MPS-PA Solutions 709743 en

MPS PA
Solutions
709743 EN
Intended use
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Order No.:
Status:
Authors:
Editorial team:
Graphics:
709743
12/2006
J. Helmich, ADIRO
H. Kaufmann
M. Linn
V. Xhemajli, C. Green, T. Schwab, ADIRO
Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2007
Internet: www.festo-didactic.com
e-mail: did@de.festo.com
The copying, distribution and utilisation of this document as well as the

communication of its contents to others without express authorisation is
prohibited. Offenders will be held liable for the payment of damages. All rights
reserved, in particular the right to carry out patent, utility model or ornamental
design registration.
Parts of this documentation may be copied solely for training purposes by the
authorised user.
Festo Didactic GmbH & Co. KG MPS PA
Contents
Solutions Filtration station
Solution 1.1: Analysis and appraisal of the system

Solution 1.1.1: Designation of the process components ______________________ 5
Solution 1.1.2: Completing the P&I diagram ________________________________ 7
Solution 1.1.3: Completing the pneumatic circuit diagram ____________________ 9
Solution 1.1.4: Determining the technical data of a system ___________________ 11
Solution 1.1.5: Drawing up the allocation list ______________________________ 13
Solution 1.2: Measurement and control
Solution 1.2.1: Characteristics of the proportional pressure regulator/filter system16
Solution 1.2.2: Logic operation _________________________________________ 19
Solution 1.2.3: Operating range and operating point of a controlled system _____ 26
Solution 1.2.4: Identifying a controlled system_____________________________ 28
Solution 1.2.5: Ramped pressure stages__________________________________ 30
Solution 1.3: Closed-loop control
Solution 1.3.1: Two-position controller __________________________________ 32
Solution 1.3.2: Closed-loop control using continuous-action controllers (P, I, PI) _ 34
Solution 1.3.3: Controller setting according to Ziegler-Nichols ________________ 39
Solutions Mixing station

Solution 2.1.1: Designation of process components ________________________
Solution 2.1.2: Completing the P&I diagram ______________________________
Solution 2.1.3: Completing the pneumatic circuit diagram ___________________
Solution 2.1.4: Determining the technical data of a system ___________________
Solution 2.1.5: Drawing up the allocation list ______________________________
43
45
47
49
51

Solution 2.2.1: Characteristics of the piping/pump system ___________________
Solution 2.2.2: Logic operation _________________________________________
Solution 2.2.3: Operating range and operating point of a controlled system_____
Solution 2.2.4: Identifying a controlled system_____________________________
Solution 2.2.5: Mixing according to quantity_______________________________
54
61
69
71
73

Solution 2.3.1: Two-position controller ___________________________________ 76
Solution 2.3.2: Closed-loop control using continuous-action controllers (P, I, PI) _ 78
Solution 2.3.3: Manual setting of control parameters _______________________ 83
Solutions Reactor station

Solution 3.1.1: Designation of process components ________________________
Solution 3.1.2: Completing the P&I diagram _______________________________
Solution 3.1.4: Determining the technical data of the system _________________
Solution 3.1.5: Drawing up the allocation list ______________________________
85
87
89
91

Solution 3.2.1: Characteristics of the heating system medium ________________ 94
Solution 3.2.2: Logic operation ________________________________________ 100
Solution 3.2.3: Operating range and operating point of a controlled system ____ 106
Solution 3.2.4: Identifying a controlled system____________________________ 108
Solution 3.3.1: Two-position controller __________________________________ 110
Solution 3.3.2: Closed-loop control using continuous-action controllers (P, I, PI) 112
Solution 3.3.3: Tuning method according to the rate of rise _________________ 117
Solutions Filling station

Solution 4.1.1: Designation of process components _______________________
Solution 4.1.2: Completing the P&I diagram ______________________________
Solution 4.1.3: Completing the pneumatic circuit diagram __________________
Solution 4.1.4: Determining the technical data of the system ________________
Solution 4.1.5: Drawing up the allocation list _____________________________
121
123
125
127
129

Solution 4.2.1: Characteristics of the metering tank-pump system ____________
Solution 4.2.2: Logic operation ________________________________________
Solution 4.2.3: Operating range and operating point of a controlled system ____
Solution 4.2.4: Identifying a controlled system____________________________
Solution 4.2.5: Inlet and outlet behaviour of the metering tank ______________
132
136
142
143
145

Solution 4.3.1: Two-position controller _________________________________ 151
Solution 4.3.2: Closed-loop control using continuous-action controllers (P, I, PI) 153
Solution 4.3.3: Optimisation method according to Chien-Hrones-Reswick (CHR)_ 158
Solutions MPS PA Filtration station
Solution 1.1: Filtration station system analysis and appraisal

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Date:
1.1.1 Designation of process components
Sheet 1 of 2
3
4
2
1
Designation of process components
Solution1.1: Filtration station system analysis and appraisal

Name:
Date:
Sheet 2 of 2
Designation
of process components
No.
Designation
Meaning or function
Pressure sensor
1B1
Filter
F101
Gate valve
V102
Butterfly valve
V103
3-way ball valve

V106
In the electrical circuit diagram and P&I diagram of the filtration station you will find
two different designations for the gate valve.
Explain the difference.
Comprehension questions
The designation V102 from the P&I diagram is a process designation. The process related functions in
an EMCS plan (Electronic Measuring Control System) are known as EMCS points. The measured
variable or another input variable, its processing, direction of action and positional data should be
based on this designation.
An EMCS point consists of a circle and is designated with a code letter ((A Z) and a code number. The
code letters are entered in the upper section of the EMCS circle and the number in the lower section.
The sequence of code letters can be established from the table "EMSR code letters to DIN 19227".
The designation 1M4 from the electrical circuit diagram describes the electrical function.
All electrical equipment of an MPS PA station is labelled with equipment designations according to
the electrical circuit diagram. The designation of equipment in the electrical circuit diagrams is
effected according to the standard DIN/EN61346-2.

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Date:
1.1.2 Completing the P&I diagram
Sheet 1 of 2
P&I diagram

Name:
Date:
Sheet 2 of 2
Functional description of
components
Designation
F
Meaning or function
Filter
Proximity sensor
LS-
Status, limit value alarm

LA+
Digital pump
P101
Valve
V
State the difference between the measuring point designations

LA+ and LS+.
The designations LA+ and LS+ differ with regard to the function within the station. Whereas both
sensors indicate the water level in the tank, LA+ signals an error message. (often in the form of
Emergency-Stop).

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1.1.3 Completing the pneumatic circuit diagram
Sheet 1 of 2
Pneumatic circuit diagram

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1.1.3 Pneumatischen Schaltplan vervollstndigen
Sheet 2 of 2
Functional description
of pneumatic components
Symbol
Meaning or function
Flow control valve
5/2-way valve
Butterfly valve with pneumatic swivel actuator
What is the meaning of the 5/2-way valve designation?

What is the function of a flow control valve on a pneumatic cylinder?
Comprehension question
The 5/2-way valve has 5 ports and 2 switching positions. One port is intended for the supply of
compressed air. The remaining 4 ports are for the connection of the working and exhaust lines.
Depending on the design, the valve can be actuated either by means of applied pressure via pilot air
or electronically.
Exhaust air flow control valves are screwed into the exhaust ports 3 and 5 of control valves and enable
the regulation of cylinder piston speed by means of exhaust air restriction. The flow control screw
facilitates an adjustable restriction of exhaust air. The exhaust air is discharged via the integrated
silencer to reduce noise levels.
10

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1.1.4 Determining the technical data of a system
Sheet 1 of 2
Implementation
Technical data
Component
Designation
Function
Characteristics
in flow
diagram
Delivers a liquid
Pump
P201
Proportional
Prop_V
0 - 10 V
Druckbereich [bar]
0.15 - 6 bar
Min. pneum. pressure [bar]

Power consumption [W]
1 bar
5.65 W
Pressure range [bar]

Sensor signal [V]
0 - 10 bar
0 - 10 V
Changes the
1B1
Measures pressure
Limit switch
LS + 101
Status, upper limit
top ( B101)
Setpoint voltage [V]
Pressure
sensor
Max. throughput [l/min]

l/min
preset setpoint
value.
direction of flow
within the station
bottom
(B101)
24 V
26 W
proportional to a
V106
Limit switch
Electrical power [W]
Regulates pressure
pressure
regulator
3-way ball
valve
from a tank via the

piping system
Voltage [V]
value
LS- 102
Status, lower limit

value
Filling amount up to contact [l] 6 l

Type (normally open/
normally closed)
Norm. open
Filling amount up to contact [l] 0 l

normally closed)
Norm. open
11
Solution 1.1: Filtration station System analysis and appraisal

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Sheet 2 of 2
Describe the design and function of a proportional pressure regulator?

