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  • YOKOGAWA TRAINING Section 10. Laboratory Exercises

    ___________________________________________________________________________________ TE 33AU1C3-01 Rev 3.4 21 July 2005 10-1

    SECTION 10

    CS3000

    LABORATORY EXCERCISES

    CONTENTS

    10. LABORATORY EXERCISES _______________________________________2 PART A - REGULATORY CONTROL EXERCISES __________________________ 2

    A1. Dual Redundant Input Exercise ________________________________________________2 A2. ID FAN Flow/Pressure Control Switching Exercise ________________________________3 A3. Ratio Control Exercise_______________________________________________________5 A4. Temperature Profile Control Exercise ___________________________________________6 A5. Boiler Level Control ________________________________________________________7

    PART B - CALCULATION FUNCTION EXERCISES ________________________ 10 B1. Boiler Control Simulation Exercise ____________________________________________10 B2. Numerical Calculations _____________________________________________________12 B3. Analog Calculation Blocks __________________________________________________13 B4. Setpoint Setting ___________________________________________________________15 B5. Calculation Exercise _______________________________________________________17 B6. Switching Calculation Exercise _______________________________________________21

    PART C - SEQUENCE TABLE EXERCISES ________________________________ 23 C1. Global Switch Exercise _____________________________________________________23 C2. Mode Setting Exercise ______________________________________________________24 C2. Pump Interlock Exercise ____________________________________________________25 C3. Relational Expression Exercise _______________________________________________27 C4. Sequence Exercise Using Switch Instrument Block _______________________________28 C5. Boiler Fill Sequence Exercise ________________________________________________30

    PART D - TUTORIALS __________________________________________________ 31 D1. System Configuration ______________________________________________________31 D2. Creation of Regulatory Control Function _______________________________________45 D3. Creation of Sequential Control Function ________________________________________64 D4. Creation of Logic Chart Function _____________________________________________84 D5. Creation of SFC Control Function____________________________________________100 D6. Creating Graphic Windows _________________________________________________101

  • YOKOGAWA TRAINING Section 10. Laboratory Exercises

    ___________________________________________________________________________________ TE 33AU1C3-01 Rev 3.4 21 July 2005 10-2

    10. LABORATORY EXERCISES

    PART A - REGULATORY CONTROL EXERCISES

    A1. Dual Redundant Input Exercise Objective: The purpose of this exercise is to gain an understanding of how the SS-DUAL module is used to provide dual redundancy where two field transmitters are used. Description: Two flowmeters are input into the DCS and are registered as PVIs. These connect to a SS-DUAL to select one of the two for output. Procedure:

    1. Hardwire the outputs in channels 3 & 4 to the input in channels 1 & 2, of the analog nest.

    2. In a control drawing, connect the two analog inputs to two PVIs, and then into

    and SS-DUAL. The output of the SS-DUAL connects to another PVI. 3. Drive the two outputs with two Manual Loaders. Tags names are as follows:

    Tag name Description Module %Z011101 Input 1 %Z011102 Input 2 %Z011103 Output 1 %Z011104 Output 2 FI100A Input Indicator 1 PVI FI100B Input Indicator 2 PVI FI100DV Input Selector SS-DUAL FI100 Selector Input Indicator PVI CV100A Output Loader 1 MLD CV100B Output Loader 2 MLD

  • YOKOGAWA TRAINING Section 10. Laboratory Exercises

    ___________________________________________________________________________________ TE 33AU1C3-01 Rev 3.4 21 July 2005 10-3

    A2. ID FAN Flow/Pressure Control Switching Exercise Objective: This exercise in regulatory control provides an example of a common control application of flow/pressure control switching using different techniques that can be employed using function blocks and control drawings. It demonstrates how an inlet draft fan can be controlled according to flow and pressure. Description: The speed of a draft fan is controlled by the DCS based on either the flowrate or the pressure of the incoming air. At low fan speeds, the fan speed is controlled by pressure. At higher speeds, the control switches to flow control. The DCS reads the pressure and the flowrate as analog inputs, into PVIs. These feed into two standard PID controllers. The outputs of these controllers are fed to a high selector switch (AS-H) which selects the higher of the two outputs for control. This signal goes through an MLD-SW for operator control and then output to the fan drive speed controller as a 4-20mA signal. When the MLD-SW is in manual, the controllers are forced into track mode. Procedure: The attached control scheme shows how the requirements above can be achieved. Note that due to the in-built pushback feature of the system, the controllers track the manual loader when it is in manual. No tracking wiring is required. Note that the AS-H was used, rather than the SS-H. This is because the input to the MLD-SW is a SET, and therefore a Cascade input. Because of the way the pushback feature works, the preceding module must have an MV through the OUT terminal. The AS-H has this, whereas the SS-H only has a PV, and therefore cannot be used in a cascade loop. Module Details: 1. FI3001 Flowrate PVI Range: 0 to 150 M3/M 2. PI3001 Pressure PVI Range: 0 to 350 KPA 3. FIC3001 Flow Controller PID Range: 0 to 150 M3/M 4. PIC3001 Pressure Controller PID Range: 0 to 350 KPA 5. SFD3001 High Output switch AS-H Range: 0 to 100% 6. FD3001 Output Station MLD-SW 7. PIO FI3001 %Z011103 PI3001 %Z011104 FD3001 %Z011110

