CENTUM VP

COURSE PROJECT

LESSON 6

OBJECTIVE OF THIS LESSON This project will allow the student to construct feedback and sequence control function blocks to manipulate a predefined batch application. The project will be built and tested in the Test Function, then anytime during the three parts, you can load the project to the FCS. This project is made up of three parts, each built on the preceding part. Information in the previous tabs will come into play, plus you will need to refer to the FCS on-line Function Manual. Create a New Project. Make your FCS an AFV10D and use the General Purpose database type. Make your HIS address HIS0164.

Create the I/O. NOTE: You will need to create a NODE #1. Make IOM #1 an analog input/output module AAI841-H (8 input/8 output) Create IOM #2 a 32-point digital input module ADV151. Create IOM #3 a 32-point digital output module ADV551. Create the function blocks, and sequence controls defined in each part.

Points to Note for the Project: On the Detail Page for the BSETUs and PIDs make the Fully-open, Tightly-shut = No. Remember to setup the totalization of the BSETUs for MIN. In the CALCU tuning panel, for the tank level, make P01 = 0.01 and P02 = 0.5. You can, at any point in this lab, make the project Current and load it to the FCS and HIS. After you have completed part 1 of this exercise create a graphic to control the process. Add to the graphic as you complete the remaining parts.

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COURSE PROJECT

LESSON 6

Ingredient 1 Ingredient 2 Ingredient 3

MIXER COOKING PROFILE (PG-L13)

LEVEL TEMP

STEAM

DRAIN PUMP

Item INGR-1 INGR-2 INGR-3

Instrument BSETU-2 BSETU-2 BSETU-2

Scale 0-1000 GPM 0-1000 GPM 0-100 GPM

BSET 500 500 50

Input %Z011101 %Z011102 %Z011103

Output %Z011109 %Z011110 %Z011111 Output TEMP.SET

Item Instrument Scale Cooking Profile PG-L13 480 Seconds (Quick return) X02=60, X03=120, X04=180, X05=240, X06=300, X07=360, X08=420 Y01=120, Y02=290, Y03=290, Y04=150, Y05=150, Y06=70, Y07=50 Item TEMP STEAM LEVEL CALC DRAIN PUMP MIXER COMP Instrument PID PID PVI CALCU SIO-11 SIO-11 SIO-11 RL Scale 50-300 DEGF 0-200 LB/H (SQRT) 0-100 % 0-100 Input %Z011107 %Z011108 CALC.CPV LEVEL.PV %Z012101 %Z012102 %Z012103

Output STEAM.SET %Z011112

%Z013101 %Z013102 %Z013103

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CENTUM VP
PART 1

COURSE PROJECT

LESSON 6

Create the instruments on the previous page, defining them as described. At the bottom of the page is the calculation to be put into the CALCU to simulate the level filling or draining in the tank. You will need to refer to the FCS Function Manual for specific details on these instruments. After they have been created, test them on a control group before you build the sequence table that will control the process. Process Steps: 1. When the process starts, add ingredients 1 & 2. When the level in the tank reaches 30%, turn on the agitator and start the temperature profile. 2. When the profile gets to zone 3 add ingredient 3. 3. When the profile finishes, open the drain and turn on the pump. 4. When the level in the tank drops to 30% turn off the agitator. 5. When the tank is empty, turn off the pump and close the drain valve. Return the table to step #1. Instruments: Make all of the fill and drain valves plus agitators to be SIO-11s Use this calculation in the CALCU feeding the reactors PVI for your level simulation. 1 program 2 alias D drain.MV *NOTE: Substitute the names shown in italics with the block names you 3 alias E ingr-1.MV created on the previous page. 4 alias F ingr-2.MV 5 alias G ingr-3.MV 6 H=P01*(E+F+G) 7 FI=RV+H-P02*D 8 IF (FI<0) THEN 9 FI=0 10 ELSE IF (FI>100) THEN 11 FI=100 12 END IF 13 CPV=FI 14 END

Calculation and PVI connection for level simulation PVI LEVEL

PV

IN CALC

IN

CPV CALCU

CENTUM VP Engineering

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CENTUM VP

COURSE PROJECT

LESSON 6

MIX-A

MIX-B

MIX-C

Ingredient Ingredient Ingredient

MIXER COOKING PROFILE (PG-L13)

LEVEL TEMP

STEAM

DRAIN PUMP

Item MIX-A

Instrument BDSET-1L

MIX-B

BDSET-1L

MIX-C

BDSET-1L

Registers to change INGR-1.BSET (500) INGR-2.BSET (500) INGR-3.BSET (50) Profile: Y01=120, Y02=290, Y03=290, Y04=150, Y05=150, Y06=70, Y07=50 INGR-1.BSET (500) INGR-2.BSET (450) INGR-3.BSET (80) Profile: Y01=120, Y02=275, Y03=260, Y04=190, Y05=170, Y06=100, Y07=50 INGR-1.BSET (250) INGR-2.BSET (600) INGR-3.BSET (40) Profile: Y01=120, Y02=250, Y03=290, Y04=265, Y05=165, Y06=90, Y07=50

CENTUM VP Engineering

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PART 2

COURSE PROJECT

LESSON 6

Part 2 allows the operator to make a pre-selected grade mix of the product. Listed on the previous page are the instrument types and the specifications to use, use the FCS On-Line Builder manual (or use this course manual) to look up specifics for what a BDSET-1 does. What is the BSET register in a BSETU used for? The process steps are the same except that the operator must select the desired mix first, and then start the process.

New Process Step: 1. When the operator starts the process, he must then select a mix, which is down loaded to the INGR and to the PROFILE from the BDSET-1.

CENTUM VP Engineering

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CENTUM VP

COURSE PROJECT

LESSON 6

MIX-A

MIX-B

MIX-C

Ingredient Ingredient Ingredient 3

MIXER COOKING PROFILE (PG-L13)

LEVEL TEMP

STEAM

DRAIN PUMP

FILL_A

FILL_B

FILL_C

LI

Store MIX-A

LI

Store MIX-B

LI

Store MIX-C

DRAIN_A

DRAIN _B

DRAIN _C

CENTUM VP Engineering

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CENTUM VP
PART 3

COURSE PROJECT

LESSON 6

Part 3 adds storage tanks for the different mixes. Make these tanks in a new control drawing. This will require reading the Reactors drain status in a new sequence table in the control drawing. Use the PVI and calculation configuration shown on page 3 of the lab for these new tanks.

Add these Process Steps: 1. When a mix is selected, create a new sequence table that will open the appropriate storage tank fill valve when the reactors drain opens after the batch completes. Close the storage fill valve when the reactor drain closes. 2. If a storage tank is above 70% full dont allow the associated mix to start and output an Operator Guide Message stating which storage tank is too full.

Instruments: 1. Make all of the fill and drain valves SIO-11s Do not connect these to the I/O, instead put the SIMM=1 on the instruments tuning panel. 2. Make 3 storage tank PVIs with CALCUs for the simulation. Modify the following calculation to fit each of the CALCUs depending upon the mix. As a starting point, make P01 and P02 = .5. 1 2 3 4 5 6 7 8 9 10 11 program alias D fill-x.MV (This is the storage tanks fill valve!) alias E drain-x.MV (This is the storage tanks drain valve!) F=P01*D FI=RV+F-P02*E IF (FI<0) THEN FI=0 ELSE CPV=FI END IF END

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Empty page.

COURSE PROJECT

LESSON 6

CENTUM VP Engineering

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