38-930-M (Manual de Practicas

E-Learning
Electricity & Electronics
Control & Instrumentation
Process Control
Mechatronics
Telecommunications
PROCON Pressure Process Rig 38-930-M
Electrical Power & Machines
Test & Measurement
PROCON Pressure Process Rig 38-930-M

For use with 38-714
Feedback Instruments Ltd, Park Road, Crowborough, E. Sussex, TN6 2QR, UK. Telephone: +44 (0) 1892 653322, Fax: +44 (0) 1892 663719. email: feedback@fdbk.co.uk website: http://www.fbk.com Manual: 38-930-M Ed01 122004 Printed in England by Fl Ltd, Crowborough
Feedback Part No. 116038930M
Notes
PROCON PRESSURE PROCESS RIG
Preface
THE HEALTH AND SAFETY AT WORK ACT 1974

We are required under the Health and Safety at Work Act 1974, to make available to users of this equipment certain information regarding its safe use.+ The equipment, when used in normal or prescribed applications within the parameters set for its mechanical and electrical performance, should not cause any danger or hazard to health or safety if normal engineering practices are observed and they are used in accordance with the instructions supplied. If, in specific cases, circumstances exist in which a potential hazard may be brought about by careless or improper use, these will be pointed out and the necessary precautions emphasised. While we provide the fullest possible user information relating to the proper use of this equipment, if there is any doubt whatsoever about any aspect, the user should contact the Product Safety Officer at Feedback Instruments Limited, Crowborough. This equipment should not be used by inexperienced users unless they are under supervision. We are required by European Directives to indicate on our equipment panels certain areas and warnings that require attention by the user. These have been indicated in the specified way by yellow labels with black printing, the meaning of any labels that may be fixed to the instrument are shown below:
CAUTION RISK OF DANGER Refer to accompanying documents
CAUTION RISK OF ELECTRIC SHOCK
CAUTION ELECTROSTATIC SENSITIVE DEVICE
PRODUCT IMPROVEMENTS
We maintain a policy of continuous product improvement by incorporating the latest developments and components into our equipment, even up to the time of dispatch. All major changes are incorporated into up-dated editions of our manuals and this manual was believed to be correct at the time of printing. However, some product changes which do not affect the instructional capability of the equipment, may not be included until it is necessary to incorporate other significant changes.
COMPONENT REPLACEMENT Where components are of a Safety Critical nature, i.e. all components involved with the supply or carrying of voltages at supply potential or higher, these must be replaced with components of equal international safety approval in order to maintain full equipment safety. In order to maintain compliance with international directives, all replacement components should be identical to those originally supplied. Any component may be ordered direct from Feedback or its agents by quoting the following information:
1.
Equipment type
2.
Component value
3. Component reference 4. Equipment serial number Components can often be replaced by alternatives available locally, however we cannot therefore guarantee continued performance either to published specification or compliance with international standards.
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Preface
DECLARATION CONCERNING ELECTROMAGNETIC COMPATIBILITY

Should this equipment be used outside the classroom, laboratory study area or similar such place for which it is designed and sold then Feedback Instruments Ltd hereby states that conformity with the protection requirements of the European Community Electromagnetic Compatibility Directive (89/336/EEC) may be invalidated and could lead to prosecution. This equipment, when operated in accordance with the supplied documentation, does not cause electromagnetic disturbance outside its immediate electromagnetic environment.
COPYRIGHT NOTICE
Feedback Instruments Limited

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of Feedback Instruments Limited.
ACKNOWLEDGEMENTS
Feedback Instruments Ltd acknowledge all trademarks. IBM, IBM - PC are registered trademarks of International Business Machines. MICROSOFT, WINDOWS XP, WINDOWS 2000, WINDOWS NT, WINDOWS ME, WINDOWS 98, WINDOWS 95, WINDOWS 3.1 and Internet Explorer are registered trademarks of Microsoft Corporation.
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Contents
TABLE OF CONTENTS 1 Pressure Rig Familiarisation

1.1 1.2 1.3 1.4 1.5 1.6 Introduction Practical 1 : System Pressurisation Practical 2 : Current Source Calibration Practical 3 : I/P Converter and Pneumatic Control Valve Operation Practical 4 : Pressure Sensor and Transmitter Practical 5 : Differential Pressure Sensor and Transmitter
1-1
1-2 1-6 1-8 1-9 1-11 1-12
Controller Familiarisation
2.1 2.2 2.3 2.4 2.5 2.6 38-300 Process Controller Control Systems Automatic Control Systems Practical 1 : Serial Communication Practical 2 : Navigating the 38-300 Practical 3 : Using the 38-300
2-1
2-2 2-2 2-4 2-9 2-14 2-22
Controller Calibration
3.1 3.2 3.3 Theory Practical 1 : 38-300 Calibration Practical 2 : Reading the 38-300
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3-2 3-8 3-12
The Pressure Sensor and Transmitter

4.1 Theory
4-1
4-2
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PROCON PRESSURE PROCESS RIG 4.2 4.3 Practical 1: Pressure Sensor and Transmitter Calibration Practical 2: Linearity and Hysteresis
Contents 4-3 4-6
The I to P Converter
5.1 5.2 5.3 Theory Practical 1: The I to P Converter Practical 2: The I to P Converter Linearity and Hysteresis
5-1
5-2 5-3 5-6
The Pneumatic Control Valve

6.1 6.2 Theory Practical 1: Characteristics of the Pneumatic Control Valve
6-1
6-2 6-3
6.3 Practical 2: Pneumatic Control Valve Characteristics at Different Pressure Ranges 6-7
System Response and the Air Receiver

7.1 7.2 7.3 Theory Practical 1: System Response without the Air Receiver Practical 2: System Response with the Air Receiver
7-1
7-2 7-3 7-6
Principles of Proportioning Valve

8.1 8.2 8.3 8.4 Theory Practical 1: Maintaining Pressure at a Set-Point Practical 2: Effects of Disturbance Practical 3: Changing the Set-Point Remotely
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8-2 8-3 8-6 8-6
Proportional only Process Control

9.1 Theory
9-1
9-2
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PROCON PRESSURE PROCESS RIG 9.2 9.3 9.4 9.5 Band Practical 1: Proportional Control- Removing Offsets Practical 2: Proportional Control- Effects of Disturbance
Contents 9-3 9-6 9-6 9-7
Practical 3: Proportional Control - Effects of Changing the Set Point Practical 4: Proportional Control - Effect of Changing the Proportional
10 Proportional + Integral Action Process Controller

10.1 10.2 10.3 10.4 Theory Practical 2: Effects of Changing the Set Point Practical 3: Effects of Changing the Integral Action Time Practical 4: Effects of Changing the Proportional Band
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10-2 10-5 10-5 10-6
11 Proportional + Derivative Action Process Controller

11.1 11.2 11.3 11.4 11.5 11.6 Theory Practical 1: P + D Control of Pressure Practical 2: Effects of Disturbance Practical 3: Effect of Changing the Set Point Practical 4: Effects of Changing the Derivative Time Practical 5: Effect of Changing the Proportional Band
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11-2 11-3 11-5 11-5 11-5 11-6
12 Optimising Proportional Integral and Derivative Controllers

12.1 12.2 12.3 12.4 Theory Practical 1: Ultimate Period/Ziegler-Nichols Practical 2: Reaction Curve Method Practical 3: Evaluation of Controller by Introducing a Disturbance
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12-2 12-3 12-6 12-7
13 PID Controller and the Air Receiver

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PROCON PRESSURE PROCESS RIG 13.1 13.2 13.3 Theory Practical 1: System Response
Contents 13-2 13-3
Practical 2: Determining Optimum Settings for the Process Controller 13-5
14 Calibration of the Differential Pressure Sensor and Transmitter 14-1

14.1 14.2 Theory 14-2
Practical 1: Calibration of the Differential Pressure Sensor and Transmitter14-3
15 Flow Control in the Process Rig

15.1 15.2 15.3 15.4 15.5 Theory Practical 1: Maintaining a flow by using the Control Valve Practical 2: Operation of Square Root Extractor Practical 3: Changing the Set Point Remotely Results Table
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15-2 15-4 15-6 15-7 15-8
TOC-4
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Chapter 1 PROCON PRESSURE PROCESS RIG Pressure Rig Familiarisation
1 Pressure Rig Familiarisation

