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
4 © Festo Didactic GmbH & Co. • Process Control System
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
6 © Festo Didactic GmbH & Co. • Process Control System
Worksheet 5.4.3 __________________________________________________ 141
Worksheet 5.4.3 __________________________________________________ 142
Exercise 5.4.3 ____________________________________________________ 143
© Festo Didactic GmbH & Co. • Process Control System 7
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
8 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 9
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
10 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 11
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
12 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 13
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
14 © Festo Didactic GmbH & Co. • Process Control System
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
EMCS task with process master display
Flowrate display automatic closed-loop control
PIC
303
EMCS task with process master display
Pressure display automatic closed-loop control
TIC
401
EMCS task with process master display
Temperature display automatic closed-loop control
Pipe input (output)
Project planning
© Festo Didactic GmbH & Co. • Process Control System 15
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
16 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 17
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
18 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 19
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Project planning
20 © Festo Didactic GmbH & Co. • Process Control System
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
• Electrical circuit diagram, Compact Workstation
• PI diagram for controlled system from Worksheet 2.3.1
• Data sheets, Compact Workstation
• Standard DIN 19227 Part 2 “Graphical symbols and code letters for process
control” (ISO3511)
Exercise 2.3.2
Project planning
© Festo Didactic GmbH & Co. • Process Control System 21
Project planning
22 © Festo Didactic GmbH & Co. • Process Control System
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
• Electrical circuit diagram, Compact Workstation
• PI diagram of the controlled system from Worksheet 2.3.1
• EMCS point list from Worksheet 2.3.2
• Data sheets, Compact Workstation
• Workbook “Control of temperature, flow rate and level” , Festo, 170677
• Standard DIN 19227 Part 2 “Graphical symbols and code letters for process
control” (ISO3511)
Exercise 2.3.3
Project planning
© Festo Didactic GmbH & Co. • Process Control System 23
Project planning
24 © Festo Didactic GmbH & Co. • Process Control System
© Festo Didactic GmbH & Co. • Process Control System 25
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
26 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 27
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
28 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 29
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
30 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 31
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
32 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 33
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
34 © Festo Didactic GmbH & Co. • Process Control System
Pump
Name: Date:
Project name:
Task: Determine the delivery rate of the pump Sheet 4 of 4
Worksheet 3.2.3
Analysis
© Festo Didactic GmbH & Co. • Process Control System 35
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
36 © Festo Didactic GmbH & Co. • Process Control System
Analysis of a proportional valve
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
© Festo Didactic GmbH & Co. • Process Control System 37
Analysis of a proportional valve
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
38 © Festo Didactic GmbH & Co. • Process Control System
Analysis of a proportional valve
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
© Festo Didactic GmbH & Co. • Process Control System 39
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
40 © Festo Didactic GmbH & Co. • Process Control System
Analysis of a process drive
Name: Date:
Project name:
Task: Determining the mode of operation of a process drive Sheet 1 of 4
• 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
© Festo Didactic GmbH & Co. • Process Control System 41
Analysis of a process drive
Name: Date:
Project name:
Task: Determining the mode of operation of a process drive Sheet 2 of 4
• What electrical signals do you need to work with the process drive?
• Give a brief description of the module’s mode of operation.
Analysis
42 © Festo Didactic GmbH & Co. • Process Control System
Analysis of a process drive
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
• Worksheet 3.4.2 Analysis of a process drive
Resources
• Sensor box data sheet
• PCS circuit documentation
• Station manual
Exercise 3.4.2
Analysis
© Festo Didactic GmbH & Co. • Process Control System 43
Analysis of a process drive
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
44 © Festo Didactic GmbH & Co. • Process Control System
Analysis of a process drive
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
• Worksheet 3.4.3 Analysis of a process drive
Resources
• Semi-rotary actuator data sheet
• Station manual
Exercise 3.4.3
Analysis
© Festo Didactic GmbH & Co. • Process Control System 45
Analysis of a process drive
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
46 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 47
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
48 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 49
Analysis of an ultrasound sensor
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
50 © Festo Didactic GmbH & Co. • Process Control System
Analysis of an ultrasound sensor
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
© Festo Didactic GmbH & Co. • Process Control System 51
Analysis of an ultrasound sensor
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
52 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 53
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
54 © Festo Didactic GmbH & Co. • Process Control System
Analysis of a flowmeter
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
© Festo Didactic GmbH & Co. • Process Control System 55
Analysis of a flowmeter
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.
