"The Unit" to learn about two typical controlled members
level & flow and to study the PID algorithms using original industrial
components.
Control modes:
2-Position control switching pump on/off
3-Position step control with slow motor valve
Continous control with speed controlled pump
Feed foreward
Cascade
Controlled members:
Waterlevel measured by bottom pressure
Waterflow measured by magnetic flow-meter
Controller:
Industrial controller or PLC
PC and TeLC software controller, special features when using PC and TeLC
software controller: Time plots of I/O and of PID - actions of output
value (Windows-software).
On-off control
3-Position step control
Y: calculated output action of PID-controller.
Y3: Transformed step-output for slow motorvalve
This mini plant combines the control
of water flow, water level, water temperature and air pressure. The unit
principle is similar to a steam generation and heat consumption process.
Because of safety the heat generation indeed is a hot water generation.
All elements are connected by PROFIBUS to an automation system.
Sensors:
Limit sensors
Capacitive level transmitter
Magnetic flow transmitter
Pt 100 temperature transmitter
Piezo-resistive pressur transmitter
Controlled members:
Pneumatic valves
Fast electric motor valves
21 kW resistor water heater
Power control:
By boiler-temperatur
By mixing ratio of boiler- and bypass-wate
Flow-rate of used water
Control:
Discrete electronic controller and automation system
TeLC Miniplants follow a standardized design principle which adopts to
some extent the real situation in an industrial plant.So is found the
field department and the control department. Field and control are both
equipped with original industrial instruments. The control department
contains the mimetic display and the control instruments. Deviating from
reality the field which is concentrated in the mimetic display is to be
physically connected with the control instruments
may be with pneumatic hoses or electric wiring.
So the trainee has got an additional task to solve. This connecting is eased
in that way that especially for the wiring needs be taken no care with normal
bipolar wiring and polarity. Connecting of pneumatics and electrics feels
equal. The standardisation of the TeLC Miniplants goes so far as the dimensions
height 1.95m and depth 0.65m are equal. Only width differs between 2.2 and
2.9 m and of course weight. Within the abbreviation naming of the units
is indicated the control task and instrumentation so e.g. here FIRCA
means: Flow - Indication
- Registration - Control
- Alarm
Wide range of Training Tasks:
identification of the process elements and their connection
put in action and calibration of elements
connection of the process with the control terminal
structurizing and configuration of transmitters and
controllers
running of the process (start & stop )
study and optimize the control performance by adjusting
the parameters
Built-up of FIRCA:
This Miniplant contains a complex circuitry using pneumatic and electric
equipment.
The fluid flow (water) can take 2 possible ways:
The stronger pump drives the water into the blue pipeline through
the magnetic F/I- transmitter , the controlvalve with positioner
and linear characteristic, the alarm actuator and a rotameter back
into the reservoir.
The second pump drives water into the red pipeline through an
orifice plate with connected p/p-transmitter and the controlvalve
without positioner but with logarithmic characteristic, a rotameter
and a handvalve for disturbance back into the reservoir.
The flowlines can be run under constant pressure conditions which
is regulated by the spill valve.
Both pumps can be connected in parallel to pump into the blue line.
Corresponding to the pneumatic and electric instrumentation p/I and
I/p signal converters are existing in the field.
The ratio control is realized with the electronic controler used as
master and the pneumatic one as slave.
The square root transfer of the pneumatic flow signal is realised
with the electric controller.
length 2,9 m, weight 195 kg. supply 380 V AC and pressed air.
TeLC Miniplants follow a standardized design principle which adopts to
some extent the real situation in an industrial plant.So is found the
field department and the control department. Field and control are both
equipped with original industrial instruments. The control department
contains the mimetic display and the control instruments. Deviating from
reality the field which is concentrated in the mimetic display is to be
physically connected with the control instruments
may be with pneumatic hoses or electric wiring.