Objective Equipment Required To familiarise the student with the rig and demonstrate how to calibrate the various components Qty Apparatus 1 1 1 1 1 38-200 Process Interface 38-300 Process Controller 38-714 Pressure Control Module 38-461 Pressure Transmitter 38-490 Digital Display Module Note: The equipment requires a supply of clean compressed air. Prerequisite Assignments Knowledge Level None None
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1.1
Introduction
The successful design and operation of industrial plant requires the optimum choices of instrumentation and control equipment together with the ability to commission, monitor and maintain such equipment. Technicians and engineers need to be trained in these skills, particularly in view of the rapid advances in the use of electronics and microcomputers in process control. This range of specially designed equipment allows practical appreciation and understanding of the whole spectrum of process control technology from the characteristics of individual components to complex control loops operating on real processes. This assignment describes the 38-714 Pressure Process Rig, which is part of the PROCON range of equipment designed to introduce and demonstrate the principles of process measurement and control. The system includes those pneumatic control components of interest to the process industries. The design allows study of component operation and connection to electrical control devices through the use of pressure/current transducers.
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1.1.1 Pressure Rig Description The Pressure Process Rig 38-714 is shown below:
The front panel of the rig incorporates a schematic diagram of the equipment which identifies the major components and relevant connections in standard pneumatic notation. The unit consists of a pipeline on which are mounted a Pneumatic Control Valve, Orifice Block and pressure tappings. The flow discharges directly to atmosphere or via an Air Receiver to vary the process lag. The valve is operated from a Current to Pressure Converter, and sensors for direct and differential pressure facilitates measurement of pressure and flow respectively.
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1.1.2 Process Rig Controller The square root extraction facility of the 38-300 Process Controller is used with the Current to Pressure Converter to provide a linear signal. Both sensors are provided with conditioners. The pipework and fittings are mounted on a support frame which is designed to stand on a bench top. The unit is designed to operate with the 38-200 and 38-300 Process Interface and Process Controller to configure open or closed loop control circuits. These are explored in greater detail within a later assignment. Compressed air for the pneumatic instrumentation and process is connected to a common inlet. Air for the instrumentation is regulated by a Regulator R1 and the operating pressure in indicated on a Gauge G1. Air for the process is regulated by a Regulator R2 and the operating pressure is indicated on Gauge G3. The pneumatic instrumentation comprises a I/P Converter and Pneumatic Control Valve. The I/P Converter accepts a 4-2O mA control signal from the 38-200 Process Interface and converts this to a 3-l5 psi pneumatic signal which operates the control valve. 1.1.3 Rig Control Valves The control valve comprises a diaphragm actuator which positions the stem of a plug type valve. An indicator on the valve stem shows the actual position of the valve. A gauge G2 indicates the pneumatic signal applied to the control valve by the I/P Converter. The 4-2O mA input to the I/P Converter can be connected to the 38-200 Process Connections or the Servo Valve connection. The air flowing through the process pipe passes through the Pneumatic Control Valve and an Orifice Block assembly before discharging to atmosphere via a Diffuser. A set of manual valves V1, V2 and V3 allow a rear-mounted air receiver to be connected in series or parallel with the process pipe to change the response of the system (to vary the process lag). The Air Receiver incorporates a pressure relief valve. Step changes may be applied to the process by bleeding air through an additional Diffuser by opening and closing the Valve V4. This rig incorporates pneumatic control components of great interest to the process industries. The design allows study of component operation and connection of control devices through the use of current to pressure converters.
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1.1.4 Process Controller and Interface This Discovery software contains an integral Chart Recorder and configuration program. This software automatically configures the 38-300 Process Controller, through a serial port allowing it to be immediately used with each practical. Before attempting any of the practicals: 1. Ensure that the Process Controller is connected to the serial port of your computer. Communication Port 1 (Com1) is used by default. 2. Ensure that the controller is given the identity '1'. If you are unsure about how to check this value, please refer to the ABB manual that is supplied with your controller. 3. Ensure that the switches on the rear of the controller are correctly set up. If they are switched incorrectly, the computer will not be able to communicate to the controller. When you start certain practicals, a small delay will occur while the computer sets the process controller parameters. When complete, the controller will begin to show the current operation of the process using a chart recorder program. You will be presented with different controls depending upon the assignment and practical that is being studied.
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1.2
Practical 1 : System Pressurisation
The following instructions describe how to set-up the 38-714 Pressure Process Rig and its associated components. Connect a supply of clean compressed air to the inlet using a reinforced air hose. The supply must be capable of providing the required volume of compressed air at the operating pressure, otherwise flow and pressure in the system will be inadequate for satisfactory demonstrations.
Warning !! The maximum supply pressure should not exceed 40psi. Supply pressure should be adequately and reliably regulated prior to presentation to the Pressure Process Rig. Use the patching diagram to identify all the relevant gauges and valves on the Pressure Rig. Open valve V1, V3 and V4 adjacent to the air tank connection, close valves V2, V5 and V6. Adjust instrumentation pressure regulator R1 to give 25psi at G1. Pull the collar out to adjust the regulator. Turn the collar clockwise to increase the downstream pressure and anticlockwise to reduce the pressure. Push the collar back into place after adjustment. Adjust process pressure regulator R2 to give 10psi at G3. Air will flow through the system, pressurising the pipes and Air Receiver to 10 psi.
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1.2.1 Patching Diagram
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1.3
Practical 2 : Current Source Calibration
Calibrate the Process Interface 38-200 Current Source as follows. 1. Connect the Current Source to the Digital Display Module 38-490 as shown in the patching diagram 2. Turn on the 38-200 Process Interface. 3. Turn the Current Source control fully anticlockwise to reduce the output to the minimum. The display should read 4 mA or 0%. If it does not, adjust the zero control using a small screwdriver or trim tool until the display shows 4 mA or 0%. 4. Turn the Current Source control fully clockwise to increase the output to the maximum. The display should read 20 mA or 100%. If it does not, adjust the span control. The Current Source is now calibrated. 1.3.1 Patching Diagram
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Practical 3 : I/P Converter and Pneumatic Control Valve Operation
Check operation of I/P Converter and Pneumatic Control Valve.
Caution !! The Pressure Sensors are very delicate instruments. They may be damaged if presented with differential pressures in excess of 30 psi. 1. Connect the I/P Converter to the 38-200 4-20 mA supply by making the connections shown in the patching diagram. 2. Turn on the 38-200 and pressurise the system as per the pressurisation practical. 3. Set the Current Source Output to minimum (4 mA) by turning the adjusting knob fully anticlockwise. Gauge G2 should indicate 3 psi with control valve fully open. The indicator on the valve stem should be in the raised position. 4. Set the Current Source Output to maximum (20 mA) by turning the adjusting knob fully clockwise. Gauge G2 should indicate 15 psi with control valve fully closed. The indicator on the valve stem should be in the lowered position. 5. Note that the indicator on the valve stem provides only an approximate indication of valve position. Note: If the pressures indicated on G2 differ from the values stated above it will be necessary to recalibrate the I/P Converter. This procedure is detailed in the I/P Converter Assignment (see Chapter 6).
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1-10
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Practical 4 : Pressure Sensor and Transmitter
Check the operation of the Pressure Sensor and Transmitter. 1. Complete the connections shown in the patching diagram. 2. Pressurise the System as in the pressurisation practical 3. Drain all pressure from the system by fully closing R2 and fully opening V2, V4 and V5. After a few moments the system will be at atmospheric pressure throughout. The Digital Display Module should show 4 mA or 0%. If it does not, adjust the zero control until the desired reading is obtained. 4. Pressurise the Air Receiver by opening V1 and closing V2 then adjusting R2 to produce a reading 0.7 bar or 10 psi on G3. After a few moments the Air Receiver pressure gauge will read 10 psi. 5. The Digital Display Module should read 20 mA or 100%. If it does not, adjust the span control until the desired reading is obtained. Repeat the above process checking readings of 0% at atmospheric pressure and 100% at 10 psi. 1.5.1 Patching Diagram
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1.6
Practical 5 : Differential Pressure Sensor and Transmitter
Check operation of Differential Pressure Sensor and Transmitter. 1. Complete the connections shown in the patching diagram. 2. Pressurise the System as in the pressurisation practical 3. Open valves V2, V4, V5, V6 and V7. Close valves V1 and V3 (ensure V7 is fully open). 4. Drain all pressure from the system by fully closing R2 and fully opening V2. After a few moments the system will be at atmospheric pressure throughout. The Digital Display Module should show 4 mA or 0% to indicate the zero flow condition. If it does not, adjust the zero control until the desired reading is obtained. 5. Create a full flow condition by adjusting R2 until a 10psi difference is shown between the reading on G4 and the reading on G5. This should easily be achieved. The Digital Display Module should show 20 mA or 100%. If it does not, adjust the span control until the desired reading is obtained. When G4 indicates 10 psi and G5 indicates zero the flow meter will show a flow of approx 24 litres/min. 1.6.1 Patching Diagram
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Chapter 2 PROCON PRESSURE PROCESS RIG Controller Familiarisation
2 Controller Familiarisation
The Process Controller (38-300) unit is powered by the Process Interface (PI) and includes the ABB Kent-Taylor Commander 300 process controller and labelled inputs and outputs, to and from the Process Interface (PI). The ABB Commander 300 is a universal digital microprocessor-based single loop programmable controller, that measures, displays and controls temperature, pressure, liquid level, flow and other process parameters. For this reason, the controller accepts a large variety of input signal types: Thermocouple (THC) Resistance thermometer (RTD) Linear voltage or current Resistance Non-linear voltage or current from temperature transmitters and other variables transduced to a suitable voltage or current.
In your case, since the 38-300 will control the Process Interface (PI), its process inputs and control outputs are of the 4-20 mA loop current type. The 38-300 features local, remote or dual set-point, and retransmission of set-point or process variable. In addition, according to the user requirements, there are four logic inputs (one on the rear) and four time proportioned, voltage activated relays, labelled n.o (normally open) and n.c (normally closed). The industry standard serial communication RS485 and RS232 interfaces are included as standard on the rear panel of the 38-300, so that a digital computer can communicate with it and control of the process carried out using the Discovery software package.
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2.1
38-300 Process Controller
The 38-300 is equipped with control algorithms for various types of control, including; On/Off PID Ramp/Soak (profile sequencing with up to 9 programs) Dual Output (Heat/Cool) Current Proportioning Time Proportioning Position Proportioning Automatic bumpless transfer from manual to auto mode and vice versa
An autotune facility is provided, which can analyse the requirements of a process under control, and select suitable control parameters for optimum performance. Anti-reset windup is a technique included to prevent a large control effort building up when attempting to eliminate a deviation caused by a physical problem. Each of these features will be explained fully as it arises through the increasing use of the 38-300 in this and further assignments. Instrument set up is restricted to authorised users through multiple levels of security. Users can select the instrument functionality required, from menus, using the eight tactile membrane keys and the three high intensity seven-segment displays plus the deviation bar graph. Configuration data is stored in non-volatile memory. 2.2 Control Systems
A control system consists of a controller and a plant. A plant is the machine, vehicle, or process that is being controlled. The controller is the system that is required to produce satisfactory results from the plant. A manual control system is one where the controller is a person. The alternative to this is an automatic control system, where the controller is a device, usually implemented electronically, either using analogue circuits or a digital computer (microprocessor). Pneumatic and hydraulic controllers can also be found in industry, these are still legitimate automatic control systems. The interface between the plant and the controller requires actuators (control elements) to provide the control action. Actuators are commonly electric, pneumatic, or hydraulic, depending on the application and power level required.
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In addition, detectors, sensors (measurement elements) and instrumentation are needed to provide information about the plant status to the controller. 2.2.1 Control Systems Continued The diagram below shows the basic elements of a control system. The flow of information between these elements can be seen.
The information that is passed between the controller and the plant is in the form of signals. These signals can be very diverse, for example electrical, pneumatic, mechanical, etc. The term transmitter is used to describe the action of the measurement element when it sends signals to the controller, which represent the measured values of the system. A control system can be open-loop or closed-loop. 2.2.2 Closed and Open Loop Control An open-loop control system utilises a controller or control actuator in order to obtain the desired response, without incorporating feedback. The input-output relationship of the system is only the cause and effect relationship of the output from the controller and the plant. In contrast to an open-loop control system, a closed-loop control system utilises an additional measure of the actual output. This is then compared to the desired output response, or reference input signal. The measure of the output is called the 'feedback signal'. A feedback control system often uses a prescribed function between the output and reference input to control the process. Often the difference between the output of the process under control and the reference input is amplified and used to control the process, so that the difference is continually reduced The notion of feedback exists in everyday life. For instance we use visual feedback to walk. Feedback not only gives verification of our actions, it allows us to cope with a
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changing environment by adjusting our actions in the presence of unforseen events and changing conditions. Feedback has similar advantages when applied to automatic control. Feedback gives an automatic control system the ability to deal with unexpected disturbances and changes in the plant behaviour. A manually controlled closed-loop system for regulating the level of fluid in a tank uses negative feedback. The input is a reference level of fluid that the operator is instructed to maintain. This reference is memorised by the operator. The operator views the level of fluid through a port in the side of the tank. The power amplifier is the operator and the sensor is visual. The operator compares the actual level with the desired level and opens or closes the valve (actuator) to adjust the flow and hence maintain the desired level. 2.3 Automatic Control Systems
The control of an industrial process by automatic rather than human means is called automation. In its modern usage, automation can be defined as a technology that uses programmed commands to operate a given process, combined with feedback of information to determine that the commands have been properly executed. This kind of automation is provided by the digital PID process controller Commander 350. Modern control systems are self-organising, adaptive, robust, able to learn about a process, and can optimise control. Automation is often used for processes that were previously operated by humans. When automated, the process can operate without human assistance or interference. In fact, most automated systems are capable of performing their functions with greater accuracy and precision, and in less time, than humans are able to do. However, semi-automated (hybrid, or human-robot) processes that incorporate human workers and robots (computer controlled machines) and manually controlled systems, still exist, since some tasks are best carried out by humans. 2.3.1 Automatic Control Systems - Classes Control systems are sometimes divided into two classes. If the object of the control system is to maintain the physical variable at some constant value in the presence of disturbances, the system is called a regulator. One example of a regulator control system is the speed-control system on the ac generators of power utility companies. The purpose of this control system is to maintain the speed of the generators at the constant value that results in the generated voltage
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having a frequency of 50 Hz in the presence of varying electrical power loads. Another example of a regulating process control system is the biological system that maintains the temperature of the human body at approximately 36oC in an environment that usually has a different temperature. The second class of control systems is the servomechanism (sometimes called a Kinetic control system). Although this term was originally applied to a system that controlled a mechanical position or motion, it is now often used to describe a control system in which a physical variable is required to follow, or track, some desired time function. An example of this type of system is an automatic landing system, in which the aircraft follows a 'ramp' trajectory to the desired touchdown point. A second example is the control systems of a robot, in which the robot 'hand' is made to follow some desired path in space. Different types of control can be carried out by the Process Controller (38-300), depending on the requirements of the process and the desired output. All types are covered thoroughly in their own assignments, but an introduction to each is given in this theory. Each type is shown by applying it to a simple level control problem, and by doing this you will gain an insight into the types of control that are available. A tank is holding liquid to feed a process. The process being supplied requires a constant head of liquid and so a control system is required to keep the tank level constant. A valve is located in the tank inlet to vary the flow rate. The diagram below illustrates the situation.
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2.3.2 Open-loop Operation The simplest strategy is to calibrate the inlet valve. By experimentation, a relationship between tank level and position of the handwheel can be obtained. If the outflow is constant, a position of the handwheel can be found that keeps the level constant. If the valve is opened a little more, so that more water is coming into the tank than is going out, then the level will rise. Conversely, if the valve is closed a little so that more water is going out than is coming in, then the level will fall. Now, if a different level is required, the handwheel can be changed to increase or decrease the flow until the new level is reached. This method is Open-Loop Operation. It is simple and will work well, provided there is no change in the outflow of the liquid, and all other parameters affecting the level in the tank remain constant. There is no electrical or mechanical feedback path, so the system is open loop, but feedback is being provided through the user. He/she is deciding if the actual level is above or below the desired level, and adjusting the actuator accordingly. 2.3.3 Feedforward Control The major cause of disturbances affecting the tank level is likely to be changes in the tank outflow rate. An increased outflow will cause the tank level to drop. Therefore, a more reasonable approach is to produce calibration curves for a number of outflow rates. By monitoring the outflow rate, the correct position of the handwheel can be determined by examining the calibration curve for the new flow. The handwheel is then adjusted to keep the tank at the required level. This technique is Feedforward Control, and requires a measurement of the outflow rate in order to calculate the change in the position of the inlet valve. Although feedforward control is an improvement over open-loop operation, it does have disadvantages that restrict its usefulness. One of these disadvantages is the calibration curves between the handwheel position, outflow and level. These must be accurate for the process to function correctly. Another is that the process may vary with time, or disturbances occur that are not included in the calibration curves or are not monitored. Under these circumstances, feedforward control will not be successful.
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2.3.4 Feedback Control We could carry out more measurements to compensate for the errors that can occur in feedforward control. However, the obvious solution to keep the level in the tank constant, is to monitor the level itself. If it deviates from the desired value, the inlet valve is adjusted by an amount dependent on the difference between the actual level and the desired level. This control strategy is called Feedback Control. Feedback control is error driven in that the control effort is a function of the difference between the desired and the actual levels. The relationship between the error and the control effort is called the control law. Feedback level control does require a more elaborate level measurement technique, and an accurate valve actuator. It also requires a signal related to the actual level (i.e a level transmitter). In addition, the valve actuator must be able to hold the valve in any position, and to also change its position gradually and smoothly. The diagram below illustrates how this may be implemented for the situation described earlier.
The important characteristic of feedback control is that it is capable of providing a range of control effort, that is, it can produce small as well as large corrections. An appropriate control law must be designed or selected to produce a satisfactory performance. 2.3.5 Control Law The control law represents the action of the controller. Common control law types are the P-type (proportional), I-type (integral) and D-type (derivative), or a combination of these, ie, PI, PID.
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Examples of feedback control systems can be found in nature, one of which is the temperature-control of the human body. This control system attempts to maintain the body temperature at a constant value. Generally, the environment tends to vary the body temperature. The body responds to a difference in temperature by perspiring, by increasing or decreasing blood flow, by shivering, and so on. This control system has one characteristic that control systems designed by humans do not often have : it normally operates in a satisfactory manner for seventy years or more. Another characteristic of this system, and one that is usually present in control systems that we design, is that if the magnitude of the error becomes too large, the system fails. 2.3.6 On/Off Feedback Control A simplification of the general feedback control type is On/Off Feedback Control. The level in our example would now only have two states; either above the desired level or below it. Monitoring can now be carried out by a float switch, mounted at the desired level. The switch produces a binary (on/off) signal that indicates whether the level is above or below the desired value. The signal can then be used to operate the inlet valve directly. When the level is above the reference value, the inlet valve is closed, and when below, it is opened. The control law in on/off control is kept simple, it switches the control effort between two extremes, depending on the sign of the error. The diagram below illustrates the control method in the context of the equipment set-up.
Whatever the cause of the change in level, provided the deviation is large enough to activate the switch, then control action will be applied to correct the situation. By using on/off control our equipment requirements have been simplified. However, there are several problems associated with on/off control.
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One problem concerns the abrupt fluctuations in flow as the valve switches between fully open and fully closed. Another problem is that the precision of on/off control depends heavily on delays associated with the switch, the inlet valve and the rate of change of flow. With lengthy delays, overflow could occur if the valve is not shut as soon as the desired level is reached. The answer is not just to make the switch quick and sensitive as this can lead to unnecessary switching caused by waves or ripples. The type of control chosen for a particular situation will depend on the accuracy required, cost of equipment, maintenance (the simpler the system, the easier it will be to maintain), disturbances expected and the degree of disturbance rejection expected, degree of human intervention required, health and safety (how dangerous is an overflow of the process in question?), and so on. 2.4 Practical 1 : Serial Communication
Practical 1 will take you through the steps that must be carried out before you can attempt any practical that uses the Process Controller (38-300) and a personal computer together. It is vital that these steps are completed successfully to allow the 38-300 to communicate with your personal computer. Steps 1 and 2 concern the physical link between the 38-300 and your personal computer. They ensure that the cable supplied to link the two devices is connected to the correct ports, and that the 38-300 is terminated correctly. It is possible to use more than one 38300 if a practical demands it, and in such a case the controllers form a chain from the computer. This is when the termination of the serial lines is important. Step 3 deals with the parameters that must be set up in the 38-300 to allow it to communicate with your personal computer. The parameters are the speed of communication (or Baud rate), the identity of the 38-300 (to allow more than one to be used), the type of parity checking and the block check character enable (the last two are both error checking facilities). These four amount to the 'language' that is being spoken, if they are set up incorrectly the 38-300 will not understand the messages being sent by your personal computer. Practical 2 considers the 38-300 in much greater detail, and explains the control panel and how it functions, but this practical must be completed first. Although you may not fully understand all of the steps yet they will become clear in the next practical. It is sufficient just to follow them for now. The reason for keeping this in a separate practical is that it can now be referenced at any time very easily. Linking the 38-300 to a computer is accomplished by completing this practical.
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2.4.1 Patching Diagram This practical has no patching diagram as its aim is to get you familiar with the procedure that must be followed before any other practical that uses the 38-300 Controller. Essentially the completed practical is the patching diagram for serial communication, although it includes steps that are not only hardware links (wires and plugs and the like) but parameter assignments in the 38-300.
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2.4.2 Practical Step 1: Link There is a serial lead supplied with your equipment to connect the Process Controller (38300) to your computer. This is plugged into the port marked RS-232 on the rear of the 38300 and to a COM Port on the rear of your computer. An adapter is commonly used to change the 25-way connector to a 9-way connector that many modern computers use. Step 2: Termination There are two switches on the rear of the 38-300, marked Termination and Connection, that deal with the communication lines to the 38-300. You will be using it as a single controller linked to your computer, so both of these switches must be ON. Step 3: Serial Parameters Plug the 38-300 power lead into one of the ac supply sockets on the rear of the Process Interface (not the switched ac supply), turn both on and observe the LED Displays. 2.4.3 Practical Setting the Serial Parameters Press and hold the Page Advance and the Increase buttons together for three seconds. It is helpful to press the Page Advance button first, then with another finger, press the Up button. Parameter Advance Button
Up Button until the RED 38-300 LED display shows LEV.6. User interface of the controller is divided into a number of levels. Each level contains a number of related parameters that can be adjusted. Pressing those two buttons together sets the controller on the first of the configuration levels, the Basic Configuration level. Press the Raise button to increase to higher levels. Press the Raise button seven times until LEV.d, the Serial Configuration Level is displayed. If a higher level is selected, press the Lower button. Raise Button
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Lower Button Use the Page Advance to move between individual parameter settings. Use the Up and Down buttons to adjust each parameter.
Up Button
Down Button Ensure that the controller is configured with the values shown in the below table. Parameter S.CFG Value 4 Description Whether 2 or 4 wire serial connection and baud rate. Value 4 indicates a 4 wire connection, running at 9600 baud. Parity error checking. Default is none. Unique address of this controller. This is defined as a part of the MODBUS protocol that the controller uses to communicate to the PC. This must be set to 2 if you are configuring a second controller.
PrtY Addr
none 1
When all parameters have been set, press the Alarm button:
Alarm Button Pressing this button will return you to the Operating Display where you can observe the Process Variable, Set Point and Controller Output.
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2.4.4 Questions 1. Why is it vital that this practical is completed before any others that involve the Process Controller (38-300) and a personal computer?
2. The first two steps deal with the physical link between the 38-300 and a computer, what does the third deal with? What would be the effect of incorrectly completing this step?
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2.5
Practical 2 : Navigating the 38-300
The following diagram shows the configuration of the front control panel of the ABB Commander 350 controller.
The buttons used on the controller are described in more detail below. 2.5.1 Controller Controls Raise
Lower
Raise is used to increase a parameter value, or step up through a selection of parameters. Lower is used to decrease a parameter value or step down through a selection of parameters. Continued pressure on these buttons causes the rate of change of the displayed variable to increase. To make small adjustments, press the keys momentarily.
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Chapter 2 PROCON PRESSURE PROCESS RIG Parameter Advance Controller Familiarisation
The various configuration options are held in a number of different 'levels', each level containing a set of related parameters. When a level has been selected, as shown within the Process Variable Display, pressing the Parameter Advance moves between different controller Frames within a level. If a parameter has changed within a level, pressing the Parameter Advance button will store the value within the controllers memory.
Auto/Manual
This button is used to change the controller operation mode between automatic and manual. In manual mode, the displays automatically revert to control output (bottom display) and the process variable values (top display), and the Raise and Lower buttons can be used to alter the control output. When in automatic mode this facility is disabled, since the output is calculated by the controller. When the controller is in manual operation, a small M can be seen in the output display. Up
Down
When the controller is in manual operation, these buttons allow the changing of the controller output. When the controller is being configured, these allow specific controller parameters to be changed.
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Alarm
During normal controller operation, this button allows the controller user to acknowledge an alarm, a state that a process may have entered into, requiring user intervention. When an alarm occurs, an alarm symbol will be seen within the bottom output panel. When the controller is being configured, this button is used to return to the Operating Display. 2.5.2 Controller Levels - Operation The controller contains two types of Level, operation levels and configuration levels. Operation levels allow the operator to change simple operational characteristics of the controller during normal functioning, while the configuration levels allow more sophisticated settings to be adjusted. This section describes the controllers Operational Levels, whereas the next describes the controllers Configuration Levels. 2.5.2.1 Level 1 : Operator Level Normal day to day operation of the controller, depending upon which Control Template has been selected. 2.5.2.2 Level 2 : Tuning Allows the setting of important control parameters used to control a process. Key parameters include Proportional Band, Integral Action time and Derivative Action Time. These concepts are explored and studied in future assignments and practicals. This level should be accessed to manually adjust operating parameters. 2.5.2.3 Level 3 : Set Points The Commander 350 has the ability to support a number of different Set Points, giving the controller flexibility. This allows Set Point variables to be configured. This Level is not explored within the software. 2.5.2.4 Level 4 : Alarm Trip Points Allows the configuration of conditions under which Alarms can occur.
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Chapter 2 PROCON PRESSURE PROCESS RIG 2.5.2.5 Level 5 : Valve Setup This level is not applicable to the PROCON training software. It is used in conjunction with special types of motorised valve. 2.5.3 Controller Levels - Configuration Levels labelled 6 though E allow the controller to be configured. For safety reasons, there are many controller settings that have to be configured through these level using the front panel of the controller, rather than the controllers RS485 communications port. Warning! Only change the configuration parameters if you are sure they need to be changed. Changing the configuration parameters without fully understanding what they are may cause your controller to enter a state which is not compatible with the PROCON assignments and practicals! If you are in doubt, do not change! 2.5.3.1 Level 6 : Basic Configuration The basic configuration level allows the operator to select a required Template, choose the type of Control Output and set the Control Action. For some PROCON practicals, the Control Action setting is required to be changed. Control Action can be set to two different modes, Direct Action or Reverse Action. The type of mode depends entirely upon the type of actuators that are used in the PROCON rig. The Pressure Rig requires the setting of Direct Action. 2.5.3.2 Level 7 : Analogue Inputs The controller is designed to be flexible, lending itself to a number of different control situations and needs. Subsequently, the controller can be configured to use different types of signalling. Analogue Inputs also allows the operator to configure the number of Decimal Places, operational Engineering Range, amongst other settings. 2.5.3.3 Level 8 : Alarms Level 8 is dedicated to the setting up of Alarms. This level contains setting for alam type, alarm trip level and hysteresis settings. It also allows alarms to be associated to relays, allowing audible warnings to alert operators. The concept of an alarm is explored within a number of PROCON assignments.
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Controller Familiarisation
The concept of an alarm is explored within a number of PROCON assignments. 2.5.3.4 Level 9 : Set Points The Commander 350 supports 4 different set points. This level allows the selection of set points and the choosing of local or remote set points in process control. It also allows Set Point Tracking, a useful control facility to start and stop processes, to be configured. 2.5.3.5 Level A : Control Configuration Level A contains general controller configuration settings, such as what should occur following a power failure and the defining of controller Output limits. 2.5.3.6 Level B : Operator Configuration In an industrial environment, it is useful to prevent access to the controller to those who do not require it. Within safety critical systems and processes, this is particularly important. The Operator Configuration level allows the enabling or disabling of certain keys, such as the Auto/Manual key, Local/Remote Set Point key and the Alarm Acknowledge Key. 2.5.3.7 Level C : Output Assignments The Commander 350 provides both Analogue (Proportional) and Digital (On/Off) Outputs. This level allows the output facilities of the controller to be configured. Since the PROCON Process Rigs only use a small fraction of the controllers overall abilities, this level should rarely be accessed. 2.5.3.8 Level D : Serial Communication Setting of the type of serial cable used, and the baud rate. This level is described in the previous practical. One of the most important parameters in this level is the Modbus address. 2.5.3.9 Level E : Calibration The controller is calibrated before it is used in the Procon system. Provision is made to adjust the controller settings. This level is described for completeness and should not have be to accessed. 2.5.4 Controller Documentation The following documentation is supplied with the controller:
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User Guide
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Chapter 2 PROCON PRESSURE PROCESS RIG Modbus Communication Guide Controller Familiarisation
It is useful to reference these manuals when carrying out practicals involving the controller. The user guide is especially useful, since it describes each level in detail. 2.5.5 Patching Diagram In a similar way to the previous practical, this practical has no patching diagram. Its aim is for you to become familiar with the Commander 350 controller, its keys and displays, its parameters and pages, and the use of a personal computer and the controller together.
2.5.6 Practical Set up the Process Controller (38-300) in exactly the same way as you did in the first practical, so that the 38-300 and your computer are able to communicate. Please go through that practical again if you are unsure. When the 38-300 is switched on it will perform a self-test, show the version of the controller operating system that is installed and the date, followed by the main operating display. To begin, ensure that the controller is set in Manual operation mode. When the controller is running in manual operation mode, parameters can be set using the front panel or by the computer. To change the controller operation mode, press the: Automatic/Manual Button
If the Process Controller is not set to manual mode, the controller will not accept new settings from the computer. Always ensure that the controller has been set to Manual mode before a practical is started.
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Chapter 2 PROCON PRESSURE PROCESS RIG 2.5.6.1 Step 1 : Configuration Setting 1 Pressing the button below to begins to transmit commands from the controller from the computer, changing a number of key parameters. A dialog box will appear when the transmission is proceeding. When the transmission has finished (after approximately 2 seconds) the box will close. Press and hold the Parameter Advance keys on the control panel until CodE is displayed. Press Parameter Advance twice more to move to the first level of the configuration displays. Press the Raise button so LEV.2 is displayed. This is the tuning level. Use the Up and Down to move between individual parameters. Record all the settings within this level. When you have done, return to the top of the level (LEV.2), and change to level 1, the operating level. Press the Parameter Advance to return to the main operating display. 2.5.6.2 Step 2 : Configuration Setting 2 Press the below button to transmit a different configuration to the controller. Using the previous instructions, record the same parameters as you did earlier and compare the two sets of values. Press Page Advance and then Enter to return to the operating page, and press Parameter Advance once to display output, shown by OP 100.0. The output can be decreased and increased with Lower and Raise. Check this. Pressing Auto/Manual will disable this facility, the output is set automatically. The LED is off, showing Auto operation. Controller Familiarisation
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2.5.7 Questions 1. When controlling the PI, of what type are the process inputs and outputs of the Process Controller (38-300)? What input signals does the 38-300 accept?
2. What is the major restriction when using the 38-300 controller in terms of monitoring process variables? What sort of control can be implemented using this controller, and so how many variables can be controlled?
3. Considering the operations carried out before the parameters on the Control and Set Point pages were recorded, and the information given in the background to this practical (2) on computer initialisation, what do you suggest is the reason for the differences in the two sets of parameter values recorded?
4. As well as saving time and effort, what is another advantage of using a computer to initialise the 38-300 before attempting a practical?
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2.6
Practical 3 : Using the 38-300
In this practical you shall make use of some of the facilities of the Process Controller (38300) that are available for different modes of control. This practical is kept simple. It introduces a number of basic features of the controller, including manual control of controller output and the use and purpose of alarms. As the assignments develop, so too will the use of the 38-300 and more of its full capacity shall be seen. 2.6.1 Manual Control Initially you will control the output of the 38-300 using the Up and Down keys on the control panel. The 38-300 will take the place of the current source on the Process Interface (PI), and the Up/Down keys will carry out the same function as the current source control knob on the PI. You will be the operator of the process, manually controlling its operation, and it is a very simple matter to set the level of the tank.
Here the manual control effort, Um, is you, changing the output at will. The actuator is the servo valve, and the measurement section is also you watching the level in the tank. Disturbance is normally included in this sort of situation to account for any fluctuations that are out of your control (environmental changes can affect the flow for example). 2.6.2 Bumpless Transfer between Automatic and Manual Control When switching control modes (manual-auto or auto-manual) a problem can arise when the automatic set-point and the measured operating point are not equal. Normally a controller will start in manual mode, where the automatic set-point is adjusted until it is equal to the required operating point. The controller output will then be adjusted until the deviation between set-point and actual operating point is zero, and the controller switched to auto mode. This ensures that the plant is operating steadily at the desired operating point at the instant of switching.
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If the actual operating point is changed (using the manual controls) but the set-point is not, when the plant has reached steady state and is switched to auto there will be a deviation (because the measured operating point is not equal to the set-point), and the automatic controller will attempt to correct this. This will cause a bump and will drive the plant away from the operating point set manually by the operator. The same effect can occur when switching from auto to manual, if the manual output control is not equal to the actual automatic controller output. The way to avoid this is to employ automatic bumpless transfer, which is a facility most modern controllers include. When using the 38-300, if there is a deviation between the desired operating point (as set by the manual controls) and the automatic set-point at the time of switching from manual to auto, the plant will continue at its desired operating point (with no bump). This is slightly anomalous as there will be a (possibly large) deviation and an incorrect setpoint, but it has prevented bumps. Although bumpless transfer is available on modern controllers, it is good engineering practice to ensure no deviation in operating points (automatic set-point and actual measured operating point) before switching modes, rather than rely on this facility. 2.6.3 Alarms The ABB Commander 350 like other industry process controllers, is capable of triggering alarms should certain predefined conditions be met. Up to 8 different alarms can be used, numbered 1 through to 8. Each alarm can be programmed separately. On the control panel of the Commander 350, an alarm LED will appear in green at the bottom of the middle LED display. The LED will flash to show that an alarm has been triggered but not acknowledged. Each alarm can be assigned a Type, a Trip Level and a Hysteresis setting. The alarm Type describes the situation that the alarm is watching for and it can be one of the following; High or Low Process Value High or Low Output High or Low Deviation High or Low calculated mathematical value
The trip level is the level of the selected type that should trigger the alarm. For example, alarm A can be set to 'high output' with a trip level of 80%. If the output of the Controller is increased to 80% or above, an alarm will be triggered.
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The hysteresis setting is another way of checking process parameters. The hysteresis setting is operational when an alarm is active, and it is specified as a percentage or in engineering units. It is best shown with the above example; alarm A has been triggered by the output of the controller increasing above 80%, and the hysteresis setting is 5%. The output is lowered, but it must decrease below 75% (80% trip level - 5% hysteresis setting) before the alarm is turned off. The output must move into the safe region by an amount equal to the hysteresis setting. When you are carrying out this practical, after the alarms have been set, the alarm settings can be seen on the Alarms Trip Point page. Press and hold the Parameter Advance key to change to the configuration mode, then press the button again twice to move to LEV.1, the operational level. Finally, press the Raise keys to move to LEV.4, the alarms level. Use the Up and Down keys to observe the parameters 2.6.4 Configuring Alarms The practical requires the operator to configure two of the controllers alarms. When the display shows LEV.4, press and hold the Raise key to move to the higher configuration levels. The alarm level is situated at level 8, as shown by the display AL_S. Use the controls on the controller to view the parameters that can be set at this level. Note particularly the tyP.n setting, where n refers to the alarm number. With the tyP.1 parameter displayed, change the setting by pressing the Raise and Lower keys. This manual control practical uses alarms to indicate control output that is too high, indicated by the letters HO, and the control output is too low, indicated by LO. All available parameters are described in the table below for completeness. Do not worry about understanding them all. Only a small fraction of the available alarm types are used.
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2.6.5 Alarm Settings Display NONE HPU and LPU HLP and LLP Hd and Ld HPn and LPn HO and LO Description No alarm currently assigned. High and Low Process Variable values High and Low Latch Process Variable High and Low Deviation High and Low Input values, where n refers to different inputs High and Low Process Output settings, potentially used to prevent actuators going beyond preset limits. Programmable mathematical calculations, high and low settings.
Lbn and Hbn
Alarms are set either by using the front panel or by the ABB configurator software, rather than using the main serial communications link for security purposes. This prevents the likelihood of software accidentally changing the alarm operation that could be used to indicate potentially hazardous process states. Since the alarms are used in a number of different ways, they will be have to be reconfigured during a number of practicals. Always remember that the alarm settings can be found at Level 8. When all alarms have been configured, the trip levels for all alarms that have been enabled, can be set using the Alarms Trip Point page. Press and hold the Parameter Advance key to change to the configuration mode, then press the button again twice to move to LEV.1, the operational level. Finally, press the Raise keys to move to LEV.4, the alarms level. Use the Up and Down keys to observe the parameters. If no alarms have been enabled, no parameters can be changed. Now that alarms are familiar, select the practical page to begin to use and configure the controller.
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2.6.7 Practical Please ensure that you have completed the first practical! Set up the process equipment as shown in the patching diagram. Ensure that the controller is set to manual operation. You can change the mode of operation by pressing the Automatic/Manual button on the front of the controller. Step 1 : Resetting the Controller Initialise the 38-300 by clicking on the Setup button below to set the controller to some default operation values. Step 2 : Configuring Alarms For safety and security reasons, the controller alarms have to be set manually. Press the Page Advance button to go to the operational setting level, LEV.1, then press the Raise button until LEV.8 is displayed. When on Level 8, set the following parameters: Parameter tyP.1 trP.1 Hy5.1 tyP.2 trP.2 Hy5.2 Value LO 40.0 40.0 HO 80.0 20.0 Description Alarm 1 Type: Controller Output Low Alarm 1 Trip Level Alarm 1 Hysteresis Alarm 2 Type: Controller Output High Alarm 2 Trip Level Alarm 2 Hysteresis
Step 3 : Manual Control using the Controller Switch on the pump (with the ac supply switch on the front of the PI). Open all manual valves. Note that the output value has been set to 50%. Increase and decrease the output by pressing the Up and Down keys. Use the whole range of output; 0%-100%. What is the DDM showing? What are the units of the output being displayed by the 38-300? Notice the operation of the alarms. Experiment with the Alarm Acknowledge button, and consider how it works. Use LEV.4, the Alarm Trip Points level to adjust the trip level and observe the alarm behaviour. Try changing the hysteresis value using LEV.8.
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Change the operation of the controller between automatic and manual mode by pressing the Automatic/Manual button. When you have finished, turn off the pump, return to LEV.8 and set all alarm types to NONE so you are ready for the next practical.
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2.6.8 Questions 1. Hysteresis, with regard to the 38-300 alarms, is the difference between the switchon level and the switch-off level of the variable assigned to the alarm. Did you find your experimental results were the same as the values set up in the controller? When is hysteresis operational, and when using it, what can be said about the variable as it moves inside the trip level?
2. When transferring between modes of the 38-300, what is a 'bump' and what are the conditions that would cause a bump? What steps should be carried out to prevent bumps, and what facility is available on modern controllers to prevent bumps? What is the anomalous situation that can occur if care is not taken when transferring modes in a modern controller?
3. Considering what you have learnt in this and previous assignments about automatic and manual control systems, split the following into Automatic Control and Manual Control: (a) A heater with a thermostat. (b) A refrigerator. (c) Filling a bath tub, (d) A burglar alarm which has been set, (e) Traffic lights at a road junction, (f) A pedestrian crossing with traffic lights, (g) A washing machine once it is turned on, (h) A petrol-driven lawnmower once it has been turned on.
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Chapter 2 PROCON PRESSURE PROCESS RIG Notes Controller Familiarisation
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Chapter 3 PROCON PRESSURE PROCESS RIG Controller Calibration
3 Controller Calibration
Objective To further explore the 38-300 process controller, its settings and how to read data from the controller using the Discovery software Qty Apparatus 1 1 Prerequisite Assignments Knowledge Level 38-200 Process Interface 38-300 Process Controller
Equipment Required
Controller Familiarisation None
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3.1
Theory
3.1.1 Controller Calibration As discussed in the previous assignment, the ABB Commander 350 Process Controller used within the 38-300 is a universal digital microprocessor-based single loop programmable controller, which can measure, display and control temperature, pressure, liquid level, flow and other process parameters. The 38-300 accepts a large variety of input signal types: Thermocouple (THC) Resistance thermometer (RTD) Linear voltage or current Resistance Non-linear voltage or current from temperature transmitters
In your case, since the 38-300 communicates with the PI, its process inputs and control outputs are of the 4-20 mA loop current type. The 38-300 features local, remote or dual set-point, and retransmission of the set-point or process variable. In addition, according to user requirements, there are logic inputs and time proportioned, voltage activated relays, labelled n.o (normally open) and n.c (normally closed). The ABB Commander controller is equipped with control algorithms for various types of control which were mentioned earlier. These will be illustrated in later assignments so that you become familiar with the full capabilities of the 38-300. The 38-300 contains analogue to digital and digital to analogue converters. The sample time of these devices must be faster than the dynamics of the process for the controller to operate the system reliably. The sample time of the 38-300 for both converters is 125 ms, which is much faster than any dynamics that exist in this process; fluids, pipes, tanks, pumps and servo valves are relatively slow elements in terms of time response and disturbance introduction. This assignment introduces you to further elements of the 38-300 controller, including calibration and they key to many PROCON assignments, the chart recorder.
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3.1.2 Practical Controller The task of a controller is to maintain the desired system performance despite any disturbances in the system. Controllers are usually implemented electronically, either using analogue circuits, or a digital computer (microprocessor). However pneumatic and hydraulic controllers are still in use. In process control, it is unusual to design a specific controller for a particular plant, because the dynamics of the plant are uncertain and often very dependent on operating conditions. Therefore, a general purpose controller is normally implemented, which has a number of variable parameters that can be set to meet the static and dynamic requirements of the control system. The static characteristics of a system are independent of time and the response of the system depends only on the inputs. The dynamic characteristics of a system depend on both time and inputs. Various types of general purpose controllers exist, and each can be characterised by its actions and methods of controlling a system. 3.1.3 General Process Controllers A block diagram of a General Process Control System is shown below:
This shows the plant, and some means of measuring a process variable. This measured variable is fed back to the controller to determine how well the system is operating. With the addition of the feedback loop it has now become a closed loop system. The controller will compare the measured output and the desired output (the Set Point) to determine the control effort. Um is the manual input, and the manual/auto switch can also be seen.
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With the switch in the manual position the control law has been disconnected from the process plant and the system is controlled by the operator only (a manual control system, the type of control we have been implementing so far). With the switch in the automatic position the control law is added to the manual input and this will determine the behaviour of the process. The process can now be controlled automatically, provided it is given desired operating levels. An automatic controller cannot determine how to control a process, it can only carry out desired control, determined by a third party, you. We shall be carrying out various types of feedback control in later assignments. 3.1.4 Digital Control Systems The use of digital computers for the control and monitoring of processes is becoming increasingly important. Digital computers offer improved performance, better management of a process, reliability, flexibility, reduced cost and can perform complex calculations that could not be done by other analogue means. Powerful software development tools (programming languages for instance) which can be run on digital computers, result in reduced development costs for computer-based control systems. A number of digital single loop controllers can be used (an example of one of these controllers being the 38-300), each carrying out the feedback control of a single variable in a multi-variable process. These controllers are called the slave controllers and are coordinated by a digital controller called the master. A master controller sends set point information to the slave controllers and receives back information on the measured variables. This type of control is called set point control and a major benefit of this type of control is that even in the event of a master controller failure, the individual slave controllers will continue to operate, and with these operating the process should continue to run. The other type of computer control is called Direct Digital Control (DDC). DDC as the name implies, uses digital controllers to determine the actual control effort applied to the process or plant. The digital controllers are microprocessor-based single loop or multi-loop controllers that control a single- or multi-variable plant, in place of the old analogue, mechanical or pneumatic controllers.
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3.1.5 Digital Control Law The digital control law of a process that determines the control effort can be obtained from two completely different design techniques. The simple method is to approximate the analogue control law with a discrete time control law. In essence we implement the existing analogue controller with a digital controller. This method has the advantage of familiarity with the analogue concepts and terminology. However, a major disadvantage is to restrict the vast capabilities of digital computers due to the digital approximation of the analogue controllers having limited capabilities.
The other method for the design of digital controllers is to design directly in discrete time. The drawback of this method is that during discrete time (i.e. during the sample times) very good control may be achieved, but between samples the controlled variable is effectively in the open loop condition and may oscillate. Design techniques must be must be accurate and thorough to encompass such eventualities. The two block diagrams show the analogue and digital discrete time controllers and how they differ. The control law in the discrete time example is implemented digitally, but the plant is a continuous analogue system. A digital to analogue converter (DAC) must be included between the controller output and the plant input, and a corresponding analogue to digital converter (ADC) between the plant output and the comparator in the feedback path. The sampling rate fs of the DAC and ADC will determine how the controller copes with oscillation and fluctuations. Consequently it must be much faster than the process dynamics, so that the digital approximation will produce similar results to the conventional analogue controller. The controller you are provided with is a single loop, digital controller. The DAC and ADC are integral parts of the controller, and as such they will not concern you through your practicals.
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Chapter 3 PROCON PRESSURE PROCESS RIG 3.1.6 Chart Recorders In this assignment you a chart recorder will be seen for the first time. The chart recorder is used to display a representation of changing analogue signals that are presented to the controller. This provides several facilities for you to monitor process variables in conjunction with the controller. As well as displaying variables in real time the chart recorder has the facility to record a curve. The recorded files can then be selected and replayed using the playback practical. Controller Calibration
3.1.7 Recording The chart recorder can naturally take a recording of an entire process. To begin a recording, press the Record button:
When pressed, button will change into a 'disk' icon, indicating at at any time the recording can be saved. The disk icon is shown as follows:
The data logging environment must be set up correctly before running the Discovery Procon Recorder. This can be found within the menu tree. If you try to quit the environment or start another practical without ending the recording, the recorded process data will not be saved.
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Chapter 3 PROCON PRESSURE PROCESS RIG 3.1.8 Playback The playback of a recorded trace can be performed by taking the chart recorder 'off-line'. This, in effect, disconnects the recorder from the controller, allowing you to load a previously saved trace set. When the 'on/off line' button is pressed, a disk icon will be shown. This allows you to load in a file from a disk. Load allows the loading of recorded data from disk: Controller Calibration
Pause will halt the chart recorder:
Clear will clear the current curve from a recorder:
Ghost will display a faint frozen curve from the instant that the button is pressed.
The scrollbar can be used for moving forwards and backwards through the replayed trace.
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Chapter 3 PROCON PRESSURE PROCESS RIG 3.2 Practical 1 : 38-300 Calibration Controller Calibration
With reference to the 38-300, measurements are carried out to monitor process parameters and to determine the control effort that should be applied when controlling a process. Such measurements ensure the correct operation of the process system. Because of this, the accuracy of these measurements must be guaranteed by proper calibration of the controller used. Calibration consists of comparing the measured value or level of a parameter, as shown by the controller being calibrated, with the known value or level of the parameter, as measured by a standard instrument of known accuracy. Calibration guarantees that the accuracy of the input or output reading in a calibrated controller will be at a certain acceptable level, when used under the environmental conditions (eg, temperature, humidity, pressure) present during the calibration process. Outside those conditions, characteristics may change, and so the accuracy of the instrument will vary to a greater or lesser extent according to its susceptibility to the modifying inputs inherent in the new environmental conditions. When a process controller is calibrated against a standard instrument, its accuracy will be either inside, or outside that required by the application measurement accuracy limits. If the controller's accuracy is outside the acceptable measurement limits, then its characteristics should be adjusted by the zero and span parameters provided, until they are within the specified measurement limits. Bear in mind that all calibration and measurement procedures should be documented, so that a record of the calibration history of any instrument will always be available. 3.2.1 Calibration Check of the Process Controller There is no need to actually calibrate the controller in this practical, not because it does not need to be accurate, but because the 38-300 has been calibrated to a level of accuracy much greater than most meters readily available to you. It has, stored in its memory, settings for the span and zero parameters of its inputs, and you may reset these to ensure the 38-300 is accurately calibrated. As mentioned in the Interface Calibration Assignment this calibration should now be carried out before every practical that uses the 38-300. The more often it is carried out the more familiar you will become with the importance of calibration and the need to carry it out before every practical. Before beginning this practical, make sure that your process interface is switched on so that the 38-300 controller is powered up.
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3.2.2 Patching Diagram This practical has no patching diagram as it only deals with parameters of the 38-300. Its aim is to show you where and how to reset the 38-300 analogue input configuration parameters.
You will use the controllers keys to locate the specific parameters and reset them. This is something that should be done before every practical using the 38-300, to ensure that all measurements made with it are within a predefined level of accuracy. 3.2.3 Perform Practical Now you have had experience of starting the initialisation process by clicking on an on screen button in the previous practical, this shall be carried out automatically from now on, when a practical is started. As mentioned in the background pages and the patching diagram associated with this practical, you will check the analogue input settings of the 38-300 controller. The Commander 350 provides three analogue inputs. Two analogue inputs are universally configurable, allowing the controller to accept Thermocouple, Resistance Thermometer, mV, Volts, mA and resistance signals. The third analogue input signal can only accept mA and mV signals. Level 7, the Analogue Input Level allows the input type, decimal point settings and engineering ranges to be configured. To go to the Analogue Input Level, press and hold the Parameter Advance and press twice more to jump to the first level. Then press the Raise button until LEV.7 is displayed.
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Parameter tyP.1 dP.1 EN1.H EN1.L bSd.1 FLt.1
Value 2 1 100.0 0.0 nonE 0
Description Input 1 Setting: 4 to 20 mA (Process Variable) Input 1 Decimal Places Input 1 Engineering Unit High Input 1 Engineering Unit Low Broken sensor drive. Input values averaged over seconds.
Ensure that the input settings for analogue inputs 2 and 3 are identical. The Broken Sensor Drive is a setting that allows an action to be carried out if an invalid signal is received. This is to ensure that a sensible operation and potentially preventative operation is performed following a sensor failure. Options include none, up and down.
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3.2.4 Questions 1. What are the steps that make up the 38-300 pre-practical setup procedure?
2. Why is it unnecessary to calibrate the 38-300 in the same way that the current source on the Process Interface was calibrated? What devices would be needed to calibrate the 38-300 to an accuracy level greater than the one it has already been calibrated to?
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3.3
Practical 2 : Reading the 38-300
In the controller familiarisation assignment you were introduced to the concept of computer initialisation of the 38-300, via the serial link. This was discussed primarily in terms of oneway communication, but it is in fact two-way. When your personal computer sends a command to the 38-300 containing information about a particular parameter, the 38-300 will acknowledge the reception of this data by sending a signal back to the computer. The signal returned to the computer contains the a number of the parameter that has been set, along with a checksum called a cyclic redundancy check, known as CRC for short. The computer calculates the same checksum as the one that is transmitted from the controller. If they do not match, this indicates that an error has occurred during transmission. In control systems, it is very important that the correct operational parameters are set and reported. If an error is present, this may cause problems within the process that is being controlled, potentially causing a dangerous situation. Since the communication is two way, rather than tell the 38-300 what a particular parameter should be, your computer can also ask for a parameter from the process controller. In this way, variables monitored by the 38-300 can be displayed by your computer. This practical will demonstrate the read facility so that you will be familiar with it for later practicals, to record and chart process variables automatically. 3.3.1 Virtual Instrumentation This practical will take the output from the current source on the PI and use it as a process variable input to the 38-300 controller. Your personal computer will monitor this process variable continuously, providing a virtual chart recorder allowing the value of the current as to be observed as you vary it by hand. As the assignments develop and the need to monitor variables increases, the computer, with its virtual instrumentation, will play a greater and greater part. As well as the chart recorder displaying a parameter graphically, there is also a virtual control bar facility. This enables you to change a parameter value by varying the position of a bar with your mouse. The value you set on the control bar is displayed in the small upper window, and this value is sent to the 38-300. Both of these display facilities are shown in the practical. Having completed it, you will then be familiar with a personal computer as a control tool in a process system.
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Chapter 3 PROCON PRESSURE PROCESS RIG The computer offers the following to the user: It initialises the 38-300 by setting up a number of its parameters. It reads operational parameters, such as the set point and process variable, displaying them in a number of ways, depending on requirements Allow the user to directly alter parameters and observe their effect by observing the process or by monitoring the process variables using virtual instrumentation. Controller Calibration
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3.3.3 Perform Practical The patching diagram corresponding to this practical should have been completed already, and the controller has been set up automatically. If an error occurs during initialisation, check the serial communication links and ensure that the controller is set to the manual operation mode. Vary the current source output from the PI and observe the response of the chart recorder onscreen. This is recording the process variable input to the 38-300. The upper control bar is controlling the set point level of the 38-300. Ensure that the 38300 is showing the set point in the Green LED display. Change this control bar setting and observe its effect on the set point level in the 38-300. The window shows the control bar value. Try entering a number directly into the control and pressing return. Observe the change on the controller. The lower control bar is controlling the output of the 38-300. This output is being fed to the DDM. Change the setting of this control bar and observe the effect, as read by the DDM. From your observations of the chart recorder, consider whether you need to adjust the 'level 7' settings you have checked within the previous practical.
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3.3.4 Questions 1. In this practical you have met two virtual instruments that are used when controlling a process with your computer. Briefly outline the different facilities that a computer offers to process control; include which direction communication is passing, and between whom.
2. What type of controller is the 38-300, and what is the nature of the subservient relationship between controller and computer.
3. Why are there steps in the curve being drawn by the chart recorder? What are these steps dependent on? How could the size of the steps be reduced, how could the curve be made smoother?
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Notes
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Chapter 4 PROCON PRESSURE PROCESS RIG The Pressure Sensor and Transmitter
4 The Pressure Sensor and Transmitter