Take a sufficient number of measurements and enter these into a chart.
• Evaluate the resulting characteristic.
Compare your result to the characteristic in the data sheet.
Resources
• Oscilloscope
• Flow meter data sheet
Worksheets
• Worksheet 3.7.2 Analysis of a flow meter
Exercise 3.7.2
Analysis
56 © Festo Didactic GmbH & Co. • Process Control System
Analysis of a flowmeter
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
© Festo Didactic GmbH & Co. • Process Control System 57
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
58 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 59
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?
• What is the measuring range of 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
60 © Festo Didactic GmbH & Co. • Process Control System
Analysis of a pressure sensor
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??
• What is the measuring range of the sensor?
Worksheet 3.8.1
Analysis
© Festo Didactic GmbH & Co. • Process Control System 61
Analysis of a pressure sensor
Name: Date:
Project name:
Task: Recording the characteristic Sheet 2 of 4
Task
• Record the characteristic of the pressure sensor.
Take a sufficient number of measurements and enter these into a chart.
• Evaluate the resulting characteristic.
Compare your result to the characteristic in the data sheet .
Resources
• Pressure sensor data sheet
Worksheets
• Worksheet 3.8.2 Analysis of a pressure sensor
Exercise 3.8.2
Analysis
62 © Festo Didactic GmbH & Co. • Process Control System
Analysis of a pressure sensor
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
© Festo Didactic GmbH & Co. • Process Control System 63
Analysis of a pressure sensor
Name: Date:
Project name:
Task: Recording the characteristic Sheet 4 of 4
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
64 © Festo Didactic GmbH & Co. • Process Control System
Analysis of a temperature sensor
Name: Date:
Project name:
Task: Determining the mode of operation of a temperature sensor Sheet 1 of 5
Task
• The thermal sensor used is a PT100.
Explain this designation. What does it mean?
• How can you measure the signal from the sensor?
• What is the resistance of the sensor at 0°C, and at 100°C?
• What is the measuring range of the sensor?
Resources
• PT100 temperature sensor data sheet
Worksheets
• Worksheet 3.9.1 Analysis of a temperature sensor
3.9 Analysis of a
temperature sensor
Exercise 3.9.1
Analysis
© Festo Didactic GmbH & Co. • Process Control System 65
Analysis of a temperature sensor
Name: Date:
Project name:
Task: Determining the mode of operation of a temperature sensor Sheet 2 of 5
• What does the designation PT100 mean?
• How can you measure the signal from the sensor?
• What is the resistance of the sensor at 0°C, and at 100°C?
• What is the measuring range of the sensor?
Worksheet 3.9.1
Analysis
66 © Festo Didactic GmbH & Co. • Process Control System
Analysis of a temperature sensor
Name: Date:
Project name:
Task: Recording the characteristic Sheet 3 of 5
Task
• Record the characteristic of the temperature sensor.
Take a sufficient number of measurements and enter these into a chart.
• Evaluate the resulting characteristic.
Compare your result to the characteristic in the data sheet .
Note
Before starting, consider the procedure for measurement. As you have to heat the
fluid in the container, the measurement is more time-consuming. If you make
mistakes during measurement, you will have replace the fluid or wait for it to cool!
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
© Festo Didactic GmbH & Co. • Process Control System 67
Analysis of a temperature sensor
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
68 © Festo Didactic GmbH & Co. • Process Control System
Temperature sensor
Name: Date:
Project name:
Task: Recording the characteristic Sheet 5 of 5
10 20 30 40 50 60 70 80 90 100 110 120
R [
Oh
m]
T[°C]
Analysis
© Festo Didactic GmbH & Co. • Process Control System 69
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
70 © Festo Didactic GmbH & Co. • Process Control System
System behavior of a container
Name: Date:
Project name:
Task: Carry out various measurements that will allow you to describe the flow behavior into and out of
the container.