The proportional pressure regulator is used to control pressure proportional to a preset setpoint
value. Its main function is to be able to replace previously manually adjustable pressure regulators
with electrical, remotely adjustable regulators, for example in order for different machine parameters
to be automatically and instantly available. An integrated pressure sensor determines the pressure at
the working port and compares this value with the setpoint value. In the case of setpoint/actual
deviations, the regulating valve remains actuated until the output pressure has reached the setpoint
value.
12

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1.1.5 Drawing up the allocation list
Sheet 1 of 3
Allocation list of
digital inputs
Allocation list of
analogue inputs
Symbol
EasyPort /
PLC address
Description
Check
Simbox
address
1B1
DI 0
I 0.0
Air jet pressure
1B2
DI 1
I 0.1
Tank B101 top
1B3
DI 2
I 0.2
Tank B101 bottom
1B4
DI 3
I 0.3
Tank B102 top
1B5
DI 4
I 0.4
Tank B102 unten
1B6/1B7
DI 5
I 0.5
Butterfly valve open and gate valve

down
1B8/1B9
DI 6
I 0.6
Butterfly valve open and gate valve

up
1PA_FREE
DI 7
I 0.7
Receiver downstream station free
EasyPort /
PLC address
Description
EW256
Actual value X (pressure)
Symbol
Check
Simubox
address
1PV1
AI0
13

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Sheet 2 of 3
Allocation list of
digital outputs
Allocation list of
analogue outputs
Symbol
PLC address
Description
1M1
DO 0
O 0.0
Air jet pressure
1M2
DO 1
O 0.1
Pump P101, waste water
1M3
DO 2
O 0.2
Pumpe P102, downstream station
1M4
DO 3
O 0.3
Gate valve
1M5
DO 4
O 0.4
Butterfly valve
1M6
DO 5
O 0.5
3-way ball valve
1M7
DO 6
O 0.6
Stirrer
1PA_BUSY
DO 7
O 0.7
PA station busy
EasyPort /
PLC address
Description
AW256
Manipulated variable Y,
Proportional pressure regulator
Symbol
Check
Check
Simubox
address
1CO1
14
EasyPort /
Simubox
address
AO 0

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Sheet 3 of 3
Describe the behaviour of the analogue final control element (proportional

pressure regulator) if actuated via an analogue signal.
The bridge in the connection board must be converted to analogue to enable analogue control of an
analogue final control element.
The analogue final control element responds as a function of the voltage applied. The valve is closed
in the unactuated state, i.e. if 0V voltage is applied. If an analogue signal is applied, the valve
response is proportional to the signal level. Pressure is thus infinitely adjustable as required.
15
Solution 1.2: Filtration station measurement and control

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1.2.1 Characteristics of the proportional pressure regulator/filter system
Sheet 1 of 3
Note
Value table
The solution has been realised using digital/analogue EasyPort and FluidLab-PA.
Voltage at
prop_V in V
0,00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
4.50
5.00
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.00
3.00
3.00
3.00
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.00
3.00
3.00
3.00
5.50
6.00
6.50
7.00
7.50
8.00
8.50
9.00
9.50
3.00
3.00
3.00
3.00
3.00
3.00
3.00
3.00
3.00
3.00
3.00
3.00
3.00
3.00
3.00
3.00
3.00
3.00
3.00
3.00
Signal
pressure
sensor in V
Pressure
in bar.
Voltage at
prop_V in V
10.00
Signal
pressure
sensor in V
Pressure
in bar.
Control of proportional pressure regulator.
16

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Sheet 2 of 3
Note
Characteristics of prop_VFilter system
17

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Sheet 3 of 3
Note
No.
Question
Answer
Comment
A small hysteresis
exists. Operating
Form of characteristic curve
Linear
Hysteresis is dependent on:
The speed of the setpoint change
range only up to
3 bar.
Greater hysteresis
with higher speeds
Slow setpoint change

H = 0.1
3
Determine hysteresis:
Fast setpoint value change
H = 0.3
What setpoint value (V)
must be set if the filter is to

be flushed using the
pressure given opposite?
p = 0.5 bar = 0.5 Volt

p = 1.0 bar = 1.0.Volt
p = 1.5 bar = 1.5.Volt
Explain the characteristic curve!

State the reasons for the system response at low voltages!
At low voltages, the proportional pressure regulator is not within the preset operating range. The
linear range of the proportional pressure regulator begins as from 0.15 volts.
18

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1.2.2 Logic operation
Sheet 1 of 7
Solution
Pushbutton S1, start of stirring subprocess

Pushbutton S2, start of filtration subprocess
Pushbutton S3, start of flushing subprocess
Note
The solution has been realised using digital/analogue EasyPort and FluidSIM
Setting condition for stirrer R104
P&I
Electr.
diagram
symbol
circuit
Address
Logic
operation
Comment
diagram
symbol
S1
&
LS- 102
1B3
DI 2
&
1B9
DI 6
&
Pushbutton
Sensor
(lower filling level at Tank B101)
Sensor
(gate valve up)
Resetting condition for stirrer R104

P&I
Electr.
diagram
symbol
circuit
Address
Logic
operation
Comment
diagram
symbol
Pushbutton
S2
S3
LS- 102
1B3
DI 2
Not sensor
(lower filling level at tank B101)
1B9
DI 6
Not sensor
(gate valve up)
Pushbutton
19

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Sheet 2 of 7
Setting condition for gate valve V102

P&I
Electr.
diagram
symbol
circuit
Address
Logic
operation
Comment
diagram
symbol
S2
&
LS- 102
1B3
DI 2
&
1B7
DI 5
&
Pushbutton
Sensor
Not sensor
(butterfly valve open)
Resetting condition for gate valve V102
20
P&I
Electr.
diagram
symbol
circuit
Address
Logic
operation
Comment
diagram
symbol
Pusbutton
S1
S3
LS+ 101
1B2
DI 1
Sensor
(upper filling level at tank B101)
LS+ 103
1B4
DI 3
Sensor
LS- 102
1B3
DI 2
Pusbutton
Not sensor

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Sheet 3 of 7
Setting condition for pump P102 - downstream station

P&I
Electr.
diagram
symbol
circuit
Address
Logic
operation
Comment
diagram
symbol
S3
&
LS- 104
1B5
DI 4
&
1B9
DI 6
&
Pushbutton
Sensor
Sensor
(gate valve up)
Resetting condition for pump P102 downstream station

P&I
Electr.
diagram
symbol
circuit
Address
Logic
operation
Comment
diagram
symbol
Pushbutton
S1
S2
LS+ 101
1B2
DI 1
Sensor
(upper filling level at B101)
LS- 104
1B5
DI 4
Not sensor
Pushbutton
21

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Sheet 4 of 7
Setting condition for pump P101 waste water pump

P&I
Electr.
diagram
symbol
circuit
Address
Logic
operation
Comment
diagram
symbol
S1
S2
LS- 102
1B3
DI 2
&
Pushbutton
Pushbutton
Sensor
Resetting condition for pump 101 waste water pump
22
P&I
Electr.
diagram
symbol
circuit
Address
Logic
operation
Comment
diagram
symbol
Pushbutton
S3
LS- 102
1B3
DI 2
LS+ 103
1B4
DI 3
&
Sensor
1B9
DI 6
&
Not sensor
(gate valve up)
Not sensor

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Sheet 5 of 7
Logic diagram
Network 1
Stirrer R104 on
Network 2
Gate valve V102 up
23

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Sheet 6 of 7
Network 3
Pump P102 downstream station on
Network 4
Pump P101 waste water pump on
24

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Sheet 7 of 7
Why is air in the piping system to be avoided?

Air in the piping system prevents the correct operation of the system.
The pump must be prevented from running dry as this will cause damage to the pump.
25

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1.2.3 Determining the operating range and operating point of a controlled system
Sheet 1 of 2
Note
Determining the operating point of the controlled system
Minimum measured
value
Operating point
Maximum measured
value
26
Pressure sensor
Manipulated variable
prop_V [V]
Pressure [bar]
Output signal [V]
O.2
0.1
0.1
1.25
1.25
6.2
2.6
2.6

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Sheet 2 of 2
Name the system conditions which could influence the operating range of the
proportional pressure regulator and effective range of the sensor.
A least 1 bar operating pressure must be available for the optimal operation of the proportional
pressure regulator.
The operating pressure has been reduced to 0 2.6 bar using a pressure limiter.
The sensor assembly position, as well as loss of air pressure, influence the measurement result of the
sensor.
27

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1.2.4 Identifying a controlled system
Sheet 1 of 2
Example for the calculation of the time constant Ts
28

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Sheet 2 of 2
What is the value determined for the system gain Ks?

What type of system, i.e. order of system are we dealing with?
What is/are the time constant/s Ts obtained?
Explain the system behaviour.
System gain Ks = 1
PT1, 1st order system
Ts = 32 ms
Self-regulating systems (PT1- controlled systems) are systems whose characteristic it is to run on.
The energy supplied then becomes = dissipated energy. The following applies in the case of a
pressure control system: The greater the applied pressure, the greater is the pressure level in the
filter. Consequently, the volumetric discharge from the filter increases with rising pressure. If the
output pressure is equal to the supply pressure, a final value (pressure compensation) exists,
whereby the pressure within the filter no longer changes.
29

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1.2.5 Pressure stages with ramp
Sheet 1 of 2
Note
30

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1.2.5 Ramped pressure stages
Sheet 2 of 2
Evaluation
What is the difference between a proportional valve and a proportional pressure

regulator?
The proportional pressure regulator is used to control a pressure proportional to a preset setpoint
value. Its main function is to be able to replace previously manually adjustable pressure regulators
with electrical, remotely adjustable regulators, for example in order for different machine parameters
to be automatically and instantly available. An integrated pressure sensor determines the pressure at
the working port and compares this value with the setpoint value. In the case of setpoint/actual
deviations, the regulating valve remains actuated until the output pressure has reached the setpoint
value.
A proportional valve enables the flow control of neutral gases and liquids. It can be used as a remotely
adjustable final control element or in control loops. The proportional valve is a directly actuated
2/2-way valve. The valve piston is raised off its seat as a function of the solenoid coil current and
releases flow from port 1 to port 2. Without current, the valve is closed. The valve is spring returned.
An external standard signal is converted into a PWM signal whereby the valve opening is infinitely
adjustable. The frequency of the PWM signal can be adjusted to the valve used.
31
Solution 1.3: Filtration station closed-loop control

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1.3.1 Two-position controller
Sheet 1 of 2
Note
Parameter
32
Standardised
value
Physical value
Setpoint value (w) at

operating point
0.21
1.26
Upper switching limit
0.5
Lower switching limit
0.5

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Sheet 2 of 2
Evaluation
How does the system respond?