Objective To calibrate the pressure sensor and pressure transmitter and to investigate the linearity and hysteresis of the sensor/transmitter. Qty Apparatus 1 1 1 1 38-200 Process Interface 38-714 Pressure Process Rig 38-461 Pressure Transmitter 38-490 Digital Display Module Note - The equipment requires a supply of clean compressed air. Optional Equipment: 0.5 Metre Mercury Manometer or Digital Pressure Sensor (not supplied). Prerequisite Assignments Knowledge Level Familiarisation
Equipment Required
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4.1
Theory
4.1.1 The Pressure Sensor and Transmitter A Pressure Sensor may be used to give a remote reading of pressure in a system. This feature will be used in later experiments to enable the level to be controlled automatically. It is necessary to calibrate an electrical sensor (with its conditioning circuit) before use to provide an output that is meaningful. The Pressure Sensor may be calibrated to suit the operating range and datum required for a particular application. The sensor supplied has an output that changes linearly with change in pressure, and hysteresis is small. Note that this characteristic will not apply to all Pressure Sensors used in process control. Resolution of the Pressure Sensor is much finer than the Bourdon gauge that is designed for indication of approximate pressure only. For accuracy in operation, a Pressure Sensor should be calibrated using a manometer or dead weight calibrator.
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4.2
Practical 1: Pressure Sensor and Transmitter Calibration
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4.2.2 Perform Practical Complete the connections as shown in patching diagram and set R1 and R2 to closed, V2 open and all other valves closed. The aim of this experiment is to calibrate the Pressure Sensor and Transmitter to give the following conditions. 1. Minimum pressure = 0 psi = 4 mA output from the Pressure Transmitter. 2. Maximum pressure = 10 psi = 20 mA output from the Pressure Transmitter Note: The Pneumatic Control Valve is designed to open with lack of air. With R1 closed and the I/P Converter disconnected, the valve will remain open.
If an accurate Manometer or Digital Pressure Gauge is available this may be connected underneath the Bourdon gauge (G5) to allow a more precise calibration to be performed. (Note that the connection is a 1/4 inch push-fitting). Experimental Details: 3. With R2 closed, the pressure in the system will be atmospheric (ie, the minimum required, 0 psi on gauge G5 or 0 mm differential on the manometer). Use a small screwdriver or trim tool to adjust the zero control on the Pressure Transmitter to give a reading of 4 mA or 0% on the Digital Display Module. 4. Open valve V4. Set the pressure in the system to the maximum required (10.0 psi on gauge G5 or 414 mm on the manometer) by adjusting valve R2. When the pressure is steady, adjust the span control on the Pressure Transmitter to give a reading of 20 mA or 100% on the Digital Display Module. 5. Repeat the minimum and maximum settings until no further adjustments of the zero and span controls is required.
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4.2.3 Results Table
Pressure (psi)
Rising Pressure
Falling Percentage
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4.3
Practical 2: Linearity and Hysteresis
4.3.1 Perform Practical Having calibrated the Pressure Sensor and Transmitter, in the previous practical it is interesting to determine the linearity of the output over the operating range from minimum to maximum pressure. 1. Adjust the pressure in the system in steps of 2 psi from 0 psi to 10 psi indicated on gauge G5. Alternatively, if using a Mercury Manometer, adjust the pressure in steps of 50 mm from 0 mm to 515 mm differential reading on the manometer. Note: 1 mmHg = 0.01934 psi 2. Record the pressure and corresponding output from the Pressure Transmitter at each step. 3. Repeat for reducing pressure in the system to investigate the hysteresis in the sensor. 4. Plot the pressure versus the output voltage to determine the linearity and hysteresis. Print out the blank table in the results table section to record your results. Perform further experiments by repeating the procedures outlined for different minimum and maximum pressures in the system.
Caution !! Do not exceed a reading of 30psi on Gauge G5 as sensor damage could occur. Please refer the Familiarisation Assignment (Chapter 1) for more information.
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Chapter 5 PROCON PRESSURE PROCESS RIG The I to P Converter
5 The I to P Converter
Equipment Required Qty Apparatus 1 1 1 1 38-200 Process Interface 38-300 Process Controller 38-714 Pressure Process Rig 38-490 Digital Display Module Note: The equipment requires a supply of clean compressed air. Prerequisite Assignments Knowledge Level Familiarisation
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5.1
Theory
5.1.1 The I to P Converter A Pneumatic Control Valve requires a current to pressure converter to change the electrical signal from the control circuit to a corresponding pressure which can actuate the valve. It is necessary to calibrate a current to pressure converter before use to provide the appropriate output to a Pneumatic Control Valve. In this pneumatic control system, the equivalent of the 4 to 20 mA electronic signal is 3 psi to 15 psi. The Pneumatic Control Valve should not be used in applications where total shut-off is required. An additional Isolating or Stop valve should be used. Note that this characteristic will apply to the majority of proportional control valves used in process control. The I/P Converter provides a largely linear conversion from current input to pneumatic output. Hysteresis is small.
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5.2
Practical 1: The I to P Converter
The aim of this experiment is to calibrate the I/P Converter to position the Pneumatic Control Valve, which is designed is designed to open with lack of air with the following characteristics: 1. 4 mA to converter = 3 psi from converter (on G2) = Pneumatic Control Valve open 2. 20 mA to converter = 15 psi from converter(on G2) = Pneumatic Control Valve closed To set up the practical, perform the following: Complete the connections shown in the patching diagram. 3. R2, V1, V3, V5 & V6 Closed . 4. R1, V2 & V4 Open 5. Adjust R1 to give a reading of 25 psi on gauge G1 For this demonstration the 38-300 Process Controller will be used in Manual operation mode to operate the I/P Converter. Calibration of the controller is not required. This practical requires that the controller is switched on and correctly connected to the computer.
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5.2.2 Perform Practical The controller will have been automatically initialised by starting this practical. The below control emulates the one that can be accessed by the controls on the front of the controller. To perform the practical, carry out the following steps: 1. Remove the plastic stoppers which seal the zero and span adjusting controls on the I/P Converter. Note the span control on the I/P Converter is called Range. 2. Adjust the zero output on the I/P Converter to give a reading of 3 psi on gauge G2. The Pneumatic Control Valve should be just on the point of starting to close. This could be described as a braced position. 3. Adjust the output from the Process Controller to 100% by using the scrollbar. 4. Adjust the span (range) control on the I/P Converter to give a reading of 15 psi on gauge G2. The Pneumatic Control Valve should be just fully closed. 5. Repeat the minimum and maximum settings until no further adjustments of the zero and span controls is required. 6. Replace the plastic stoppers on the zero and span controls. 7. Check the operation of the Pneumatic Control Valve. 8. With the output from the controller set to 0%, adjust valve R2 until a reading of 10 psi is indicated on gauge G5. Valve V2 should be open, all other valves should be closed. 9. Adjust the output from the Process Controller to 100%. 10. Observe that the pressure in the system falls to zero with the valve closed. 11. Adjust the output from the controller to intermediate settings (eg, 40% and 60%) and observe the change in valve position and the change in pressure on gauge G5. Note: The Pneumatic Control Valve is not designed to isolate totally when in the position. A small amount of air will leak past the valve seat and from the system.
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An Isolation or Stop Valve is required to completely remove leakage. The small amount of air bleeding through the valve causes the float in the flow meter to attempt to lift very slightly and a clicking noise can be heard from the flow meter. 5.3 Practical 2: The I to P Converter Linearity and Hysteresis
5.3.1 Perform Practical The aim of the practical is to investigate the linearity and hysteresis of the I/P Converter. Like the previous practical, adjusting of the Control Output variable will be performed. 1. Reset the trainer to the initial settings as described in the previous practical. 2. Close valve R2. 3. Ensure that the controller output is set to 0% (4 mA). 4. Confirm that the corresponding output from the I/P Converter is 3 psi on gauge G2. 5. Adjust the controller output from 0% to 100% in steps of 10% and record the corresponding pressure from the I/P Converter on gauge G2. Repeat for reducing inputs to the I/P Converter. Record the observations using the results table then plot the input versus the output for rising and falling inputs to determine the linearity and hysteresis of the I/P Converter. Note: The pressure gauge used to perform this experiment has a stated accuracy of only 3% of full scale.
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5.3.2 Results Table
Controller Output (%)
Increasing G2 psi
Decreasing G2 psi
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Notes
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Chapter 6 PROCON PRESSURE PROCESS RIG The Pneumatic Control Valve
6 The Pneumatic Control Valve