Sheet 2 of 5
• What result to you expect to get?
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
© Festo Didactic GmbH & Co. • Process Control System 71
System behavior of a container
Name: Date:
Project name:
Task: Carry out various measurements that will allow you to describe the flow behavior into and out of
the container.
Sheet 3 of 5
• What result to you expect to get?
Level [mm] Time [s] Level [mm] Time [s]
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:
Inlet valve open, outlet valve
closed, pump not running
Analysis
72 © Festo Didactic GmbH & Co. • Process Control System
System behavior of a container
Name: Date:
Project name:
Task: Carry out various measurements that will allow you to describe the flow behavior into and out of
the container.
Sheet 4 of 5
• What result to you expect to get?
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
Measurement 3:
Inlet valve open, outlet valve
open, pump running.
Analysis
© Festo Didactic GmbH & Co. • Process Control System 73
System behavior of a container
Name: Date:
Project name:
Task: Carry out various measurements that will allow you to describe the flow behavior into and out of
the container.
Sheet 5 of 5
0 60 120 180 240 300
0
100
200
300
360
© Festo Didactic GmbH & Co. • Process Control System 74
The following application tasks are designed to help the trainee learn to use the
controlled systems and the controllers. A controlled system is to be taken into
operation with defined parameters. The behavior of the system is to be observed
while it is in operation.
Target audience and required prior knowledge
This task requires technical understanding. The tasks are designed to give the
trainees an introduction to control engineering. The trainees should have a
theoretical knowledge of the fundamentals of control engineering.
This task is designed to allow the trainee to see theory in a practical example and
thus enhance their knowledge.
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
© Festo Didactic GmbH & Co. • Process Control System 75
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
76 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 77
Commissioning a level-controlled system
Name: Date:
Project name:
Task: Determining the setpoint Sheet 2 of 7
• Are you using close-loop or open-loop control of the level?
• Is it possible to maintain a constant level manually?
Pump voltage measured for mean measured value
Mean
measured value
[mm]
Pump voltage
[V]
Worksheet 4.1.1
Commissioning
78 © Festo Didactic GmbH & Co. • Process Control System
Commissioning a level-controlled system
Name: Date:
Project name:
Task: Determining the operating range and operating point of a controlled system. Sheet 3 of 7
Purpose of the exercise
The purpose of the exercise is to replace a person as a controller by an automatic
controller. The actual value is to be measured by a sensor. The pump is to be
switched ON and OFF by means of a controller.
Task
Determine a suitable setpoint (desired level) to be used for commissioning of the
controller. Take the operating range of the sensor into account.
Enter the value of the sensor into the worksheet supplied when you have reached
the desired level.
Procedure
1. 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
© Festo Didactic GmbH & Co. • Process Control System 79
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
80 © Festo Didactic GmbH & Co. • Process Control System
Commissioning a level-controlled system
Name: Date:
Project name:
Task: Operating a controlled system with set values. Sheet 5 of 7
Task
Commission the level-controlled system. Observe the following points:
Preparation
Acquaint yourself with the operation and parameterization of your controller
(industrial controller, PLC or FluidLab-PA). When preparing the controlled system,
please observe the notes in Worksheet 4.1.1.
1. 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
© Festo Didactic GmbH & Co. • Process Control System 81
Commissioning a level-controlled system
Name: Date:
Project name:
Task: Operating a controlled system with set values Sheet 6 of 7
Task
• How does the system respond? Describe your impressions.
• Close valve V112 with the controller running. How does the system respond?
Describe your impressions.
Worksheets
• Worksheet 4.1.3 “Commissioning a level-controlled system”
Exercise 4.1.4
Commissioning
82 © Festo Didactic GmbH & Co. • Process Control System
Commissioning a level-controlled system
Name: Date:
Project name:
Task: Operating a controlled system with set values. Sheet 7 of 7
• How does the system respond with the outlet valve closed?
How does the system respond with the outlet valve open?
Worksheet 4.1.3/4.1.4
Commissioning
© Festo Didactic GmbH & Co. • Process Control System 83
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
84 © Festo Didactic GmbH & Co. • Process Control System
Commissioning a flow controlled-system
Name: Date:
Project name:
Task: Manual operation of a controlled system Sheet 1 of 10
Task
The flow rate in a pipe system is to be kept constant.
