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Karl Phelan

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Control of a Pharmaceutical Batch Process By Karl Phelan Project Document submitted to the Faculty of the Institute of Technology, Blanchardstown In partial fulfilment of the requirements for the degree of Bachelor of Science In Sustainable Electrical & Control Technology APPROVED: _______________________ David Peyton, Co-Advisor _______________________ Gerard Duke, Co-Advisor

April 27th, 2012 Dublin, Ireland Keywords: Batch Process, PLC, LabVIEW, VSD Level Measurement, Temperature Measurement

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Declaration Page

Student Name: Karl Phelan ID Number: B00036379 Course: Sustainable Electrical & Control Technology Year: 3 Lecturer: Mr David Peyton/Gerard Duke Title of Assignment: Final Project

Due Date:

27/04/2012

Date Submitted:

27/04/2012

I hereby certify that the material, which is submitted in this assignment/project, is entirely my own work and has not been submitted for any academic assessment other than as part fulfilment of the assessment procedures for the programme Bachelor of Science in Sustainable Electrical & Control Technology(BN039). Any sources cited have been duly acknowledged in the text.

Signed: ____________________________

Date: 27/04/2012

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1 Acknowledgements

I would like to express my deepest thanks to the lecturers of the BSc. Sustainable Electrical & Control Technology course for their unfaltering support over the last 3 years. They have provided me invaluable knowledge required to undertake this project. In particular I would like to thank David Peyton and Gerard Duke for their hard work and dedication in setting up this course as a whole. If it wasnt for these two none of this would be possible. During the course of the previous semester Dave and Ger have provided help on numerous occasions when I found myself languishing in a problem. Their patience and understanding is a model for all. Of the many lecturers on the faculty there are several who have provided a helping hand whenever needed. I would sincerely like to give thanks to John Kilcoyne and Owen Flood. They have provided vital assistance in their respective fields of knowledge when required over the course of the project. Without their help I wouldnt have gotten this far in the project. I would also like to thank the lab technician Ciaran OBrien for maintaining the hardware with which we used to build the project. I would like to thank my colleague Francis Gibson for his input and help on the project. I believe we worked well as a team and I feel privileged to have been paired with him during the project. As a final word I would like to say I appreciate the opportunity to attend this course of study. The Institute has provided me with a great opportunity to better myself both as a professional and personal individual.

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2 Abstract

The following document comprises of the completed final year project for the control of a batch process (pharmaceutical). The project was undertaken over a 12 week period by student Karl Phelan who is enrolled in BSc. Sustainable Electrical & Control Technology degree course in the Institute of Technology, Blanchardstown. Compiled inside this document is the knowledge gained by the student over the previous semester and years. Discussed within is an overview of the project and what is required of the student as outlined in the project specification document. It was required by the student to create a control process for the pharmaceutical development of two recipes in a vessel. A selector switch selects either of the two recipes which must be controlled in a specific manner as outlined in the project specification chapter. There are several sections to this document which can be described as: A literature review which comprises of an overall description of each component used to complete the project. A description of the project specification. A control and monitoring strategy which describes in detail the specific components used to build the project, the software used to build the process and methods which were undertaken to put it all together. There is a chapter of technical drawings which describe how each component is physically connected. The programming and monitoring methods are discussed in detail in later chapters and provide an overview of what software was used and how effectively it was utilised. As a whole the document encompasses several weeks of hard work broken down into a formatted product for ease of understanding for the reader.

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3 Contents
1 2 3 4 5 6 7 Acknowledgements ............................................................................................. iii Abstract ...............................................................................................................iv Contents .............................................................................................................. v Acronyms .......................................................................................................... viii List of Figures......................................................................................................ix Introduction ......................................................................................................... 1 Literature Review Introduction............................................................................. 3 7.1 7.2 Introduction ................................................................................................... 3 Variable Speed Drives .................................................................................. 5 Eurotherm 601 Series (HA464518) ........................................................ 5

7.2.1 7.3

Electrical Installation; Eurotherm 601 ............................................................ 8 Control and Power .................................................................................. 8

7.3.1 7.4 7.5 7.6 7.7 7.8 7.9 7.10 8

Operating Configuration ................................................................................ 9 Thermocouple Temperature Measurement and Calibration ........................ 11 Thermocouple Temperature Calibrations .................................................... 13 PLC (FX3G & FX2N -5A) ............................................................................ 15 Level Measurement using Pressure Methods ............................................. 16 Current/Voltage Calibrator........................................................................... 18 Octocoupler ............................................................................................. 18

Project Specification.......................................................................................... 19 8.1 8.2 8.3 Recipe 1: ..................................................................................................... 19 Recipe 2: ..................................................................................................... 19 Tasks .......................................................................................................... 21

Control and Monitoring Strategy........................................................................ 22 9.1 9.2 Introduction ................................................................................................. 22 The Process ................................................................................................ 23 v

Karl Phelan 9.2.1 9.2.2 9.2.3 9.2.4 9.2.5 9.2.6 9.2.7 9.2.8 9.3

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K Type Thermocouple .......................................................................... 23 Pressure Transmitter ............................................................................ 23 Mitsubishi FX3G & Programming Station ............................................. 24 Mitsubishi FX2n-5A ................................................................................ 25 Eurotherm Variable Speed Drive .......................................................... 26 National Instruments myDaq ................................................................ 28 Monitoring Station/ LabVIEW ................................................................ 29 Block Diagram of Process .................................................................... 30

Schedule of Inputs and Outputs .................................................................. 31 Mitsubishi FX3g PLC Inputs/Outputs .................................................... 31 Mitsubishi FX2n-5A Special Function Block Inputs/Outputs ................. 32 National Instruments My DAQ .............................................................. 33 Eurotherm Variable Speed Drive 601 ................................................... 33 Octo-Coupler ........................................................................................ 34 Calibrators ............................................................................................ 34

9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.3.6 9.4

ISA 5.1 Process Drawings........................................................................... 35 Process Drawing .................................................................................. 35 PLC Wiring Diagram ............................................................................. 36 myDaq Card ......................................................................................... 37 Eurotherm Variable Speed Drive .......................................................... 38

9.4.1 9.4.2 9.4.3 9.4.4 10

PLC Programming Station .............................................................................. 39 Melsoft GX Developer .............................................................................. 39 Functions ................................................................................................. 39 Ladder Description ................................................................................... 41

10.1 10.2 10.3 11

LabVIEW Monitoring Station .......................................................................... 53 Introduction .............................................................................................. 53 Front Panel .............................................................................................. 54 vi

11.1 11.2

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Block Diagram.......................................................................................... 55 Individual Function Description.......................................................... 56

11.3.1 12

Individual Review ........................................................................................... 59 Timetable ................................................................................................. 61

12.1 13

Bibliography.................................................................................................... 63

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4 Acronyms
AC Alternating Current DC Direct Current SELV Separate Extra Low Voltage PLC Programmable Logic Controller V Voltage A Amps mA Milliamps I/O Inputs & Outputs VSD Variable Speed Drive SCADA Supervisory Control & Data Acquisition DAQ Data Acquisition

