EMCS Technology Exercises Worksheets V2

Process Control System DE 05/06

Exercises for

Process Control

System

Courseware

2 © Festo Didactic GmbH & Co. • Process Control System

This courseware has been developed and manufactured exclusively for vocational

and continuing training in process automation and control engineering.

The training company and / or trainers have the duty to ensure that trainees observe

all safety precautions described in the accompanying manuals and data sheets.

Festo Didactic GmbH & Co. and ADIRO Automatisierungstechnik GmbH will not be

liable for any damage or injury to trainees, the training company and / or other third

parties resulting from use of the equipment for any other purpose than training,

unless Festo Didactic GmbH & Co. or ADIRO Automatisierungstechnik GmbH has

caused such damage or injury willfully or through negligence.

Order no

Designation Courseware

Description Exercises for process and control engineering

Status 05/2006

Authors Jürgen Helmich, Stefan Knoblauch, Andreas Wierer (ADIRO)

Translation Williams Technical Communication Pty Ltd, Brisbane

Graphics Jürgen Helmich, Stefan Knoblauch (ADIRO)

Layout Jürgen Helmich (ADIRO)

© Festo Didactic GmbH & Co., 05/2006

Internet: www.festo.com/didactic http://www.festo.com/didactic/de/ProcessAutomation

e-mail: [email protected]

The copying, distribution and utilization of this document as well as the communication of its contents

to others without expressed authorization is prohibited. Offenders will be held liable for the payment of

damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental

design registration.

Intended use

© Festo Didactic GmbH & Co. • Process Control System 3

Intended use _________________________________________________________ 2

Contents ____________________________________________________________ 3

1 Introduction______________________________________________________ 7

1.1 Material covered ______________________________________________ 8

1.2 Important notes_______________________________________________ 9

1.3 Operator’s responsibilities _____________________________________ 9

1.4 Trainees’ responsibilities_______________________________________ 9

1.5 Hazards associated with operating the Process Control System _______ 10

2 Project planning _________________________________________________ 11

2.1 PI diagram __________________________________________________ 12

2.2 Equipment list _______________________________________________ 15

Exercise 2.2 _______________________________________________________ 15

Worksheet 2.2.1 ___________________________________________________ 16

2.3 Project planning – Controlled system ____________________________ 17

Exercise 2.3.1 _____________________________________________________ 18

Exercise 2.3.2 _____________________________________________________ 20

Exercise 2.3.3 _____________________________________________________ 22

3 Analysis ________________________________________________________ 25

3.1 Analysis of the container_______________________________________ 26

Exercise 3.1.1 _____________________________________________________ 26

Worksheet 3.1.1 ___________________________________________________ 27

3.2 Analysis of a pump ___________________________________________ 28

Exercise 3.2.1 _____________________________________________________ 28

Worksheet 3.2.1 ___________________________________________________ 29

Exercise 3.2.2 _____________________________________________________ 31

Worksheet 3.2.2 ___________________________________________________ 32

Exercise 3.2.3 _____________________________________________________ 33

Worksheet 3.2.3 ___________________________________________________ 34

3.3 Analysis of a proportional valve ________________________________ 35

Exercise 3.3.1 _____________________________________________________ 35

Worksheet 3.3.1 ___________________________________________________ 36

Exercise 3.3.2 _____________________________________________________ 37

Worksheet 3.3.2 ___________________________________________________ 38

3.4 Analyze of a process drive _____________________________________ 39

Exercise 3.4.1 _____________________________________________________ 39

Worksheet 3.4.1 ___________________________________________________ 40

Exercise 3.4.2 _____________________________________________________ 42

Worksheet 3.4.2 ___________________________________________________ 43

Exercise 3.4.3 _____________________________________________________ 44

Worksheet 3.4.3 ___________________________________________________ 45

3.5 Analysis of a heating element___________________________________ 46

Exercise 3.5.1 _____________________________________________________ 46

Worksheet 3.5.1 ___________________________________________________ 47

3.6 Analysis of an ultrasound sensor _______________________________ 48

Contents

Inhalt


Exercise 3.6.1 _____________________________________________________ 48

Worksheet 3.6.1 ___________________________________________________ 49

Exercise 3.6.2 _____________________________________________________ 50

Worksheet 3.6.2 ___________________________________________________ 51

3.7 Analysis of a flow meter _______________________________________ 53

Exercise 3.7.1 _____________________________________________________ 53

Worksheet 3.7.1 ___________________________________________________ 54

Exercise 3.7.2 _____________________________________________________ 55

Worksheet 3.7.2 ___________________________________________________ 56

3.8 Analysis of a pressure sensor __________________________________ 59

Exercise 3.8.1 _____________________________________________________ 59

Worksheet 3.8.1 ___________________________________________________ 60

Exercise 3.8.2 _____________________________________________________ 61

Worksheet 3.8.2 ___________________________________________________ 62

3.9 Analysis of a temperature sensor________________________________ 64

Exercise 3.9.1 _____________________________________________________ 64

Worksheet 3.9.1 ___________________________________________________ 65

Exercise 3.9.2 _____________________________________________________ 66

Worksheet 3.9.2 ___________________________________________________ 67

3.10 System behavior of a container _______________________________ 69

Exercise 3.10.1 ____________________________________________________ 69

Worksheet 3.10 ____________________________________________________ 70

4 Commissioning __________________________________________________ 74

4.1 Commissioning a level-controlled system _________________________ 75

Exercise 4.1.1 _____________________________________________________ 76

Worksheet 4.1.1 ___________________________________________________ 77

Exercise 4.1.2 _____________________________________________________ 78

Worksheet 4.1.2 ___________________________________________________ 79

Exercise 4.1.3 _____________________________________________________ 80

Exercise 4.1.4 _____________________________________________________ 81

Worksheet 4.1.3/4.1.4 ______________________________________________ 82

4.2 Commissioning a flow controlled-system _________________________ 83

Exercise 4.2.1 _____________________________________________________ 84

Worksheet 4.2.1 ___________________________________________________ 85

Exercise 4.2.2 _____________________________________________________ 86

Worksheet 4.2.2 ___________________________________________________ 87

Exercise 4.2.3 _____________________________________________________ 88

Worksheet 4.2.3 ___________________________________________________ 89

Exercise 4.2.4 _____________________________________________________ 90

Worksheet 4.2.4 ___________________________________________________ 91

Exercise 4.2.5 _____________________________________________________ 92

Worksheet 4.2.5 ___________________________________________________ 93

4.3 Commissioning a pressure-controlled system______________________ 94

Exercise 4.3.1 _____________________________________________________ 95

Inhalt

Worksheet 4.3.1 ___________________________________________________ 96

Exercise 4.3.2 _____________________________________________________ 97

Worksheet 4.3.2 ___________________________________________________ 98

Exercise 4.3. 3 _____________________________________________________ 99

Worksheet 4.3.3 __________________________________________________ 100

Exercise 4.3.4 ____________________________________________________ 101

Worksheet 4.2.4 __________________________________________________ 102

Exercise 4.3.5 ____________________________________________________ 103

Worksheet 4.3.5 __________________________________________________ 104

4.4 Commissioning a temperature-controlled system__________________ 105

Exercise 4.4.1 ____________________________________________________ 106

Worksheet 4.4.1 __________________________________________________ 107

Exercise 4.4.2 ____________________________________________________ 108

Worksheet 4.4.2 __________________________________________________ 109

Exercise 4.4.3 ____________________________________________________ 110

Worksheet 4.4.3 __________________________________________________ 111

5 Control engineering______________________________________________ 113

5.1 Identifying the controlled system_______________________________ 114

Exercise 5.1.1 ____________________________________________________ 115

Worksheet 5.1.1 __________________________________________________ 116

Worksheet 5.1.2 __________________________________________________ 117

5.2 Controller functions__________________________________________ 118

Exercise 5.2.1 ____________________________________________________ 119

Worksheet 5.2.1 __________________________________________________ 120

Exercise 5.2.2 ____________________________________________________ 121

Worksheet 5.2.2 __________________________________________________ 122

Exercise 5.2.3 ____________________________________________________ 123

Worksheet 5.2.3 __________________________________________________ 124

Exercise 5.2.4 ____________________________________________________ 125

Worksheet 5.2.4 __________________________________________________ 126

Exercise 5.2.5 ____________________________________________________ 127

5.3 Worksheet 5.2.5 ____________________________________________ 128

Exercise 5.2.6 ____________________________________________________ 129

Worksheet 5.2.6 __________________________________________________ 130

5.4 Controller setting using the Ziegler-Nichols method________________ 131

Exercise 5.3.1 ____________________________________________________ 132

Worksheet 5.3.1 __________________________________________________ 133

Exercise 5.3.2 ____________________________________________________ 134

Exercise 5.3.3 ____________________________________________________ 135

Worksheet 5.3.2 __________________________________________________ 136

5.5 Controller parameterization using the Chien-Hrones-Reswick method _ 137

Exercise 5.4.1 ____________________________________________________ 138

Worksheet 5.4.1 __________________________________________________ 139

Exercise 5.4.2 ____________________________________________________ 140

Inhalt


Worksheet 5.4.3 __________________________________________________ 141

Worksheet 5.4.3 __________________________________________________ 142

Exercise 5.4.3 ____________________________________________________ 143


The Festo Didactic Learning System for Process Engineering is based on various

training prerequisites and vocational requirements. The Process Control System

Compact Workstation allows vocational and continuing training that is highly

practice-oriented. The hardware comprises industrial components that have been

didactically prepared.