Describe the control behaviour.
Name typical areas of application for two-position controllers.
The manipulated variable with this controller type can only assume two defined states. The controller
output in this case switches to and fro between these two states, depending on whether the upper or
lower threshold value has been exceeded. In our example, the manipulated variable jumps to its
maximum value at the moment of switch-on until the controlled variable reaches the upper threshold
value. The controller responds by decreasing the manipulated variable. The controlled variable
decreases until the lower setpoint value is reached and the reverse procedure begins.
Depending on requirement, the hysteresis can be increased or reduced, i.e. the switching interval is
reduced or prolonged.
The two-position controller is particularly suitable for the control of systems with large time constants;
in our example the control of pressure. Other areas of application are for example the control of a
compressor, the control of room temperature or humidity.
33

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1.3.2 Closed-loop control using continuous-action controllers (P, I, PI)
Sheet 1 of 5
Parameter
Setpoint value (w) at operating

point
34
Standardised
value
0.21
Physical
value [bar]
1.3

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Sheet 2 of 5
Implementation
P controller
Example for Kp = 5
35

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Sheet 3 of 5
Implementation
I controller
Example for Tn = 5
36

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Sheet 4 of 5
Implementation
PI controller
Example for Kp = 2, Tn = 5
37

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Sheet 5 of 5
How does the system respond with closed-loop control using a P controller?
How does the system respond with closed-loop control using an I controller?
How does the system respond with closed-loop control using a PI controller?
Which PI parameter pair results in the smallest overshoot and/or smallest
adjustment time?
Which controller is suitable for this controlled system if the system deviation is to
be corrected to zero?
P controller: The system responds relatively rapidly to the input step. The disadvantage is the
remaining system deviation. If the Kp selected is too large, the system starts to oscillate.
I controller: The system responds very slowly to a setpoint value change. The advantage is that the
system deviation is corrected to zero.
PI controller: The system responds relatively quickly to a setpoint value change. The system deviation
is completely is completely corrected. The PI controller combines the positive properties of a P and I
controller. The P component ensures a quick step response and the I controller ensures that system
deviations are corrected to the setpoint value.
Since the pressure control system is a P-controlled system, the I controller is ideally suited for closedloop control.
38

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1.3.3 Optimisation method to Ziegler-Nichols
Sheet 1 of 4
Note
39

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Sheet 2 of 4
Evaluation
Which value have you selected and why?

What is the value determined for Kp, Tn, Tv?
What criteria are you using to evaluate your result?
Kp: P controller:
2.2
PI controller:
1.98
PID controller:
2.64
Tn: PI controller:
0.298
PID controller:
0.175
Tv: PID controller:
0.042
On the basis of the preset parameters, different response patterns can be read at the step response.
In the case of closed-loop control using a P controller, the output signal is relatively quick in the
steady state, although the system deviation cannot be corrected. If the experiment is conducted using
a PI controller, a slight overshoot of the output variable can be observed. The setpoint value is
reached quickly without remaining system deviation. The PID controller effects the fastest correction
of the system deviation. The steady state is reached after a few overshoots.
40

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Sheet 3 of 4
Example for Kpr = 2.2.
Example for Kpr = 1.98, Tn = 0.298.
41

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Sheet 4 of 4
Example for Kpr = 2.64, Tn = 0.175, Tv = 0.042.
42
Solutions MPS PA Mixing station
Solution 2.1: Mixing station system analysis and appraisal

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Date:
Sheet 1 of 2
3
2
1
4
5
Designation of
process components
No.
Designation
Meaning or function
2/2-way ball valve
V201
Holding tank
B201
Proximity sensor tank B201 top

2B2
Flow sensor
2B1
Mixing pump
P201
43

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Sheet 2 of 2
You will find two different designations for the proximity sensor tank B201 top in
the electrical circuit diagram and P&I diagram for the mixing station.
The designation from the P&I diagram is a process designation. The process related functions in an
EMCS plan (EMCS = Electronic Measuring Control System) are known as EMCS points. The measured
variables or other input variables, their processing, direction of action and positional data should
follow from this designation.
An EMCS point consists of an EMCS circle and is designated with a code letter (A-Z) and a code
number. The code letters are entered in the upper section of the EMCS circle and the numbering in the
lower section. The sequence of code letters can be established on the basis of the table "EMSR code
letters to DIN 19227".
The designation from the electrical circuit diagram describes an electrical function.
All electrical equipment of an MPS PA station is identified by means of equipment designations

according to the electrical circuit diagram. The designation of equipment in the electrical circuit
diagrams is effected according to the standard DIN/EN61346-2.
44

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Date:
Sheet 1 of 2
Solutions
P&I diagram
components
Designation
FI
Flow sensor
FIC
Flow sensor
LS-
Proximity sensor
LA+
P201
V
Meaning or function
Analogue pump
Valve
45

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Sheet 2 of 2
Evaluation
What is the difference between the designations of the measuring points FI and
FIC?
What is the difference between the designations of the measuring points LA+ and
LS+?
The designations FI and FIC are process designations. An EMCS point consists of an EMCS circle and is
designated by a code letter (A-Z) and a code number. The code letters are entered in the upper section
of the EMCS circle and the numbering in the lower section. The sequence of the code letters is
established on the basis of the table "EMSR code letters to DIN 19227".
Example: F stands for flow; I stands for display (indicator); C corresponds to closed-loop control, i.e.
the sensor supplies an analogue signal in the form of an actual value of the control loop.
The designations LA+ and LS+ differ with regard to their function within the station. Whilst both
sensors indicate the water level within the tank, LA+ signals an error (alarm) message (often used as
Emergency-Stop.
46
Solution2.1: Mixing station system analysis and appraisal

Name:
Date:
Sheet 1 of 2
47
Solution2.1: Mixing station system analysis and appraisal

Name:
Date:
Sheet 2 of 2
pneumatic components
Symbol
Meaning or function
Flow control valve
5/2-way valve
Butterfly valve with pneumatic swivel actuator
What is the meaning of the 5/2-way valve designation?

What is the function of an exhaust air flow control?
compressed air. The remaining 4 ports are for the connection of the working and exhaust lines.
Depending on the design, the valve can be actuated either by means of applied pressure via pilot air
or electronically.
Exhaust air flow control valves are screwed into the exhaust ports 3 and 5 of control valves and enable
the regulation of cylinder speed by means of exhaust air restriction. The flow control screw facilitates
an adjustable restriction of exhaust air. The exhaust air is discharged via an integrated silencer to
reduce noise levels.
48

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2.1.4 Determining the technical data of the system
Sheet 1 of 2
Technical data
Component
Designation
Function
Characteristics
in flow
diagram
Pump
Flow sensor
P201
2B1
Pumps water into

the mixing tank
Voltage [V]
24 V
Electrical power [W]

26 W
9 l/min
Measures
Measuring principle:
throughput of
liquid
The rotor generates pulses which are

converted into a voltage signal t
Measuring range [l/min]
Sensor signal [Hz]
Measuring
transducer
F/U
2A1
Limit switch
top
2B6
Limit switch
2B7
bottom
0.3-9 l/min
40-1200 Hz
Adapts the sensor

signal
Input:
Status, upper limit
Filling quantity up to contact [l] 6 l
value
in tank B204

normally closed)
Status, lower limit
Filling quantity up to contact [l]
value
in tank B204

normally closed)
Square-wave frequency generator 0-1 kHz
Norm. open
o.5 l
Norm. open
49

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Sheet 2 of 2
What is the frequency delivered by the flow sensor for a flow rate of 2l/min?
Solution by calculation is required!
K Factor = 8000
f=
Impulse
dm 3
1
s
Impulse
l
8000
min
dm 3 = 0.3 8000Impulse = 40 Impulse
fmin =
s
60s
s
Impulse
l
8000
2
min
dm 3 = 2 8000Impulse = 266,67 Impulse
f 2l / min =
s
60s
s
0.3
50

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Date:
Sheet 1 of 3
Allocaion list of
digital inputs
Symbol
EasyPort /
PLC address
Description
Check
Simbox
address
Allocation list of
analogue inputs
2B1
DI 0
I 0.0
Flow sensor
2B2
DI 1
I 0.1
Holding tank B201 top
2B3
DI 2
I 0.2
Holding tank B201 bottom
2B4
DI 3
I 0.3
2B5
DI 4
I 0.4
2B6
DI 5
I 0.5
Mixing tank B204 top
2B7
DI 6
I 0.6
Mixing tank B204 bottom
2PA_Free
DI 7
I 0.7
Receiver PA downstream station

free
EasyPort /
PLC address
Description
Check
IW256
Actual value X (flow)
Symbol
Simubox
address
2PV1
AI0
51

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2.1.5 Erstellen der Zuordnungsliste
Sheet 2 of 3
Allocation list of
digital outputs
Allocation list of
analogue outputs
Symbol
PLC address
Description
Check
2M1
DO 0
O 0.0
Mixing pump P201 on
2M2
DO 1
O 0.1
Pump P202, downstream station, on
2M3
DO 2
O 0.2
Mixing valve V201 on
2M4
DO 3
O 0.3
2M5
DO 4
O 0.4
Not busy
DO 5
Not busy
Not busy
Not busy
DO 6
Not busy
Not busy
2PA_Busy
DO 7
O 0.7
Sender PA station busy
EasyPort /
PLC address
Description
Check
AW256
Manipulated variable Y, (pump

P201)
Symbol
Simubox
address
2CO1
52
EasyPort /
Simubox
address
AO 0

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Date:
Sheet 3 of 3
What particular situation should be considered if the analogue final control

element (pump) is to be digitally controlled?
The bridge in the connection board must be converted to digital to enable digital control of the
analogue final control element.
53
Solution 2.2: Mixing station measurement and control

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Date:
2.2.1 Characteristics of the piping/pump system
Sheet 1 of 7
Note
Value table
holding tank 1
The solution has been realised using digital/analogue EasyPort, and FluidLab-PA.
Voltage at
pump
control in V
Flow sensor
signal in V
Flow rate
in l/min.
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
4.50
5.00
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.2
0.7
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.12
0.44
5.50
6.00
6.50
7.00
7.50
8.00
8.50
9.00
9.50
1.5
1.7
1.9
2.6
3.0
3.5
3.8
4.1
4.4
4.8
1.1
1.25
1.45
1.9
2.4
2.6
2.9
3.05
3.3
3.6
Voltage at
pump
control in V
Flow sensor
signal in V
Flow rate
in l/min.
10.00
Water is pumped only from holding tank 1.
54