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5 List of Figures
Figure 1 Eurotherm 601(Stubby Lathe Usa, 2007) ..................................................... 6 Figure 2 601 Control Terminal Description (Stubby Lathe Usa, 2007) ....................... 7 Figure 3 Open Tank(Peyton, 2009) .......................................................................... 16 Figure 4 Voltage/Current Calibrator(RS-Online, 2012) ............................................. 18 Figure 5 Sample Octocoupler(Lakshmi Anand K, 2008) .......................................... 18 Figure 6(Peyton, 2009)............................................................................................. 23 Figure 7 FX3G PLC(Mitsubishi, 2006)...................................................................... 24 Figure 8 VSD Input Terminals(Stubby Lathe Usa, 2007) ......................................... 26 Figure 9c Parameter 13 Settings (Stubby Lathe Usa, 2007) .................................... 27 Figure 10 Special Funtion Block(Mitsubishi, 2008) .................................................. 32 Figure 11 myDAQ Terminals(National Instruments, 2010) ....................................... 33 Figure 12 ISA 5.1 Process Drawing ......................................................................... 35 Figure 13 PLC Wiring Diagram ................................................................................ 36 Figure 14 myDAQ Wiring Diagram ........................................................................... 37 Figure 15 Eurotherm Variable Speed Drive .............................................................. 38 Figure 16 Hold On Example ..................................................................................... 40 Figure 17 Ladder Line 0 ........................................................................................... 41 Figure 18 Ladder Line 19 ......................................................................................... 41 Figure 19 Ladder Line 43 ......................................................................................... 43 Figure 20 Ladder Line 79 ......................................................................................... 44 Figure 21 Ladder Line 98 ......................................................................................... 44 Figure 22 Ladder Line 105 ....................................................................................... 45 Figure 23 Ladder Line 112 ....................................................................................... 45 Figure 24 Ladder Line 116 ....................................................................................... 45 Figure 25 Ladder Line 120 ....................................................................................... 46 Figure 26 Ladder Line 124 ....................................................................................... 46 Figure 27 Ladder Line 128 ....................................................................................... 47 Figure 28 Ladder Line 131 ....................................................................................... 47 Figure 29 Ladder Line 136 ....................................................................................... 48 Figure 30 Ladder Line 143 ....................................................................................... 48 Figure 31 Ladder Line 159 ....................................................................................... 49 Figure 32 Ladder Line 169 ....................................................................................... 50 ix

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Figure 33 Ladder Line 182 ....................................................................................... 50 Figure 34 Ladder Line 190 ....................................................................................... 51 Figure 35 Ladder Line 195 ....................................................................................... 51 Figure 36 Ladder Line 200 ....................................................................................... 51 Figure 37 Ladder Line 206 ....................................................................................... 52 Figure 38 LabVIEW Front Panel .............................................................................. 54 Figure 39 LabVIEW Block Diagram .......................................................................... 55 Figure 40 LabVIEW Start/Stop Function .................................................................. 56 Figure 41 LabVIEW Motor Control ........................................................................... 56 Figure 42 LabVIEW Temperature & Level Control/Recipe Selection ....................... 56

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6 Introduction

The following document comprises of the final year project of student Karl Phelan, B00036379. Karl is attending Year 3 of course BN039, Sustainable Electrical & Control Technology. As part of semester 2, year 3 of the programme it is required that students undertake a final project. The assigned project for the module has been selected as Control of a Batch Process. A batch process is used to control the production of a product usually made from raw materials, be it in liquid form or solid state, in manufacturing/process plants such as those in the pharmaceutical industry. The automation of a batch process provides a much more efficient and safe way to deliver on production targets, quality assurance and reduce capital expenditure. The context for which this project is being mimicked is, as said above, for controlling a batch process in a pharmaceutical plant. This document encompasses the main bulk of work put in by students Karl Phelan and Francis Gibson over a period of roughly 12 weeks each Wednesday. Contained within this document is a structured and detailed layout of each task carried out to complete this project and also an in-depth look at the main components and methods used to achieve the completed process. The literature review will attempt to provide the reader with an overview of each component, rather than a detailed and specific look at a particular component. An indepth review of each component will be provided in the Control & Monitoring Strategy chapter. A schedule of inputs and outputs for each component is provided along with several drawings within this document ranging from ISA 5.1 specification drawings to simple wiring diagrams. It is hoped that these graphical depictions will provide the user with

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a greater understanding of how the process has been linked together in order for the process to work as one. It is hoped that by writing this document the reader can easily understand the control of this particular pharmaceutical process with ease and clarity.

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7 Literature Review Introduction


7.1 Introduction
The following chapter provides a general overview of the hardware and software being used to construct this process. This chapter will attempt to provide the reader with an overview of each component and describe to the reader what role each component has when designing the control of a batch process. This chapter also comprises of the Final Year Project Plan of student Karl. Karl is attending Year 3 of course BN039, Sustainable Electrical & Control technology. As part of Semester 2 of the programme it is required that students undertake this module. Topics Covered in this literature review include: Variable Speed Drives o This topic will deal with what a VSD is and how it can benefit the process. The specific type of speed drive applicable to this project will also be discussed in brief. Configuration of the 601 Series Speed Drive o The Eurotherm 601 series speed drive is the particular drive to be used for this project and in this chapter its configuration will be discussed. Thermocouple Temperature Measurement and Calibration o This sub chapter deals with thermocouples. What are thermocouples and what uses they provide. PLCs (Specifically Mitsubishi FX3G and 2n-5A) o Programmable Logic Controllers are the main component of most processes as they instruct the other components what to do. In this chapter the Mitsubishi FX3G and special function block FX2n-5A will be briefly discussed.

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Level Measurement using Pressure Methods o Level measurement can be achieved using many different methods. The pressure method is specific to this process and it will be briefly discussed here.

Current/Voltage Calibrators o Current/Voltage calibrators are to be used to simulate the 4-20mA signal that would generally be supplied from both the pressure and level field devices. In this chapter calibrators will be described and their use expanded on.

Octocouplers o Octocouplers provide the ability to switch between two different voltages safely.

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7.2 Variable Speed Drives


Variable speed drives are used in industry to control the speed of an AC electric motor. This is done by controlling the frequency at which electrical power is supplied to the motor. Variable speed drives are used for many reasons, most notably the ability to run at pre-set speeds as selected by a technician or motor operator. This can be useful for energy saving and process applications as the motor can be operated at less than full speed. This can be achieved by manipulating parameters on the speed drive control centre.(ABB, 2008) 7.2.1 Eurotherm 601 Series (HA464518) The Eurotherm 601 Range Variable Speed Drive will be used in this project. The 601 range of frequency inverters has been designed for speed control of standard 3phase induction motors. This range of VSD covers motor power ratings from 0.37kW to 2.2kW (Stubby Lathe Usa, 2007) A useful feature of the 601 is the ability to program the parameters on the device without the need for an external device. A quick glance at the manual will provide the operator with the knowledge and information required to program the speed drive to a required standard. Most of the 601 range can operate from either a single phase two wire supply of 22 to 240 volts or on a 3 wire 380 to 460 volt supply at 50 or 60 Hertz. An advanced microprocessor technology provides a pulse width modulation strategy for quiet operation. The control terminals on the 601 are SELV (separated extra low voltage).(Stubby Lathe Usa, 2007)

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Figure 1 Eurotherm 601(Stubby Lathe Usa, 2007)

7.2.1.1 LED Display There is an LED display built into the speed drive to provide the user with quick access to programmable parameters. 7.2.1.2 Function Keys The function keys are used to navigate around the main machine interface. 7.2.1.3 Instruction Pull-out Guide This panel is where the user can see sufficient information on the basic operation of the VSD. The following information is shown: Drive status Decoded titles of parameters Decoding of numbers assigned to each operating mode 6

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Functions of each control terminal.(shown below)