The courseware – in combination with the Compact Workstation of the Process

Control System – provides a system that is suitable for practice-oriented training of

new key competencies:

• Social skills

• Technical competence

• Methodoligical competence

Teamwork, cooperation and organizational skills can be trained at the same time.

Real project phases can be trained during the learning projects, including:

• Planning

• Assembly

• Programming

• Commissioning

• Operation

• Maintenance

• Troubleshooting

1 Introduction

Project planning


Material from the following areas can be covered:

• Mechanical engineering

• Mechanical design of a station

• Process engineering

• Reading and creating flow diagrams and documentation.

• Installation of piping for process components

• Electrical engineering

• Correct wiring of electrical components

• Sensors

• Correct use of sensors

• Measurement of non-electrical, process-engineering and control-engineering

variables

• Learning to use and parameterize fieldbus technology such as PROFIBUS

• Closed-loop control engineering

• Fundamentals of closed-loop control engineering

• Expanding measuring chains to closed control loops

• Analysis of controlled systems

• P, I, D controls

• Optimization of a control loop

• Controlling system (industrial controller)

• Configuration, parameterization and optimization of an industrial controller

• Commissioning

• Commissioning a control loop

• Commissioning a processing plant

• Troubleshooting

• Checking, maintaining and repairing process plants

• Controlling and monitoring processes with a PC

• Systematic troubleshooting a processing plant

1.1

Material covered

Project planning


The basic prerequisite for safe handing and fault-free operation of a Process Control

System station is knowledge of the basic safety instructions and regulations.

These operating instructions contain the most important safety instructions for safe

operation of a station.

In particular, the safety instructions are to be observed by all persons working at the

workstation.

In addition, local rules and accident-prevention regulations must be observed.

The operator is responsible for ensuring that people working at the workstation are

limited to:

• Those with a basic knowledge of work safety and accident prevention and who

have been instructed in the operation of the station.

• Those who have read and understood the safety chapter and warning notices in

these operating instructions and have signed to this effect.

All persons assigned to working with the workstation are required to carry out the

following before starting work:

• To observe the basic regulations for work safety and accident prevention.

• To read and understand the safety chapter and warning notices in these

operating instructions and sign to this effect.

1.2

Important notes

1.3

Operator’s

responsibilities

1.4

Trainees’

responsibilities

Project planning


The workstation has been built in accordance with the state of the art and

recognized safety regulations. Nonetheless, operation of the station can result in the

danger of injury or death to the user or third parties or damage to the machine or

other property.

The station is only to be used

• For the intended purpose and

• When in perfect condition from a safety point of view.

Any faults that could compromise safety must be eliminated immediately!

1.5

Hazards associated with

operating the Process

Control System


Project planning of a process plant should include the following documents:

• Specifications

• Process description, associated conditions such as environmental protection

• Start of scheduling and schedule monitoring

• Planning of flow diagrams

• Basic flow diagram

• Process flow diagram

• Piping and instrumentation diagram (PI diagram)

• Function diagrams

• Design of process plant

• Environmental protection requirements

• Specification of all equipment, Instrumentation and Control (EMCS) point list

• EMCS point plan – outline

• EMCS point plan – detailed

• Wiring and terminal diagrams

• Assembly plans

• Installation planning

• Acquisition

• Assembly, commissioning and acceptance of the system

The planning of a process-engineering project should be practiced using a PI

diagram, an EMCS point list and an EMCS point plan for a controlled system.

2 Project planning

Project planning


The development of a PI diagram is a significant part of the project work. A PI

diagram explains the EMCS functions using measuring points and final control

elements.

EMCS point designation

The process-related functions in an EMCS plan (Electrical, Instrumentation &

Control) are described by EMCS points. The designation indicates the measured

variables or other input variables, their processing, the direction of control action,

and location.

A EMCS point consists of an EMCS circle and is designated by code letters (A-Z) and

a code number. The code letters are entered in the upper half of the EMCS circle, the

number in the lower half. The sequence of the code letters is based on the following

table “EMCS code letters DIN 19227”.

Example: L I C

First letter Supplementary letter 1st following letter

Level Display Automatic closed-loop

control

The coding system for the EMCS points can be freely selected. Sequential numbering

makes sense, as an EMCS points code must only occur once, even if there are

several measuring points with the same measured variable.

For more information, please see DIN standard 19227 Part 1.

2.1

PI diagram

LIC

102

Project planning


EMCS code letters DIN 19227

Measured variable or other input variable,

final control element Letter

First letter Supplementary letter

“Processing letter

Sequence: O,I,R,C,S,Z,A”

A Error message

B

C Automatic closed-loop control

D Density Difference

E Electrical variables Sensor function

F Flow rate, through put Ratio

G Displacement, length, position

H Manual input, manual intervention Upper limit value(High)

I Display

J Measuring point sensing

K Time

L Level (including interface applications) Lower limit value (Low)

M Humidity

N

O Indicator, Yes/no output

P Pressure

Q Material properties, quality variables Integral, sum

R Radiation variables Recording

S Speed, rotational speed, frequency Switching, sequence and logic control

T Temperature Transducer function

U Composite variables Composite drive functions

V Viscosity Final control element function

W Weight force, mass

X Other variables

Y Arithmetic function

Z Emergency intervention, preventive triggering,

protective device, safety-related message

+ Upper limit value

/ Intermediate value

- Lower limit value

Project planning


Examples for EMCS symbols

EMCS symbols DIN 19227

Pipe

Pipe with direction of flow

P101

M

Pump, controlled, flange-mounted motor

B101

Container, top open

B303

Container, closed

V102

Valve, manually operated

V206

Control valve with actuator

E401

Heating element

LIC

102

EMCS task with process master display

Level display automatic closed-loop control

FIC

201


Flowrate display automatic closed-loop control

PIC

303


Pressure display automatic closed-loop control

TIC

401


Temperature display automatic closed-loop control

Pipe input (output)

Project planning


An equipment list provides a first indication which controlled system should be used

for the measurement and which components are relevant to it.

Equipment list

Name: Date:

Controlled system:

Task: Create an equipment list Sheet 1 of 1

Task

• Draw up an equipment list for the controlled system based on the information

given. Consider which of the items of equipment and elements listed in the

worksheet you need for setup of the system or controlled system and mark these

in the worksheet.

• View the individual components and the data sheets and acquaint yourself with

the variables used in the system.

Resources

• Worksheet 2.2.1 Equipment list

• Compact Workstation Manual, Chapter “Function and design”

• Collection of data sheets

2.2

Equipment list

Exercise 2.2

Project planning


Equipment list

Name: Date:

Controlled system:

Task: How to plan a equipment list Page 1 of 1

• Which components are necessary for the chosen close-loop control system?

Components

PLC / controller

Tank

pressure gauge

pump

ultrasonic sensor

pressure sensor

flow rate sensor

temperature sensor

proportional valve

industrial controller

proximity switch

float switch, overflow

float switch for raising level

pressure tank

SCADA

piping and hand valves

heating

Worksheet 2.2.1

Equipment list

Project planning


Draw up a flow diagram, an EMCS point list and an EMCS point plan for a controlled

system.

The Compact Workstation comprises the following controlled systems (controls):

• Level

• Flow rate

• Pressure

• Temperature

For use of the individual controlled systems, please use the manual valve settings

given in the manual.

2.3

Project planning –

Controlled system

Project planning


Project planning for a controlled system – PI diagram

Name: Date:

Controlled system:

Task: Draw up a PI diagrams for a controlled system Sheet 1 of 3

Preparation

Read the documentation for the Compact Workstation.

Task

Based on the overall flow diagram of the Compact Workstation, draw the flow

diagram for the selected controlled system with all components relevant to the

controlled system.