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Sheet 2 of 7
Value table
Holding tank 2
Voltage at
pump
control in V
Flow sensor
signal in V
Flow rate
in l/min.
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
4.50
5,00
0.0
0.0
0.0
0.0
0.0
0.0
0.1
0.2
0.3
0.8
1,7
0.0
0.0
0.0
0.0
0.0
0.0
0.06
0.18
0.27
0.6
1,2
5.50
6.00
6.50
7.00
7.50
8.00
8.50
9.00
9.50
1.9
2.2
2.5
2.8
3.0
3.2
3.6
3.9
4.4
4.8
1.4
1.6
1.8
2.3
2.4
2.7
2.95
3.3
3.6
Voltage at
pump
control in V
Flow sensor
signal in V
Flow rate
in l/min.
2.1
10.00
55

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Sheet 3 of 7
Value table
holding tank 3
Voltage at
pump
control in V
Flow sensor
signal in V
Flow rate in
l/min.
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
4.50
5.00
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.2
0.5
1.1
1.5
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.13
0.4
0.8
1.1
5.50
6.00
6.50
7.00
7.50
8.00
8.50
9.00
9.50
1.8
2.2
2.7
2.9
3.1
3.5
3.8
4.2
4.4
4.7
1.3
1.65
2.0
2.2
2.4
2.6
2.8
3.1
3.5
Voltage at
pump
control in V
Flow sensor
signal in V
Flow rate in
l/min.
10.00
56

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Sheet 4 of 7
Value table
holding tank 1 3
Voltage at
pump
control in V
Flow sensor
signal in V
Flow rate
in l/min.
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
4.50
5.0
0.0
0.0
0.0
0.0
0.0
0.0
0.1
0.2
0.8
1.
1.
0.0
0.0
0.0
0.0
0.0
0.0
0.04
1.18
0.6
1.0
1.3
5.50
6.00
6.50
7.00
7.50
8.50
9.00
9.50
2.1
2.4
2.7
3.0
3.6
3.9
4.1
4.3
4.7
4.9
1.55
1.8
2.0
2.3
2.7
2.9
3.1
3.3
3.5
3.7
Voltage at
pump
control in V
Flow sensor
signal in V
Flow rate in
l/min.
8.0
10.00
Water is pumped simultaneously from all holding tanks.

All holding tanks are filled identically prior to starting.
57

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Sheet 5 of 7
Holding tank 1
Holding tank 2
58
Solution 2.2: Mixing station measuring and control

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Sheet 6 of 7
Holding tank 3
Holding tank 1 3
59

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Sheet 7 of 7
Compare the characteristic curves and discuss the possible causes which result
in their differences.
State the reasons for the system response with a decreasing quantity of water in
the holding tank.
State the reasons for the system behaviour at low voltages.
What would be the effect on the characteristic curves of different quantities of
water in the holding tank?
The cause of the different characteristic curves is the different piping systems on the one part and the
different quantities of water in the holding tank on the other. Depending on the length of the
controlled system, the work to be carried out increases in order to pump the liquid into the mixing
tank. With a decreasing fill level in the holding tanks, the pressure of the water gauge drops to the
tank floor whereby the pressure in the piping system also decreases. This means that the decrease in
flow velocity is proportional to the reducing tank level.
At low voltages the pump does not operate within its operating range. The pump delivers its full
capacity only after a certain voltage is reached.
Different quantities of water result in different characteristic curves. The maximum flow rate of liquid
drops with a decrease in the level of water in the holding tanks. The characteristic curve exhibits a
flatter rise.
60

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Sheet 1 of 8
Note
Pushbutton S1, to pump water from tank B201 into tank B204
Pushbutton S2, to pump water from tank B202 into tank B204
Pushbutton S3, to pump from tank B203 into tank B204
Pushbutton S4, to pump water from tank B204 back into tank B201 or B202 or
B203.
The solution has been realised using digital/analogue EasyPort, and FluidSIM.
Setting condition for valve V201

P&I
Electr.
diagram
symbol
circuit
Address
Logic
operation
Comment
diagram
symbol
S1
&
LS202
2B3
DI 2
&
Pushbutton
Sensor
(lower fill level at tank B201)
Resetting condition for valve V201

P&I
Electr.
diagram
symbol
circuit
Address
Logic
diagram
symbol
S1
LS202
2B3
DI 2
Comment
operation
Not pushbutton
Not sensor
61

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Sheet 2 of 8

P&I
Electr.
diagram
symbol
circuit
Address
Logic
operation
Comment
diagram
symbol
S2
&
LS203
2B4
DI 3
&
Pushbutton
Sensor
62
P&I
Electr.
diagram
symbol
circuit
Address
Logic
Comment
operation
diagram
symbol
S2
LS203
2B4
DI 3
Not pushbutton
Not sensor

Name:
Date:
Sheet 3 of 8

P&I diagram
symbol
Electr. circuit
diagram symbol
Address
Logic
operation
S3
&
LS204
2B5
DI 4
&
Comment
Pushbutton
Sensor
(lower fill level at B203)

P&I diagram
Electr. circuit
symbol
diagram symbol
Address
Logic
Comment
operation
S3
LS204
2B5
DI 4
Not pushbutton
Not sensor
Setting condition for pump P201

P&I diagram
symbol
Electr. circuit
diagram
Address
Logic
operation
Comment
S1
Pushbutton
S2
Pushbutton
S3
Pushbutton
Resetting condition for pump P201

P&I diagram
symbol
Electr. circuit
diagram symbol
Address
S1
&
Not pushbutton
S2
&
Not pushbutton
S3
&
Not pushbutton
Logic
operation
Comment
63

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Sheet 4 of 8

P&I
Electr.
diagram
symbol
circuit
Address
Logic
operation
Comment
diagram
symbol
S4
&
LS 206
2B7
DI 6
&
Pushbutton
Sensor
Resetting condition for pump P202
64
P&I
Electr.
diagram
symbol
circuit
Address
Logic
Comment
operation
diagram
symbol
S4
LS 206
2B7
DI 6
Not pushbutton
Not sensor

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Sheet 5 of 8
Logic diagram
Network 1
Network 2
65

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Sheet 6 of 8
Network 3
Network 4
66
Pump P201 mixing pump on

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Sheet 7 of 8
Network 5
Pump P202 mixing pump on
67

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Sheet 8 of 8
Why should air in the piping system be avoided?

Air in the piping system prevents the correct operation of a system.
Pumps must be prevented from running dry as this will cause damage to the pump.
68

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2.2.3 Determining the operating range and operating points of a controlled system
Sheet 1 of 2
Note
Determining the operating point of the flow rate control system
Manipulated
variable
pump P201
[V]
Minimum measured
Flow sensor
operating range of pump
Flow rate
[l/min.]
Output signal
measuring
transducer [V]
Float flow meter
Display value
[l/h]
3.3
0.1
0.1
--
Operating point
6.6
2.6
2.6
125-
Maximum measured
value
10
4.9
4.9
240
value
69

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Sheet 2 of 2
Evaluation
State the system conditions which could influence the operating range of the
pump and the measuring range of the sensor.
Air in the piping system can influence the operating range of the pump. In addition the system is
dependent on the fill level of the holding tank. With a high fill level a high flow rate is reached, which
decreases with a drop in fill level. With a time variant measurement, the maximum flow rate therefore
decreases proportional to the current fill level.
If the pump is not operated within its operating range, e.g. if the selected pump voltage is too low, this
results in inaccurate measurement results. The operating range of the pump depends on the particular
piping system.
70

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Sheet 1 of 2
Note
71

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Sheet 2 of 2

What type of system, i.e. order of system, are we dealing with?
What is/are the time constant(s) obtained?
Explain the system behaviour?
Ks = 1
PT1, 1st order system.
Ts = 1.0s.
Self-regulating systems (PT1-controlled systems) are systems whose characteristics it is to run on to
a final steady-state value after a certain time. The energy supplied then becomes dissipated energy.
The following applies in the case of a flow rate control system: Once the pump is switched on, the
pump blades within the pump start to draw in the liquid from the piping system and pump it to the
other side into the mixing tank. During this, the flow velocity increases rapidly. If the flow energy is
equal to the driving force of the pump blades, a steady state (equilibrium) exists whereby the flow
velocity no longer changes.
72

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2.2.5 Mixing according to quantity
Sheet 1 of 3
Note
73

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Sheet 2 of 3
Determining the operating point of the flow rate control system
Desired
No.
quantity
[ml]
Holding tank
Voltage at
pump [Volt]
Mixing tank
From tank No.

Water level
before
Water level after
Before
After
2650
2470
1000
1200
2600
2410
1200
1400
2750
2650
1400
1490
2700
2500
1000
1250
2600
2400
1250
1450
2650
2550
1450
1550
2800
2600
1000
1250
2640
2420
1250
1400
2580
2460
1400
1500
10
2740
2520
1000
1250
2610
2400
1250
1450
2610
2500
1450
2600
1
2
11
12
74
500
500
500
500

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Date:
Sheet 3 of 3
Why cant the transfer of a specific quantity be time-controlled?