Figure 2 601 Control Terminal Description (Stubby Lathe Usa, 2007)

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7.3 Electrical Installation; Eurotherm 601

The Eurotherm 601 has been designed and built to comply with EC Directive 89/336/EEC on EMC. The following wiring guidelines must be adhered to prevent interference with other electrical equipment. 7.3.1 Control and Power

To wire the control terminals or the power terminals: Remove the terminal cover Insert a flat-bladed screwdriver (size 3.5 mm max.) inside the smallest hole. Lever the screwdriver keeping it firmly pressed into the hole. The cage will open. Insert the stripped wire (5mm to 6mm/0.22in.) or wire crimp inside the cage keeping the screwdriver in position. Remove the screwdriver. Note the cage provides the correct force for a secure connection.(Stubby Lathe Usa, 2007)

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7.4 Operating Configuration

It is possible to control the 601 in two ways: Remote mode using the analogue and digital input and outputs on the control terminal Local mode using the keypad

On the LED display it is possible to adjust built in parameters to manipulate the drive to specific needs. There are 15 parameters which can be set by the user. The 601 comes pre-set with factory defaults which will suit many applications. As mentioned above it is possible to change these parameters to meet specific needs when designing a process. The parameters relevant to this project are as follows: P1 - Minimum Speed (Pre-set 1): This is the frequency at which the 601 will run when zero set point is applied.(Unless clamped by P2) Range is 0 to 240 Hz and default is 0Hz P2 Maximum Speed (Pre-set 4): This is the frequency at which the 601 will run when max set point is applied Range is 0 to 204 Hz and default is 50/60Hz P3 - This is the ramp up time. The time taken to go from 0 to max speed. Range from 0.1-999s. Default is 10 seconds. P4 This is the ramp down speed. The time taken to go from max speed to 0. Range from 0.1-999s. Default is 10 seconds. P8 Jog Speed (Pre-set 2): The speed at which the 601 will run if control terminal 9 is high. Range is 0 240 Hz. Default is 10Hz P9 Pre-set Speed 3. The speed at which the 601 will run when p13 = 2, CT 8 is low and CT 9 is high. P13 Set point select. Used for selecting a 4-20mA set point.

(Stubby Lathe Usa, 2007)

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The pre-set speeds allow the process designer to program the speed drive to run at the required speeds. These will be discussed later in the report. The ramp up and down speed provides a way to bring the motor to the required speed at a quicker pace if needed. Parameter 13 allows to operator to set the speed drive to run at its pre-set speeds (setting 2) or to drive the motor by running through 0-10V or 4-20mA ranges by selecting settings 0 and 1 respectively.

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7.5 Thermocouple Temperature Measurement and Calibration


A thermocouple is a device that is made up of two differing metal alloys. They both produce a voltage which is proportional to a temperature difference. Thermocouples are widely used in the control and automation industry for temperature measurement. Thermocouples can provide a millivolt differential which can then be converted into a temperature equivalent and vice versa.(Omega, 2010) In this project a K Type thermocouple is to be used to measure temperatures ranging from 0-50 degrees Celsius and from 250-350 degrees Celsius. A temperature transmitter will be used to simulate temperatures. Thermocouples are very rugged and inexpensive and can operate over a wide temperature range. A thermocouple is created whenever two dissimilar metals touch. The contact point of these two metals produces a small open-circuit voltage as a function of temperature. Each thermocouple type has a reference table with corresponding millivolt figures. The corresponding voltages for a K-Type thermocouple are as follows: 50oC 2.023 Millivolt 250oC 10.153 Millivolt 350oC - 14.293 Millivolt Several types of thermocouples are available; these thermocouples are designated by capital letters that indicate their composition. A table is shown below: (National Instruments, 2012) Thermocouple Type B E J K N Platinum 30% Rhodium Nickel chromium alloy Iron Nickel chromium alloy Nickel chromium 11 Platinum-6% rhodium Copper-nickel alloy Copper-nickel alloy Nickel-aluminum alloy Conductors Positive Conductors Negative

silicon Nickel-silicon-magnesium

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R S T (National Instruments, 2012)

Platinum-13% rhodium Platinum-10% rhodium Copper

Copper-nickel alloy

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7.6 Thermocouple Temperature Calibrations

Temperature Calibration provides a means to identify any inaccuracies in the thermocouple. To calibrate the thermocouple, two methods of calibration are used. Thermal Calibration Electrical Calibration

Thermal calibration consists of heating or cooling the probe to various temperatures. During this process the output voltage or resistance values are recorded and will be compared to reference values. The calibration of the thermocouple should be carried out while it is in use by comparing it to a nearby comparison thermocouple. If the thermocouple is removed and placed in a calibration bath, the output integrated over the length is not reproduced exactly.(Engineering Toolbox, 2010)

Electrical Calibration consists of using a simulator that represents the probe that is to be connected to the transmitter. Resistance and millivolt sources can be used to simulate RTDs and thermocouples respectively. (Kuphaldt, 2009)

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Errors that can be found during calibration are: Span Zero Linearity Hysteresis

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7.7 PLC (FX3G & FX2N -5A)


A PLC is an industrial, digital computer which can monitor the state of input switches or sensors. It then uses that information to operate output switches and internal relays. It does this by way of an internal software program such as Melsoft GX developer. PLCs are used in many different applications and have endless uses for industrial purposes. Some uses for PLCs are: Lift and Escalator Operation Batch Processing Traffic Lights Power Distribution

PLCs have the ability to read several types of programming code, most notably: Ladder Programming SFC Programming (Sequential Function Chart)

The programming code used for this program is ladder programming. With the information written by the process designer the PLC can control the process to a specific pattern. In the case of this project the Mitsubishi FX3G will be used to drive the VSD and to provide information and control function/testing function to LabVIEW. A PLC, combined with a special function block, has the ability to read voltage and current signals from field devices such as level or temperature transmitters. In order to do this in this project the Mitsubishi FX2n-5A has been selected. The FX2N-5A is a special function block which can be added to the FX3G. The FX2N-5A can be used to acquire and transfer generated analogue signals. These can then be converted into comparable digital signals. These signals are accessed by the PLC using the T0 and FROM functions. The FX2N-5A has 4 analogue input channels and 1 analogue output channel.

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7.8 Level Measurement using Pressure Methods


Level measurement can be achieved through various methods, for example: Pressure Ultrasonic Nuclear Radar

Level measurement is a useful ability when dealing with a container or tank of any sort. It allows the operator to see how much liquid, gas or solid substance is currently inside the tank. A differential pressure or hydrostatic transmitter can be used to measure the level in the tank for this process because the tank being used is open to

atmosphere.(Peyton, 2011) As the tank being used is an open tank the hydrostatic level measurement method will be used to measure its level.

Figure 3 Open Tank(Peyton, 2009)

The specific gravity of the liquid being processed is set at 1.13. The Upper Range Value is calculated by Height X Specific Gravity. The height of the tank being used has been found to be 10 Meters. Calculations for this specific project are as follows: 16

Karl Phelan Recipe 1: @50% Level

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Temperature Transmitter = 12mA URV= 5 X 1.13 = 5.65 mH2O LRV = 0 X 1.13 = 0 mH2O

Recipe 2: @80% Level Temperature Transmitter = 16.8mA URV = 8 X 1.13 = 9.04 mH2O LRV = 0 X 1.13 = 0 mH2O

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7.9 Current/Voltage Calibrator


A current/voltage calibrator is used to mimic a current or voltage signal which would normally be generated by field devices such as the pressure transmitter or a temperature transmitter. In the case of this project the simulator will be mimicking a 4-20mA signal from the devices mentioned previously.

