To demonstrate wide range of experiments, applications and advanced control techniques using industry standard instrumentation and controls.

Transcription

1 MI 330 UNIVERSAL PROCESS CONTROL TRAINER OBJECTIVE To demonstrate wide range of experiments, applications and advanced control techniques using industry standard instrumentation and controls. FEATURES DCS control MODBUS communication SCADA software Manual tuning and Autotuning Patchboard configurable experiments Facility to introduce external controller SS wetted parts Inbuilt compressor and plunger pump with VFD Study of I/P, DPT, control valve, valve positioner Study of rotameter, orificemeter, venturimeter Temperature, flow, level, pressure control On-off, P, PI, PID control, PLC control Open loop tuning by process reaction curve Closed loop tuning by Zigler Nicholas method Staility analysis by Bode plot Cascade, Feed-forward and Ratio control Three element control and interactive control SETUP Universal Process Control Trainer Code 330 resembles a typical small industrial process plant with different processes and parameters. The plant is controlled using DCS control (Hybrid controller) with SCADA software for supervisory control systems. A jack plug and socket patch board provided at the interface of the process facilitates configuration of different experiments and allows user to develop and test own control strategies. The patch board also allows direct access to transmitters and control elements enabling user to connect external controllers, PLCs & DCSs. The product layout is designed to educate, train and develop the user to cover various aspects of process control. User can configure the product from study of basic components to advanced study of complex process control loops using advanced DCS control.

2 SETUP SUBASSEMBLIES Heating tank module 1) Heating tank module consisting of Heating tank, Heater, RTD sensors, heating control unit and Piping. 2) Control panel module with DCS controller, power supply units, push buttons and patch board. 3) I/P converter module with I/P converters, pressure regulators and pressure gauges. 4) Water supply module consisting of plunger pump, centrifugal pump, water supply tank, rotameter, VFD for plunger pump, float switches, solenoid valve and piping. 5)Control valve module consisting of two pneumatic control valves, valve positioned and position transmitter 6) Process tanks module consisting of process tank (SS) with pressure transmitter, level tank with level transmitter and interconnected piping. 7) Flow sensing elements consisting of orifice meter, venturimeter and DP transmitter. 8) Air supply module consisting air compressor These modules and components are mounted on standalone type structure and interconnected with valves and piping. Along with MNC grade controllers and transmitters, an industrial grade SS used for wetted parts increases reliability of the product manifold RANGE OF EXPERIMENT Study of component basics 1. Study of I/P : Input-output, Calibration 2. Study of DP transmitter: Input /output 3. Study of control valve characteristics: Valve coefficient and control valve characteristics 4. Study of valve positioner: Input/output

3 Study of flow measuring devices 5. Study of Rotameter: Calibration 6. Study of Orifice meter: Coefficient of discharge 7. Study of Venturi meter: Coefficient of discharge Interacting and non interacting study 8. Study of interacting system: Step response 9. Study of non interacting system: step response Single loop feedback control PID control, tuning, Stability of following processes 10. Temperature control of direct heating process 11. Flow control of pump outlet 12. Flow control of process outlet 13. Level control by inlet flow manipulation using pneumatic valve 14. Level control by outlet flow manipulation using pneumatic valve 15. Level control by inlet flow manipulation using Plunger pump 16. Pressure control of closed tank (Air) 17. Pressure control of closed tank (Water) Multi-loop control 18. Cascade control (Level + Flow) 19. Cascade control (Temperature + Flow) 20. Cascade control (Level + Pressure) 21. Feed forward control (temperature) 22. Feed forward + Feedback control (Level) 23. Ratio control (Flow) 24. Three element control (Level) Multi input multi output control 25. Pressure and Level control (Interactive loops) 26. Level and Flow control (Interactive loops) Study of PLC 27. PLC Study and control SOFTWARE Set up is supplied with Hybrid control designer software and Wonderware in touch SCADA Software package (64 tags) which helps in learning basics of SCADA programming. The software can be operated in development and runtime mode. The experiments are conducted in

4 Runtime mode and the engineering can be viewed / modified in Development mode. The software is easy to use, flexible & scalable with features like Data access, trend plots, Data logging, Printing, Data export. UTILITIES REQUIRED Electric supply Provide 230 VAC +/- 10V (16A), 1 ph, electric supply with proper earthing. (Neutral Earth voltage less than 5 VAC) 5A, 3pin socket with switch (3No.) 16A, 3pin socket with switch (1No.) Water supply Continuous, clean and soft water LPH with suitable drain arrangement. Computer IBM compatible, standard configuration with USB port for Hardware lock. Monitor: Screen resolution 1280x1024. Space L4000 mm x W3000 mm x H2000 mm Support table Size: 800Wx800Dx750H in mm for computer SPECIFICATIONS Product Product code 330 Universal Process Control Trainer Type of control DCS and SCADA Control unit Hybrid controller, AI 8, AO 4, DI 16, DO 16, Control loops 8 with Communication RS232, RS485, Ethernet Software packages i) DCS: Hybrid Control Designer ii) SCADA: Wondware In touch 64 Tags Temperature sensor RTD, PT100, Range deg.c, 2Nos Temperature transmitter PT100, Type 2 wire, Range deg.c, Output 4-20mA, 2Nos Flow transmitter DPT, Type 2 wire, Range mm H2O, Output 4 20 ma, Sq. root Level transmitter DPT, Type 2 wire, Range mm H2O, Output 4 20 ma, Linear Level transmitter GPT, Type 2 wire, Range mm H2O, Output 4 20 ma Pressure transmitter GPT, Type 2 wire, Range bar, Output 4 20 ma Position transmitter Type Electronic, 2 wire, O/P 4 20mA I/P converter Input 4-20mA, Output 3-15 psig (2Nos) Heating control Proportional power controller (SSR), Input 4-20 ma Heater Type Electrical 2 coil, Capacity 3 KW Rotameter LPH Process tank Capacity 7.5liter, 0-100% scale, SS304 Interacting tank Capacity 7.5liter, 0-500mm scale, SS304 (2Nos) Supply tank Capacity 27liter, SS304 Float switch Type Magnetic (2 nos.) Solenoid valves Type 2/2way normally closed, 1/4"BSP, water(2nos) Control valve Type: Pneumatic, Size:1/2", Input: 3 15psig, Linear & Equal % (2Nos) Power supply Supply 230VAC, output 24V DC (2Nos) VFD Input single phase 200VAC, 1.1A, output AC3 phase Pump Fractional horse power, type centrifugal Plunger pump Positive displacement Plunger pump, Cap 200Lph Air filter regulator Range kg/cm2 Pressure gauge Flow measurement devices Compressor Range kg/cm2(3nos), Range 0-7 kg/cm2 Orifice meter (3Nos), Venturi meter 1 Hp,3.8CFM, 10 kg/cm^2 with 45 lit inbuilt tank receiver

5 Overall dimensions 1150mmL x 800mmW x 1900mmh