Worksheets

• Worksheet 2.3.1 – PI diagram

Resources

• Electrical circuit diagram, Compact Workstation

• Pipe and instrument flow diagram, Compact Workstation

• Data sheets, Compact Workstation

• Workbook “Control of temperature, flow rate and level” , Festo, 170677

• Standard DIN ISO EN 10628 “Flow diagrams for process plants – general rules”

(replaces DIN 28004)

• Standard DIN 19227 Part 1 “Graphical symbols and code letters for process

control” (ISO3511)

Exercise 2.3.1

Project planning


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Project planning


Project planning for a controlled system – EMCS point list

Name: Date:

Controlled system:

Task: Complete an EMCS point list for a controlled system Sheet 2 of 3

Task

Complete the EMCS point list for the selected controlled system.

Worksheets

• Worksheet 2.3.2 – EMCS point list

Resources


• PI diagram for controlled system from Worksheet 2.3.1




Exercise 2.3.2

Project planning


Project planning


Project planning for a controlled system – EMCS points plan

Name: Date:

Controlled system:

Task: Draw an EMCS point plan of a controlled system Sheet 3 of 3

Task

Create the EMCS point plan for the selected controlled system.

Worksheets

• Worksheet 2.3.3– EMCS points plan

Resources


• PI diagram of the controlled system from Worksheet 2.3.1

• EMCS point list from Worksheet 2.3.2


• Workbook “Control of temperature, flow rate and level” , Festo, 170677



Exercise 2.3.3

Project planning


Project planning



In the exercises, commissioning a system is divided into three areas:

• Analysis of the components, sensors and actuators

• System behavior

• Commissioning of the controlled systems

The analysis is to cover the function of the actuators and sensors of the Process

Control System.

The following questions are to be answered:

• How does an actuator function?

• Of what parts does an actuator comprise?

• What is the characteristic of a sensor?

• Acquisition of measured values based on practical examples

• Processing and evaluation of measured values

The following exercises are provided to support training in the area of

measurements on actuators and sensors.

The following application task offers a good introduction to the topic of

measurement technology. The task is to understand the function of a flowrate

sensor by recording the characteristic and working with the data sheet.

Target audience and required prior knowledge

This task requires basic technical understanding and basic knowledge of electrical

engineering. The tasks are designed to provide the trainee with an introduction to

various controlled systems. To this end, it makes sense to look at the individual

components first.

3 Analysis

Instructor’s notes

Analysis


Volume of the container

Name: Date:

Project name:

Task: Calculation of container volume Sheet 1 of 1

Task

• Calculate the volume (capacity) of the container.

• Determine the relationship between the volume (liters) and the container scale

(indicated in mm). How much water is in the container if it is filled to a level of

300 mm?

What volume is required to achieve a reading of 100 or 1 mm on the scale?

Worksheets

• Worksheet 3.1.1 Analysis of the container

Resources

• Container data sheet

• Workstation manual

3.1

Analysis of the container

Exercise 3.1.1

Analysis


Analysis of the container

Name: Date:

Project name:

Task: Calculate the volume of the container Sheet 1 of 1

Calculating the volume of the container

Container height h = 300 mm

Container width w =

Container depth d =

Worksheet 3.1.1

Where:

Find:

Solution:

Analysis


Analysis of a pump

Name: Date:

Project name:

Task: Determining how a pump functions Sheet 1 of 3

Task

• What type of pump is used in the Festo Didactic Process Control System?

• Count how many other different types of pump there are and name the main

differences to different types of pumps.

• What are the advantages and disadvantages of the individual pump types?

• What are all the things that must be taken into account when using the pump?

• Calculate the rated current of the pump.

Worksheets

• Worksheet 3.2.1 Determine how a pump functions – type, operation, component

parts

Resources

• Pump data sheet

• Station manual

3.2

Analysis of a pump

Exercise 3.2.1

Analysis


Analysis of a pump

Name: Date:

Project name:

Task: Determining how a pump functions – type Sheet 1 of 4

• What type of pump is it? Name the main differences to different types of pumps.

Worksheet 3.2.1

Analysis


Analysis of a pump

Name: Date:

Project name:

Task: Determining how a pump functions – operation Sheet 2 of 4

• What must be taken into account when using the pump?

• Calculating the rated current

Where:

Find:

Solution:

Analysis


Analysis of a pump

Name: Date:

Project name:

Task: Determining the structure of a pump Sheet 2 of 3

Task

• Name the component parts of the pump.

Compare your results with the data sheet.

Exploded view of the pump

Worksheets

• Worksheet 3.2.2 Component parts of the pump

Resources

• Pump data sheet

• Station manual

Exercise 3.2.2

Analysis


Analysis of a pump

Name: Date:

Project name:

Task: Determining how a pump functions – Components Sheet 3 of 4

Exploded view of pump

No. Name of part

1

2

3

4

5

6

7

8

9

Worksheet 3.2.2

Analysis


Analysis of a pump

Name: Date:

Project name:

Task: Determining the delivery rate of a pump Sheet 3 of 3

Task

Determine the delivery rate of a pump.

• Which components of the Process Control System can you use to complete this

task? Identify the parts and – if appropriate – do the tasks associated with the

parts before undertaking the measurement.

• How do you undertake the measurement? Plan the steps.

• Calculate the delivery speed of the pump.

• Calculate the delivery rate of the pump.

• Analyze you measurement and your result compared those of other groups.

Worksheets

• Worksheet 3.2.3 Delivery rate

Resources

• Collection of data sheets

• Book of tables

• Stopwatch

• FluidLab-PA with EasyPortDA

• Station manual

Exercise 3.2.3

Analysis


Pump

Name: Date:

Project name:

Task: Determine the delivery rate of the pump Sheet 4 of 4

Worksheet 3.2.3

Analysis


Analysis of a proportional valve

Name: Date:

Project name:

Task: Determine mode of operation of a proportional valve Sheet 1 of 2

Task

Acquaint yourself with the mode of operation of a proportional valve.

• What does the term “proportional valve” mean?

• What electrical signals do you need to work with a proportional valve?

Worksheets

• Worksheet 3.3.1 Analysis of a proportional valve

Resources

• Proportional valve data sheet

• Station manual

3.3

Analysis of a

proportional valve

Exercise 3.3.1

Analysis



Name: Date:

Project name:

Task: Determine mode of operation of a proportional valve Sheet 1 of 2

• What does the term “proportional valve” mean?

• What electrical signals do you need to use a proportional valve?

Worksheet 3.3.1

Analysis



Name: Date:

Project name:

Task: Determining the flow rate of a proportional valve Sheet 2 of 2

Task

• What is the maximum rate at which you can pump the medium used through the

proportional valve? Note that other components between the pump and

proportional valve may cause flow resistance.

On what is this value dependent?

• What possibilities are there for adjusting the valve?

Worksheets

• Worksheet 3.3.2 Analysis of a proportional valve

Resources

• Data sheets

• Station manual

Exercise 3.3.2

Analysis



Name: Date:

Project name:

Task: Determine the flow rate of a proportional valve Sheet 2 of 2

• What is the maximum rate at which you can pump the medium used through the

proportional valve? What does this value depend on?

• What possibilities are there for adjusting the valve?

Worksheet 3.3.2

Analysis


Analysis of a process drive

Name: Date:

Project name:

Task: Determining the mode of operation of a process drive Sheet 1 of 3

Task

Acquaint yourself with the mode of operation of the process drive.

• Draw up a parts list for the process drive module.

• What electrical signals are used to drive the process drive?

• Describe briefly the mode of operation of this module.

Worksheets

• Worksheet 3.4.1 Analysis of a process drive

Resources

• Data sheets

• Station manual

3.4

Analyze of a

process drive

Exercise 3.4.1

Analysis



Name: Date:

Project name:


• What components is the process drive made up of?

Draw up a list of parts

Item List of parts, process drive Type Quantity

1

2

3

4

5

6

7

8

9

10

Worksheet 3.4.1

Parts list for process drive

module

Analysis



Name: Date:

Project name:


• What electrical signals do you need to work with the process drive?

• Give a brief description of the module’s mode of operation.

Analysis



Name: Date:

Project name:

Task: Determining the mode of operation a sensor box Sheet 2 of 3

Task

• What function does the sensor box fulfill? Name the signals you receive from the

sensor box and, where appropriate, how you can record these signals.

Worksheets


Resources

• Sensor box data sheet

• PCS circuit documentation

• Station manual

Exercise 3.4.2

Analysis



Name: Date:

Project name:

Task: Explain briefly the mode of operation of the sensor box Sheet 3 of 4

• What function does the sensor box fulfill? Name the signals you receive from the

sensor box and, where appropriate, how you can record these signals.

Worksheet 3.4.2

Analysis



Name: Date:

Project name:

Task: Determining the mode of operation a semi-rotary actuator Sheet 3 of 3

Task

• What type of drive is it?