Figure 4 Voltage/Current Calibrator(RS-Online, 2012)

7.10 Octocoupler
Ocotocouplers are used when the switching of voltages is required. They can be used, for example, when connecting a low voltage device with a medium or high voltage device. They work by transferring an electrical signal or voltage from one part of a circuit to the other whilst isolating each circuit from each other for safety.(Lakshmi Anand K, 2008)

Figure 5 Sample Octocoupler(Lakshmi Anand K, 2008)

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8 Project Specification
The project specification gives a brief but clear and concise layout of what is required of the student when attempting to complete the project. The following information is adapted in full from the project brief. A PLC based strategy must be developed to control a batch process in a vessel in a pharmaceutical plant. A selector switch selects either of two recipes which must be controlled as laid out below:

8.1 Recipe 1:
When a green start pushbutton is pressed an agitator in the vessel is run at 10% of its rated speed for 30 seconds and stopped. The inlet valve to the vessel then opens. The vessel is filled with a product with a specific gravity of 1.13 to 50% of its level range. The inlet valve closes and a heater in the vessel is switched on. When the temperature of the product reaches 250C the heater switches off. An agitator switches on and runs at 50% of its maximum speed for 45 seconds at the end of which it is switched off. A red pushbutton is used to stop the process at any time.

8.2 Recipe 2:
When a green pushbutton is pressed an agitator in the vessel is run at 10% of its rated speed for 10 seconds and stopped. The inlet valve to the vessel then opens. The vessel is filled with a product with a specific gravity of 1.13 to 80% of its level range. The inlet valve closes and a heater in the vessel is switched on. When the temperature of the product reaches 350C the heater switches off. An agitator switches on and runs at 65% of its maximum speed for 1 minute at the end of which it is switched off. A red pushbutton is used to stop the process at any time. If the temperature in the vessel drops to 50C, operation of the recipes must be disabled. A maintenance key-switch must be used to reset the recipe. The level in the vessel is measured using a gauge pressure transmitter with a 4-20 mA output. The temperature in the vessel is measured using a K type thermocouple connected to a temperature transmitter with a 4-20 mA output. Operation of a selector switch switches the PLC to maintenance mode. This disables the recipe control program and enables 19 a signal from an external

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maintenance/monitoring station to drive the agitator motor to any speed between 0 and 100% full speed. A maintenance/monitoring station is required to enable display and recording of system operating information and to allow system testing to be carried out. The maintenance/monitoring station will be developed using National Instruments LabVIEW software. The monitoring station should provide digital and analogue representation of analogue variables. In maintenance mode the station should

provide a facility to drive the agitator motor through its full speed range for test purposes. Students will be expected to implement extra design and presentation elements and advanced functions in their LabVIEW monitoring station. For example, the use of maths functions, data logging/trending, alarm functions, file exporting etc. may be incorporated to enhance the station. The recipe control program will be implemented using a Mitsubishi FX3G PLC. Speed control of the agitator motor will be achieved using a Eurotherm Variable Speed Drive.

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8.3 Tasks
All discrete field devices to be wired, tested and commissioned as appropriate. Level transmitter to be configured and calibrated. Temperature transmitter to be configured and calibrated. Mitsubishi PLC to be configured and communications established with programming software. Variable speed drive to be wired, configured and tested. Program to be written, annotated and tested offline to meet the required specification. Program to be implemented and correct operation confirmed. LabVIEW maintenance/monitoring station to be developed, tested and implemented. All documentation to be completed. (See section 5) A progress log to be maintained by each project team member and a weekly progress report is to be jointly presented to the project supervisor. A final formal presentation of the project report to be presented to project supervisor(s) and examiners

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9 Control and Monitoring Strategy


9.1 Introduction
The control and monitoring strategy deals with the use of each component, all hardware used and how each of these components fit together to implement the batch control process. In order for the project to work as a whole it was necessary to incorporate a large number of components. All components used complement each other and rely on each other to function. Not only were field/discrete devices and hardware used to implement the process but also software. Software was used to program the processes and to monitor and test the processes whilst running and whilst in maintenance mode. In this chapter several of these components and hardware devices will be discussed and detailed in full. Drawings will be included to show how each component fits together and a full schedule of each components inputs and outputs will be included. Discussed within this chapter: Programming Station o Melsoft GX Developer Monitoring Station o National Instruments LabVIEW Hardware o Programmable Logic Controller Mitsubishi FX3G FX 2n-5A Eurotherm HA464518

o Variable Speed Drive o National Instruments myDaq o ISO-Tech ILC421 o Octo-coupler MCT61133H o K-Type Thermocouple o Pressure Transmitter

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9.2 The Process


It can be seen from the brief what is required in this process. The brief describes a pharmaceutical batch process. An open tank of 10 meters in height was selected as an adequate size to house the recipes. An inlet valve when opened allows the flow of ingredients into the tank. Housed within the tank itself is an agitator which churns and mixes the ingredients to the required consistency. The agitator is controlled from the manipulation of the variable speed drive. The tank is fitted with a heating element to raise the temperature to a specific degree and also with a pressure transmitter to determine the level of the tank so as the correct amount of liquid substance can be entered into the tank. 9.2.1 K Type Thermocouple A K-Type thermocouple is used to determine the temperature within the tank at any given time. It has a range of 0-1000oC which is more than adequate to fit its purpose on this process. This is connected to a temperature transmitter and sent back to the PLC and LabVIEW monitoring station through way of the National Instruments myDaq signal acquirer and generator. 9.2.2 Pressure Transmitter A pressure transmitter is used to measure the level through pressure methods. This is also connected to the PLC and LabVIEW monitoring station.

Figure 6(Peyton, 2009)

The use of the pressure and temperature transmitters in conjunction with the process program (PLC Ladder) and the numerous fail safes allow the safe and efficient running of this process at all times. 23

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9.2.3 Mitsubishi FX3G & Programming Station The programmable logic controller used to drive the process was the Mitsubishi FX 3G PLC. The user generates a series of code to control the components which are wired to the PLC. This code is known as a logic ladder. The logic ladder for this project was written using the Melsoft GX Developer. The ladder is basically a set of instructions which tell the PLC how to handle all the components used in the process. Depending on how the ladder is written the user can tell the PLC which outputs to switch on depending on which input has been operated by the user. For example, a green push button to start the process.

Figure 7 FX3G PLC(Mitsubishi, 2006)

The PLC is the brain of the process. In this project the PLC controls every aspect of the process from the starting of the process to controlling the variable speed drive to receiving and sending analogue and digital signals through the special function block. These commands are carried out through the several input and output terminals on the PLC. The use of the compare function was utilised when programming the level and temperature commands. This allows the PLC to operate certain functions or outputs when a required level or temperature has been reached. To and From commands are used in the ladder program to instruct the PLC to read and write the analogue signals coming to and from the pressure, temperature transmitters and other components such as the myDaq and variable speed drive.

