 5.2.2 Mode of operation of a I controller Name:
Date:
Controlled system: Task: Determining the mode of operation of a controlled system with I controller
Sheet 4 of 12
• How does the system respond to control by an I controller?
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Control engineering
Exercise 5.2.3 Mode of operation of a PI controller Name:
Date:
Controlled system: Task: Determining the mode of operation of a controlled system with a PI controller
Sheet 5 of 12
Task • Try to control the controlled system with a PI controller. Set the parameters shown in the table. • Describe your result. How does the system respond? Parameter list
®
Parameter
Value
Parameter
Value
KP
2
TN
10
KP
2
TN
5
KP
5
TN
10
KP
5
TN
5
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Control engineering
Worksheet 5.2.3 Mode of operation of a PI controller Name:
Date:
Controlled system: Task: Determining the mode of operation of a controlled system with PI controller
Sheet 6 of 12
• How does the system respond to control by a PI controller?
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Control engineering
Exercise 5.2.4 Mode of operation of a PD controller Name:
Date:
Controlled system: Task: Determining the mode of operation of a controlled system with a PD controller
Sheet 7 of 12
Task • Why does it not make sense to try a D controller here? • Is a controller only equipped with a D part used in other systems? • Try to control the controlled system with a PD controller. Set the parameters shown in the table. • Describe your result. How does the system respond?
Parameter list
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Parameter
Value
Parameter
Value
KP
2
TV
1
KP
2
TV
5
KP
5
TV
1
KP
5
TV
5
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Control engineering
Worksheet 5.2.4 Mode of operation of a PD controller Name:
Date:
Controlled system: Task: Determining the mode of operation of a controlled system with PD controller
Sheet 8 of 12
• How does the system respond to control by a PD controller?
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Control engineering
Exercise 5.2.5 Mode of operation of a PID controller Name:
Date:
Controlled system: Task: Determining the mode of operation of a controlled system with a PID controller
Sheet 9 of 12
Task • Try to control the controlled system with a PID controller. Set the parameters shown in the table. • Describe your result. How does the system respond?
Parameter list
®
Parameter
Value
Parameter
Value
Parameter
Value
KP
1
TN
1
TV
1
KP
1
TN
2
TV
1
KP
1
TN
2
TV
5
KP
1
TN
5
TV
1
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Control engineering
Worksheet 5.2.5 Mode of operation of a PID controller Name:
Date:
Project name: Task: Determining the mode of operation of a controlled system with PID controller
Sheet 10 of 12
• How does the system respond to control by a PID controller?
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Control engineering
Exercise 5.2.6 Selection of controller functions Name:
Date:
Controlled system: Task: Selection of suitable controller functions for a controlled system
Sheet 11 of12
Task • Which controller is suitable for which controlled system? • Assign the P, I , PI and PID controllers to the level-, flow-, pressure- and temperature-controlled systems with the aid of Worksheet 5.2.6.
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Control engineering
Worksheet 5.2.6 Mode of operation of controllers Name:
Date:
Project name: Task: Assignment of a controller to a controlled system
Sheet 12 of 12
• Which controller is suitable for which controlled system? • Assign the P, I , PI and PID controllers to the level-, flow rate-, pressure- and temperature-controlled systems with the aid of worksheet 5.2.6.
Permanent control deviation
No permanent control deviation
P
PI
PD
PID
Level
Flowrate
Pressure
Temperature
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Control engineering
5.3 Controller setting using the Ziegler-Nichols method
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Control engineering
Exercise 5.3.1 Controller setting using the Ziegler-Nichols method Name:
Date:
Controlled system: Task: Describe the procedure used in the Ziegler-Nichols method
Sheet 1 of 5
Task • What procedure must you adopt when using the Ziegler-Nichols method? Name the sequence of steps. • How must you configure the controller to use the Ziegler-Nichols method? • Which values must you know in order to use the Ziegler-Nichols method?
Resources • Worksheet
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Control engineering
Worksheet 5.3.1 Ziegler- Nichols method Name:
Date:
Project name: Task: Describe the procedure used in the Ziegler-Nichols method
Sheet 2 of 5
• Sequence of steps
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Control engineering
Exercise 5.3.2 Controller setting using the Ziegler-Nichols method Name:
Date:
Controlled system: Task: Use the Ziegler-Nichols method
Sheet 3 of 5
Task • Calculate and parameterize a suitable controller for a controlled system using the Ziegler-Nichols method.
Resources • Worksheet
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Control engineering
Exercise 5.3.3 Controller setting using the Ziegler-Nichols method Name:
Date:
Controlled system: Task: Test and examine your results
Sheet 4 of 5
Task • Test the results you obtained in 5.3.2. Are your values correct? If necessary, locate the error and recalculate the values. • Are you happy with the result achieved? Indicate briefly what could be better. Explain.
Resources • Worksheet
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Control engineering
Worksheet 5.3.2 Ziegler- Nichols method Name:
Date:
Project name: Task: Test and examine your results
Sheet 5 of 5
• Are you happy with the result achieved with the Ziegler- Nichols method? Indicate briefly what could be better. Explain.
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Control engineering
5.4 Controller parameterization using the Chien-HronesReswick method
The following application task offers trainees the opportunity to observe a controlled system in operation. The procedure does not aim to provide trainees with a slow introduction to control engineering, but to present them with a finished controller and then to acquaint them with the individual components. In this task a standard controller parameterization procedure is explained. The aim is to show trainees that control of a system can be achieved with simple standard methods. Target audience and required prior knowledge This task requires technical understanding. The task is designed to give the trainee an introduction to control engineering. Theoretical knowledge of control engineering is required.
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Control engineering
Exercise 5.4.1 Controller parameterization using the Chien-Hrones-Reswick method Name:
Date:
Controlled system: Task: Describe the procedure used in the Ziegler-Nichols method
Sheet 1 of 6
Task • What procedure must you adopt when using the Chien-Hrones-Reswick method? • Which values must you know in order to use the Chien-Hrones-Reswick method?
Resources • Worksheet 5.4.1
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Control engineering
Worksheet 5.4.1 Controller parameterization using the Chien-Hrones-Reswick method Name:
Date:
Project name: Task: Describe the procedure used in the Ziegler-Nichols method
Sheet 2 of 6
• Procedure
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Control engineering
Exercise 5.4.2 Controller parameterization using the Chien-Hrones-Reswick method Name:
Date:
Controlled system: Task: Use the Chien-Hrones-Reswick method
Sheet 3 of 6
Task • Calculate and parameterize a suitable controller for a controlled system using the Chien-Hrones-Reswick method.
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Control engineering
Worksheet 5.4.3 Controller parameterization using the Chien-Hrones-Reswick method Name:
Date:
Controlled system: Task: Use the Chien-Hrones-Reswick method
Sheet 4 of 6
Task • Calculate and parameterize a suitable controller for a controlled system using the Chien-Hrones-Reswick method.
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Control engineering
Worksheet 5.4.3 Controller parameterization using the Chien-Hrones-Reswick method Name:
Date:
Project name: Task: Determine the controller parameters and test the controller
Sheet 5 of 6
• In what way could the results achieved with the Chien-Hrones-Reswick method be better? Describe briefly and explain.
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Control engineering
Exercise 5.4.3 Controller parameterization using the Chien-Hrones-Reswick method Name:
Date:
Controlled system: Task: Test and examine your results.
Sheet 6 of 6
Task • Test the results you obtained in 5.4.1 Are your values correct? If necessary, locate the error and recalculate the values. • Are you happy with the result achieved? Indicate briefly what could be better. Explain.
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Control engineering
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