Preparation
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
© Festo Didactic GmbH & Co. • Process Control System 85
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
86 © Festo Didactic GmbH & Co. • Process Control System
Commissioning a flow controlled-system
Name: Date:
Project name:
Task: Determining the operating range and operating point of a controlled system. Sheet 3 of 10
Purpose of the exercise
The purpose of the exercise is to replace a person as a controller by an automatic
controller. The actual value is to be measured by a sensor. The pump is to be
switched ON and OFF by means of a controller.
Task
Based on the data sheets of the components, develop the measuring chain
controlled system – sensor – transducer (if a transducer is present).
Determine a suitable setpoint (constant flow rate) for commissioning of the control.
Take the operating range of the sensor (actual value) and the pump (final control
element) into account.
Enter the measured values for the mean flow rate into the worksheet. Calculate the
missing values, for example the maximum measurable flow rate of the transducer.
Procedure
1. What is the measured value for minimum flow? What signal does the flow meter
deliver before and after the transducer (for Level Workstation or Compact
Workstation).
2. Switch the pump on (max.). Measure the output signal of the transducer.
3. What measured value is exactly midway between the minimum and maximum
flow rate? Set this as the operating point for the pump voltage. Measure the
sensor signal and the output signal of the transducer.
4. What is the pump voltage for a constant flow rate at the operating point?
Worksheets
Worksheet “Commissioning a flow controlled-system”
Exercise 4.2.2
Commissioning
© Festo Didactic GmbH & Co. • Process Control System 87
Commissioning a flow-controlled system, Controlling the flow rate with a pump as final control element
Name: Date:
Project name:
Task: Determining the operating range and operating point of a controlled system. Sheet 4 of 10
Determining the measuring chain of a flow-controlled system with a pump as final
control element
Flow control
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
88 © Festo Didactic GmbH & Co. • Process Control System
Commissioning a flow controlled-system, Controlling the flowrate with a pump as final control element
Name: Date:
Project name:
Task: Operating a controlled system with set values Sheet 5 of 10
Task
Commission the flow controlled-system.
Preparation
Acquaint yourself with the operation and parameterization of your controller
(industrial controller, PLC or FluidLab-PA). When preparing the controlled system,
please observe the notes in Worksheet 4.2.1.
• Set the manual valves so that the medium can flow directly through manual valve
V104.
Parameterization
Please set the following parameters for the controller:
Parameter Value
KP 1
TN
[s] 2
TV [s] 0
• Start the controller.
Worksheets
Worksheet “Commissioning a flow controlled-system”
Exercise 4.2.3
Commissioning
© Festo Didactic GmbH & Co. • Process Control System 89
Commissioning a flow-controlled system, Controlling the flow rate with a pump as final control element
Name: Date:
Project name:
Task: Operating a controlled system with set values Sheet 6 of 10
• Describe your impressions
Worksheet 4.2.3
Commissioning
90 © Festo Didactic GmbH & Co. • Process Control System
Commissioning a flow controlled-system, Controlling the flow rate with a pump as final control element
Name: Date:
Project name:
Task: Determining the operating range and operating point of a controlled system. Sheet 7 of 10
Task
For commissioning of the flow controlled-system, determine the operating range of
the proportional valve and a suitable operating point.
Enter the mean flow rate of the proportional valve into the worksheet.
Preparation
Set the proportional valve to minimum maximum flow rate. You will find instructions
for adjustment in the data sheet for the proportional valve .
Procedure
1. Switch the pump on and activate the proportional valve (Workstation).
For 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
© Festo Didactic GmbH & Co. • Process Control System 91
Commissioning a flow-controlled system, Controlling the flowrate with a pump as final control element
Name: Date:
Project name:
Task: Determining the operating range and operating point of a controlled system. Sheet 8 of 10
Determining the operating range of a flow-controlled system with a proportional
valve as final control element
Flow control
Proportional value
operating range
Sensor 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
[ 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 4.2.4
Commissioning
92 © Festo Didactic GmbH & Co. • Process Control System
Commissioning a flow controlled-system, Controlling the flow rate with a proportional valve as final control element
Name: Date:
Project name:
Task: Operating a controlled system with set values Sheet 9 of 10
Task
Commission the flow controlled-system with the proportional valve as the final
control element. Set the proportional valve (see notes in the data sheet).