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As required in the project specification the use of timer functions, internal relays and indicator lamps also provide essential information in the PLC monitor mode and also in the monitoring station to allow for efficient operation of the process. There are seven input terminals and 5 output terminals on the FX3G PLC. This is more than adequate for the operation of this batch process. The PLC is electrically connected to several push buttons which allows for the operation of several functions including: Start Stop Recipe Selection Maintenance Mode Selection

The output terminals on the PLC control several features in this process including, but not limited to, the variable speed drive and indicator lamps.(Mitsubishi, 2009)

9.2.4 Mitsubishi FX2n-5A The special function block being used in this project is the Mitsubishi FX
2n-5A.

The special function block is an additional piece of hardware which allows the PLC to process analogue signals and utilise those signals for programming purposes. There are 4 input terminals and 1 output terminal on the special function block. For this process the signals being used allow the PLC to determine the level and temperature being measured inside the process tank. With this knowledge the user can write code to turn on or off the agitator or an indicator, for example, when the liquid is at a specific level or temperature. The special function block can be used for the utilisation of analogue signals, both generated and acquired. For example, in this project analogue signals are used to drive the motor through its full range of speed for maintenance purposes. The special function block is connected electrically to the myDaq card for signal processing and to the Eurotherm VSD for maintenance mode testing.(Mitsubishi, 2008) 25

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9.2.5 Eurotherm Variable Speed Drive The Eurotherm HA464518 was selected as a suitable speed drive. The speed drive is mechanically connected to the agitator (motor) housed within the process tank. Once a certain set of instruction are met within the PLC the variable speed drive will begin to operate. Depending on what instructions have been fulfilled the variable speed drive will operate at different speeds to meet the requirements of the process. The VSD is electrically connected to the PLC, special function block and to neutral. (For maintenance testing) 9.2.5.1 Speed Drive Settings There are several parameter settings which can affect the operation of the VSD. Parameter 13, for example, is used to control the speed of the motor. For this project setting zero is selected when running maintenance mode whilst setting 2 allows the PLC to instruct the motor to run at pre-set speeds which the user can define. This image shows a schedule of inputs available on the speed drive and what each terminal is used for. For setting up speed control it is necessary to access and manipulate parameters on several different drive. These

the speed

parameters control the pre-set speeds on the speed drive. The images below show an
Figure 8 VSD Input Terminals(Stubby Lathe Usa, 2007)

excerpt from the Eurotherm manual:

Figure 9a User Adjustable A(Stubby Lathe Usa, 2007)

Parameters

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Figure 9b User Adjustable Parameters B(Stubby Lathe Usa, 2007)

In order for the speed drive to run on these pre-sets we must access parameter 13 and select setting 2. As the motor runs at 50Hz max speed we can deduce that if we divide 50/100 it will give us 1% of the motors overall speed (0.5 Hz). The project specification asks for several speeds: 10% 50% 65%

Therefore we can calculate that 5Hz is the equivalent of 10% (0.5 x 10) etc. From the manual we can then enter the correct hertz range in the required parameters. Parameter 1 0Hz (0%) Parameter 2 32.5Hz (65%) Parameter 8 5Hz (10%) Parameter 9 25Hz (50%) In order for these pre-set speeds, in
Figure 9c Parameter 13 Settings (Stubby Lathe Usa, 2007)

parameter 13, to operate correctly it is necessary to apply 24V and 0V in a specific sequence. This can be seen in this image. In setting 2 in order for pre-set speed 2 to run a 24V signal must be applied to terminal 8 and a 0V signal applied to terminal 9. The same applies to pre-set speed 4 except for this to operate a 24V signal must be applied to both terminal 8 & 9 simultaneously.

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9.2.6 National Instruments myDaq The myDaq card allows for the generation and acquiring of analogue and digital signals to and from the PLC and variable speed drive when used in conjunction with the monitoring station. The monitoring station is used to view the status of the process whilst running or in maintenance mode. The myDaq is connected electrically to the pressure transmitter, temperature transmitter and also to the special function block to allow the operation of maintenance mode. The myDaq has the ability to generate and acquire: 2 analogue outputs 2 analogue inputs 7 digital inputs/outputs

For this process all the analogue inputs, 1 analogue output and 4 digital outputs are being utilised. The analogue signals are used to read and write signals from the transmitters and to the PLC etc. whilst the digital signals allow for the operation of the program through the LabVIEW user interface rather than by the operation of push buttons and selector switches. The digital signals need to be sent through an octocoupler in order for the safe operation of the process as the NI MyDaq is powered by a 5V DC supply whilst the PLC is powered by a 24V DC supply.

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9.2.7 Monitoring Station/ LabVIEW National Instruments LabVIEW has been selected to provide a monitoring station and to a lesser extent a control station for the process in question. The monitoring station is a visual representation of the process and can provide realtime information about the operation of the process. In essence the monitoring station is a GUI (graphical user interface) for the process. The level, temperature, start and stop, and recipe selection are among some of the processes that are being monitored on this station. These processes are monitored and controlled by utilising signals which the MyDaq card is generating and receiving from the field devices. An additional feature that was implemented into the monitoring station is the ability to control the process.

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9.2.8 Block Diagram of Process The following block diagram shows a graphical representation of how each component is physically connected to each other. It is only a simple representation and should not be considered a wiring/schematic diagram.

GX Developer

LabVIEW

Mitsubishi FX3G PLC

Mitsubishi FX2n-5A

X1

X2

R1

R2

TT

PT

V S D

As can be seen above, each component is interlinked through the main hub which is the Mitsubishi PLC. Although mentioned previously, we can see from the block diagram, it is blatantly obvious that the PLC is the main component and control centre for the whole process.

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9.3 Schedule of Inputs and Outputs


The following list is a schedule of all the inputs and outputs of each component used to assemble the batch control process. Each component is laid out below with all terminals shown. The destination point for each terminal is also shown. These connections form the basis for the batch process as they allow the co-operation and communication of each component when required. 9.3.1 Mitsubishi FX3g PLC Inputs/Outputs Input Terminal X1 X2 X3 X4 X5 X6 X7 Destination Card 1 - Terminal EC / Green PB Card 2 - Terminal EC / Red PB Spare Spare 2 Way Selector Switch (Maintenance Switch) DAQ Card Digital I/O Port 2 (Recipe 1) DAQ Card Digital I/O (Recipe 2)

Output Terminal Y0 Y1 Y2 Y3 Y4 Y5

Destination Port 8 on Eurotherm speed drive (Motor 10%) Port 9 on Eurotherm speed drive (Motor 50%) Port 9 on Eurotherm speed drive (Motor 65%) Inlet Valve Light (Yellow Indicator) Heater Light (Red Indicator) Level Reached Light (Green Indicator)

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9.3.2 Mitsubishi FX2n-5A Special Function Block Inputs/Outputs Input Terminal IN1 V+ IN1 VIN1 I+ IN2 V+ IN2 VIN2 I+ IN3 V+ IN3 VIN3 I+ Destination Red lead on the current simulator for level AI 0+ on myDAQ Link with IN1 V+ Red lead on the current simulator for Temperature AI 1+ on myDAQ Link with IN2 V+ Link with DAQ Card AO 0 Link with DAQ Card AGND Spare

Figure 10 Special Funtion Block(Mitsubishi, 2008)

Output Terminal OUT V+ OUT VOUT I+

Destination Port 2 on the Variable Speed Drive Port 3 on the Variable Speed Drive Blank

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9.3.3 National Instruments My DAQ Terminals AO 0 AO AGND AI 0+ AI 0AI 1+ AI 1DIO 0 DIO 1 DIO 2 DIO 3 DIO DGND Destination IN3 V+ on the special function block 1 IN3 V- on the special function block 1 IN1 V- on the special function block 1 Negative lead on level transmitter IN1 V+ on the special function block 1 Negative Lead on Temperature Transmitter Terminal A on the opto-coupler card 1 Terminal A on the opto-coupler card 2 Terminal A on the opto-coupler card 3 Terminal A on the opto-coupler card 4 Terminal C on the opto-coupler card 1,2,3,4