• How does it work?

Worksheets


Resources

• Semi-rotary actuator data sheet

• Station manual

Exercise 3.4.3

Analysis



Name: Date:

Project name:

Task: Determining the mode of operation a semi-rotary actuator Sheet 4 of 4

• What type of drive is it?

• How does it work?

Worksheet 3.4.3

Analysis


Analysis of a heating element

Name: Date:

Project name:

Task: Operation of a heating element Sheet 1 of 1

Task

• What do you have to take into account when using the heating element?

• Calculate the rated current of the heating element.

• To what temperature may you heat the water in the container?

Resources

• Heating element data sheet

• Station manual

Worksheets

• Worksheet 3.5.1 Heating element

3.5

Analysis of a heating

element

Exercise 3.5.1

Analysis


Analysis of a heater element

Name: Date:

Project name:

Task: Operation o of a heater element Sheet 1 of 1

• What are all the things you have to take into account when using the heating

element?

• Calculate the rated current of the heater.

Worksheet 3.5.1

Where:

Find:

Solution:

Analysis


Analysis of an ultrasound sensor

Name: Date:

Project name:

Task: Operation of an ultrasound sensor Sheet 1 of 2

Task

• Study the ultrasound sensor data sheet to become acquainted with its mode of

operation.

Briefly describe the mode of operation in your own words.

• What do you need to take into account if you wish to achieve an accurate

measurement with an ultrasound sensor?

• Measure the output signal of the sensor with a voltmeter.

Sketch the measurement setup in the worksheet.

Calculate parts need, if required.

• How is the sensor signal measured in the system?

Give possible reasons why the circuit was designed in this way?

Resources

• Ultrasound sensor data sheet

• PCS system manual

Worksheets

• Worksheet 3.6.1 Ultrasound sensor

3.6

Analysis of an

ultrasound sensor

Exercise 3.6.1

Analysis



Name: Date:

Project name:

Task: Operation of an ultrasound sensor Sheet 1 of 3

• Describe the mode of operation of the ultrasound sensor in your own words.

What do you need to take into account if you wish to achieve accurate

measurements?

Worksheet 3.6.1

Space for calculations and

sketches

Analysis



Name: Date:

Project name:

Task: Recording the characteristic of an ultrasound sensor Sheet 3 of 2

Task

• Record the characteristic of the ultrasound sensor.

Take a sufficient number of measurements and enter these into a chart.

• Evaluate the resulting characteristic.

Where is the optimum operating range of the sensor, or to what level must the

container be filled for the ultrasound sensor to operate optimally?

Resources

• Ultrasound sensor data sheet

Worksheets

• Worksheet 3.6.2 Ultrasound sensor

Exercise 3.6.2

Analysis



Name: Date:

Project name:

Task: Recording the characteristic of an ultrasound sensor Sheet 2 of 3

Level [mm] Signal [V]

20

40

60

80

100

120

140

160

180

200

220

240

260

280

300

Worksheet 3.6.2

Analysis


Ultrasound sensor

Name: Date:

Project name:

Task: Recoding the characteristic of the sensor Sheet 3 of 3

1 2 3 4 5 6 7 8 9 10

50

100

150

200

250

Fü

llsta

nd

[m

m]

Sensorsignal [V]

300

Level [mm]

signal [V]

Analysis


Analysis of a flowmeter

Name: Date:

Project name:

Task: Operation of a flow meter Sheet 1 of 2

Task

• How does the flow meter work?

What other types of flow meter are there?

• How can you measure signals from the sensor?

• What is the measuring range of the sensor?

Resources

• Flow meter data sheet

Worksheets

• Worksheet 3.7.1 Analysis of a flow meter

3.7

Analysis of a

flow meter

Exercise 3.7.1

Analysis



Name: Date:

Project name:

Task: Determine the mode of operation of a flow meter Sheet 1 of 4

• How does the flow meter work?

What other types of flow meter are there?

• How can you measure signals from the sensor?

• What flow rates can be measured with the sensor?

Lower limit of measuring range:

Upper limit of measuring range:

Worksheet 3.7.1

Analysis



Name: Date:

Project name:

Task: Recording the characteristic and calculations Sheet 2 of 2

Task

• Based on the data in the data sheet, calculate the minimum and maximum

output frequency of the sensor.

• Record the characteristic of the flow meter.



Compare your result to the characteristic in the data sheet.

Resources

• Oscilloscope

• Flow meter data sheet

Worksheets

• Worksheet 3.7.2 Analysis of a flow meter

Exercise 3.7.2

Analysis



Name: Date:

Project name:

Task: Calculate the output frequency of a flow meter Sheet 2 of 4

• Calculate the minimum and maximum output frequency of the sensor.

Worksheet 3.7.2

Where:

Find:

Solution:

Analysis


Analysis of a flow meter

Name: Date:

Project name:

Task: Determine the characteristic of a flow meter Sheet 3 of 4

Procedure

1. First calculate the frequency (Hz) for the flow rates.

2. Measure the frequency with the oscilloscope and set the pump voltage to the

desired frequency or flow rate.

3. Calculate the flow rate in the upper container that has to be reached within 1

minute for the set pump output.

4. Determine the flow rate for 1 minute experimentally.

Flow rate [l/min] Frequency [Hz] Calculated flow rate

after 1 min

Measured flow after

1 min

1

2

3

5

6

7

8

9

10

Measured-value table

Analysis


Analysis of a flow meter

Name: Date:

Project name:

Task: Recording the characteristic of a flow meter Sheet 4 of 4

Diagram

100 200 300 400 500 600 700 800 900 1000 1100 1200

1

2

3

4

5

6

7

8

9

10

Du

rch

flu

ss [

l/m

in]

Frequenz [1/s]

flow rate

[mm]

frequency [1/s]

Analysis


Analysis of a pressure sensor

Name: Date:

Project name:

Task: Determining the mode of operation of a pressure sensor Sheet 1 of 2

Task

• How does the pressure sensor work?

What other types of pressure sensor are there?

• How can you measure the signal from the sensor?


Resources

• Pressure sensor data sheet

Worksheets

• Worksheet 3.8.1 Analysis of a pressure sensor

3.8 Analysis of a

pressure sensor

Exercise 3.8.1

Analysis



Name: Date:

Project name:

Task: How does a pressure sensor work? Sheet 1 of 4

• How does a pressure sensor work? What other types of pressure sensor are

there?

• How can you measure the signal from the sensor??


Worksheet 3.8.1

Analysis



Name: Date:

Project name:

Task: Recording the characteristic Sheet 2 of 4

Task

• Record the characteristic of the pressure sensor.



Compare your result to the characteristic in the data sheet .

Resources

• Pressure sensor data sheet

Worksheets

• Worksheet 3.8.2 Analysis of a pressure sensor

Exercise 3.8.2

Analysis



Name: Date:

Project name:

Task: Determine the mode of operation of a pressure sensor Sheet 3 of 4

3.8.1 Measured-value table

Pressure [mbar] Voltage [V] Notes

0 0

50 1.25

100 2.5

150 4.75

200 5.0

250 6.25

300 7.5

350 8.75

400 10

Worksheet 3.8.2

Analysis



Name: Date:

Project name:


3.8.2 Diagram

1

2

3

4

5

6

7

8

9

10

Sp

an

nu

ng

[V

]

Druck [mbar]

voltage [V]

pressure [mbar]

Analysis


Analysis of a temperature sensor

Name: Date:

Project name:

Task: Determining the mode of operation of a temperature sensor Sheet 1 of 5

Task

• The thermal sensor used is a PT100.

Explain this designation. What does it mean?


• What is the resistance of the sensor at 0°C, and at 100°C?


Resources

• PT100 temperature sensor data sheet

Worksheets

• Worksheet 3.9.1 Analysis of a temperature sensor

3.9 Analysis of a

temperature sensor

Exercise 3.9.1

Analysis



Name: Date:

Project name:

Task: Determining the mode of operation of a temperature sensor Sheet 2 of 5

• What does the designation PT100 mean?


• What is the resistance of the sensor at 0°C, and at 100°C?


Worksheet 3.9.1

Analysis



Name: Date:

Project name:


Task

• Record the characteristic of the temperature sensor.



Compare your result to the characteristic in the data sheet .

Note

Before starting, consider the procedure for measurement. As you have to heat the

fluid in the container, the measurement is more time-consuming. If you make

mistakes during measurement, you will have replace the fluid or wait for it to cool!

For technical and physical reasons, you cannot measure the entire characteristic of

the sensor. The maximum temperature in the container must not exceed 60°C.

Please observe the safety instructions in the manual for your station/system.