Preparation
Acquaint yourself with the operation and parameterization of your controller
(industrial controller, PLC or FluidLab-PA). When preparing the controlled system,
please observe the notes in Worksheet 4.3.1.
• Set the manual valves so that the medium can flow directly through proportional
valve V106.
Parameterization
Please set the following parameters for the controller:
Parameter Value
KP 2
TN
[s] 1
TV [s] 0
• Start the controller.
Worksheets
• Worksheet 4.2.5 “Commissioning a flow controlled-system”
Exercise 4.2.5
Commissioning
© Festo Didactic GmbH & Co. • Process Control System 93
Commissioning a flow-controlled system, Controlling the flow rate with a proportional valve as final control element
Name: Date:
Project name:
Task: Operating a controlled system with set values Sheet 10 of 10
• Describe your impressions
Worksheet 4.2.5
Commissioning
94 © Festo Didactic GmbH & Co. • Process Control System
To complete the task you need either:
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
© Festo Didactic GmbH & Co. • Process Control System 95
Commissioning a pressure-controlled system
Name: Date:
Project name:
Task: Manual operation of a controlled system Sheet 1 of 10
Task
Commission the pressure-controlled system. The pressure level in the pressure
reservoir is to be kept constant at a certain value.
Preparation
• Fill approx. 5l of water into the lower container.
• Close all manual valves.
• Set the manual valves so that the medium can be pumped directly into the
pressure reservoir.
• Pump the water into the pressure reservoir and carefully open pressure relief
valve V107 until the pressure reservoir is half-filled with air and half-filled with
water. Close pressure relief valve V107. The pressure relief valve is NEVER to be
opened during measurements or normal operation!
Please note that the entire system must not contain more water than the capacity of
one container!
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
96 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 97
Commissioning a pressure-controlled system
Name: Date:
Project name:
Task: Determining the operating range and operating point of a controlled system Sheet 3 of 10
Purpose of the exercise
The purpose of the exercise is to replace a person as a controller by an automatic
controller. The actual value is to be measured by a sensor. The pump is to be
switched ON and OFF by means of a controller.
Task
Based on the data sheets of the components, develop the measuring chain
controlled system – sensor – transducer (if a transducer is present).
Determine a suitable setpoint (constant pressure in the container) for
commissioning of the control. Take the operating range of the sensor (actual value)
and the pump (final control element) into account.
Enter the measured values for the mean reservoir pressure into the worksheet.
Calculate the missing values.
Procedure
1. What is the measured value for minimum pressure? What signal does the
pressure sensor deliver?
2. Switch the pump ON (max.). Measure the sensor signal. What is the maximum
pressure the sensor can read?
3. What measured value is exactly midway between the minimum and maximum
levels? Set the operating point for the pump voltage to this value. Measure the
sensor signal.
4. What is the pump voltage for a constant pressure close to the operating point?
Worksheets
• Worksheet “Commissioning a pressure-controlled system”
Exercise 4.3.2
Commissioning
98 © Festo Didactic GmbH & Co. • Process Control System
Commissioning a pressure-controlled system, Controlling the pressure with a pump as final control element
Name: Date:
Project name:
Task: Determining the operating range and operating point of a controlled system Sheet 4 of 10
Determining the measuring chain of a pressure-controlled system with a pump as
final control element
Pressure control
Pump operating range
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
[ 0.0 – 1.0 ] Pump voltage
[V]
Convert the measured value into a dimensionless value in the range [0-0 – 1.0]. This
means that the maximum measurable pressure of 400 mbar would have the value
1.0.
Worksheet 4.3.2
Commissioning
© Festo Didactic GmbH & Co. • Process Control System 99
Commissioning a pressure-controlled system
Name: Date:
Project name:
Task: Operating a controlled system with set values Sheet 5 of 10
Task
Commission the pressure-controlled system with set values for the control
parameters.