Figure 11 myDAQ Terminals(National Instruments, 2010)

9.3.4 Eurotherm Variable Speed Drive 601 Terminals Port 1 Destination Negative connect to 24 V DC supply

(Maintenance Mode) Port 2 Port 3 Port 4 Port 5 Port 6 Port 7 Port 8 OUT V+ on the special function block 1 OUT V- on the special function block 1 Blank Blank Link with Port 7 (Ready Signal) Link with Port 6 (Ready Signal) Y0 on the PLC 9 (Motor 10%) 33

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Y1, Y2 on the PLC (Y1 - Motor 50%/ Y2 Motor 65%)

Port 10 9.3.5 Octo-Coupler Card 1 - Terminal AC-EC Card 2 - Terminal AC-EC Card 3 Terminal AC-EC Card 4 Terminal AC-EC Terminal C on AC Terminal E on EC 9.3.6 Calibrators Calibrator 1 Red Lead Calibrator 1 Black Lead Calibrator 2 Red Lead Calibrator 2 Black Lead

Blank

X1 X2 X6 X7 DGND on myDaq 24V Supply

IN1 V+ on Special Function Block AI 0- on NI myDAQ IN2 V+ on Special Function Block AI 1- on NI myDAQ

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9.4 ISA 5.1 Process Drawings


9.4.1 Process Drawing

Figure 12 ISA 5.1 Process Drawing

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Figure 13 PLC Wiring Diagram

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Figure 14 myDAQ Wiring Diagram

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9.4.4 Eurotherm Variable Speed Drive

Figure 15 Eurotherm Variable Speed Drive

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10 PLC Programming Station


10.1 Melsoft GX Developer
The Melsoft GX developer was used to build the program needed to run the process to the required specification. The GX developer is a graphical user interface to allow the process designer to input functions and rules that the PLC must follow.

10.2 Functions
To The to command can be used to transfer data from a buffer in the PLC to the special function block. From The from command is used to transfer data from the special function block to the controller base unit. CMP Function This is the compare function. The compare function allows us to compare two figures, such as a registry and a numeric figure. For example, CMP D10 K50 M10. This logic is basically telling the PLC to compare registry D10 with a figure 50 and store the result in M10. Registry Function The registry function is denoted by the letter D. For example D10. The registry is used to save constants such as numerical figures. Divide The divide function, DIV, is used to divide two functions or constants. Inputs Inputs are used to control outputs and other functions such as timers and counters etc. X1, for example, is usually used as a start button for a program. Outputs Outputs are triggered by inputs and other functions. Outputs can be timers, internal relays, motor, or indicators etc.

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Internal Relay Internal Relays are used as internal memory and can be used for switching or to store data. For example when used in conjunction with a compare function it may read: CMP D10 K50 M10. This means that the result of the comparison between D10 and K50 will be stored in M10. The significance of M10 is that it is used as the first of 3 consecutive outputs which are set depending on the result of the comparison. o Device is on: Value greater than 10 (M10) o Device is on: Value equal to 10 (M11) o Device is on: Value less than 10 (M12) Timer T (Number) K (Number). An internal timer can be used to run outputs and for switching relays etc. An example of a timer is as follows: T1 K 50. This translates to Timer 1 running for 5 seconds. Range The set range, as per the manufacturer, for the PLC for input devices are from 0-32000. For example and 4-20 mA calibrator will range at 0 when at 4mA and 32000 when at 20mA. Hold On A hold on is the equivalent of a latch. It will keep an output switched on until the user or a user generated control tells the output to switch off. The following is an example of a hold on. M4 is held on when M20 is true as it is paralleled with M20.

Figure 16 Hold On Example

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10.3 Ladder Description

Figure 17 Ladder Line 0

0 - The initial pulse M8002 sets up the PLC to read data on its first scan cycle only. The To command is sending data from the data register K0 in the PLC to the special function block 0. It specifies the input mode of channel 1 through 4. In this ladder it is setting up the PLC to read current signals from channels 1, 2 and 4 and read voltage signals from channel 3. K1 corresponds to the amount of data or, bits, which the PLC should read. In this case K1 corresponds to 16 bits. The second To function specifies the analogue output channels output mode. It also specifies the input mode of channel 1 through 4. Although this function is setting up the PLC to read current signals from channels 1, 2, 3 and 4. K1 corresponds to the amount of data or, bits, which the PLC should read. K1 corresponds to 16 bits.

Figure 18 Ladder Line 19

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19 The pulse M8000 is constantly reading data from the special function block to the PLC. Line 19 shows the PLC reading the current value of channels 1 through 4 and stores that data in buffer address 6. 20 Line 20 is a divide function and its objective is to take readings from D1, which corresponds to channel 1 (Input 1) on the special function block. A 4-20mA calibrator is connected to input 1. The current supplied by the calibrator is converted to correspond to the 0-32000 range. This is then divided by 320 and the result stored in data registry 10. Data in registry 10 corresponds to a liquid level measured by a pressure transmitter. 21 Line 21 is also a divide function and corresponds to channel 2(Input 2) on the special function block. A 4-20mA calibrator is connected to input 2. The current supplied by the calibrator is converted to correspond to the 0-32000 range. This is then divided by 32 and stored in data registry 20. Data registry 20 corresponds to the temperature read by a K-Type thermocouple.

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Figure 19 Ladder Line 43

43 M8000 tells the PLC to constantly read the data from the compare statements. As seen previously the data for D1 (scaled) is being stored in D10. In line 43 we are comparing this data with a number, K50. Should the scaled figure exceed 50; M10, an internal relay will be switched on. In line two; registry D10 is again used, this time for recipe 2. Should the data in registry D10 exceed 80 then internal relay, M20, will be switched on. Line 3 compares data from registry D20. It is compared with a figure of 250 which corresponds to a temperature limit. Should this be exceeded the internal relay M30 will be switched on. Line 4 again compares data in registry D20, this time with 350. Should this be exceeded the internal relay M40 will be activated. Line 5 allows for the addition of safety features further down the ladder to provide an override for the process should the temperature drop below 50

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Degrees. Data from registry 20 is compared with 50. Should this be exceeded the relay M50 will be switched on.

Figure 20 Ladder Line 79

79 The constant pulse M8000 tells the PLC to constantly run the logic associated with it through each scan cycle. The first line is telling the PLC to read data as a voltage, through a 0-10V range, and store the data in buffer address 1 on the special function block 0. K1 corresponds to the amount of data to be read in bits. 80 The To command is taking data from the data register D3 on the PLC and is transferring it to the buffer address 14 on the special function block K0. K1 corresponds to the amount of data that is to be read in bits.

Figure 21 Ladder Line 98

98 In order for the M1 relay to be switched on the following must be true: The X6, recipe 1, selector switch must be selected The X1 start button must be pressed The normally closed stop button must be depressed The maintenance switch must not be engaged The recipe must not read below 50oC.(M8)

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Figure 22 Ladder Line 105

105 In order for M2 to be switched on the following must be true: X7, recipe 2, selector switch must be selected X1, start button, must be pressed X2, stop button, must be depressed X5, maintenance switch must not be selected. The recipe must not be below 50oC. (M8)

Figure 23 Ladder Line 112

112 M3 will be switched on if the level has reached 50% of its max level. The data from M10, if on, will switch on the relay M3.