Resources

• Thermometer

Worksheets

• Worksheet 3.9.2 Analysis of a temperature sensor

Exercise 3.9.2

Caution

Analysis



Name: Date:

Project name:

Task: Measuring the temperature sensor signals Sheet 4 of 5

T[°C] R[Ohm]

0

10

20

30

40

50

60

70

80

90

100

Worksheet 3.9.2

Measured-value table

Analysis


Temperature sensor

Name: Date:

Project name:


10 20 30 40 50 60 70 80 90 100 110 120

R [

Oh

m]

T[°C]

Analysis


To complete the task you need either:

Level Control Station, Compact System, Compact Workstation or

Level Workstation.

System behavior of a container

Name: Date:

Project name:

Task: Determining the behavior of flow into and out of a container Sheet 1 of 5

Preparation

Fill approx. 10l water into the container. This corresponds to a level of approx.

300mm.

Task

The behavior of flow into and out of the container is to be determined.

• Measure the behavior for the container with the pump switched on, outlet valve

closed and inlet valve open.

• Measure the behavior for the container with the pump switched off, outlet valve

closed and inlet valve open.

• Measure the behavior for the container with the pump switched on, outlet valve

open and inlet valve open.

What result do you expect for each of the measurements?

Write down the behavior you expect in the prepared worksheet before starting

measurements.

Make a sufficient number of measurements and enter these into the prepared

coordinate systems.

Do not forget to label the axes!

Compare the characteristics. What do you notice?

Resources

• Stopwatch

• Worksheet 3.10.1 System behavior of a container

3.10

System behavior of a

container

Exercise 3.10.1

Analysis



Name: Date:

Project name:

Task: Carry out various measurements that will allow you to describe the flow behavior into and out of

the container.

Sheet 2 of 5

• What result to you expect to get?

Level [mm] Time [s] Level [mm] Time [s]

10 160

20 170

30 180

40 190

50 200

60 210

70 220

80 230

90 240

100 250

110 260

120 270

130 280

140 290

150 300

Worksheet 3.10

Measurement 1:

Inlet valve open, outlet valve

closed, pump running

Analysis



Name: Date:

Project name:


the container.

Sheet 3 of 5



300 150

290 140

280 130

270 120

260 110

250 100

240 90

230 80

220 70

210 60

200 50

190 40

180 30

170 20

160 10

Measurement 2:


closed, pump not running

Analysis



Name: Date:

Project name:


the container.

Sheet 4 of 5



10 160

20 170

30 180

40 190

50 200

60 210

70 220

80 230

90 240

100 250

110 260

120 270

130 280

140 290

150 300

Measurement 3:


open, pump running.

Analysis



Name: Date:

Project name:


the container.

Sheet 5 of 5

0 60 120 180 240 300

0

100

200

300

360


The following application tasks are designed to help the trainee learn to use the

controlled systems and the controllers. A controlled system is to be taken into

operation with defined parameters. The behavior of the system is to be observed

while it is in operation.


This task requires technical understanding. The tasks are designed to give the

trainees an introduction to control engineering. The trainees should have a

theoretical knowledge of the fundamentals of control engineering.

This task is designed to allow the trainee to see theory in a practical example and

thus enhance their knowledge.

Defined parameters are given for commissioning of the controllers used. The

parameters were determined using comparable controlled systems, but part

tolerances could result in malfunctioning of the controlled systems used. In this case

adjustments have to be made to the parameters.

4 Commissioning

Note

Commissioning


To complete the task you require either:

Level-Control System, Compact System, Compact Workstation or

Level Workstation.

Flow diagram of a level-controlled system – for example, the PCS Level Workstation

4.1

Commissioning a level-

controlled system

Commissioning


Commissioning a level-controlled system

Name: Date:

Project name:

Task: Manual operation of a controlled system Sheet 1 of 7

Task

The level of a container is to be kept constant.

Preparation

Fill approx. 10l water into the lower container.

Please note that the entire system must not contain more water than the capacity of

one container!

Settings and procedure

5. Deairate the pipe system of the level-controlled system.

6. Set the manual valves so that the medium can flow directly into the upper

container. Leave the outlet valve closed so that no water can flow out of the

container.

7. Open the outlet valve so that water can flow out of the container. Try to

maintain the level at a constant midrange reading by switching the pump ON

and OFF (0/24VDC).

8. Use analog control of the pump to improve the result. At what pump voltage is

the mean measured value of the controlled system constant?

Are you using closed- or open-loop control to regulate the level? Give reasons for

your answer.

Worksheets

• Worksheet “Commissioning a level-controlled system”

Exercise 4.1.1

Note

Commissioning



Name: Date:

Project name:

Task: Determining the setpoint Sheet 2 of 7

• Are you using close-loop or open-loop control of the level?

• Is it possible to maintain a constant level manually?

Pump voltage measured for mean measured value

Mean

measured value

[mm]

Pump voltage

[V]

Worksheet 4.1.1

Commissioning



Name: Date:

Project name:

Task: Determining the operating range and operating point of a controlled system. Sheet 3 of 7

Purpose of the exercise

The purpose of the exercise is to replace a person as a controller by an automatic

controller. The actual value is to be measured by a sensor. The pump is to be

switched ON and OFF by means of a controller.

Task

Determine a suitable setpoint (desired level) to be used for commissioning of the

controller. Take the operating range of the sensor into account.

Enter the value of the sensor into the worksheet supplied when you have reached

the desired level.

Procedure

1. Determine the values for the sensor based on the data sheet.

2. What is the reading on the container scale for minimum level? What signal does

the ultrasound sensor deliver before and after the transducer (for Level

Workstation or Compact Workstation).

3. Switch on the pump to fill the upper container to maximum. What is the reading

on the container scale?

Measure the sensor signal and the transducer output signal.

4. What measured value is exactly midway between the minimum and maximum

levels? Measure the sensor signal and the transducer output signal.

Worksheets

• Worksheet “Commissioning a level-controlled system”,

Exercise 4.1.2

Commissioning


Commissioning a controlled system

Name: Date:

Project name:

Task: Determining the operating range and operating point of a controlled system Sheet 4 of 7

Determining the operating range of the level sensor

Sensor Transducer

Level

h [mm]

Output signal

I [mA]

Output signal

U [V]

Max. measured value

Mean measured value

Min. measured value

Worksheet 4.1.2

Commissioning



Name: Date:

Project name:

Task: Operating a controlled system with set values. Sheet 5 of 7

Task

Commission the level-controlled system. Observe the following points:

Preparation

Acquaint yourself with the operation and parameterization of your controller

(industrial controller, PLC or FluidLab-PA). When preparing the controlled system,

please observe the notes in Worksheet 4.1.1.

1. Set the manual valves so that the medium can flow directly into the upper

container.

2. Open the outlet valve so that water can flow out of the container.

Parameterization

Please set the following parameters for the controller:

Parameter Value

KP 10

TN

[s] 5

TV [s] 0

• Start the controller.

Worksheets

• Worksheet 4.1.3 “Commissioning a level-controlled system”

Exercise 4.1.3

Commissioning



Name: Date:

Project name:

Task: Operating a controlled system with set values Sheet 6 of 7

Task

• How does the system respond? Describe your impressions.

• Close valve V112 with the controller running. How does the system respond?

Describe your impressions.

Worksheets

• Worksheet 4.1.3 “Commissioning a level-controlled system”

Exercise 4.1.4

Commissioning



Name: Date:

Project name:

Task: Operating a controlled system with set values. Sheet 7 of 7

• How does the system respond with the outlet valve closed?

How does the system respond with the outlet valve open?

Worksheet 4.1.3/4.1.4

Commissioning


To complete the task you require either:

Flow Control System, Compact System, Compact Workstation or

Flow Workstation.

Flow diagram for flow controlled-system – for example, PCS Flow Workstation

4.2

Commissioning a flow

controlled-system

Commissioning


Commissioning a flow controlled-system

Name: Date:

Project name:


Task

The flow rate in a pipe system is to be kept constant.

Preparation

Fill approx. 4l water into the (lower) container. Please note that the entire system

must not contain more water than the capacity of one container!

Settings

Set the manual valve so that the medium can flow, for example, via manual valve

V104. There should be no flow through other valves and assemblies. Please observe

the settings in the manual.

Procedure

1. Switch the pump on.

2. Try to keep the flow rate at a constant 2l/min by switching the pump ON and

OFF.

3. Use analog control of the pump to improve the result. At what pump voltage is

the flow rate constant at 2l/min?

• Are you using open-loop or closed-loop control of the flow? Give reasons for your

answer.

• Is it possible to achieve a constant flow rate through manual operation? Give

reasons for your answer.