Preparation
Acquaint yourself with the operation and parameterization of your controller
(industrial controller, PLC or FluidLab-PA). When setting up the controlled system,
please observe the notes in Worksheet 4.3.1.
Parameterization
A functioning control system comprises a controlled system and a controlling unit
(controller). This requires various parameters. Please set the following parameters
for the controller:
Parameter Value
KP 1,0
TN
[s] 2,0
TV [s] 0,1
• Start the controller.
• How does the system respond? Describe your impressions on the worksheet
provided.
Worksheets
• Worksheet “Commissioning a pressure-controlled system”, IBN_P_AB04_3
Exercise 4.3. 3
Commissioning
100 © Festo Didactic GmbH & Co. • Process Control System
Commissioning a pressure-controlled system, Controlling the pressure with a pump as final control element
Name: Date:
Project name:
Task: Operating a controlled system with set values Sheet 6 of 10
• Describe your impressions
Worksheet 4.3.3
Commissioning
© Festo Didactic GmbH & Co. • Process Control System 101
Commissioning a pressure-controlled system
Name: Date:
Project name:
Task: Determining the operating range and operating point of a controlled system. Sheet 7 of 10
Task
Determine the working range and a suitable operating point for a proportional valve
for commissioning of a pressure-controlled system.
Enter the measured value for the mean operating pressure that can be controlled
with the proportional valve into the worksheet.
Preparation
Set the proportional valve to minimum / maximum flow rate. (This is not a
typographical error!). You will find instructions on adjustment in the data sheet for
the proportional valve .
Procedure
1. Switch the pump ON and activate the proportional valve (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
102 © Festo Didactic GmbH & Co. • Process Control System
Commissioning a pressure-controlled system, Controlling the pressure with a proportional valve as final control element
Name: Date:
Project name:
Task: Determining the operating range and operating point of a controlled system Sheet 8 of 10
Determining the operating range of the pressure-controlled system with a
proportional valve as final control element
Pressure control
Pump operating range
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
[ 0.0 – 1.0 ] Pump voltage
[V]
Convert the measured value into a dimensionless value in the range [0-0 – 1.0]. This
means that the maximum measurable pressure of 400 mbar would have the value
1.0.
Worksheet 4.2.4
Commissioning
© Festo Didactic GmbH & Co. • Process Control System 103
Commissioning a pressure-controlled system
Name: Date:
Project name:
Task: Operating a controlled system with set values Sheet 9 of 10
Task
Commission the pressure-controlled system with proportional valve with set values
for the control parameters .
Preparation
Acquaint yourself with the operation and parameterization of your controller
(industrial controller, PLC or FluidLab-PA). When preparing the controlled system,
please observe the notes in Worksheet 4.3.1.
Parameterization
A functioning control system comprises a controlled system and a controlling unit
(controller). This requires various parameters. Please set the following parameters
for the controller:
Parameter Value
KP 3.0
TN
[s] 8.0
TV [s] 2.0
• Open manual valve V109 (see 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
104 © Festo Didactic GmbH & Co. • Process Control System
Commissioning a pressure-controlled system, Controlling the pressure with a proportional valve as final control element
Name: Date:
Project name:
Task: Operating a controlled system with set values Sheet 10 of 10
• Describe your impressions
Worksheet 4.3.5
Commissioning
© Festo Didactic GmbH & Co. • Process Control System 105
To complete the task you need either:
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
106 © Festo Didactic GmbH & Co. • Process Control System
Commissioning a temperature-controlled system
Name: Date:
Project name:
Task: Manual operation of a controlled system Sheet 1 of 6
Preparation
Fill approx. 5l water into the (lower) container for temperature-controlled system.
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
© Festo Didactic GmbH & Co. • Process Control System 107
Commissioning a temperature-controlled system
Name: Date:
Project name:
Task: Manual operation of a controlled system Sheet 2 of 6
• Are you using open-loop or closed-loop control of temperature?
• Is it possible to maintain a constant temperature manually?