Figure 24 Ladder Line 116

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116 M4 will be switched on if the level has reached 80% of its max level. The data from M20, if on, will switch on the relay M4. X2 must be depressed.

Figure 25 Ladder Line 120

120 The heater relay (Recipe 1), M5, will switch on if: M30 has to be activated. The temperature must exceed 250 oC. X2 must be depressed.

Figure 26 Ladder Line 124

124 The heater relay (Recipe 2), M6, will switch on if: M40 has to be activated. The temperature must exceed 350 oC. X2 must be depressed.

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Figure 27 Ladder Line 128

128 Timer, T3, when activated will turn on relay M7

Figure 28 Ladder Line 131

131 The M8 relay is to turn on when the temperature falls below 50 oC. Although this can only be true when: Or And The temperature must initially exceed 50oC. M4 is active M3 is active

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Figure 29 Ladder Line 136

136 The output, Y1, drives the motor at 50% of its rated speed. In order for the motor to run: M5 must be on M1 must be on Timer, T3, must not be met. Timer, T1, must be finished running. The level must be at 50% (M3) M7 must not be switched on.

Figure 30 Ladder Line 143

143 The motor Y0 will run when: M1 run relay is switched on Until T1 has been met. M1 and T1 will not affect the motor Y2 as the timer T2 can only be activated when recipe 2 is selected. The M2 run relay can activate the motor Y0 while the timer T2 is running but will stop when the timer has finished.

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The Motor Y2 will run when: M6 is activated The M2 run relay has been switched on The level has reached 80% on recipe 2 (M4) The timer, T2, has completed While T4 is running.

Figure 31 Ladder Line 159

159 The Valve Inlet will activate once:

Recipe 1: T1 has been completed The temperature, M30, is below 250oC The level, M3, is below 50%

Recipe 2: T2 has been completed The temperature, M40, is below 350oC The level, M4, is below 80%

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Figure 32 Ladder Line 169

169 The heater Y4 will activate once: Recipe 1: The level, M10, has been reached The temperature is below 250oC M1, run relay, is activated Timer, T1, has completed X2 is depressed

Recipe 2: The level, M20, has been reached The temperature is below 350oC M2, run relay, is activated Timer, T2, has completed X2 is depressed

Figure 33 Ladder Line 182

182 The level met indicator will switch on once: Recipe 1: The level, M10, has been met 50

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Timer, T1, has been completed Run relay, M1, is active

Recipe 2: The level, M20, has been met Timer, T2, has been completed Run relay, M2, is active

Figure 34 Ladder Line 190

190 Timer 1 will run for 30 seconds once the M1 run relay is activated and whilst X2 is depressed.

Figure 35 Ladder Line 195

195 Timer 2 will run for 10 seconds once the M2 run relay is activated and whilst X2 is depressed.

Figure 36 Ladder Line 200

200 Timer 3 will run for 45 seconds once the heater temperature, M5, and the level relay, M3, have been met. X2 must also be depressed.

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Figure 37 Ladder Line 206

206 Timer 4 will run for 60 seconds once the heater temperature, M6, and the level relay, M20, have been met. X2 must also be depressed.

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11 LabVIEW Monitoring Station


11.1 Introduction
The National Instruments LabVIEW program was used to create a monitoring station for this batch process. LabVIEW provides the user with a SCADA type graphical user interface and monitoring station for controlling processes. In regards to this project LabVIEW was used to provide a graphical interface and monitoring station for the overall process. The project specification required that LabVIEW be used to monitor and record system operating data and provide digital and analogue representation of analogue variables such as the liquid level in the tank and the temperature in the tank at any given time. Addition requirements included the possibility of testing the variable speed drive while the process was in maintenance mode. This would have to be achieved by utilising analogue and digital signals in conjunction with the PLC and special function block. Extra functions have also been installed within the program to allow for a complete control of the process from LabVIEW regardless of the discrete devices, i.e. pushbuttons. Data logging has been added to the program to allow for easy exporting of all data collected during operation of the process.

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11.2 Front Panel

Figure 38 LabVIEW Front Panel

The front panel allows the user to view operating information such as: The level in the tank The temperature of the liquid within the tank A level reached indicator for both 50% and 80% levels on recipe 1 & 2 A temperature reached indicator for both recipe 1 & 2 A line chart for both level and temperature o These can be exported to an excel document Interactive buttons are available to the user to allow him/her to control the process start and stop function without the need for using hardwired push buttons Recipe selection can also be controlled from the interface For maintenance mode operation, as required in the project specification, it is possible to test the agitator speed drive from 0% to 100% of its speed.

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11.3 Block Diagram

Figure 39 LabVIEW Block Diagram

The block diagram is used to build to process general user interface, i.e. the front panel. In the block diagram the necessary connections are made by the process designer to allow the front panel to display the required information. In the case of this project the DAQ Assistants are used to generate and acquire the required signals from the myDAQ card. These can then be manipulated by way of mathematical and visual functions to be displayed on the front panel. The DAQ Assistants must be encased in a while loop in order for them to work.

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11.3.1 Individual Function Description This function is known as a DAQ Assistant. When used in conjunction with the myDAQ card, it allows for the control of the process start and stop function directly from LabVIEW.

Figure 40 Function

LabVIEW

Start/Stop

This function allows for the motor to be tested whilst in

maintenance mode. This option can only be used when the user operates a maintenance switch.
Figure 41 LabVIEW Motor Control

Figure 42 LabVIEW Temperature & Level Control/Recipe Selection

The knob on the left provides the operator with a function to drive the motor through its full range while the numerical indicator will relay what exact speed the motor is running at. The knob has a range of 0-100. 56

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This figure is then divided by a numerical constant, 10, as the signal being generated has a range of 0-10V. This is because industry generally uses a 0-10V range for voltage signals and a 4-20mA signal for current signals. In this case we are generating a 0-10V signal. The divided numerical figure is then sent to the DAQ Assistant (myDAQ) to be transferred to the special function block and ultimately the variable speed drive. The figure above shows the Temperature & Level Control DAQ Assistant. This is the process monitoring function to allow the user to view real-time temperature and liquid level. It is interconnected with the recipe selection DAQ Assistant to allow the dual use of level and temperature indicators. This is essentially an interlock so that certain indicators will not illuminate for the wrong recipe. For example if recipe 1 is selected only the 250oC and Level 50% indicators may operate as they are recipe 1 specification and vice versa. Coming from the Temperature and Level DAQ Assistant we can see a multiplexer and index array. These functions will separate the two signals being acquired within the DAQ Assistant and allow the process designer to create a graphical display of the acquired information. There are two branches coming from the index array. As the current signals being acquired are in the 4-20mA range both figures are multiplied by 1000 to convert each numeric to usable digits. At this point the constant numeric, 4, is subtracted from each figure to convert the range from 4-20 to 0-16. This allows the lowest possible figure of 4 to be converted to 0 on any graphical indicator, such as a tank. This figure is then multiplied by a numerical constant, 6.25, for the level signal and 62.5 for the temperature signal. These figures will convert each respective signal into a 0-100% range for level and 0-1000oC range for temperature. For example if the signal acquired from the pressure transmitter on the tank is 15.4mA the following mathematical function will be carried out: 15.4mA x 1000= 15.4A 15.4A 4= 11.4A 57

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11.4A x 6.25= 71.25%

The tank indicator should read a liquid level of 71.25%. The same principal applies to the temperature indicator. For each respective signal the numerical result is then represented in a graphical display. Level is indicated in a tank display Temperature is indicated in a thermometer display.