  • YOKOGAWA TRAINING Section 10. Laboratory Exercises

    ___________________________________________________________________________________ TE 33AU1C3-01 Rev 3.4 21 July 2005 10-4

    Set up a Control Group called IDFAN, with all of the tags in it. Call up IDFAN on the operator display and set up the function blocks as follows:

    FD3001 - set to AUT SFD3001 - set to AUT - set SW = 4 PIC3001 - set to AUT - set SV = 250 FIC3001 - set to AUT - set SV = 100

    Vary the set points such that the MVs of the blocks move up and down. Notice how the greater of the two MVs is the one selected for output. Put FD3001 into MAN and change its output. Notice how this value is pushed back to the preceding blocks, both the SFD3001 and the controllers. All of these blocks are in IMAN and are tracking this value. Test Function If test function is already running, then the wiring between the inputs and outputs will not have been done. TO set this up, do the following procedure.

    1. In the Test Function Panel, click on the Tools menu and select Wiring Editor 2. Select Tools Auto-Wiring (at the bottom of the menu). Select DR0002. 3. Select File Open and select DR0002. 4. Select File Download.

    The I/O is now wired together.

    FI

    PI

    PIC

    PID

    PID

    FIC

    High Signal Selector

    Hand Auto Station

  • YOKOGAWA TRAINING Section 10. Laboratory Exercises

    ___________________________________________________________________________________ TE 33AU1C3-01 Rev 3.4 21 July 2005 10-5

    A3. Ratio Control Exercise Objective: The purpose of this exercise is to learn how to use the Ratio block to perform ratio control. Description: The flow controller controls the additive flowrate. The setpoint to this controller is from a RATIO control block, and its input is the main flow. The operator sets the SV of the RATIO block to (say) 0.1, so that the setpoint of the flow controller is 0.1 of the main flow. Procedure: The attached control scheme shows how the requirements above can be achieved.

    The MLD FI201 simulates the main line flow, and this can be adjusted by the operator accordingly. The LAG block simulates the dosing flow. To set the lag time of the block, set the I value to around 5 seconds. Set the setpoint of the ratio block (FR200) to 0.1. Set FIC200 to CAS. Thus the setpoint to FIC200 will be a tenth of the flow from FI201.

    FIC200

    PID

    FR200

    RATIO

    FI200

    LAG

    FT201

    MLD

    INOUT

    MV SET

    MV

    INCPV

    IN

  • YOKOGAWA TRAINING Section 10. Laboratory Exercises

    ___________________________________________________________________________________ TE 33AU1C3-01 Rev 3.4 21 July 2005 10-6

    A4. Temperature Profile Control Exercise Objective: The purpose of this exercise is to learn how to use the PG-L13 block to perform temperature profile control. Description: The flow controller controls the temperature of the process. The setpoint to this controller is from a PG-L13 block, and the profile created by the PG-L13 block will drive the setpoint of the controller. Procedure: The attached control scheme shows how the requirements above can be achieved.

    Set up the TQ200 in the tuning panel as follows:

    X01 = 0 Y01 = 0 X02 = 30 Y02 = 50 X03 = 45 Y03 = 50 X04 = 70 Y04 = 85 X05 = 95 Y05 = 85 X06 = 120 Y06 = 0

    Set ZONEND = 5 Set TIC200 to CAS Set TQ200 to AUT The PG-L13 should now run through its program defined by the X, Y values given above. The X values are time in seconds, and each value represents the time from the beginning, not from the previous zone. Set TQ200 to CAS. In this case, the program loops