Worksheet 4.4.1
Commissioning
108 © Festo Didactic GmbH & Co. • Process Control System
Commissioning a temperature-controlled system
Name: Date:
Project name:
Task: Determining the operating range and operating point of a controlled system Sheet 3 of 6
Purpose of the exercise
The purpose of the exercise is to replace a person as a controller by an automatic
controller. The actual value is to be measured by a sensor. The heater is to be
switched ON and OFF by means of a controller.
Task
Determine the signal delivered by your temperature sensor when submerged in the
heated medium (Worksheet 4.4.1). Measure the resistance of the temperature
sensor. Calculate the temperature from this.
Worksheets
• Worksheet “Commissioning a temperature-controlled system”
Exercise 4.4.2
Commissioning
© Festo Didactic GmbH & Co. • Process Control System 109
Commissioning a temperature-controlled system
Name: Date:
Project name:
Task: Determining the operating range and operating point of a controlled system Sheet 4 of 6
Determining the measuring chain of the temperature-controlled system with a
heater as the final control element
Temperature control
Heater operating range
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]
Convert the measured value into a dimensionless value in the range [0-0 – 1.0]. This
means that the maximum measurable temperature of 100 °C would have the value
1.0.
Worksheet 4.4.2
Commissioning
110 © Festo Didactic GmbH & Co. • Process Control System
Commissioning a temperature-controlled system
Name: Date:
Project name:
Task: Operating a controlled system with set values Sheet 5 of 6
Task
Commission the temperature-controlled system with heater.
Parameterization
Please parameterize your controller with the following values:
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
© Festo Didactic GmbH & Co. • Process Control System 111
Commissioning a temperature-controlled system
Name: Date:
Project name:
Task: Operating a controlled system with set values Sheet 6 of 6
• Describe your impressions
Worksheet 4.4.3
Commissioning
112 © Festo Didactic GmbH & Co. • Process Control System
© Festo Didactic GmbH & Co. • Process Control System 113
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
114 © Festo Didactic GmbH & Co. • Process Control System
The time response of a controlled system must be known for optimum controller
selection. This allows conclusions to be drawn regarding the dynamic response of
the controlled system and the controller settings to be determined.
The time response of a controlled system is determined by recording a transient
response of the system. For systems with delay, such as where there is energy
storage, the time constant of the controlled system is determined by applying a
tangent or, in the case of multiple delays, an inflectional tangent.
5.1
Identifying the controlled
system
Control engineering
© Festo Didactic GmbH & Co. • Process Control System 115
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
116 © Festo Didactic GmbH & Co. • Process Control System
Identification of a controlled system
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
© Festo Didactic GmbH & Co. • Process Control System 117
Identification of a controlled system
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
118 © Festo Didactic GmbH & Co. • Process Control System
The following theoretical exercises allow trainees to consolidate their knowledge of
control engineering.
The purpose of the exercise is to give the trainee the opportunity to see how a real
controlled system responds to various controllers and why it is necessary to find a
suitable controller and to parameterize it correctly.
Target audience and required prior knowledge
This exercise requires technical understanding. Basic knowledge of control
engineering is absolutely essential.
This exercise is for control technicians and trainees who have to make use of basic
control engineering.
5.2
Controller functions
Control engineering
© Festo Didactic GmbH & Co. • Process Control System 119
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
120 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 121
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.
• Describe your result. How does the system respond?
Parameter list
Parameter Value
TN 10
TN 5
TN 2
Exercise 5.2.2
Control engineering
122 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 123
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.
• Describe your result. How does the system respond?
Parameter list
Parameter Value Parameter Value
KP 2 TN 10
KP 2 TN 5
KP 5 TN 10
KP 5 TN 5
Exercise 5.2.3
Control engineering
124 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 125
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.
• Describe your result. How does the system respond?
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
126 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 127
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.
• Describe your result. How does the system respond?