Why is the method of mixing according to quantity better?
Why is the quantity of water still not exact using this method?
At what pump voltage do you get minimal measurement inaccuracies?
The flow rate during pumping is not constant which is why time-controlled measurement leads to
inaccurate results.
When mixing according to quantity the actual flow rate is acquired and accumulated continuously
until the desired quantity of water is obtained. This method allows more accurate measurement..
Even so, the results do not meet expectation 100%. The reason lies within the system itself. The pump
and moving liquid are relatively inert. At the time it is switched off, the blades still continue to rotate
by a few rotations and so continues to transport a small quantity of liquid. Consequently, flow does
not stop immediately the pump is switched off but just a few split seconds later. The higher the flow
velocity, the more inaccurate is the measurement result. The same is the case with very low flow
velocities.
Minimal measurement inaccuracies are obtained using an applied pump voltage of 7 volts. The exact
quantity specified is pumped from the holding tanks into the mixing tank.
75
Solution 2.3: Mixing station closed-loop control

Name:
Date:
Sheet 1 of2
Note
Standardised
Physical
value
Value
Parameter
O.35
2.63
0.4
0.4
operating point
76

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Sheet 2 of2

State some typical areas of application for two-position controllers.
The manipulated variable with this type of controller can only assume two defined states - in our
example 0 and Vmax, whereby the controller output switches to and fro between these two states,
depending on whether the upper or lower threshold value is exceeded. In our example, the
manipulated variable jumps to its maximum value the moment it is activated until the controlled
variable reaches the upper threshold value. The pump is switched off. The controlled variable now
decreases until the lower threshold value is reached and the reverse procedure begins.
The hysteresis can be increased or reduced according to requirement, i.e. the switching interval
reduced or extended.
The two-position controller is particularly suitable for the control of systems with large time constants;
in our example the regulation of a flow rate control system. Other areas of application are for example
the control of an air reservoir (compressor), the control of room temperature or humidity.
77

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Sheet 1 of 5
Note
Parameter
0.3
Stadardised
Physical
value
value l/min
2.6
point
78

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Sheet 2 of 5
P controller
Example for Kpr = 50
79

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Sheet 3 of 5
I controller
Example for Tn = 2
80

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Sheet 4 of 5
PI controller
Example for Kpr = 2, Tn = 2
81

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Sheet 5 of 5
How does the system respond with closed-loop control using a PI controller?
Which PI parameter pair results in the smallest overshoot and/or shortest
settling time?
Which controller is suitable for this controlled system, if the system deviation is
to be corrected to zero?
P controller: The system responds relatively rapidly to the input step. The disadvantage is the
remaining system deviation. If the Kp selected is too large, the system starts to oscillate.
I controller: The system reacts very slowly to a setpoint value change. The advantage is that the
system deviation is corrected to zero.
PI controller: The system reacts relatively fast to a setpoint value change. The system deviation is
completely corrected. The PI controller combines the positive characteristics of a P and I controller.
The P component ensures a fast step response, the I controller ensures that system deviations are
corrected to the setpoint value.
The smallest overshoot is obtained for Kpr=2 and Tn =2.
Since the flow rate control system is a P controlled system, the I controller is optimally suitable for
closed-loop control.
82

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2.3.3 Manual tuning of controller parameters without knowledge of the system behaviour
Sheet 1 of 2
Note
83

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Date:
Sheet 2 of 2
What is the value determined for Kp?

The following values result for Kp and Tp for the setpoint value in the operating point:
Kp=2;
Tn=2;
Accuracy: The system deviation is completely corrected and maximum accuracy is therefore achieved.
This is due to the I component of the controller. Its function is to reach the exact setpoint value and
thus correct the system deviation between the input and output signal. The P component ensures a
fast system response.
Speed: A change in the parameters Kp and Tn influences the speed of the system. The greater the
reset time Tn, the greater is the rise time, whereby too small a selected Tn can result in overshoot. The
following applies for the proportional coefficient Kp: The larger the Kp, the smaller is the rise time. If
the Kp selected is too large, this results in overshoot of the characteristic curve and, in a worst case
scenario, in an oscillating system.
84
Solutions MPS PA Reactor station
Solution 3.1: Reactor station system analysis and appraisal

Name:
Date:
Sheet 1 of 2
85

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Sheet 2 of 2
Designation of
process components
No.
Designation
Meaning or function
Temperature sensor
TIC301
Reactor tank
B301
Stirrer
R304
Heater
W303
Cooling pump
P301
You will find two different designations for the heater in the electrical circuit diagram
and P&I diagram of the reactor station.
variables or other input variables, their processing, direction of action and positional data should
An EMCS point consists of a circle and is designated with a code letter (A-Z) and a code number. The
code letters are entered in the upper section of the EMCS circle and the numbering in the lower
section. The sequence of code letters can be established on the basis of the table "EMCS code letters
to DIN 19227".
The designation in an electrical circuit diagram describes an electrical function.
86

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Sheet 1 of 2
P&I diagram
87

Name:
Date:
Sheet 2 of 2
of components
Designation
Meaning or function
Heater
W303
Temperature sensor
TIC
Proximity sensor
LS+

LA+
Temperature sensor, alarm

TA+
Valve
V
What is the difference between the measuring point designations TIC and TA+?
What is the difference between the measuring point designations LA+ and LS+?
The designations TA+ and TIC are process designations. An EMCS point consists of an EMCS circle and
is designated with a code letter (A-Z) and a code number. The code letters are entered in the upper
section of the EMCS circle and the numbering in the lower section. The sequence of code letters is
established on the basis of the table "EMCS code letters to DIN 19227".
Example: T stands for temperature; I stands for display; C corresponds to automatic control, i.e. the
sensor supplies an analogue signal in the form of an actual value of the control loop.
TA corresponds to a sensor with alarm
The designations LA+ and LS+ differ with regard to their function within the station. Whilst both
sensors indicate the level of water within the tank, LA+ signals an error message (often used as
Emergency-Stop.
88

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Sheet 1 of 2
Component
Designation
Function
Characteristics
Heats water in the

reactor tank
Heating capacity [W]

Control voltage [V DC]
in flow
diagram
W303
Heater
1000 W
24 V
Temperature
TIC301
Measures water
The change in the electrical resistance of the
temperature
platinum wire is measured and converted
sensor
Pump
into a voltage
P301
Limit switch
top
LS+ 302
Limit switch
LS- 303
bottom
Transfers water via

pump
Measuring range [C]

Sensor resistor
-50 - 150C
PT100
Voltage [V]
24 V
Electric power [W]

26 W
9 l/min
Status, upper limit
value
Type (n. open/n.closed
Status, lower limit
value
Type (n. open/n.closed)
n.open
contact
n.open
contact
89

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Sheet 2 of 2
What is the resistance supplied by the temperature sensor for a temperature of

20 C?
What is the meaning of the term Pt100?
The sensor supplies a resistance of approx. 107.8 ohm for a temperature of 20C.
The temperature sensor contains a platinum resistance thermometer with a positive temperature
coefficient. The sensor has a basic resistance value of 100 ohm at 0C. (PT=Platinum).
90

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Sheet 1 of 3
Note
Allocation list of
digital inputs
Allocation list of
analogue inputs
For Simatic S7-300 CPU

Symbol
EasyPort /
PLC address
Description
Check
Simubox
address
3B1
DI 0
I 0.0
Temperature sensor
3B2
DI 1
I 0.1
3B3
DI 2
I 0.2
Not busy
DI 3
I 0.3
Not busy
Not busy
DI 4
I 0.4
Not busy
Not busy
DI 5
I 0.5
Not busy
Not busy
DI 6
I 0.6
Not busy
3PA_Free
DI 7
I 0.7

free
EasyPort /
PLC address
Designation
EW 256
Actual value X (temperature)
Symbol
Check
Simubox
address
3PV1
AI0
91

Name:
Date:
Sheet 2 of 3
Allocation list of
digital outputs
Allocation list of
analogue outputs
Symbol
PLC address
Designation
3M1
DO 0
O 0.0
Heater W303 on
3M2
DO 1
O 0.1
Pump P301
3M3
DO 2
O 0.2
Pump P302
3M4
DO 3
O 0.3
Stirrer R304
Not busy
DO 4
O 0.4
Not busy
Not busy
DO 5
O 0.5
Not busy
Not busy
DO 6
O 0.6
Not busy
2PA_Busy
DO 7
O 0.7
Sender PA Station busy
EasyPort /
PLC address
Designation
AW 256
Manipulated variable Y, (heater

W303)
Symbol
Check
Check
Simubox
address
3CO1
92
EasyPort /
Simubox
address
AO 0

Name:
Date:
Sheet 3 of 3
What particular situation in the reactor station should be considered if the

analogue final control element (heater) is to be digitally controlled?
To enable digital control of the analogue final control element, the bridge in the connection board
must be converted to digital.
93
Solution 3.2: Reactor station measurement and control

Name:
Date:
3.2.1 Characteristics of the heating system medium
Sheet 1 of 6
Measurement 1
Symbol
Designation
Parameter
3M1
Heater
Power P
3M1
Heater
Voltage V
3M1
Heater
Eficiency factor
H2O
Water
Specific heat capacity c
H2O
Water
H2O
Water
Desired temperature Tmax
36.C
H2O
Water
Temperature difference T
15 K
H2O
Water
Measurement 1 mass m
Heating time
Time t
P=
94
Value
522 W
5.2 V DC
0.8 ( 80%)
4182 J/(kg*K)
Minimum temperature (room temperature)

Tmin
21.C
4l
600 s
m c T
t

Name:
Date:
Sheet 2 of 6
Measurement 2
Symbol
Designation
Parameter
3M1
Heater
Power P
800 W
3M1
Heater
Voltage U
8 VDC
3M1
Heater
Efficiency factor
H2O
Water
H2O
Water
H2O
Water
44 C
H2O
Water
23 K
H2O
Water
Heating
time-
Time t
T =
Wert

Tmin
0,8 ( 80%)
4182 J/(kg*K)
21 C
4l
600 s
Pt
mc
Tmax = T + Tmin
95

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Date:
Sheet 3 of 6
Measurement 3
Symbol
Designation
Parameter
3M1
Heater
Power P
800 W
3M1
Heater
Voltage V
8 VDC
3M1
Heater
Efficiency factor
H2O
Water
H2O
Water
H2O
Water
33 C
H2O
Water
12 K
H2O
Water
Heating time
Time t
T =
96
Value
0.8 ( 80%)
4182 J/(kg*K)

Tmin
19,5 C
8l
600 s
Pt
m c

Name:
Date:
Sheet 4 of 6
Value table
measurement 1
Time in s
10
20
30
40
50
100
200
300
400
500
600
2.1
2.1
2.1
2.1
2.1
2.2
2.4
2.7
3.0
3.3
3.6
21
21
21
21
21
22
24
27
30
33
36
100
200
300
400
500
600
Temperature
sensor signal
in V
Temperature
in C.
4 l of water are heated.
Value table
measurement 2
Time in s
10
20
30
40
50
2.1
2.1
2.1
2.1
2.2
2.3
2.65
3.15
3.6
4.05
4.5
21
21
21
21.5
22
23
26.5
31.5
36
40.5
45
Temperature
sensor signal
in V
Temperature
in C.
Value table
measurement 3
Time in s
10
20
30
40
50
1.9
1.9
19
19
100
200
300
400
500
600
1.95
2.0
2.0
2.1
2.3
2.55
2.75
3.0
3.25
19,5
20
20
21
23
25.5
27.5
30
32.5
Temperature
sensor signal
in V
Temperature
in C.
97

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Date:
Sheet 5 of 6
Characteristic curve of
The controlled systems
98

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Date:
Sheet 6 of 6
How does the heating time change?