Located in the block diagram is also the ability to export data, for both level and temperature, from a line graph. These can be exported to excel for further analysis. The numerical constants on the right of the diagram 50, 80, 250, and 350 are triggered by the respective numeric from the mathematical function discussed previously. These work in conjunction with the recipe selection DAQ Assistant and operate indicators on the front panel when the right requirements are met.

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12 Individual Review
From the beginning, the project provided to myself and Francis Gibson, was a challenge. We felt that at the time of selection we had received a project slightly on the more difficult end of the scale. Nonetheless I believe we worked hard and tried our best to fulfil the project specification and in the end I believe we succeeded in not only meeting each requirement of the project specification but also exceeding the project specification in some ways. The physical side of the project was only available to us on a Wednesday for roughly 7 hours per week. Within that time we had to work on very challenging aspects of the project implementation. Outside of that time we troubleshot the tougher aspects of the project which we had trouble with. Over the course of the project we ran into many troubling aspects and had to overcome these in order to continue. One aspect that we found very troubling and time consuming was resetting and rebuilding the project with the shared equipment supplied by the Institute each week. Although this was time consuming and sometimes caused problems to appear which hadnt on previous weeks I believe that it helped us to understand the physical build and operation of the process in a more detailed manner which wouldnt have occurred otherwise. I believe that working with the equipment each week brought a better understanding of the project and helped to solidify the knowledge gained throughout the term. We found whilst building the processes and physical equipment that some troubleshooting solutions werent applicable to our situation which forced us to find new ways to overcome the problems. For instance we found that, to drive the motor in maintenance mode, we couldnt use a current signal and had to settle for a voltage signal. This problem took up a large portion of one afternoon and caused many a headache. It took several weeks but we quickly built the physical connections required of the process. The hardest part of the project was the programming and monitoring

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stations and adding the physical connections required to provide a monitoring station for the process. Designing a suitable ladder programme for the project was an on-going struggle as each week we acquired new knowledge which would require us to alter certain aspects of the ladder logic to fit the requirements. Working with the special function block provided a challenge as the logic required us to include new functions which we had not worked with previously in other modules. I really found that the modules we took in previously years became useful tools for problem solving, troubleshooting and as information sources to help in designing and building the process. I can see how they all led up to and helped provide the ability for myself, and for each student, to complete this module in the best way possible. The several PLC modules from previous semesters provided invaluable knowledge when attempting to build the ladder logic required for this project. Whilst undertaking those modules we spent a lot of time working with ladder building and also physically wiring PLCs. This helped me to better understand each aspect of the PLC. Most modules provided useful knowledge when attempting this project yet several standouts such as: Computer Interfacing Technology Process Measurement & Control PLCs 1 & 2

To a lesser extent, modules such as the following provided knowledge of electrical/electronic components, motors and wiring etiquette. Digital, Analogue & Industrial Electronics Electrical Practice Electrical Power & Machines

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The Computer Interfacing Technology module was the sole module in which we used LabVIEW. Whilst undertaking this module we completed several laboratory exercises such as data acquisition which was a large part of the project. During the Process Measurement & Control module we gained knowledge in the methods of level measurement through pressure methods and also through temperature measurement using thermocouples. These modules provided me with the necessary tools to complete this project and ultimately to put myself forward as a useful member of my team.

12.1 Timetable
In the beginning we started by setting up a project plan so as we could track our progress and keep on schedule. This was submitted in week two to the project supervisors for review. We started out by looking at the variable speed drive and the user manual for the Eurotherm 601 series. We researched how to set up the VSD to our required specification through the different parameters and also how to physically connect the VSD to each other component as required. Soon after this we started to test several ladder program variations to gauge which worked best for our project. Keeping in line with the project plan we began attempting the acquisition of analogue signals from the transmitters to the special function block. We found great difficulty writing the logic for this and it took two weeks to get it right. We spent a lot of time researching the manual for the FX2n-5A function block to understand how to scale the signals and compare these signals to provide the working functionality required by the project specification. Once we had completed work on the VSD and PLC we attempted to focus on the myDaq card and the monitoring station. We had trouble with the generation and acquisition of signals at first yet overcame those with guidance from supervisors and research.

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Karl Phelan

Control of a Batch Process

27-04-2012

In the final weeks we tidied and rearranged the logic ladder and monitoring station to reflect a better and professional manner. Compiling this project document allowed me to take a step back and have an overall view on the whole project and how it all fit together in the end. To conclude I really feel that the 3 years of knowledge greatly benefitted myself, and all students, when attempting to complete this project. In the end I feel I was given a great opportunity when given this project as I find myself greatly interested in automation and process control after completing the project and hope to continue in this stream of engineering.

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Karl Phelan

Control of a Batch Process

27-04-2012

13 Bibliography
ABB, 2008. What is a speed drive? [Online] Available at: http://www.abb.com/cawp/db0003db002698/a5bd0fc25708f141c12571f10040fd37.a spx [Accessed April 2012]. Engineering Toolbox, 2010. Thermocouples. [Online] Available at:

http://www.engineeringtoolbox.com/thermocouples-d_496.html [Accessed February 2012]. Kuphaldt, T., 2009. Lessons in Industrial Instrumentation. PA Control. Lakshmi Anand K, D.o.M.P.C., 2008. [Online] Available at:

http://www.ustudy.in/node/7519 [Accessed April 2012]. Mitsubishi, 2006. FX3G PLC. [Online] Available at: http://www.mitsubishi-

automation.com/products/compactplc_FX3G.html [Accessed April 2012]. Mitsubishi, 2008. FX2n-5A User Manual. [Online] Available at:

http://www.automationsystemsandcontrols.net.au/PDF's%20Mitsubishi/Manuals/FPL C/FX2N-5A%20USER'S%20MANUAL.pdf [Accessed April 2012]. Mitsubishi, 2009. FX. [Online] Available at: https://my.mitsubishi-

automation.com/downloads/view/doc_loc/2340/166388.pdf?id=2340&saveAs=0&for m_submit=View+now [Accessed April 2012]. National Instruments, 2010. Manuals. [Online] Available at:

http://www.ni.com/pdf/manuals/373060e.pdf [Accessed April 2012]. National Instruments, 2012. Temperature Measurement with a Thermocouple or RTD. [Online] Available at: http://zone.ni.com/devzone/cda/tut/p/id/4252 [Accessed February 2012]. National Instruments, 2012. Temperature Measurements with Thermocouples: HowTo Guide. [Online] Available at: http://zone.ni.com/devzone/cda/tut/p/id/7108

[Accessed February 2012]. Omega, 2010. Thermocouples An Introduction. [Online] Available at:

http://www.omega.com/prodinfo/thermocouples.html [Accessed February 2012].

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Peyton, D., 2009. [Online] Available at: moodle.itb.ie [Accessed February 2012]. Peyton, D., 2011. Level Measurement using Pressure Methods. [Online] Available at: http://moodle.itb.ie/file.php/895/Level/dplevel.pdf [Accessed February 2012]. RS-Online, 2012. Current and Voltage Calibrator. [Online] Available at: http://uk.rsonline.com/web/p/current-voltage-calibrators/7012814/ [Accessed April 2012]. Stubby Lathe Usa, 2007. Eurotherm 601 VFD Manual. [Online] Available at: http://stubbylatheusa.com/manuals/Eurotherm_601_VFD_Manual.pdf.

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