Parameter list
Parameter Value Parameter Value Parameter Value
KP 1 TN 1 TV 1
KP 1 TN 2 TV 1
KP 1 TN 2 TV 5
KP 1 TN 5 TV 1
Exercise 5.2.5
Control engineering
128 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 129
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
130 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 131
5.4
Controller setting using the
Ziegler-Nichols method
Control engineering
132 © Festo Didactic GmbH & Co. • Process Control System
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
© Festo Didactic GmbH & Co. • Process Control System 133
Ziegler- Nichols method
Name: Date:
Project name:
Task: Describe the procedure used in the Ziegler-Nichols method Sheet 2 of 5
• Sequence of steps
Worksheet 5.3.1
Control engineering
134 © Festo Didactic GmbH & Co. • Process Control System
Controller setting using the Ziegler-Nichols method
Name: Date:
Controlled system:
Task: Use the Ziegler-Nichols method Sheet 3 of 5
Task
• Calculate and parameterize a suitable controller for a controlled system using the
Ziegler-Nichols method.
Resources
• Worksheet
Exercise 5.3.2
Control engineering
© Festo Didactic GmbH & Co. • Process Control System 135
Controller setting using the Ziegler-Nichols method
Name: Date:
Controlled system:
Task: Test and examine your results Sheet 4 of 5
Task
• Test the results you obtained in 5.3.2.
Are your values correct? If necessary, locate the error and recalculate the values.
• Are you happy with the result achieved?
Indicate briefly what could be better. Explain.
Resources
• Worksheet
Exercise 5.3.3
Control engineering
136 © Festo Didactic GmbH & Co. • Process Control System
Ziegler- Nichols method
Name: Date:
Project name:
Task: Test and examine your results Sheet 5 of 5
• Are you happy with the result achieved with the Ziegler- Nichols method?
Indicate briefly what could be better. Explain.
Worksheet 5.3.2
Control engineering
© Festo Didactic GmbH & Co. • Process Control System 137
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.
Target audience and required prior knowledge
This task requires technical understanding. The task is designed to give the trainee
an introduction to control engineering. Theoretical knowledge of control engineering
is required.
5.5
Controller parameterization
using the Chien-Hrones-
Reswick method
Control engineering
138 © Festo Didactic GmbH & Co. • Process Control System
Controller parameterization using the Chien-Hrones-Reswick method
Name: Date:
Controlled system:
Task: Describe the procedure used in the Ziegler-Nichols method Sheet 1 of 6
Task
• What procedure must you adopt when using the Chien-Hrones-Reswick method?
• Which values must you know in order to use the Chien-Hrones-Reswick method?
Resources
• Worksheet 5.4.1
Exercise 5.4.1
Control engineering
© Festo Didactic GmbH & Co. • Process Control System 139
Controller parameterization using the Chien-Hrones-Reswick method
Name: Date:
Project name:
Task: Describe the procedure used in the Ziegler-Nichols method Sheet 2 of 6
• Procedure
Worksheet 5.4.1
Control engineering
140 © Festo Didactic GmbH & Co. • Process Control System
Controller parameterization using the Chien-Hrones-Reswick method
Name: Date:
Controlled system:
Task: Use the Chien-Hrones-Reswick method Sheet 3 of 6
Task
• Calculate and parameterize a suitable controller for a controlled system using the
Chien-Hrones-Reswick method.
Exercise 5.4.2
Control engineering
© Festo Didactic GmbH & Co. • Process Control System 141
Controller parameterization using the Chien-Hrones-Reswick method
Name: Date:
Controlled system:
Task: Use the Chien-Hrones-Reswick method Sheet 4 of 6
Task
• Calculate and parameterize a suitable controller for a controlled system using the
Chien-Hrones-Reswick method.
Worksheet 5.4.3
Control engineering
142 © Festo Didactic GmbH & Co. • Process Control System
Controller parameterization using the Chien-Hrones-Reswick method
Name: Date:
Project name:
Task: Determine the controller parameters and test the controller Sheet 5 of 6
• In what way could the results achieved with the Chien-Hrones-Reswick method
be better?
Describe briefly and explain.
Worksheet 5.4.3
Control engineering
© Festo Didactic GmbH & Co. • Process Control System 143
Controller parameterization using the Chien-Hrones-Reswick method
Name: Date:
Controlled system:
Task: Test and examine your results. Sheet 6 of 6
Task
• Test the results you obtained in 5.4.1
Are your values correct? If necessary, locate the error and recalculate the values.
• Are you happy with the result achieved?
Indicate briefly what could be better. Explain.
Exercise 5.4.3