Compare the characteristic curves and discuss the possible causes which result
in the different characteristic curves.
How does the curve behaviour with double the quantity?
How does the curve behave if the heating capacity is increased?
How does the stirring influence the curve?
The speed of heating depends on the quantity of water and heating capacity.
The different values of the test parameters are the causes of the different characteristic curves. The fill
level quantity and the level of heating capacity considerably influence the test result. Thus, if the
heating capacity is doubled during the same test time, this results in temperature change almost
doubling, whereby if the quantity of water is doubled during the same test time and at the same
heating capacity the temperature change is virtually halved.
The stirring process ensures the water content is evenly heated during the test and also ensures a
virtually linear temperature curve.
99

Name:
Date:
Sheet 1 of 6
Pushbutton S1, to heat water

Pushbutton S2, to stirr water
Pushbutton S3, to recirculate water
Note
Solution has been realised using digital/analogue EasyPort and FluidSIM

Setting condition for heater W301
P&I
Electr.
diagram
symbol
circuit
Address
Logic
operation
Comment
diagram
symbol
S1
&
LS- 303
3B3
DI 2
&
Pushbutton
Sensor
Resetting condition for heater W301
100
P&I
Electr.
diagram
symbol
circuit
Address
Logic
Comment
operation
diagram
symbol
S1
LS- 303
3B3
DI 2
Not pushbutton
.
Not sensor

Name:
Date:
Sheet 2 of 6
Setting condition for stirrer R304

P&I
Electr.
diagram
symbol
circuit
Address
Comment
diagram
symbol
S2
LS- 303
Logic
operation
3B3
&
DI 2
&
Pushbutton
Sensor
Resetting condition for stirrer R304

P&I
Electr.
diagram
symbol
circuit
Address
Comment
diagram
symbol
S2
LS- 303
Logic
operation
3B3
DI 2
Not pushbutton
Not sensor
101

Name:
Date:
Sheet 3 of 6
Setting condition for pump 301

P&I
Electr.
diagram
symbol
circuit
Address
Logic
operation
Comment
diagram
symbol
S2
&
LS- 303
3B3
DI 2
&
LS- 302
3B2
DI1
&
Pushbutton
Sensor
Not sensor
(upper fill level at tank B301)
Resetting condition for pump 301

P&I
Electr.
diagram
symbol
circuit
Address
Comment
diagram
symbol
S2
102
Logic
operation
LS- 302
3B2
DI 1
LS- 303
3B3
DI 2
Not pushbutton
Sensor
(upper fill level at tank B301)
Not sensor

Name:
Date:
Sheet 4 of 6
Logic diagram
Network 1
Heater W301 on
Network 2
Stirrer R304 on
103

Name:
Date:
Sheet 5 of 6
Network 3
104
Pump P301

Name:
Date:
Sheet 6 of 6
Why must air in the piping system be avoided?

Air in the piping system prevents efficient operation of the system.
The pumps must be prevented from running dry as this will damage the pump.
105

Name:
Date:
Sheet 1 of 2
Note
The solution has been realised using digital/analogue EasyPort and FluidLab -PA.
Determining the operating point of the temperature control system
Temperature sensor
Operating range of heater
Temperature
[C]
Output signal
measuring transducer [V]
Room temperature
2.0
Operating point
40 C
4.0
Maximum measured
value
60 C
6.0
Minimum measured
value
106

Name:
Date:
Sheet 2 of 2
heater and the measuring range of the sensor.
Different system conditions can influence the operating range of the heating element and temperature
sensor. One aspect is the medium itself and the quantity to be heated. This aspect is to be considered
if other liquids apart from water are to be heated. In this case the different temperature coefficients
need to be taken into consideration. Furthermore, the fill level should not fall below the lower fill level
sensor. This may damage the heating element and water tank.
A further influencing factor is the tank in which the medium is heated. Here temperature maintenance,
i.e. the heat dissipated to the environment, plays a role, whereby the efficiency factor of the heating
process depends on the insulation of the water tank.
To enable you to work more easily with the characteristic curve plotted, it is important that the liquid
is evenly heated. Therefore the stirrer should be in continuous operation throughout the
measurement test. In the case of stagnant media, heat is not evenly distributed but only around the
heating element and temperature may vary considerably in the various areas of the water tank.
107

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Date:
Sheet 1 of 2
Tt T u
Tu
108

Name:
Date:
Sheet 2 of 2
Evaluation
What is the value of the are time constants Tt and Tu obtained?

Explain the system response?
Tt=7s
Tu=663s
The dead time in the example can be attributed to the fact that heating capacity is not fully available
at the heating element the moment it is switched on. It takes a while until the heating element outputs
the specified heating power to its environment. The medium between the heating element and
temperature sensor needs to be heated first and then the temperature sensor by the medium itself.
The first signal at the output is measured when the heated liquid reaches the sensor.
The slow system reaction results in a correspondingly high delay time. This depends on the quantity
and type of medium to be heated.
109
Solution 3.3: Reactor station closed-loop control

Name:
Date:
Sheet 1 of 2
Note
Parameter
Value
0.4
operating point
Example for digital increase in heating using a two-position controller
110

Name:
Date:
Sheet 2 of 2

Is a two-position controller suitable for this control task?
Describe the control response.
The system responds with an increase in the water temperature. If the preset threshold values are
exceeded or fallen short of, the heating is switched on or off. Depending on the quantity of the liquid,
such switching intervals can involve long time spans.
Two-position controllers are used most frequently for temperature control. Unlike in the case of other
control examples, such as speed control, the actual value does not need to be continuously
monitored, since it is not crucial to set the temperature value exactly at the setpoint value. However, a
two-position controller can be used nevertheless for precision control by adjusting the hysteresis
appropriately. The switching frequency can thus be influenced according to threshold values
specified.
111

Name:
Date:
Sheet 1 of 5
Note
Parameter
Dimensionless
Value
value
0.3
30
point
112

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Date:
Sheet 2 of 5
Implementation
P controller
Example for Kp = 10
113

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Date:
Sheet 3 of 5
Implementation
I controller
Example for Tn = 50
114

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Date:
Sheet 4 of 5
Implementation
PI controller
Example for Kp = 5, Tn = 50
115

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Date:
Sheet 5 of 5
How does the system respond with closed-loop control using PI controller?
settling time?
P controller: The system responds relatively fast. The disadvantage is the remaining system deviation
at the output. A P controller cannot be operated without a system deviation, i.e. the manipulated
variable would also be zero.
I controller: The system responds very slowly to a setpoint change. The advantage is that the system
deviation is corrected to zero.
PI controller: The system responds relatively fast to a setpoint change. The system deviation is
completely corrected. The PI controller combines the positive properties of P and I controllers. The
P component ensure a fast step response; the I controller ensures that the system deviation is
Kp=5 and Tn=50 result in the smallest overshoot and shortest settling time.
116

Name:
Date:
3.3.3 Tuning method according to the rate of rise
Sheet 1 of 4
Tt Tu
Vm ax =
Controller
PI
PID
Kp
KP =
Tn
X
t
Tv
100% y
VMAX TU y H
KP =
100% y
1.2 VMAX TU yH
KP =
100% y
0.83 VMAX TU yH
Y=
Maximum
correcting
range
(100%)
TN = 3.3 TU
TN = 2 TU
Description
TV = 0.5 TU
YH=
Specified
step height
117

Name:
Date:
Sheet 2 of 4
What are the values determined for Kp, Tn, Tv?