Objective To demonstrate manual operation of the Pneumatic Control Valve and to determine its characteristics (pressure/position). Qty Apparatus 1 1 1 1 1 38-200 Process Interface 38-300 Process Controller 38-714 Pressure Process Rig 38-461 Pressure Transmitter 38-490 Digital Display Module Note: The equipment requires a supply of clean compressed air.
Equipment Required
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6.1
Theory
6.1.1 The Pneumatic Control Valve The plug-type valve provides a fine adjustment of flow through the valve and is ideal for the purpose of pressure control. A 4-20 mA control signal may be used to open or close a valve to any intermediate position. This facility to operate a valve remotely allows a process to be controlled automatically when the valve is connected to an appropriate sensor and controller. Although the Pneumatic Control Valve supplied does not have a truly linear characteristic, it is satisfactory for control purposes at the operating pressure suggested. As the pressure is increased, the relationship becomes less linear. The control valve must be carefully selected to give the correct characteristics over the normal range of operation.
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6.2
Practical 1: Characteristics of the Pneumatic Control Valve
The Pneumatic Control Valve comprises a plug type valve operated by a pneumatic actuator which receives a 3 to 15 psi pneumatic signal from a Current to Pressure Converter. The most useful characteristic of the control valve is the relationship between current input to the I/P Converter and pressure in the process pipe downstream of the valve. The relationship between current input and corresponding process variable is relevant in control applications. The aim of this practical is to demonstrate how the valve may be opened or closed to any intermediate position using a 4-20 mA current and to obtain the characteristics of pressure versus position. The Process Controller is factory calibrated in the following way: 1. Span 100% represents 20 mA input or output 2. Zero 0% represents 4 mA input or output The Pressure Sensor and Transmitter are calibrated in the following way: 3. 0 psi at G5 produces 4mA from Pressure Transmitter, representing 0% of range 4. 10 psi at G5 produces 20mA from Pressure Transmitter, representing 100% of range For this demonstration the 38-300 Process Controller will be used in Manual operation mode to operate the I/P Converter. Calibration of the controller is not required. This practical requires that the controller is switched on and correctly connected to the computer. 6.2.1 Settings To prepare for the practical, complete the following steps: 1. Connect the equipment as shown in the patching diagram. 2. Set V1, V3 & V6 Closed. 3. Set R1, R2, V2, V4 & V5 Open. 4. Adjust R1 to give 25psi on gauge G1. 5. Adjust R2 to give 10 psi on gauge G5 with the Pneumatic Control Valve open.
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Before starting the practical ensure that all connections in the patching diagram have been carried out and the the controller is operating in manual mode. This is shown by the orange M displayed in the bottom LED display of the controller. 6.2.2 Patching Diagram
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6.2.3 Perform Practical The controller will have been automatically initialised by starting this practical. A control within the chart recorder emulates the one that can be accessed by the controls on the front of the controller and displays the value of the process variable. The Pneumatic Control Valve should now be fully open as the control output is 0%. Observe the bottom LED display which should show 0. To perform the practical, complete the following steps: 1. Check that the maximum pressure is 100% on the process variable display of the controller (10 psi on gauge G5). If not adjust R2. 2. Close the Pneumatic Control Valve by setting the controller output to 100% (20mA). Check that the process variable falls to 0% (0 psi on gauge G5). 3. Adjust the position of the valve in steps of 10% from 0% to 100% by adjusting the controller output manually. 4. At each position of the valve record the corresponding pressure on the process variable display or chart recorder. 5. Repeat the procedure for the valve opening in steps of 10% to determine any hysteresis. Record the observations using the results table.
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6.2.4 Results Table
Controller Output (%)
Process Variable (%)
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6.3
Practical 2: Pneumatic Control Valve Characteristics at Different Pressure Ranges
The aim of this practical is to demonstrate the change in characteristic when operated over a different range of pressures. The Pressure Sensor may be recalibrated to operate over a different range; eg, 0 to 12 psi. However, for the purpose of demonstration, the pressures may be read directly on gauge G5 to avoid the need for recalibration. 1. Adjust regulator R2 to give a reading of 12 psi on gauge G5 with the Pneumatic Control Valve fully open. 2. Repeat the procedure from the previous practical but read the corresponding pressures directly on gauge G5. 3. Observe the change in characteristic using the below chart recorder noting that the change from 10 psi to 12 psi operating pressure is a relatively small change.
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Notes
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Chapter 7 PROCON PRESSURE PROCESS RIG System Response and the Air Receiver
7 System Response and the Air Receiver