Worksheets

• Worksheet “Commissioning a flow controlled-system”

Exercise 4.2.1

Note

Commissioning


Commissioning a flow-controlled system, Controlling the flow rate with a pump as final control element

Name: Date:

Project name:

Task: Operator as controller Sheet 2 of 10

• Are you using closed-loop or open-loop control of flow?

• Is it possible to maintain a constant flow rate manually?

Worksheet 4.2.1

Commissioning


Commissioning a flow controlled-system

Name: Date:

Project name:






Task

Based on the data sheets of the components, develop the measuring chain

controlled system – sensor – transducer (if a transducer is present).

Determine a suitable setpoint (constant flow rate) for commissioning of the control.

Take the operating range of the sensor (actual value) and the pump (final control

element) into account.

Enter the measured values for the mean flow rate into the worksheet. Calculate the

missing values, for example the maximum measurable flow rate of the transducer.

Procedure

1. What is the measured value for minimum flow? What signal does the flow meter

deliver before and after the transducer (for Level Workstation or Compact

Workstation).

2. Switch the pump on (max.). Measure the output signal of the transducer.


flow rate? Set this as the operating point for the pump voltage. Measure the

sensor signal and the output signal of the transducer.

4. What is the pump voltage for a constant flow rate at the operating point?

Worksheets

Worksheet “Commissioning a flow controlled-system”

Exercise 4.2.2

Commissioning



Name: Date:

Project name:


Determining the measuring chain of a flow-controlled system with a pump as final

control element

Flow control

Pump operating range

Sensor Transducer

Flow rate

Q [l/min]

Signal

f [Hz]

Flow rate

Q [l/min]

Output

signal

f [Hz]

Input

signal

f [Hz]

Output

signal

U [V]

Flow rate

Q [l/min]

MAX

MIN

Mean value of the operating range of the control system with a pump as the final

control element

Mean measured value

[l/min]

Dimensionless value

[ 0.0 – 1.0 ] Pump voltage

[V]

Convert the measured value into a dimensionless value in the range [0-0 – 1.0]. This

means that the maximum measurable flow rate of 7.5 l/min would have the value

1.0.

Worksheet 4.2.2

Commissioning


Commissioning a flow controlled-system, Controlling the flowrate with a pump as final control element

Name: Date:

Project name:


Task

Commission the flow controlled-system.

Preparation




• Set the manual valves so that the medium can flow directly through manual valve

V104.

Parameterization


Parameter Value

KP 1

TN

[s] 2

TV [s] 0


Worksheets

Worksheet “Commissioning a flow controlled-system”

Exercise 4.2.3

Commissioning



Name: Date:

Project name:


• Describe your impressions

Worksheet 4.2.3

Commissioning


Commissioning a flow controlled-system, Controlling the flow rate with a pump as final control element

Name: Date:

Project name:


Task

For commissioning of the flow controlled-system, determine the operating range of

the proportional valve and a suitable operating point.

Enter the mean flow rate of the proportional valve into the worksheet.

Preparation

Set the proportional valve to minimum maximum flow rate. You will find instructions

for adjustment in the data sheet for the proportional valve .

Procedure

1. Switch the pump on and activate the proportional valve (Workstation).

For PCS stations/Compact Systems with Bürkert or Siemens industrial

controllers switch the “PUMP” and “VALVE” switches ON.

2. Increase the output voltage for proportional valve V106.

3. What is the reading for the minimum flow rate through proportional valve V106?

What signal does the flow meter deliver before and after the transducer (for

Level Workstation or Compact Workstation).

4. Switch the pump ON (max.). Measure the sensor signal and the output signal of

the transducer.

5. What measurement is exactly midway between minimum and maximum flow

rate? Set this as the operating point for the pump voltage. Measure the sensor

signal and the output signal of the transducer.

6. What is the pump voltage for constant flow rate at the operating point?

Worksheets

• Worksheet “Commissioning a flow controlled-system”

Exercise 4.2.4

Commissioning


Commissioning a flow-controlled system, Controlling the flowrate with a pump as final control element

Name: Date:

Project name:


Determining the operating range of a flow-controlled system with a proportional

valve as final control element

Flow control

Proportional value

operating range

Sensor Transducer

Flow rate

Q [l/min]

Signal

f [Hz]

Flow rate

Q [l/min]

Output

signal

f [Hz]

Input

signal

f [Hz]

Output

signal

U [V]

Flow rate

Q [l/min]

MAX

MIN

Mean value of the operating range of the control system with a proportional valve

as the final control element

Mean measured value

[l/min]

Dimensionless value


[V]


means that the maximum measurable flow rate of 7.5 l/min would have the value

1.0.

Worksheet 4.2.4

Commissioning


Commissioning a flow controlled-system, Controlling the flow rate with a proportional valve as final control element

Name: Date:

Project name:


Task

Commission the flow controlled-system with the proportional valve as the final

control element. Set the proportional valve (see notes in the data sheet).

Preparation




• Set the manual valves so that the medium can flow directly through proportional

valve V106.

Parameterization


Parameter Value

KP 2

TN

[s] 1

TV [s] 0


Worksheets

• Worksheet 4.2.5 “Commissioning a flow controlled-system”

Exercise 4.2.5

Commissioning


Commissioning a flow-controlled system, Controlling the flow rate with a proportional valve as final control element

Name: Date:

Project name:



Worksheet 4.2.5

Commissioning



pressure-controlled system, Compact System, Compact Workstation or

Pressure Workstation.

Flow diagram for the pressure-controlled system – for example: PCS Pressure Workstation

4.3

Commissioning a pressure-

controlled system

Commissioning


Commissioning a pressure-controlled system

Name: Date:

Project name:


Task

Commission the pressure-controlled system. The pressure level in the pressure

reservoir is to be kept constant at a certain value.

Preparation

• Fill approx. 5l of water into the lower container.

• Close all manual valves.

• Set the manual valves so that the medium can be pumped directly into the

pressure reservoir.

• Pump the water into the pressure reservoir and carefully open pressure relief

valve V107 until the pressure reservoir is half-filled with air and half-filled with

water. Close pressure relief valve V107. The pressure relief valve is NEVER to be

opened during measurements or normal operation!

Please note that the entire system must not contain more water than the capacity of

one container!

Procedure

Try to maintain a constant pressure in the pressure reservoir by switching the pump

ON and OFF.

Task

• Are you using open-loop or closed-loop control of the pressure? Give reasons for

your answer.

• Is it at all possible to maintain a constant pressure by manual operation? Give

reasons for your answer.

Worksheets

• Worksheet 4.3.1 “Commissioning a pressure-controlled system”

Exercise 4.3.1

Note

Commissioning


Commissioning a pressure-controlled system, Controlling the pressure with a pump as final control element

Name: Date:

Project name:

Task: Operator as controller Sheet 2 of 10

• Are you using open-loop or closed-loop control of the pressure?

• Is it possible to maintain constant pressure manually?

Worksheet 4.3.1

Commissioning



Name: Date:

Project name:






Task

Based on the data sheets of the components, develop the measuring chain

controlled system – sensor – transducer (if a transducer is present).

Determine a suitable setpoint (constant pressure in the container) for

commissioning of the control. Take the operating range of the sensor (actual value)

and the pump (final control element) into account.

Enter the measured values for the mean reservoir pressure into the worksheet.

Calculate the missing values.

Procedure

1. What is the measured value for minimum pressure? What signal does the

pressure sensor deliver?

2. Switch the pump ON (max.). Measure the sensor signal. What is the maximum

pressure the sensor can read?


levels? Set the operating point for the pump voltage to this value. Measure the

sensor signal.

4. What is the pump voltage for a constant pressure close to the operating point?

Worksheets

• Worksheet “Commissioning a pressure-controlled system”

Exercise 4.3.2

Commissioning



Name: Date:

Project name:


Determining the measuring chain of a pressure-controlled system with a pump as

final control element

Pressure control


Sensor

Measuring range

Pressure

p [mbar]

Signal

U [V]

Pressure

p [mbar]

Output signal

U [V]

MAX

MIN

Mean value of the operating range of the pressure-controlled system with a pump

as the final control element

Mean measured value

[l/min]

Dimensionless value


[V]


means that the maximum measurable pressure of 400 mbar would have the value

1.0.

Worksheet 4.3.2

Commissioning



Name: Date:

Project name:


Task

Commission the pressure-controlled system with set values for the control

parameters.

Preparation


(industrial controller, PLC or FluidLab-PA). When setting up the controlled system,


Parameterization

A functioning control system comprises a controlled system and a controlling unit

(controller). This requires various parameters. Please set the following parameters

for the controller:

Parameter Value

KP 1,0

TN

[s] 2,0

TV [s] 0,1


• How does the system respond? Describe your impressions on the worksheet

provided.