So the trainee has got an additional task to solve. This connecting is eased
in that way that especially for the wiring needs be taken no care with normal
bipolar wiring and polarity. Connecting of pneumatics and electrics feels
equal. The standardisation of the TeLC Miniplants goes so far as the dimensions
hight 1.95m and depth 0.65m are equal. Only width differs between 2.2 and
2.9 m and of course weight. Within the abbreviation naming of the units
is indicated the control task and instrumentation so e.g. here LIRCA
means: Level - Indication
- Registration - Control
- Alarm
Wide range of Training Tasks:
identification of the process elements and their connectio
put in action and calibration of elements
connection of the process with the control terminal
structurizing and configuration of transmitters and
controllers
running of the process (start & stop )
study and optimize the control performance by adjusting
the parameters
Built-up of LIRCA:
The fluid flow is easy to ceive:
Water is pumped out of the reservoir through the magnetic flow transmitter
and the control valve with positioner into the perspex vessel. The vessel
is discharged by handvalve back into the reservoir again. The level L/p-transmitter
is on gravity principle. The vessel can be pressurized by controlling
two valves with positioners in split range connection. For operation with
3 pneumatic controllers a p/p transmitter and an I/p- converter are installed
in the field.
By this configuration are created 3 dependant control
loops: FIC, LIC and PIC. The pneumatic 3-pen recorder is for high speed
registration. The alarm device is activated by the alarm actuator in the
field. The delay units can be intermitted into every signal path. The
pump delivery is variable through a bypass. Flow can also be restricted
by a handvalve before the entry to the vessel. The control loops FIC and
LIC can be connected in cascade with FIC as follower to improve control
performance at upstream disturbances.
Width 2.9 m net weight 220 kg. services AC 3-phase and
pressed air.
TeLC Miniplants follow a standardized design
principle which adopts to some extent the real situation in an industrial
plant.So is found the field department and the control department. Field
and control are both equipped with original industrial instruments. The
control department contains the mimetic display and the control instruments.
Deviating from reality the field which is concentrated in the mimetic
display is to be physically connected with the control instruments may
be with pneumatic hoses or electric wiring. So the trainee has got an
additional task to solve. This connecting is eased in that way that especially
for the wiring needs be taken no care with normal bipolar wiring and polarity.
Connecting of pneumatics and electrics feels
equal. The standardisation of the TeLC Miniplants
goes so far as the dimensions hight 1.95m and depth 0.65m are equal. Only
width differs between 1.8 and 2.9 m and of course weight. Within the abbreviation
naming of the units is indicated the control task and instrumentation so
e.g. here TIRCA means: Temp
- Indication - Registration
- Control - Alarm
Wide range of Training Tasks:
identification of the process elements and their connection
put in action and calibration of elements
connection of the process with the control terminal
structurizing and configuration of transmitters and
controllers
running of the process (start & stop )
study and optimize the control performance by adjusting
the parameters
Buildup of TIRCA:
TIRCA is a heat treating process. The furnace heats up to 1000 °C
rather fast. The special isolation material efects a not too longtime
accumulation of heat. The water basin down under the furnace is for cooling
the piece of metal. The metalpiece and a pair of pliers belong to the
equipment.
Electric power installations:
continous power regulator phase control
continous power regulator thyristor control
on/ off power regulator tyristor switch
variable transformer for the current supply disturbance
TeLC Miniplants follow a standardized design
principle which adopts to some extent the real situation in an industrial
plant.So is found the field department and the control department. Field
and control are both equipped with original industrial instruments. The
control department contains the mimetic display and the control instruments.
Deviating from reality the field which is concentrated in the mimetic
display is to be physically connected with the control instruments may
be with pneumatic hoses or electric wiring. So the trainee has got an
additional task to solve. This connecting is eased in that way that
especially for the wiring needs be taken no
care with normal bipolar wiring and polarity. Connecting of pneumatics and
electrics feels equal. The standardisation of the TeLC Miniplants goes so
far as the dimensions hight 1.95m and depth 0.65m are equal. Only width
differs between 2.2 and 2.9 m and of course weight. Within the abbreviation
naming of the units is indicated the control task and instrumentation so
e.g. here PIRCA means: Press
- Indication - Registration
- Control - Alarm
Wide range of Training Tasks:
identification of the process elements and their connection
put in action and calibration of elements
connection of the process with the control terminal
structurizing and configuration of transmitters and
controllers
running of the process (start & stop )
study and optimize the control performance by adjusting
the parameters
Buildup of PIRCA:
A digital electronic controller is to be connected to
the pressure control loop. 2 lines can be activated for the control. The
pneumatic control valves have different capacity. For interfacing are
used the p/I-transmitter and I/p-converter. A system of needle valves
with positionscales together with the 3 reservoirs allow the simulation
of delays up to third capacity. For data logging an electric 3-pen recorder
with variable paper speed is existing. The alarm device can be connected
to the alarm actuator in the field.
Dimensions:
width 2.2 m weight 170 kg, services AC 1-phase and
pressed air