Process Control Systems - Industrial Automation Training

1 WorkbookLearning system for Automation and Communications171 149 Process Control system Control of temperature, flowand filling levelOrder No.:171 149 Description:WORKBOOKD esignation: :10/1997 , M. SchwarzGraphics:D. SchwarzenbergerAuthors:H. Bischoff*, D. Hofmann*, E. v. TerziEditor:F. Ebel* Technische Universit t DresdenInstitut f r AutomatisierungstechnikD-01062 Dresden 1997 by Festo Didactic GmbH & Co., Rechbergstra e 3, D-73770 DenkendorfThe copying, distribution and utilization of this document as well as thecommunication of its contents to others without expressed authorizationis prohibited. Offenders will be held liable for the payment of rights reserved, in particular the right to carry out patent, utility mo-del or ornamental design.

2 5 Notes regarding the concept of the workbook .. 6 Notes on safety and procedure .. 7 Part AExercises and WorksheetsExercise 1 Overview of project design Process .. A1-1 Exercise 2 Core project design Fundamental methodology forthe project design of Automation Systems .. A2-1 Execise 3 Closed-loop Control synthesis and design ofbinary Control Systems .. A3-1 Exercise 4 Process protection measures .. A4-1 Exercise 5 Connection of Pt100 temperature sensors .. A5-1 Exercise 6 Closed-loop Control technology setting ofcontrol parameters .. A6-1 Part BFundamentalsChapter 1 Fundamentals of closed-loop Control is closed-loop Control technology?

3 Is a system ? .. and closed-loop Control .. terminology .. system .. of the dynamic responseof a controlled system .. response .. response of a controller .. details of controllers .. B1-20 1 Table of contentsFesto Didactic Process Control of operation of various controller types .. proportional controller .. integral-action controller .. PI controller .. PD controller .. PID controller .. B1-27 Chapter 2 Projecting of automated .. of small-scale experimental system .. of project design Process .. Core project design Fundamental methodology forthe project design of Automation Systems .

4 Regarding project configuration .. specification - Performance specification .. flow diagram .. block diagrams .. regarding the project design of auxiliary power .. regarding assembly project design .. Control loop synthesis .. comments .. analysis / Model configuration .. configuration and parameterisation .. of Automation devices .. comments .. fundamentals .. protection measures .. B2-102 Chapter 3 Commissioning and maintenance of Process and Automation system .. comments Commissioning strategy .. of auxiliary power (Part 1 and Part 2) .. of closed Control loops, binary Control Systems and safety devices.

5 The stand-by modeof the technical Process .. of technical Process Systems (small-scale experimental system ) .. finding and error handling Damage prevention Training .. B3-132 Table of contentsProcess Control system Festo DidacticChapter 4 Fault is meant by maintenance? .. repairs in the event of malfunction .. for systematic repairs .. finding .. fault finding .. documentation .. analysis .. analysis .. B4-12 Part CSolutionsSolution 1 Overview of project design Process .. C1-1 Solution 2 Core project design Fundamental methodology for the project design of Automation Systems .

6 C2-1 Solution 3 Closed Control loop synthesis and planning of binary Control Systems .. C3-1 Solution 4 Process protection measures .. C4-1 Solution 5 Connection of Pt100 temperature sensors .. C5-1 Solution 6 Closed loop Control technology .. C6-1 3 Table of contentsFesto Didactic Process Control SystemPart DAppendixChapter 1 ProVis Process visualisation prerequisites .. of ProVis .. the program .. D1-34 Table of contentsProcess Control system Festo DidacticPrefaceThe Festo Didactic Learning system for Automation and Communica-tions is designed to meet various Training needs and professional re-quirements and consists of the following Training packages.

7 Basic packages provide basic knowledge covering a wide range packages deal with the important topics of open andclosed loop Control packages explain the basic function of automated packages facilitate vocational and further Training in linewith Industrial authors have produced this book in order to present to you themain Training contents relating to the Automation of continuous proces-ses in a practice-related form intended for vocational and further train-ing. To this end, the extensive experience available at Festo Didacticand at the Department of Automation Technology at the Dresden Uni-versity of Technology has been gathered and combined in the form ofthis authors, Dr.

8 Eng. H. Bischoff and Dr. Eng. D. Hofmann, both holdposts at the Department of Automation Technology at the Dresden Uni-versity of Technology and are responsible for student Training in theareas of project designing of Automation Systems , comprehensive prac-tical Training in Process Automation and the design of closed controlloops and binary Control authors feel that this workbook will provide a meaningful contribu-tion towards application-related vocational and further Training , andhope that those who have studied the book will have gained some use-ful readers are invited to contribute with tips.

9 Criticisms and suggestionsfor the further improvement of this 1997 The authors 5 PrefaceFesto Didactic Process Control SystemLayout of the workbookThe workbook is made up as follows:Section A CourseSection B FundamentalsSection C SolutionsSection D AppendixSection A Course is designed to teach project design and closedcontrol loop synthesis with the help of practical exercises. Section B Fundamentals contains general technical knowledge asan addition to the Training contents of the practical exercises in SectionA. It provides an explanation of the essential technical terminology andestablishes the theoretical correlations with the help of C Solutions represents the results of the practical exercisesand provides brief D Appendix contains the software for the ProVis ConceptProcess Control system Festo DidacticNotes regarding safety and procedure Notes regarding safetyThe following advice should be followed in the interest of your ownsafety.

10 GeneralTrainees must not work on the station unless supervised by a observe the specifications given in the data sheets for theindividual components, and in particular all advice regarding safety!ElectricsElectrical connections are to be wired up or disconnected only whenpower is disconnected!The heater is operated using 230 V AC. Please observe the currentsafety regulations during commissioning!(DIN VDE 0113 [EN 60204])MechanicsMount all components on the maximum operating temperature of the containers of + 65 Cmust not be not operate the heater, unless the heating element is fully immer-sed in the fluid.