Worksheets

• Worksheet “Commissioning a pressure-controlled system”, IBN_P_AB04_3

Exercise 4.3. 3

Commissioning



Name: Date:

Project name:



Worksheet 4.3.3

Commissioning



Name: Date:

Project name:


Task

Determine the working range and a suitable operating point for a proportional valve

for commissioning of a pressure-controlled system.

Enter the measured value for the mean operating pressure that can be controlled

with the proportional valve into the worksheet.

Preparation

Set the proportional valve to minimum / maximum flow rate. (This is not a

typographical error!). You will find instructions on adjustment in the data sheet for

the proportional valve .

Procedure

1. Switch the pump ON and activate the proportional valve (Workstation).

For PCS stations/Compact Systems with Bürkert or Siemens industrial

controllers switch the “PUMP” and “VALVE” switches ON.

2. What is the measured value for the minimum pressure through proportional

valve V106? What signal does the pressure sensor deliver?

3. Increase the output voltage for proportional valve V106 to maximum.

Measure the sensor signal and the output signal of the transducer.

4. What measurement is exactly midway between minimum and maximum flow

rate? Set this as the operating point for the pump voltage. Measure the sensor

signal and the output signal of the transducer.

5. What is the pump voltage for system pressure at the operating point?

Worksheets

• Worksheet “Commissioning a pressure-controlled system”, IBN_P_AB04_3

Exercise 4.3.4

Commissioning


Commissioning a pressure-controlled system, Controlling the pressure with a proportional valve as final control element

Name: Date:

Project name:


Determining the operating range of the pressure-controlled system with a

proportional valve as final control element

Pressure control


Sensor

Measuring range

Pressure

p [mbar]

Signal

U [V]

Pressure

p [mbar]

Output signal

[V]

MAX

MIN

Mean value of the operating range of the pressure-controlled system with a

proportional valve as the final control element

Mean measured value

[l/min]

Dimensionless value


[V]


means that the maximum measurable pressure of 400 mbar would have the value

1.0.

Worksheet 4.2.4

Commissioning



Name: Date:

Project name:


Task

Commission the pressure-controlled system with proportional valve with set values

for the control parameters .

Preparation




Parameterization

A functioning control system comprises a controlled system and a controlling unit

(controller). This requires various parameters. Please set the following parameters

for the controller:

Parameter Value

KP 3.0

TN

[s] 8.0

TV [s] 2.0

• Open manual valve V109 (see flow diagram) between the pressure reservoir and

the supply tank a minimum amount to achieve a constant “system load” and

start the controller.

• How does the system respond? Describe your impressions in the worksheet

provided.

Worksheets

• Worksheet “Commissioning a pressure-controlled system”

Exercise 4.3.5

Commissioning


Commissioning a pressure-controlled system, Controlling the pressure with a proportional valve as final control element

Name: Date:

Project name:



Worksheet 4.3.5

Commissioning



Temperature-Control System, Compact System, Compact Workstation or

Temperature Workstation.

Flow diagram for a temperature-controlled system – for example, PCS Temperature Workstation

4.4

Commissioning a

temperature-controlled

system

Commissioning


Commissioning a temperature-controlled system

Name: Date:

Project name:


Preparation

Fill approx. 5l water into the (lower) container for temperature-controlled system.

Please note that the entire system must not contain more medium than the capacity

of one container!

Settings

Fill the lower container so that the heating element is completely submerged. The

higher the level in the container, the longer it will take to heat the medium.

Task

Measure the current temperature of the medium. Add 5K.

Attempt to reach and maintain this temperature by switching the heater ON and OFF.

For safety reasons, the heater is limited to a maximum temperature of 60°C.

• Are you using open-loop or closed-loop control? Give reasons for your answer.

Worksheets

• Worksheet “Commissioning a temperature-controlled system”

Exercise 4.4.1

Note

Commissioning



Name: Date:

Project name:


• Are you using open-loop or closed-loop control of temperature?

• Is it possible to maintain a constant temperature manually?

Worksheet 4.4.1

Commissioning



Name: Date:

Project name:




controller. The actual value is to be measured by a sensor. The heater is to be


Task

Determine the signal delivered by your temperature sensor when submerged in the

heated medium (Worksheet 4.4.1). Measure the resistance of the temperature

sensor. Calculate the temperature from this.

Worksheets

• Worksheet “Commissioning a temperature-controlled system”

Exercise 4.4.2

Commissioning



Name: Date:

Project name:


Determining the measuring chain of the temperature-controlled system with a

heater as the final control element

Temperature control

Heater operating range

Sensor

Measuring range Transducer

Temperature

t [°C]

Resistance

R [Ω]

Temperature

t [°C]

Resistance

R [Ω]

Input resistance

R [Ω]

Output signal

U [V]

Temperature

t [°C]

MAX 60

MIN 20

Mean value of the operating range of the temperature-controlled system with a

heater as the final control element

Mean measured value

t [°C]

Dimensionless value

[0.0 - 1.0]


means that the maximum measurable temperature of 100 °C would have the value

1.0.

Worksheet 4.4.2

Commissioning



Name: Date:

Project name:


Task

Commission the temperature-controlled system with heater.

Parameterization

Please parameterize your controller with the following values:

Parameter

FluidLab-PA

2-point

controller

Parameter

Bürkert

industrial PID

controller

Sipart DR19

industrial PID

controller

KP 4.0

TN 2500 Switching

hysteresis 0.05

TV 0.0

• Use the pump to circulate the medium during normal operation.

Start the controller.

• How does the system respond? Describe your impressions.

Worksheets

• Worksheet “Commissioning a temperature-controlled system”, IBN_T_AB04_4

Exercise 4.4.3

Commissioning



Name: Date:

Project name:



Worksheet 4.4.3

Commissioning



Machines and systems often require variables such as pressure, temperature, flow

rate or level to be controlled to a predetermined value. Also, these values should not

change in the event of faults. This type of task is undertaken by a controller.

Closed-loop control engineering covers all problems associated with this task.

The variable to be controlled is measured, converted and supplied to the automatic

controller as an electrical signal.

The controller then compares this value (or value curve) with the preset value. The

corrective action to be taken in the system is then derived.

Finally, a suitable point for corrective action to influence the controlled variable must

be determined, for example, the heater’s regulator. Here, the response of the system

is important.

Standard DIN 19226 applies:

Closed-loop control is a process whereby one variable, namely the variable to be

controlled (controlled variable) is continuously monitored, compared with another

variable, namely the reference variable, and – depending on the outcome of this

comparison – influenced in such a manner as to bring about adaptation to the

reference variable despite any disturbance variables. This feedback results in a

closed action loop.

The control technician is responsible for:

• Identification of the controlled system

• Definition of the controlled variable

• Determination of measuring point

• Determination of disturbance variables

• Selection of the final control elements

• Determining whether a controller will result in worthwhile benefit

• Selection of suitable controller(s)

• Installation of controller(s) in compliance with regulations

• Commissioning, parameterization and optimization

These topics are covered in greater detail in the following exercises, which are

designed to give trainees an introduction to control engineering.

Trainees should have a basic theoretical knowledge of control engineering.

5 Control engineering

Closed-loop control

Control engineering


The time response of a controlled system must be known for optimum controller

selection. This allows conclusions to be drawn regarding the dynamic response of

the controlled system and the controller settings to be determined.

The time response of a controlled system is determined by recording a transient

response of the system. For systems with delay, such as where there is energy

storage, the time constant of the controlled system is determined by applying a

tangent or, in the case of multiple delays, an inflectional tangent.

5.1

Identifying the controlled

system

Control engineering


Identification of a controlled system

Name: Date:

Controlled system:

Task: Determining the time response of a controlled system Sheet 1 of 2

Task

Determine the transient response of the controlled system at the operating point.

The operating point is determined in Chapter 4, Commissioning.

• What type of system is it or of which order is it? Sketch the curve in Worksheet

5.1.1.

• Determine the order by drawing a tangent to the curve and comparing the curve

in Worksheet 5.1.1.

• Graphically determine the time constant of the controlled system in Worksheet

5.1.2.

Resources

• Work book, Control of Temperature, Flow rate and Level, 170677

Worksheets

• Worksheet 5.1.1 “Determining the order”

• Worksheet 5.1.2 “Determining the time constant”

Exercise 5.1.1

Control engineering



Name: Date:

Controlled system:

Task: Determining the order of a controlled system Sheet 1 of 1

• What type of system is it or of which order is it? Sketch the curve:

• Determine the order by drawing a tangent to the curve and comparing the curve:

Order:

Worksheet 5.1.1

process value / actual value

time

time

process value / actual value

order

order

Control engineering



Name: Date:

Controlled system:

Task: Determining the time constant of a controlled system Sheet 1 of 1

• Determine the time constant of the controlled system.