Objective Equipment Required To determine the system response with and without the Air Receiver by manually operating the Pneumatic Control Valve. Qty Apparatus 1 1 1 1 1 38-200 Process Interface 38-300 Process Controller 38-714 Pressure Process Rig 38-461 Pressure Transmitter 38-490 Digital Display Module Note: The equipment requires a supply of clean compressed air.
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7.1
Theory
7.1.1 System Response and the Air Receiver Proportional adjustment of flow into the process pipe gives a steady pressure at the required value provided the process characteristics remain constant, ie a change in conditions in the system necessitates a corresponding change in valve position to maintain the pressure. The Pneumatic Control Valve provides proportional adjustment of flow into the process pipe by remote operation using a 3-15 psi control signal. Without the Air Receiver, disturbances cause the process variable to change very quickly. With the Air Receiver in series, changes in process variable are much less fast. The Air Receiver has the effect of changing the response of the process (time constant).
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7.2
Practical 1: System Response without the Air Receiver
The current output from the Pressure Transmitter should be connected to the process variable input of the Process Controller to indicate the pressure in the process pipe as measured by the sensor. The chart recorder which is found on the main practical page is used to give a clear indication of the responses. The changes may best be observed by watching the pressure indicated on gauge G5 (the digital changes on the process variable display may be too rapid to observe). The Process Controller is factory calibrated where Span 100% represents 20 mA input or output and Zero 0% represents 4 mA input or output. The Pressure Sensor and Transmitter are calibrated where 0 psi at G5 produces 4 mA from pressure transmitter, representing 0% of range and 10 psi at G5 produces 20 mA from pressure transmitter, representing 100% of range. Before carrying out the practical, connect the equipment as shown in the patching diagram. 7.2.1 Settings To prepare for the practical, complete the following steps: 1. V1, V3, V5 & V6 Closed. 2. R1, R2, V2 & V4 Open. 3. Adjust R1 to give 25 psi on gauge G1. 4. Adjust R2 to give 10 psi on gauge G5 with Pneumatic Control Valve open. Before starting the practical ensure that all connections in the patching diagram have been carried out and the controller is operating in manual mode. This is shown by the orange M displayed in the bottom LED display of the controller.
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7.2.3 Perform Practical The object of the demonstration is to maintain the pressure of the air in the process pipe at a preset value. The output from the controller will have been initially set to 50% (the bottom display will show 50.0) and note the corresponding process variable (pressure in the process pipe) on the chart recorder when the system has settled. To perform the practical, complete the following steps: 1. Change the output from the controller to 60%. Observe the change in process variable. 2. Change the output from the controller to 50%. Note that the process variable returns to the original value. 3. Adjust the position of the Pneumatic Control Valve to give a process variable reading of 50%. Note the output from the controller. 4. Open valve V5 to give additional outflow and observe the response of the process variable. 5. Re-adjust the output from the controller to return the process variable to 50%. 6. Close valve V5 and observe the response of the process variable. Adjust the controller output to its original value and observe that the process variable returns to 50%.
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7.3
Practical 2: System Response with the Air Receiver
This practical is very similar to the previous practical. To perform the practical, carry out the following two steps. 1. Fully open valve V1, open V3 and close valve V2 so that the air leaving the process pipe travels through the Air Receiver before discharging. 2. Repeat the procedure outlined in the previous practical and observe the slower changes in response with the Air Receiver in series with the process pipe.
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Chapter 8 PROCON PRESSURE PROCESS RIG Principles of Proportioning Valve
8 Principles of Proportioning Valve