Kp: P controller:
PI controller:
PID controller:
1
= 2.14
(0.017 * 11) * 0.4
0.83
= 1.78
(0.017 * 11) * 0,4
1, 2
= 2,57
( 0.017 * 11) * 0.4
Tn: PI controller: 3.3 *11 = 36.3

PID controller: 2.0 *11 = 22
Tv: PID controller: 0.5 *11 = 5.5
On the basis of the preset parameters, different modes of behaviour can be established by the step
response. With closed-loop control using a P controller, the manipulated variable is set to a
predefined value. The manipulated variable decreases towards zero with decreasing system deviation.
The system deviation is not fully corrected.
In the case of a PI controller, the value of the manipulated variable increases to a certain point and
then slowly decreases as in the case of a P controller. The maximum value of the output variable is
above the setpoint value. A steady state can be assumed in this case since the cooling of the liquid is
associated with long periods.
The best result so far can be obtained with a PID controller, whereby the steady state is above the
setpoint value as in the case of a PI controller, although the setpoint value is reached more quickly in
the case of a PID controller.
118

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Date:
Sheet 3 of 4
Example of P controller
Example of PI controller
119

Name:
Date:
Sheet 4 of 4
Example of PID controller
120
Solutions MPS PA Bottling station
Solution 4.1: Bottling station system analysis and appraisal

Name:
Date:
Sheet 1 of 2
2
4
1
121

Name:
Date:
Sheet 2 of 2
Designation of
process components
No.
Designation
Meaning or function
Conveyor motor
4M3
Holding tank
B401
Metering tank
B402
Metering valve
V403
Feed separator
4M4
You will find two different designations for the metering valve in the electrical circuit
diagram and flow diagram for the bottling station.
variable or other input variables, their processing, direction of action and positional data should
An EMCS point consists of an EMCS circle and is designated with a code letter (A-Z) and a code
number. The code letters are entered in the upper section of the EMCS circle and the numbering in the
lower section. The sequence of code letters is established on the basis of the table "EMCS code letters
to DIN 19227".
The designation in an electrical circuit diagram describes an electrical function.

122

Name:
Date:
Sheet 1 of 2
P&I diagram
123

Name:
Date:
Sheet 2 of 2
of components
Designation
Meaning or function
Acoustic sensor
LIC 403
Proximity sensor
LS-

LA+
Analogue pump
P 401
Valve
V
What is the difference between V401 and V402?

What is the difference between the measuring point designations LA+ and LS+?
The valve V402 is a hand valve. V401 is a non-return valve. It allows a medium to flow in one direction
and inhibits it in the other direction.
The designations LA+ and LS+ differ with regard to their function within the station. Whereas both
sensors indicate the level of water in the tank, LA+ signals an error message. (often used as
Emergency-Stop.
124
Solution4.1: Bottling station system analysis and appraisal

Name:
Date:
Sheet 1 of 2
125
Solution4.1: Bottling station system analysis and appraisal

Name:
Date:
Sheet 2 of 2
pneumatic components
Symbol
Meaning or function
Silencer
5/2-way valve
Double-acting cylinder
What does the designation 5/2-way valve mean?

What is the function of a silencer?
compressed air. The remaining 4 ports are for the connection of working and exhaust lines. Depending
on design, the valve can be either pneumatically actuated via pilot air or electronically actuated.
The silencer reduces the noise levels of escaping air.
126

Name:
Date:
Sheet 1 of 2
Technical data
Component
Designation
Function
Pump
P401
Pumps water into

mixing tank
Characteristics
Voltage [V]
24 V
Electric power [W]

26 W
9 l/min
An acoustic signal is generated and the
Acoustic
4B1
sensor
Geared
motor
4B2
Limit switch
4B3
reflection time is measured. This signal is
of water.
converted into a voltage signal
Transports bottles
Limit switch
top
bottom
Measures the level
to the filling
position
Measuring range [mm]

Sensor signal [V]
300-50 mm
0-10 V
Voltage [V]
24 V
Nominal current[A]
1.5 A
Speed of
drive shaft [r.p.m.]
65 r.p.m.
Status, upper limit
value
in Tank B401
Type (n. open/n. closed contact)

n. open contact
Status, lower limit
value
in tank B401
Type (n. open/n. Closed contact)

n. open contact
127

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Date:
Sheet 2 of 2
What is the voltage supplied by the acoustic sensor for a filling quantity of 2l?
2.5l 10V
0l 0V
2l 8V
128

Name:
Date:
Sheet 1 of 3
Allocation list of
digital inputs
Allocation list of
analogue inputs
Symbol
EasyPort /
PLC address
Description
Check
Simubox
address
4B1
DI 0
I 0.0
Acoustic sensor B402
4B2
DI 1
I 0.1
4B3
DI 2
I 0.2
4B4
DI 3
I 0.3
Bottle at start of conveyor
4B5
DI 4
I 0.4
Bottle being filled
4B6
DI 5
I 0.5
Bottle at end of conveyor
Not busy
DI 6
I 0.6
Not busy
4PA_Free
DI 7
I 0.7
EasyPort /
PLC address
Description
EW256
Actual value X (fill level)
Symbol

free
Check
Simubox
address
4PV1
AI0
129

Name:
Date:
Sheet 2 of 3
Allocation list of
digital outputs
Allocation list of
analogue outputs
Symbol
PLC address
Description
4M1
DO 0
O 0.0
Pump P401 on
4M2
DO 1
O 0.1
Filling valve On
4M3
DO 2
O 0.2
Conveyor motor on
4M4
DO 3
O 0.3
Feed separator active
Not busy
DO 4
O 0.4
Not busy
Not busy
DO 5
O 0.5
Not busy
Not busy
DO 6
O 0.6
Not busy
4PA_Busy
DO 7
O 0.7
Sender PA station busy
EasyPort /
PLC address
Description
AW256
Manipulated variable Y, (pump

P401)
Symbol
Check
Check
Simubox
address
4CO1
130
EasyPort /
Simubox
address
AO 0

Name:
Date:
Sheet 3 of 3
What particular situation should be considered in the bottling station if the

analogue final control element (pump) is to be digitally controlled?
To enable digital control of the analogue final control element (pump), the bridge in the connection
board must be converted to digital.
131
Solution 4.2: Bottling station measurement and control

Name:
Date:
4.2.1 Characteristics of the metering tank/pump system
Sheet 1 of 4
Note
Value table
closed drain valve
Voltage at
pump
control in V
0.00
0.50
1.00
1.50
2.00
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
5.50
6.00
6.50
6.7
max
1.5
Max
2.0
3.00
3.50
4.00
4.50
5.00
0.0
0.0
0.0
0.0
1.2
3.3
0.0
0.0
0.0
0.0
0.0
0.18
0.5
7.00
7.50
8.00
8.50
9.00
9.50
max
max
max
max
max
max
max
max
max
max
max
max
max
max
max
max
Acoustic
sensor
signal in V
Fill level
in l.
Voltage at
pump
control in V
Acoustic
sensor in V
Fill level
in l.
10.00
Closed drain valve.
132

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Date:
Sheet 2 of 4
Value table
open drain valve
Voltage at
pump
control in V
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
4.50
5.00
sensor
signal in V
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
Fill level in l.
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
5.50
6.00
6.50
7.50
8.00
8.50
9.00
9.50
0.0
0.0
0.0
2.2
4.6
6.9
9.4
max
max
max
0.0
0.0
0.0
0.33
0.87
1.56
2.33
max
max
max.
Acoustic
Voltage at
pump
control in V
7.0
10.00
Acoustic
sensor
signal in V
Fill level
in l.
Drain valve fully open.
133

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Date:
Sheet 3 of 4
Note
Example for closed drain valve

Red characteristic curve: 5.0 V
Blue characteristic curve: 5.5 V
Green characteristic curve: 6.0 V
134

Name:
Date:
Sheet 4 of 4
Compare the characteristic curves and discuss the possible causes leading to
their differences.
Explain the reasons for the system behaviour at low voltages.
The back pressure in the metering tank is constantly increasing, the higher water level rises and
the pump has to counteract this. Depending on the rate of delivery of the pump a steady state
occurs where the fill level remains virtually constant.
The pump only pumps water into the metering tank as of approx. 4.5V if the drain valve is closed,
and as of 7V if the drain valve is fully open.
Note: The bend in the characteristic curve at 0.5 l can be attributed to the shape of the metering
tank. In the lower section, the volume is not linear in relation to the delivery height.
135

Name:
Date:
Sheet 1 of 6
Pushbutton S1, pumps water

Pushbutton S2, fills bottles
Pushbutton S3, transports bottles
Note
The solution has been realised using digital/analogue EasyPort and FluidSIM.

P&I
Electr.
diagram
symbol
circuit
Address
Logic
operation
Comment
diagram
symbol
S1
&
LS- 202
4B3
DI 2
&
Pushbutton
Sensor
Resetting condition for pump V401
136
P&I
Electr.
diagram
symbol
circuit
Address
Logic
operation
Comment
diagram
symbol
S1
Not pushbutton
S2
Pushbutton
LS- 202
4B3
DI 2
Not sensor

Name:
Date:
Sheet 2 of 6

P&I
Electr.
diagram
symbol
circuit
Address
Logic
operation
Comment
diagram
symbol
S2
&
4B5
DI4
&
Pushbutton
Diffuse sensor
(bottle at filling position)

P&I
Electr.
diagram
symbol
circuit
Address
Logic
Comment
operation
diagram
symbol
S1
S3
S2
4B5
DI4
Pushbutton
Pushbutton
Not pushbutton
Not diffuse sensor

137

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Date:
Sheet 3 of 6
Setting condition for conveyor motor 4M3

P&I
Electr.
diagram
symbol
circuit
Address
Logic
operation
Comment
diagram
symbol
S3
&
4B4
DI3
&
Pushbutton
Diffuse sensor
(bottle at start of conveyor)
Resetting condition for conveyor motor 4M3

P&I
Electr.
diagram
symbol
circuit
138
Address
Logic
operation
Comment
diagram
symbol
4B5
DI4
Diffuse sensor

Name:
Date:
Sheet 4 of 6
Logic diagram
Network 1
Pump P401 on
Network 2
Metering valve V403 on
139

Name:
Date:
Sheet 5 of 6
Network 3
140
Conveyor motor 4M3 on

Name:
Date:
Sheet 6 of 6
Why should air in the piping system be avoided?