Procedure

1. Apply an (origin) tangent to the curve.

2. Draw the “maximum value” as a horizontal line at the maximum actual value.

3. Draw a perpendicular as a vertical line (90° to the maximum value) at the

intersection of “maximum value” and “tangent”.

4. Draw a horizontal line at the intersection of the curve and the perpendicular.

The actual value at this point should be 63% of the "maximum value".

5. Read off on the time scale how long the system needs to reach 63%. This is the

time constant.

Worksheet 5.1.2

S = output variable

when t = T, T = 63%

Control engineering


The following theoretical exercises allow trainees to consolidate their knowledge of

control engineering.

The purpose of the exercise is to give the trainee the opportunity to see how a real

controlled system responds to various controllers and why it is necessary to find a

suitable controller and to parameterize it correctly.


This exercise requires technical understanding. Basic knowledge of control

engineering is absolutely essential.

This exercise is for control technicians and trainees who have to make use of basic

control engineering.

5.2

Controller functions

Control engineering


Mode of operation of a P controller

Name: Date:

Controlled system:

Task: Determining the mode of operation of a controlled system with a P controller Sheet 1 of 2

Task

• Try to control the controlled system with a P controller. Set each of the

amplification factors given in the table in turn.

• Record the transient response.

• Describe your result. How does the system respond?

Parameter list

Parameter Value

KP 2

KP 5

KP 10

Exercise 5.2.1

Control engineering


Mode of operation of a P controller

Name: Date:

Project name:

Task: Determining the mode of operation of a controlled system with P controller Sheet 2 of 2

• How does the system respond to control by a P controller?

Worksheet 5.2.1

Control engineering


Mode of operation of a I controller

Name: Date:

Controlled system:

Task: Determining the mode of operation of a controlled system with an I controller Sheet 1 of 2

Task

• Try to control the controlled system with an I controller. Set the parameters

shown in the table.


Parameter list

Parameter Value

TN 10

TN 5

TN 2

Exercise 5.2.2

Control engineering


Mode of operation of a I controller

Name: Date:

Controlled system:

Task: Determining the mode of operation of a controlled system with I controller Sheet 2 of 2

• How does the system respond to control by an I controller?

Worksheet 5.2.2

Control engineering


Mode of operation of a PI controller

Name: Date:

Controlled system:

Task: Determining the mode of operation of a controlled system with a PI controller Sheet 1 of 2

Task

• Try to control the controlled system with a PI controller. Set the parameters

shown in the table.


Parameter list

Parameter Value Parameter Value

KP 2 TN 10

KP 2 TN 5

KP 5 TN 10

KP 5 TN 5

Exercise 5.2.3

Control engineering


Mode of operation of a PI controller

Name: Date:

Controlled system:

Task: Determining the mode of operation of a controlled system with PI controller Sheet 2 of 2

• How does the system respond to control by a PI controller?

Worksheet 5.2.3

Control engineering


Mode of operation of a PD controller

Name: Date:

Controlled system:

Task: Determining the mode of operation of a controlled system with a PD controller Sheet 1 of 2

Task

• Why does it not make sense to try a D controller here?

• Is a controller only equipped with a D part used in other systems?

• Try to control the controlled system with a PD controller. Set the parameters

shown in the table.


Parameter list

Parameter Value Parameter Value

KP 2 TV 1

KP 2 TV 5

KP 5 TV 1

KP 5 TV 5

Exercise 5.2.4

Control engineering


Mode of operation of a PD controller

Name: Date:

Controlled system:

Task: Determining the mode of operation of a controlled system with PD controller Sheet 2 of 2

• How does the system respond to control by a PD controller?

Worksheet 5.2.4

Control engineering


Mode of operation of a PID controller

Name: Date:

Controlled system:

Task: Determining the mode of operation of a controlled system with a PID controller Sheet 1 of 2

Task

• Try to control the controlled system with a PID controller. Set the parameters

shown in the table.


Parameter list

Parameter Value Parameter Value Parameter Value

KP 1 TN 1 TV 1

KP 1 TN 2 TV 1

KP 1 TN 2 TV 5

KP 1 TN 5 TV 1

Exercise 5.2.5

Control engineering


Mode of operation of a PID controller

Name: Date:

Project name:

Task: Determining the mode of operation of a controlled system with PID controller Sheet 2 of 2

• How does the system respond to control by a PID controller?

5.3 Worksheet 5.2.5

Control engineering


Selection of controller functions

Name: Date:

Controlled system:

Task: Selection of suitable controller functions for a controlled system Sheet 1 of 2

Task

• Which controller is suitable for which controlled system?

• Assign the P, I , PI and PID controllers to the level-, flow-, pressure- and

temperature-controlled systems with the aid of Worksheet 5.2.6.

Exercise 5.2.6

Control engineering


Mode of operation of controllers

Name: Date:

Project name:

Task: Assignment of a controller to a controlled system Sheet 2 of 2

• Which controller is suitable for which controlled system?

• Assign the P, I , PI and PID controllers to the level-, flow rate-, pressure- and

temperature-controlled systems with the aid of worksheet 5.2.6.

Permanent control deviation No permanent control deviation

P PD PI PID

Level

Flowrate

Pressure

Temperature

Worksheet 5.2.6

Control engineering


5.4

Controller setting using the

Ziegler-Nichols method

Control engineering


Controller setting using the Ziegler-Nichols method

Name: Date:

Controlled system:

Task: Describe the procedure used in the Ziegler-Nichols method Sheet 1 of 5

Task

• What procedure must you adopt when using the Ziegler-Nichols method? Name

the sequence of steps.

• How must you configure the controller to use the Ziegler-Nichols method?

• Which values must you know in order to use the Ziegler-Nichols method?

Resources

• Worksheet

Exercise 5.3.1

Control engineering


Ziegler- Nichols method

Name: Date:

Project name:


• Sequence of steps

Worksheet 5.3.1

Control engineering



Name: Date:

Controlled system:

Task: Use the Ziegler-Nichols method Sheet 3 of 5

Task

• Calculate and parameterize a suitable controller for a controlled system using the

Ziegler-Nichols method.

Resources

• Worksheet

Exercise 5.3.2

Control engineering



Name: Date:

Controlled system:

Task: Test and examine your results Sheet 4 of 5

Task

• Test the results you obtained in 5.3.2.

Are your values correct? If necessary, locate the error and recalculate the values.

• Are you happy with the result achieved?

Indicate briefly what could be better. Explain.

Resources

• Worksheet

Exercise 5.3.3

Control engineering


Ziegler- Nichols method

Name: Date:

Project name:

Task: Test and examine your results Sheet 5 of 5

• Are you happy with the result achieved with the Ziegler- Nichols method?


Worksheet 5.3.2

Control engineering


The following application task offers trainees the opportunity to observe a

controlled system in operation. The procedure does not aim to provide trainees with

a slow introduction to control engineering, but to present them with a finished

controller and then to acquaint them with the individual components.

This task standard controller parameterization procedure. The aim is to show

trainees that control of a system can be achieved with simple standard methods.


This task requires technical understanding. The task is designed to give the trainee

an introduction to control engineering. Theoretical knowledge of control engineering

is required.

5.5

Controller parameterization

using the Chien-Hrones-

Reswick method

Control engineering


Controller parameterization using the Chien-Hrones-Reswick method

Name: Date:

Controlled system:


Task

• What procedure must you adopt when using the Chien-Hrones-Reswick method?

• Which values must you know in order to use the Chien-Hrones-Reswick method?

Resources

• Worksheet 5.4.1

Exercise 5.4.1

Control engineering



Name: Date:

Project name:


• Procedure

Worksheet 5.4.1

Control engineering



Name: Date:

Controlled system:

Task: Use the Chien-Hrones-Reswick method Sheet 3 of 6

Task


Chien-Hrones-Reswick method.

Exercise 5.4.2

Control engineering



Name: Date:

Controlled system:

Task: Use the Chien-Hrones-Reswick method Sheet 4 of 6

Task


Chien-Hrones-Reswick method.

Worksheet 5.4.3

Control engineering



Name: Date:

Project name:

Task: Determine the controller parameters and test the controller Sheet 5 of 6

• In what way could the results achieved with the Chien-Hrones-Reswick method

be better?

Describe briefly and explain.

Worksheet 5.4.3

Control engineering



Name: Date:

Controlled system:

Task: Test and examine your results. Sheet 6 of 6

Task

• Test the results you obtained in 5.4.1

Are your values correct? If necessary, locate the error and recalculate the values.

• Are you happy with the result achieved?


Exercise 5.4.3

Documents

EMCS Technology Exercises Worksheets V2