Content To control pressure in the process pipe using the Pressure Sensor and three-term Process Controller with 4-20 mA proportional output to an I/P Converter and Pneumatic Control Valve. This experiment is intended to introduce and demonstrate the principle of using a proportioning valve. Experiments 7 to 9 introduce the for setting up a Process Controller. Qty Apparatus 1 1 1 1 1 38-200 Process Interface 38-300 Process Controller 38-714 Pressure Control Module 38-461 Pressure Transmitter 38-490 Digital Display Module Note: The equipment requires a supply of clean compressed air.
Objective
Equipment Required
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8.1
Theory
8.1.1 Principles of Proportioning Valve Pressure in the process pipe can be controlled using a Pressure Sensor and Process Controller configured for proportional output (4-20 mA) to position a Pneumatic Control Valve as required. Proportional control of the Pneumatic Control Valve allows the pressure to be held at the required set point despite changes in the upstream and downstream conditions. The pressure in the system may be changed by setting an alternative set point on the controller. No adjustment to the process or sensor is required provided the inlet and outlet conditions are compatible with the new setting. 8.1.2 Using the Controller All practicals require the controller control action to be set to Direct Action. The control action can be checked, and altered if necessary, by using the front panel of the controller. To set the controller to Direct Action carry out the following steps: Press and hold the Parameter Advance button three times to change to the Operator Level (level 1). Press the Up button five times. Between levels 5 and 6, the Up key will have to be pressed for slightly longer. Press the Parameter Advance button three times to access the Control Action setting. This is represented by the display C.ACt. Change the setting to dIr, indicating Direct Action. To exit the configuration level, press and hold the Parameter Advance key to return to the top of the level, return to Level 1, then press and hold Parameter Advance once again to return to the main display. Many practicals require the controller to operate in Automatic mode. When the controller is controlling a process in Automatic mode, the properties of the process rig and characteristics of different control algorithms can be explored. Changing between Manual and Automatic mode is a simple matter of pressing the Auto/Manual button.
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8.2
Practical 1: Maintaining Pressure at a Set-Point
The object of the demonstration is to maintain the pressure at the set point (50% process variable on the controller corresponds to 5 psi on gauge G5). To maintain a steady pressure in the process pipe, the Pneumatic Control Valve must be opened to the appropriate position by the Process Controller and continually adjusted to compensate for changes upstream or downstream in the system. The Air Receiver has been included in the circuit to give a slow response to the process. To setup the practical, perform the following steps: 1. Complete the connections shown in the patching diagram. 2. V2, V5 & V6 Closed. 3. R1, R2, V1, V3 & V4 Open. 4. Adjust R1 to give 25 psi on gauge G1. 5. Adjust R2 to give 10 psi on gauge G5 with Pneumatic Control Valve open. The Air Receiver pressure will begin to rise towards 10 psi.
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8.2.2 Perform Practical The below chart recorder should connected to the Pressure Transmitter output/controller input and controller output/current to pressure converter input 4-20 mA loops to provide a record of the response. This practical has initialised the Process Controller, setting the Set Point at 50%, the Proportional Band to 300%, Integral Action time to 5 Seconds and Derivative Action Time turned off. When ready, set the controller to automatic mode, by pressing the automatic/manual button. The M shown in the bottom display should disappear. If the set-up is correct, air should be delivered to the process pipe and discharge at the outlet with the pressure remaining at 50% (process variable). Observe that the pressure is controlled at the set point.
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8.3
Practical 2: Effects of Disturbance
Complete the connections shown in the patching diagram, and ensure that you have performed the previous practical. 1. Open valve V5 to give an additional outflow from the system. 2. Observe the response of the system. The Pneumatic Control Valve will open to give the required additional flow of air to maintain the pressure in the process pipe at the set point. 3. Close valve V5. Observe the response as the Pneumatic Control Valve closes to maintain the pressure. 4. Observe the changes in air flow on the flow meter. 8.4 Practical 3: Changing the Set-Point Remotely
In the basic set-up, the pressure was controlled about a mean value of 50% which corresponds to 5 psi on gauge G5. 1. Adjust the set point to 70% on the Process Controller. 2. Observe how the pressure changes to the required setting and the position of the Pneumatic Control Valve varies to suit the conditions. 3. Adjust the set point to 40% on the Process Controller. Once again, observe the changes in the level and the valve operation.
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Chapter 9 PROCON PRESSURE PROCESS RIG Proportional only Process Control
9 Proportional only Process Control

Objective To demonstrate the characteristics of a Proportional (P) only Process Control and the response to a change in set point or a disturbance in the process. Qty Apparatus 1 1 1 1 1 38-200 Process Interface 38-300 Process Controller 38-714 Pressure Control Module 38-461 Pressure Transmitter 38-490 Digital Display Module Note: The equipment requires a supply of clean compressed air. Knowledge Level It is assumed that the operator understands the meaning of Proportional Band.
Equipment Required
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9.1
Theory
9.1.1 Proportional only Process Control As the process variable deviates from the set point, the output from the controller will change in an attempt to restore the process variable to the set point. A small setting of Proportional Band means a large change in controller output (large movement of the valve) for a small deviation from the set point. If the setting of the Proportional Band is too small, the control loop will be unstable and continuous large scale oscillation of the control valve will occur. If the setting of the Proportional Band is too large, the process variable will be offset from the set point by a large amount. The controller centralises the Proportional Band about the set point. If a new set point is instructed by the operator, the controller will produce an output of 50% (12 mA) when the process variable matches the new set point. The operator can offset the output to give accurate control of the process by setting the system up manually before transferring to Automatic Control. Changing from Automatic to Manual (operator) control, as described within the previous practical, is a simple matter of pressing the Automatic/Manual button located on the third row, second column of the controller. The M LED will disappear when the controller is controlling the process. Any changes in the process (e.g. change in outflow from the process tank) will result in an offset from the set point. Any offset applied to the controller output will be transferred if a new set point is instructed; ie, the output will be centralised about the new set point but offset by the amount of offset at the previous set point. The optimum setting of Proportional Band is the smallest setting which will allow the process to operate with minimum offset while not allowing the system to become unstable.
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Practical 1: Proportional Control- Removing Offsets
The object of the demonstration is to control the pressure in the process pipe using a Ponly controller to operate the Pneumatic Control Valve. The controller fitted in the 38-300 has an option for the removal of offsets in proportional only systems. This option is known as manual reset and allows the operator to reduce the offsets to zero by offsetting the proportional band between 0 and 100% in 0.1% increments. The Manual Reset option will only function when no Integral Action has been selected. This would have been set when this practical is fully initialised. To view the Manual Reset setting on the controller, press and hold the Parameter Advance button until CoDE is displayed. Press twice to move to level 1, the operators setting level, LEU.1. Press the green Raise button to move the Tuning level (LEV.2). Finally, press the Parameter Advance button three times until rSt.1 is displayed. This is the manual reset value. This setting is only used when the controller is running in Automatic mode. When set to manual mode, a default is used. Before continuing, connect the equipment as shown in the patching diagram. On the process rig set valves V1, V3 and V6 to closed and valves V2, V4 and V5 to open.
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9.2.2 Perform Practical Initialisation has set the Proportional Band to 300% and set the setpoint to 50%, and turned the Derivative Action off. To perform the practical and to consider how the manual reset function operates, the following steps must be followed: 1. Adjust the manual reset option until the measured value is 50%, hence there is no offset. 2. Change the set point to 40% and observe the effect on offset. Notice the offset has returned. Hence we have shown the manual reset option only reduces the offset for a given setpoint. Moving the setpoint requires the operator to make an adjustment to the amount of normal reset. 3. Return the setpoint to 50% and observe the offset is removed using the procedure previously outlined. 4. Close valve V4 and observe the effect on the offset. Adjust the manual reset until the offset is reduced to zero. We have shown that when there is a change in demand in the process the controller requires manual adjustment to reduce the offset in a Proportional only system. 5. Reduce the Proportional Band to 200% and observe the effect on the offset. Notice the offset is unaffected by the changed PB. 6. Reduce the Proportional Band to 100% and open valve V4 to introduce a step response on the system. Observe the oscillating response from the process. It takes around 20 seconds to settle. 7. Increase the Proportional Band to 400% and close valve V4. Once the system has settled, open valve V4. Notice how less oscillatory the process is.
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Chapter 9 PROCON PRESSURE PROCESS RIG 9.3 Proportional only Process Control
Practical 2: Proportional Control- Effects of Disturbance
To follow on from the previous practical, the Proportional Band would have been initially set to 300% and the Set Point set to 50%. 1. Open valve V3 a little more to give a disturbance to the process. 2. Observe the response of the system. The Pneumatic Control Valve will open to give additional inflow to maintain the pressure at the set point. 3. Observe the offset from the set point. 4. Return valve V4 to its original position. Observe the response as the Pneumatic Control Valve closes to maintain the pressure. Observe that the pressure returns to the set point. 9.4 Practical 3: Proportional Control - Effects of Changing the Set Point
The measured variable and the set point are both shown on the chart recorder display. Initially the Set Point is set to 50%. You are required to change the controller output using the front panel, and change the controller between Automatic and Manual mode. To perform this practical, carry out the following steps: 1. Adjust the Set Point to 70% on the Process Controller. 2. The Pneumatic Control Valve will open to increase the flow into the process pipe to compensate for the increased pressure requirement. Observe that the pressure does not achieve the revised set point. 3. Adjust the Set Point to 30% on the Process Controller. Once again, observe the changes in the pressure and the valve operation. 4. Adjust the Set Point to 50% on the Process Controller. 5. Observe that the pressure returns to the SetPoint. 6. Adjust the Set Point to 70% on the Process Controller. 7. Manually adjust output from the controller to maintain the process variable at 70%. 8. Set the controller to Automatic operation and observe that offset from the Set Point is removed. 9. Adjust the Set Point to 50% on the Process Controller. 10. Observe that the process variable is offset from the SetPoint.
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9.5
Practical 4: Proportional Control - Effect of Changing the Proportional Band
This practical explores the effect of changing the Proportional Band. 1. Set the Proportional Band to 20% on the controller. Repeat the previous practical and observe the reduction in offsets. 2. Set the Proportional Band to 5% on the controller. Repeat the previous practical and observe the dramatic reduction in offsets. 3. Set the Proportional Band to 1% on the controller. Observe that the process has become unstable; ie, the Proportional Band setting is too small.
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Notes
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Chapter 10 Proportional + Integral Action Process Controller
10 Proportional + Integral Action Process Controller