Air in the piping system prevents correct operation of the system.
Pumps must be prevented from running dry as this will cause damage.
141

Name:
Date:
Sheet 1 of 1
Determining the operating point of the fill level control system

Acoustic sensor
operating range of pump
Manipulated
Minimum measured
value
Operating point
Maximum measured
value
variable of pump
P201 [V]
Fill level
[l]
Output signal [V]
0.5
3.3
5.5
1.5
6.6
2.5
9.9
pump and measuring range of the sensor.
Where does the linear range of the controlled system begin?
The position of the drain valve, piping system, mounting position of the sensor level, whether filling is
from the bottom or the top
The linear range of the controlled system begins at 0.5 l.
142

Name:
Date:
Sheet 1 of 2
63%
Ts
Example of the calculation of the time constant Ts
143

Name:
Date:
Sheet 2 of 2

What type of system is it, i.e. of what order?
What is/are the time constant(s) obtained?
Explain the reasons for the system behaviour?
System gain Ks= 0.867
PT1, 1st order system.
Ts= 59.5s
A characteristic of PT1 controlled systems is to run on to a final steady-state value when the energy
supplied = dissipated energy; in this case, the pump capacity against the pressure of the metering
tank.
144

Name:
Date:
4.2.5 Inflow and outflow behaviour of the metering tank
Sheet 1 of 6
Measurement 1
drain valve closed,
pump on
Pump voltage in V
Fill level [l]
Time [s]
Fill level [l]
Time [s]
0.5
4.0
1.8
15.25
0.6
5.2
1.9
16.0
0.7
6.2
2.0
17.0
0.8
6.7
2.1
17.75
0.9
8.0
2.2
18.5
1.0
8.5
2.3
19.5
1.1
9.0
2.4
20.25
1.2
10.25
2.5
21.00
1.3
11.25
2.6
1.4
12.0
2.7
1.5
13.0
2.8
1.6
13.75
2.9
1.7
14.5
3.0
145

Name:
Date:
Sheet 2 of 6
Measurement 2
drain valve open,
pump off
146
Pump voltage in V
Fill level [l]
0V
Time [s]
Fill level [l]
Time [s]
3.0
1.7
9.6
2.9
1.6
10.8
2.8
1.5
12.0
2.7
1.4
13.2
2.6
1.3
14.4
2.5
1.2
15.6
2.4
1,5
1.1
17.0
2.3
2,6
1.0
18.2
2.2
3,8
0.9
19.4
2.1
5,0
0.8
20.6
2.0
6,2
0.7
21.8
1.9
7,4
0.6
23.2
1.8
8,6
0.5
24.6
Solution 4.2: Bottling station Messen und Steuern

Name:
Date:
Sheet 3 of 6
Measurement 3
drain valve open,
pump on
Pump voltage in V
Fill level [l]
Time [s]
Fill level [l]
Time [s]
0.5
10
1.8
37.5
0.6
11
1.9
41
0.7
13
2.0
44
0.8
15
2.1
47
0.9
17
2.2
50
1.0
19
2.3
54
1.1
21
2.4
57.5
1.2
23
2.5
61.5
1.3
25
2.6
1.4
27
2.7
1.5
29.5
2.8
1.6
32.5
2.9
1.7
35
3.0
147

Name:
Date:
Sheet 4 of 6
Example of inflow behaviour filling from the bottom with drain valve closed
Example for outfow behaviour
148

Name:
Date:
Sheet 5 of 6
Example for inflow behaviour filling from the bottom with drain valve open
Special solution:
Example for inflow behaviour filling from the top with drain valve closed
149

Name:
Date:
Sheet 6 of 6
How does the curve progress in measurement 1?

What is the difference between the curve progressions of measurements 1
and 3?
Why does the curve progression of measurement 2 exhibit a decaying behaviour?
A linear behaviour is evident in measurement 1, provided that the pump capacity is sufficiently high.
In the case of measurement 3, the filling process takes longer until the metering tank is full and a
decaying behaviour is also apparent. This can be attributed to the fact that the pump not only has to
counteract the water pressure in the metering tank, but in addition also has to cope with the drain
quantity rate.
Measurement 2 exhibits linear as opposed to decaying behaviour. The cause of this is that the level in
the metering tank is not sufficient to illustrate this. The slightly different progression from 0.5 l can be
attributed to the shape of the metering tank.
In the case of measurement 3, the open drain valve prevents a rapid rise of liquid in the metering tank
since part of the liquid delivered flows back into the holding tank via the open valve. However, since
the outflow via the valve is less than the inflow via the pump, part of the liquid reaches the metering
tank and the fill level gradually increases. If the system moves into its steady state (fill level does not
rise further), the liquid is pumped back virtually directly into the holding tank via the drain valve, since
the set pump performance is no longer sufficient to overcome the water pressure in the metering tank.
The water pressure practically seals the metering tank.
150
Solution 4.3: Bottling station closed-loop control

Name:
Date:
Sheet 1 of 2
Note
Parameter
Value
0.67
operating point
Upper switching value
0.1
Lower switching value
0.1
Example of two-position controller
151

Name:
Date:
Sheet 2 of 2

State some typical areas of application of a two-position controller.
With this controller type, the manipulated variable can only assume two defines states, in our example
0V and 10V(Vmax). The output of the controller switches to and fro between these two states
depending on whether the upper or lower threshold value is exceeded. In our example the
manipulated variable increases to its maximum value at the moment of switch-on until the controlled
variable reaches the upper threshold value. The pump is switched off and the controlled variable now
decreases until the lower threshold value is reached when the reverse process takes over.
The two-position controller is particularly suitable for the control of systems with large time constants.
Other areas of application are for example the control of a reservoir (compressor), the control of room
temperature or humidity.
152

Name:
Date:
Sheet 1 of 5
Note
Parameter
Dimensionless
Value
value
0.67
1.51
point
153

Name:
Date:
Sheet 2 of 5
P controller
Example for Kpr = 10
154

Name:
Date:
Sheet 3 of 5
I controller
Example for Tn = 10
155

Name:
Date:
Sheet 4 of 5
PI controller
Example for Kpr = 2, Tn = 5
156

Name:
Date:
Sheet 5 of 5
How does the system react with closed-loop control using an I controller?
How does the system react with closed-loop control using a PI controller?
settling time?
Which controller is suitable for this controlled system if the system deviation is to
be corrected to 0?
P controller: The system responds relatively fast to the input step. The disadvantage is the remaining
system deviation. If the Kp selected is too large, the system starts to oscillate.
I controller: The system responds very slowly to a setpoint change. The advantage is that the system
deviation is corrected to zero after a certain period. If the Tn is too small, the system becomes limit
stable? or instable.
PI controller: The system responds relatively fast to a setpoint change. The system deviation is
completely corrected. The PI controller combines the positive characteristics of a P and I controller.
The P component ensures a fast step response, the I controller ensures that the system deviations are
Kpr=2 and Tn =5 result in the smallest overshoot.
Both a PI controller and an I controller would be suitable. The PI controller reaches the settling time
fastest.
157

Name:
Date:
4.3.3 Controller tuning according to Chien-Hrones-Reswick
Sheet 1 of 2
Note
The solution has been realised using digital/analogue EasyPort and FluidLab PA.
Tg
Tu
158

Name:
Date:
4.3.3 Controller tuning according to Chien-Hrones-Reswick
Sheet 2 of 2
Which controller have you selected and why?

What are the values determined for Kp, Tn, Tv?
What criteria do you use to evaluate your result?
Kp: P controller:
0.3 Tg 0.3 7
* = 2.1
*
=
Ks Ts
1 1
PI controller:
0.35 Tg 0.35 7
*
=
* = 2.45
1
1
Ks Ts
PID controller:
0.6 Tg 0.6 7
*
=
* = 4. 2
1 1
Ks Tu
Tn: PI controller: 1.2 * Tu = 1.2 *1 = 1.2

PID controller:
Tg= 7
Tv: PID controller: 0.5 * Tu = 0.5 *1 = 0.5
With the preset parameters, various behaviours can be observed from the step response. In the case
of closed-loop control using a P controller, the output signal is relatively quick in the steady state,
although the system deviation cannot be corrected. If the test is carried out using a PI controller, a
slight overshoot can be observed. The setpoint value is reached quickly without remaining system
deviation. The PID controller corrects the system deviations the fastest. A steady state is obtained
after a few small overshoots.
159
160

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Solutions Filtration station

Solution 1.1: Analysis and appraisal of the system

Solution 2.1: Analysis and appraisal of the system

Solution 2.2: Measurement and control

Solution 2.3: Closed-loop control

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Solutions Reactor station

Solution 3.1: Analysis and appraisal of the system

Solution 3.2: Measurement and control

Solutions Filling station

Solution 4.1: Analysis and appraisal of the system

Solution 4.2: Measurement and control

Solution 4.3: Closed-loop control

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Solutions MPS PA Filtration station

Solution 1.1: Filtration station system analysis and appraisal

1.1.1 Designation of process components

Designation of process components

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Solutions MPS PA Filtration station

Solution1.1: Filtration station system analysis and appraisal

1.1.1 Designation of process components

3-way ball valve

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Solutions MPS PA Filtration station

Solution 1.1: Filtration station system analysis and appraisal

1.1.2 Completing the P&I diagram

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Solutions MPS PA Filtration station

Solution 1.1: Filtration station system analysis and appraisal

1.1.2 Completing the P&I diagram

Status, limit value alarm

State the difference between the measuring point designations

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Solutions MPS PA Filtration station

Solution 1.1: Filtration station system analysis and appraisal

1.1.3 Completing the pneumatic circuit diagram

Pneumatic circuit diagram

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Solutions MPS PA Filtration station

Solution 1.1: Filtration station system analysis and appraisal

1.1.3 Pneumatischen Schaltplan vervollstndigen

Butterfly valve with pneumatic swivel actuator

What is the meaning of the 5/2-way valve designation?

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Solutions MPS PA Filtration station

Solution 1.1: Filtration station system analysis and appraisal

1.1.4 Determining the technical data of a system

Min. pneum. pressure [bar]

Pressure range [bar]

Status, upper limit

Setpoint voltage [V]

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Max. throughput [l/min]

Electrical power [W]

from a tank via the

Status, lower limit

Filling amount up to contact [l] 6 l

Filling amount up to contact [l] 0 l

Solutions MPS PA Filtration station