Objective To demonstrate the characteristics of a (P + I) Proportional + Integral Action Process Controller and the response to a change in set point or a disturbance to the process. Qty Apparatus 1 1 1 1 1 38-200 Process Interface 38-300 Process Controller 38-714 Pressure Control Module 38-461 Pressure Transmitter 38-490 Digital Display Module Note: The equipment requires a supply of clean compressed air. Knowledge Level It is assumed that the operator understands the meaning of Proportional Band and Integral Action.
Equipment Required
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10.1 Theory 10.1.1 Proportional + Integral Action Process Controller Integral Action will remove offsets from the set point which occur with Proportional control. Correction is applied to the output from the controller while any deviation from the set point exists. A short setting of Integral Action Time means greater Integral Action effect on the output from the controller. (The output is corrected more frequently). he amount of correction applied to the output by the Integral Action is related to the Proportional Band setting. (A large Proportional Band means a smaller correction due to the Integral Action). Increasing the time constant of the system makes the process more oscillatory and increases the setting time.
Caution !! Note: Short settings of the Integral Action Time can be used in the pressure control demonstration to give fast correction of large offsets because the system responds quickly to changes.
In a process where disturbances take a long time to affect the process variable, the amount of Integral Action must be limited (ie use longer Integral Action Time) to avoid problems of saturation. If the IAT setting is too small, extreme actuation of the control valve will occur before the process has responded to initial valve adjustments. 38-100 and 38-600 involve processes with longer response times and may be used to demonstrate this feature.
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10.1.2 Practical 1: P +I Control and Effects of Disturbance The object of the demonstration is to control the pressure in the process pipe using a P+I controller to operate the Pneumatic Control Valve. As the Pneumatic Control Valve is open when 4 mA is applied to the current/pressure converter and a pressure below the set point requires the valve to be opened, the Process Controller is configured for Direct action. To setup the practical, perform the following steps: 1. Complete the connections shown in the patching diagram. 2. Set V1, V3 & V6 to Closed. 3. Set R1, R2, V2, V4 & V5 to Open. 4. Adjust R1 to give 25 psi on G1. 5. Adjust R2 to give 10 psi on G5 with the Pneumatic Control Valve open. 10.1.3 Perform Practical The controller is initialised for 300% Proportional Band and 5 seconds Integral Action Time. To perform the practical, carry out the following steps: 1. Allow the system to settle with no deviation. 2. Close valve V4 further to give a disturbance to the process. 3. Observe the response of the system. The Pneumatic Control Valve will close to reduce the pressure at the set point. Observe that the initial offset from the set point is gradually removed as the Integral Action moves to the required position. 4. Now open V4 and observe the system responding by increasing the airflow until the pressure is returned to the setpoint.
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10.2 Practical 2: Effects of Changing the Set Point Connect the patching diagram as shown and setup the Pressure Rig as described in the previous practical. 1. Adjust the Set Point to 70% on the Process Controller. 2. Observe the initial response due to Proportional Action followed by the gradual correction due to Integral Action. 3. Adjust the Set Point to 30% on the Process Controller. Once again, observe the changes in the pressure and the valve operation. 4. Adjust the Set Point to 50% on the Process Controller and allow the process to settle at the Set Point. 10.3 Practical 3: Effects of Changing the Integral Action Time In this practical, change the Integral Action Time to 1 second on the controller using the below control and observe the reduced effect of the Integral Action (the effect is the same but the time taken to reduce the offset is decreased). The effect of the Integral Action Time can be observed by following the below steps that were seen in the previous practical. 1. Adjust the Set Point to 70% on the Process Controller. 2. Observe the response. 3. Adjust the Set Point to 30% on the Process Controller. Once again, observe the changes. 4. Adjust the Set Point to 50% on the Process Controller and allow the process to settle at the Set Point.
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10.4 Practical 4: Effects of Changing the Proportional Band 1. Set the Proportional Band to 200% and the Integral Action to 5 seconds on the controller. 2. Apply a disturbance to the process or change the set point, as described in the first and second practicals and observe the response of the process. 3. Besides the reduced offset due to Proportional Action observe that the amount of correction applied by Integral Action is increased. 4. Open valves V1 & V3 and close V2 to connect the air receiver. Observe the effect of this while repeating the above.
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Chapter 11 Proportional + Derivative Action Process Controller
11 Proportional + Derivative Action Process Controller

Objective To demonstrate the characteristics of a (P + D) Proportional + Derivative Action Process Controller and the response to a change in set point or a disturbance to the process. Qty Apparatus 1 1 1 1 1 38-200 Process Interface 38-300 Process Controller 38-714 Pressure Control Module 38-461 Pressure Transmitter 38-490 Digital Display Module Note: The equipment requires a supply of clean compressed air. Knowledge Level It is assumed that the operator understands the meaning of Proportional Band and Derivative Action.
Equipment Required
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11.1 Theory 11.1.1 Proportional + Derivative Action Process Controller Derivative Action cannot reduce offsets from the set point which result with Proportional control. Correction is applied to the output from the controller whenever the process variable is changing. (The faster the process variable changes, the larger the amount of correction due to Derivative Action). A short setting of Derivative Action Time means less Derivative Action effect on the output of the controller. (Any correction applied to the output lasts for a shorter period of time). The amount of correction applied to the controller output by the Derivative Action is related to the proportional Band setting. (A large Proportional Band means a smaller correction due to the Derivative Action).
Caution !! Note: Short settings of the Derivative Time may be applied to this pressure process for the purpose of demonstration provided the setting of the Proportional Band is not too small.
If the Derivative Time setting is too long, the corrections to the control valve will be excessive and the process will be unstable. Derivative Action is usually applied to processes which have a slow reaction rate, moderate lags and small changes in load to the process. The large initial correction to the control valve allows the process to stabilise more quickly. The 38-100 Basic Process Rig and 38-600 Temperature Process Rig involve processes with longer response times and may be used to demonstrate this feature.
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11.2 Practical 1: P + D Control of Pressure The object of the demonstration is to control the pressure in the process pipe using a P+D controller to operate the Pneumatic Control Valve. To set-up the equipment for this practical, perform the following steps: 1. Complete the connections shown in the patching diagram. 2. Set V1, V3 & V6 Closed. 3. Set R1, R2, V2, V4 & V5 Open. 4. Adjust R1 to give 25psi on G1. 5. Adjust R2 to give 10psi on G5 with the Pneumatic Control Valve open. The controller is set for a 50% Proportional Band and a Derivative Action Time of 6 seconds from the initialisation of this practical. Carry out the procedure for removal of offsets detailed in the Proportional Control Removing Offsets practical. The chart recorder is connected to the Pressure Transmitter output/controller input and controller output/current to pressure converter input to provide a record of the response.
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11.3 Practical 2: Effects of Disturbance Connect the patching diagram as shown and setup the Pressure Rig as described in the previous practical. 1. Close valve V4 further to give a disturbance to the process. 2. Observe the response of the system as the Pneumatic Control Valve closes to reduce the pressure at the set point. Observe the large initial closing of the control valve occurs as the process variable moves away from the set point followed by an opening of the valve as the process variable approaches the set point. Note that the offset from the set point is not removed by the Derivative Action. 3. Return valve V4 to its initial position. Observe the response as the Pneumatic Control Valve opens to maintain the pressure. Observe that the large movements of the control valve as the process variable moves away from and towards the set point. 11.4 Practical 3: Effect of Changing the Set Point Connect the patching diagram as shown and setup the Pressure Rig as described in the first practical. 1. Adjust the set point to 70% on the Process Controller. 2. Observe the initial response due to Derivative Action followed by the conventional response due to the Proportional action. Note once again that the deviation from the set point is not corrected. 3. Adjust the set point to 30% on the Process Controller. Once again, observe the changes in the pressure and the valve operation. 11.5 Practical 4: Effects of Changing the Derivative Time Connect the patching diagram as shown and setup the Pressure Rig as described in the first practical. 1. Adjust the Derivative Action Time in steps of 1 until the process becomes unstable. This will happen at a setting of 8 or 9. 2. Repeat the steps described within the previous practical by adjusting the Set Point values from 70% to 30% to observe the increased effect of the Derivative Action (the effect is the same but the time taken for the valve to return to the position dictated by the Proportional setting is increased).
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11.6 Practical 5: Effect of Changing the Proportional Band Connect the patching diagram as shown and setup the Pressure Rig as described in the first practical. 1. Ensure the Proportional Band is set to 20% and the Derivative Action Time is set to 6 seconds. 2. Apply a disturbance to the process by opening valves V6 and V7 or change the set point. 3. Besides the reduced offset due to Proportional Action observe that the amount of correction applied by Derivative Action is increased.
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Chapter 12 Optimising Proportional Integral and Derivative Controllers
12 Optimising Proportional Integral and Derivative Controllers

Content To demonstrate typical procedures for optimising the settings of a three-term controller to suit a particular process. When selecting the settings for a three-term controller, consideration must be given to those characteristics of the process which affect its controllability. These are load changes (how large and how fast), process lags (capacity lags and resistance lags), process reaction lags, response lags of sensors etc. and dead time. Objective The object of this experiment is to use one of the widely used field methods for optimising the P, I and D settings on the controller to suit the characteristics of the process. In this instance the Ultimate Period/Ziegler-Nichols (closed loop) and Reaction Curve (open loop) methods will be used. Qty Apparatus 1 1 1 1 1 38-200 Process Interface 38-300 Process Controller 38-714 Pressure Control Module 38-461 Pressure Transmitter 38-490 Digital Display Module The equipment requires a supply of clean compressed air. Knowledge Level It is assumed the user understands the meanings of Proportional Band, Integral Action and Derivative Action.
Equipment Required
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12.1 Theory 12.1.1 Optimising PID Controllers Techniques exist which allow the settings of a three-term controller to be determined to suit a particular process. The settings predicted by these techniques will differ and should be treated as a starting condition for the setting up of the controller. Satisfactory control may be obtained from these settings but the commissioning engineer may need to make fine adjustments to obtain the required operating characteristics.
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12.2 Practical 1: Ultimate Period/Ziegler-Nichols The object of this experiment is to use one of the widely used field methods for optimising the P, I and D settings on the controller the suit the characteristics of the process. In this instance, the Ultimate Period/Ziegler-Nichols (closed loop) method will be used. To setup this practical, perform the following steps: 1. Complete the connections shown in the patching diagram. 2. Set V1, V3 & V6 to Closed. 3. Set R1, R2, V2, V4 & V5 to Open. 4. Adjust R1 to give 25 psi on G1. 5. Adjust R2 to give 10 psi on G5 with V2 open and V4 closed.
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12.2.2 Perform Practical The chart recorder is connected to the Pressure Transmitter output/controller input and controller output/current to pressure converter input 4-20 mA loops to provide a record of the process response. Data for the analysis is obtained using the controller configured for Proportional control only. Integral and Derivative settings on the controller will have been turned off when this practical has initialised. To complete the practical, perform the following steps: 1. Allow the process variable to settle then apply a step change to the process by closing valve V4. 2. As the process variable remains steady, decrease the Proportional Band and reapply a step change (by closing V4. 3. Continue adjusting the Proportional Band and applying a step change until the process variable continually oscillates. Note the setting of the Proportional Band at which continual cycling occurs. 4. From the trace obtained on the recorder measure the Period of the oscillation Pc in minutes. The optimum settings for the controller may be calculated as follows: P only P+I P+I+D PB = 2 PB = 2.2 PB = 1.7 PBc PBc IAT = 0.83 Pc PBc IAT = 0.50 Pc DAT = 0.13 Pc
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12.3 Practical 2: Reaction Curve Method The object of this experiment is to use one of the widely used field methods for optimising the P, I and D settings on the controller the suit the characteristics of the process. In this instance, the Reaction Curve (open loop) method will be used. A typical response curve is shown below:
Draw a straight line through the point of maximum slope so that the line intersects the time axis. Measure the dead time L in minutes. (Time at which step change is applied to time where straight line intersects time axis). Calculate the maximum slope R Determine R1 using the equation:
When setup is complete and the practical has started, perform the following steps: 1. Set the controller for Manual operation. 2. Adjust the output from the controller to give a steady pressure in the system with the process variable display showing 50%. 3. Leave the controller in Manual operation and apply a step disturbance to the process by changing the position of the Pneumatic Control Valve slightly. Note the step change applied (M%). 4. The step change will result in a new pressure in the system. The open loop response may be analysed from the chart recorder to determine the optimum settings for P, I & D.
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The optimum settings for the controller may be calculated as follows: P only PI PID PB = R1 x L IAT= 3.0 L DAT=0.3 L to0.5 L
PB = 1.1 (R1 x L)
PB = 0.5 (R1 x L) to 0.8 (R1 x L)
IAT= 2.0 L to2.5 L
12.3.1 Perform Practical Connect the patching diagram as shown and setup the Pressure Rig as described in the first practical. Like the previous practical, a chart recorder is used. Calculate the optimal controller settings using the equations and information from the background page. Compare the values obtained with those obtained using the Ziegler-Nichols method. See the previous practical for details. 12.4 Practical 3: Evaluation of Controller by Introducing a Disturbance In this practical, explore the operating settings that have been previously discovered, observing what occurs when a disturbance is introduced to the process. When the main practical page is opened, follow the below instructions: 1. Enter the settings of P, I and D to be evaluated on the Process Controller using the control boxes that are displayed within the chart recorder. 2. Set the set point to 50%. 3. Set the controller to Manual operation and adjust the valve position to maintain the required set point (50% process variable, 4 psi on G5). 4. Set the controller to Automatic operation then apply a disturbance by opening valve V4. 5. Observe the behaviour of the process. 6. Repeat the procedure for the settings of the controller suggested by the other technique.
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12.4.1 Perform Practical Enter the previously discovered settings into the parameter controls below then set the controller to run in Automatic mode. When the process is running, introduce a disturbance and observe the effects.
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Chapter 13 PROCON PRESSURE PROCESS RIG PID Controller and the Air Receiver
13 PID Controller and the Air Receiver

Objective To demonstrate the effect of the Air Receiver on the response of the process and to determine the optimum settings for the Process Controller. Qty Apparatus 1 1 1 1 1 38-200 Process Interface 38-300 Process Controller 38-714 Pressure Control Module 38-461 Pressure Transmitter 38-490 Digital Display Module The equipment requires a supply of clean compressed air. Knowledge Level It is assumed that the operator understands the meaning of Proportional Band, Integral Action and Derivative Action.
Equipment Required
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13.1 Theory 13.1.1 PID Controller with the Air Receiver The addition of the Air Receiver makes the response of the system correspondingly slower. (Pressure cannot change as quickly in the process pipe when a disturbance occurs or a new set point is instructed). Any change in the response of a process will necessitate a change in the settings of the three terms on the controller to achieve optimum control. Where the response of a process will change in operation, the controller must be configured to give stable control under all operating conditions. This may necessitate a reduction in performance at some conditions.
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13.2 Practical 1: System Response To perform the practical, setup the equipment using the following steps: 1. Connect the equipment as shown in the patching diagram with the Air Receiver in series with the process pipe. 2. V2, V4 & V6 to Closed. 3. Set R1, R2, V1, V3 & V5 to Open. 4. Adjust R1 to give 25 psi on G1. 5. Adjust R2 to give 10 psi on G5 with the Pneumatic Control Valve open. The chart recorder is connected to the Pressure Transmitter output/controller input and controller output/current to pressure converter input 4-20mA loops to provide a record of the response. The Set Point of the system has been set to 50%. Observe the response of the system when valve V4 is opened and closed to give a disturbance. Isolate the Air Receiver from the process pipe by opening V2 and closing V1 and V3. Apply a disturbance to the new configuration and observe the change in response.
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13.3 Practical 2: Determining Optimum Settings for the Process Controller 13.3.1 Patching Diagram
13.3.2 Perform Practical Using the techniques described in the previous assignment, determine the optimum settings for the three-term controller to suit the two systems. Apply the optimum settings for each system and evaluate their responses using valve V4 to apply a step change to the outflow from the system. Observe that the process becomes unstable if the settings relating to the Air Receiver in series are applied to the process without the Air Receiver.
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Chapter 14 Calibration of the Differential Pressure Sensor and Transmitter
14 Calibration of the Differential Pressure Sensor and Transmitter

Objective Equipment Required To calibrate the Differential Pressure Sensor and Differential Pressure Transmitter. Qty Apparatus 1 1 1 1 1 38-200 Process Interface 38-300 Process Controller 38-714 Pressure Process Rig 38-472 Differential Pressure Transmitter 38-490 Digital Display Module The equipment requires a supply of clean compressed air.
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14.1 Theory 14.1.1 Calibration of the Differential Pressure Sensor and Transmitter A Differential Pressure Sensor may be used to give a remote reading of the differential pressure in a system. It is necessary to calibrate an electrical sensor before use to provide an output which is meaningful. The Differential Pressure Sensor may be calibrated to suit the operating range and datum required for a particular application. The readings obtained can be related to actual flow rates from the flowmeter.
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14.2 Practical 1: Calibration of the Differential Pressure Sensor and Transmitter The aim of this experiment is to calibrate the Differential Pressure Sensor/Transmitter to suit the process. The Differential Pressure Sensor is connected to the tappings upstream and downstream of an Orifice Block located in the process pipe. Pressure drop across the Orifice Block is related to the flow of air in the pipe (pressure drop is proportional to the square of the flow). The aperture in the Orifice Block is 1.5 mm in diameter. The flowmeter installed on the 38-714 allows the relationship between the actual flow rate and the output from the sensor to be considered. The sensor and transmitter can be calibrated to the minimum and maximum conditions of flow through the pipe so as to be of use in control applications (the corresponding real values of the flow being known from the flowmeter reading). 14.2.1 Preparing for the Practical For this set of demonstrations the controller will be used manually to operate the control valve via the I/P Converter and to monitor the differential pressure in the process pipe. 1. Complete the connections shown in the patching diagram. 2. Set V1, V3, V4 & V5 to Closed. 3. Set R1, R2, V2, V6 and V7 to fully open. 4. Adjust R1 to give 25 psi on G1. 5. Adjust R2 to give 15 psi on G4 with the Pneumatic Control Valve open. 6. Adjust V4 to give 5 psi on G5. 7. Re-adjust R2 and V4 until G4 reads 15 psi and G5 reads 5.
8. Once there is a pressure difference of 10 psi between G4 and G5, reduce the
pressure with R2 until G4 reads 10 psi. G5 will now be reading zero.
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14.2.3 Perform Practical To perform the calibration, follow the below steps: 1. Connect the compressed air supply to the inlet.
Caution !! The Pneumatic Control Valve is designed to open with lack of air. With 4 mA input to the I/P Converter, the valve will remain open. 2. Set the controller to Manual operation and open the control valve by setting output to 0%. 3. With the Pneumatic Control Valve open adjust R2 to give a flow rate of 25 L/min, adjust the span on the differential pressure transducer to give 100% reading on the controller. 4. Increase the controller output to close the control valve until the flow is zero, gauge G5 will read 0 psi. Use the trim tool supplied with 38-300 to adjust the zero control on the Differential Pressure conditioning module to give a reading of 4.0 mA on the Digital Display Module. 5. Set the flow in the system to the maximum required by opening the Pneumatic Control Valve (pressure process variable should return to 100%). When the flow is steady, adjust the span control on the Differential Pressure conditioning module to give a reading of 20.0 mA on the Digital Display Module. 6. Repeat the minimum and maximum settings until no further adjustments of the zero and span controls is required. The Differential Pressure Sensor/Transmitter has now been calibrated to give readings from 4-20 mA (0-100% if used with the Process Controller) corresponding to the range of flow rates available in the process pipe.
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Chapter 15 PROCON PRESSURE PROCESS RIG Flow Control in the Process Rig
15 Flow Control in the Process Rig

Objective To control flow in the process pipe using a Differential Pressure Sensor/Orifice Block with square root extractor and three-term Process Controller with a 4-20 mA proportional output to an I/P Converter and Pneumatic Control Valve. Qty Apparatus 1 1 1 1 1 1 38-200 Process Interface 38-300 Process Controller 38-714 Pressure Process Rig 38-462 Differential Pressure Transmitter 38-490 Digital Display Module Configurator serial cable The equipment requires a supply of clean compressed air.
Equipment Required
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15.1 Theory 15.1.1 Flow Control in the Process Pipe Flow in the process pipe can be measured using a Differential Pressure Sensor connected to an Orifice Block. As the pressure drop across the Orifice Block changes with the square of the velocity, the output from the Differential Pressure Sensor is highly non-linear. The output from the Transmitter can be linearised using a square root extractor to provide a signal which is proportional to flow. Flow in the process pipe can be controlled using a flow sensor/conditioner and Process Controller configured for proportional output (4-20 mA) and square-root extraction to an I/P Converter to position a Pneumatic Control Valve as required at the inlet to the pipe. Proportional control of the pneumatic control valve allows the flow to be held at the set point without the undue oscillations which are inherent in an on/off control system. The flow in the pipe may be changed by setting an alternative set point on the controller. No adjustment to the process or sensor is required provided the inlet and outlet conditions are compatible with the new setting. 15.1.2 Controller Advanced Settings The ABB Commander 350 process controller contains a large number of features that are not immediately accessible. There is a simple reason for hiding some features and making others easily available. Parameters such as P, I and D will be familiar to all process control engineers. Using the ABB Commander 350, it is possible to 'fine tune' the controller so that it can successfully control processes in situations where the input (and output) signals are not linear. Advanced users can mathematically change the signals that the PID controller accepts and generates. This is achieved using a feature called a 'maths block'. Normal users of a process controller will want to access common parameters, like the PID and offset settings. The more intricate settings of the controller are hidden from immediate view, preventing them to be changed accidentally. So your controller can be configured easily, ABB has created a separate pathway so the controller settings can be adjusted. This pathway is separate from the serial communication pathway used to obtain the state of a process and change the main operational parameters.
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This separation is made for safety reasons. A potentially dangerous situation may arise if the linearity setting is accidentally changed during the middle of a process. The issue of safety and security can again be seen in the 'level' scheme that the controller adopts, where only the highest most important levels can be changed when the controller is in manual mode. Controller settings can be changed by using a special Configurator program, developed by ABB. This software requires a special cable that connects the controller to the computer using the circular jack plug located at the rear of the controller. 15.1.3 Using the Configurator Software This practical requires the Square Root Lineariser to be used. This is one of many different linearisers that can be used with the Commander 350 controller. When the Configurator software has started and has found the PROCON controller (remember to check the number of the communications port if problems arise), select the Advanced Level option, shown in the bottom right of the display. When the advanced options are displayed, select the Maths Block option. A representation of the maths block dialog is shown below.
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15-3
Ensure that the Maths Block 1 type is set to Square Root, and the Square Root Source is set to Analogue Input 1. When you are happy with the settings, transfer them to the controller. Be careful to only change the parameters you need to change. A skilled process control engineer who is familiar with computer controls will always know how to return to a known 'good' setting. Important! The controllers memory is non-volatile, meaning it remembers its settings when the power is turned off. When you have finished using the practicals within this assignment, the lineariser must be turned off. If you forget to do this, other users may observe behaviour that may be difficult to understand!
15.2 Practical 1: Maintaining a flow by using the Control Valve The object of the demonstration is to maintain the flow at mid range in the process pipe (50% set point) by adjusting the opening of the Pneumatic Control Valve to allow the required amount of air to flow through the pipe. The Process Controller is should be configured to use a square root lineariser. To learn about how to configure the controller to use a lineariser, refer to the previous theory and the controller instruction manual for more information. To prepare for this practical, carry out the following steps: 1. Complete the connections shown in patching diagram. 2. V1, V3, V4, &V5 Closed. 3. V2, V6 & V7 (fully open) R1 & R2 Open. 4. Adjust R1 to give 25 psi on G1. 5. Adjust R2 to give 25 L/min on the flow meter with the Pneumatic Control Valve open.
15-4
38-930-M
38-930-M
15-5
15.2.2 Perform Practical For this demonstration, the Process Controller is configured for three-term control. The Set Point is set to 50%, the Proportional Band to 300% and the Integral Time is set to 5 seconds. Derivative Time is turned off. If the set-up is correct, air should discharge from the main orifice. The flow should remain at 50% (process variable). Observe that the flow is controlled at the set point. 15.3 Practical 2: Operation of Square Root Extractor To prepare for the practical, perform the following steps: 1. Connect the equipment as shown in Patching Diagram. 2. Open valves V2, V4, V5, V6 & V7 (fully open). 3. Close valves V1 & V3. 4. With the control valve fully open adjust the flow rate to 24 L/min. This should give a pressure drop of about 10 psi across the orifice plate (G4 - G5 = 10 psi). 5. Set the span on the differential pressure transmitter to 100%. 6. Reduce the flow to zero and set the zero on the differential pressure transmitter to 0%. 15.3.1 Perform Practical To demonstrate the effect of the square root extractor, the output from the differential pressure transmitter will be plotted against flow with the square root option set on the process controller. With the controller in manual mode set the o/p to 0%. Increase the output in steps of 10% up to 100%. Record the process variable display on the controller and the actual flow rate on the flow meter. Repeat the reading with the square root extraction option turned off. Plot the two sets of data flow against process variable. Print out the blank table in the results table section to record your results.
15-6
38-930-M
15.4 Practical 3: Changing the Set Point Remotely 15.4.1 Perform Practical In the basic set-up the flow was controlled about a mean value of 50%. Adjust the set point to 60% on the Process Controller by using the control along side the chart recorder. Observe how the flow changes to the required setting and the position of the Pneumatic Control Valve varies to suit the conditions. Adjust the set point to 40% on the Process Controller. Once again, observe the changes in the flow and the valve operation. If required, the flow process may be studied in detail by following the procedures detailed in the Proportional Only to the Three-Term Controller assignment. Optimum controller settings and effects of the Air Receiver may also be investigated.
38-930-M
15-7
Chapter 15 PROCON PRESSURE PROCESS RIG 15.5 Results Table Practical 2, Table 1 Controller O/P 0 10 20 30 40 50 60 70 80 90 100 Practical 2, Table 2 Controller O/P 0 10 20 30 40 50 60 70 80 90 100 Flow L/min Process Variable % Flow L/min Process Variable % Flow Control in the Process Rig
15-8
38-930-M

38-930-M (Manual de Practicas

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E-Learning

Electricity & Electronics

Control & Instrumentation

PROCON Pressure Process Rig 38-930-M

Electrical Power & Machines

Test & Measurement

PROCON Pressure Process Rig 38-930-M

Feedback Part No. 116038930M

PROCON PRESSURE PROCESS RIG

THE HEALTH AND SAFETY AT WORK ACT 1974

CAUTION RISK OF DANGER Refer to accompanying documents

CAUTION RISK OF ELECTRIC SHOCK

CAUTION ELECTROSTATIC SENSITIVE DEVICE

PROCON PRESSURE PROCESS RIG

DECLARATION CONCERNING ELECTROMAGNETIC COMPATIBILITY

Feedback Instruments Limited

PROCON PRESSURE PROCESS RIG

TABLE OF CONTENTS 1 Pressure Rig Familiarisation

The Pressure Sensor and Transmitter

Contents 4-3 4-6

The Pneumatic Control Valve

System Response and the Air Receiver

Principles of Proportioning Valve

Proportional only Process Control

Contents 9-3 9-6 9-6 9-7

10 Proportional + Integral Action Process Controller

11 Proportional + Derivative Action Process Controller

12 Optimising Proportional Integral and Derivative Controllers

13 PID Controller and the Air Receiver

Contents 13-2 13-3

Practical 2: Determining Optimum Settings for the Process Controller 13-5

14 Calibration of the Differential Pressure Sensor and Transmitter 14-1

Practical 1: Calibration of the Differential Pressure Sensor and Transmitter14-3

15 Flow Control in the Process Rig

Chapter 1 PROCON PRESSURE PROCESS RIG Pressure Rig Familiarisation

1 Pressure Rig Familiarisation

Chapter 1 PROCON PRESSURE PROCESS RIG Pressure Rig Familiarisation

Chapter 1 PROCON PRESSURE PROCESS RIG Pressure Rig Familiarisation

Chapter 1 PROCON PRESSURE PROCESS RIG Pressure Rig Familiarisation

Chapter 1 PROCON PRESSURE PROCESS RIG Pressure Rig Familiarisation

Chapter 1 PROCON PRESSURE PROCESS RIG Pressure Rig Familiarisation

Practical 1 : System Pressurisation

Chapter 1 PROCON PRESSURE PROCESS RIG Pressure Rig Familiarisation

1.2.1 Patching Diagram

Chapter 1 PROCON PRESSURE PROCESS RIG Pressure Rig Familiarisation

Practical 2 : Current Source Calibration

Chapter 1 PROCON PRESSURE PROCESS RIG Pressure Rig Familiarisation

Practical 3 : I/P Converter and Pneumatic Control Valve Operation

Check operation of I/P Converter and Pneumatic Control Valve.

Chapter 1 PROCON PRESSURE PROCESS RIG Pressure Rig Familiarisation

1.4.1 Patching Diagram

Chapter 1 PROCON PRESSURE PROCESS RIG Pressure Rig Familiarisation

Practical 4 : Pressure Sensor and Transmitter

Chapter 1 PROCON PRESSURE PROCESS RIG Pressure Rig Familiarisation

Practical 5 : Differential Pressure Sensor and Transmitter

Chapter 2 PROCON PRESSURE PROCESS RIG Controller Familiarisation

Chapter 2 PROCON PRESSURE PROCESS RIG Controller Familiarisation

38-300 Process Controller

Chapter 2 PROCON PRESSURE PROCESS RIG Controller Familiarisation

Chapter 2 PROCON PRESSURE PROCESS RIG Controller Familiarisation

Chapter 2 PROCON PRESSURE PROCESS RIG Controller Familiarisation

Chapter 2 PROCON PRESSURE PROCESS RIG Controller Familiarisation

Chapter 2 PROCON PRESSURE PROCESS RIG Controller Familiarisation