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Transcript of Armfield Process Plant Trainer
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 18
The Armfield Process Plant Trainer can be used to demonstrate a
complete range of process control methods and strategies
Manual control single feedback loops through to sophisticated cascade
loops and distributed supervisory control of the whole process by a
remotely located computer can be demonstrated
The system is a miniature replication of a true production process The
student is presented with real process control problems with realistic
dynamic behaviour and instabilities
KEY FEATURES
gt Multiple inputs multiple sensors multiple control strategies
- Manual control single feedback loops through to sophisticated
cascade loops
gt Temperature level flow and conductivity control loops can
be implemented
gt Effects of lsquodead timersquo
gt Operational sequencing including startup and shutdown
gt Recycle implications on process control
gt Onoff proportioning PID PLC SCADA
gt Fault simulation and diagnosis
gt Includes computer interface (USB) plus sophisticated LabVIEWtrade based
educational and data logging software
ISSUE 4The latest version of this data sheet is available at
wwwarmfieldcoukpct23mkii
PROCESS PLANT TRAINER 991251 PCT23MKIIPCT SERIES PROCESS CONTROL TECHNOLOGY
ExcludingDLMxrange
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 28
PCT23MkII Control console
The PCT23MkII is a bench top process controlsystem comprising a process unit mounted
on an ABS plinth an electrical control consoleand control software which can be run onany Windows PC with a spare USB port
a) Process Unit
The process is modelled on an industrial hightemperature short time (HTST) pasteurisation processIn this process the product stream has to be kept ata predetermined temperature for a minimum timeusually for bacteriological purposes This is effectedby the use of a holding tube which delays theproduct stream thus posing particular process controlproblems and introducing the concept of lsquodead timersquo
Other reasons why the HTST process is a particularlysuitable basis for teaching process control are theuse of a three stage heat exchanger (recycle heatingand cooling) and the use of a divert valve to rejectinadequately treated product Again these importantindustrial principles pose real process controlproblems and help maintain the studentsrsquo interest
Further process control problems are illustrated by theuse of two feed tanks with different level sensor types
Solenoid driven valves control the filling and emptyingof these tanks These enable different level controlstrategies to be developed and provide startup andshutdown operational sequencing capability
The unit includes a wide range of instrumentation fortemperature and flow measurement It also includesa conductivity sensor enabling simple processconcentration experiments to be performed
The unit comprises
bull Feed system with peristaltic pump
bull Water heating unit with peristaltic pumpbull Water cooling system
bull Plate heat exchanger with holding tube
bull Flow sensor in feed line
bull Conductivity sensor
bull Four temperature sensors
bull Level sensor in product tank
bull Highlow level switches in washingreagent tank
bull 2-way solenoid valves for filling feed tanks andcooling water to exchanger
bull 3-way solenoid valves for selectingfeed tank and diverting waste product
bull Connections to the electrical console
b) Control Console
The control console provides the electrical interfaceand signal conditioning for the process module It alsoincludes a USB interface for a Windowsreg computerThe process module sensor outputs can be displayedin engineering units on an integral LED display Theoutputs are also available for external monitoring
The drive signals to the process module can beselected as either manual control from the front panelcontrol from a PC via the USB bus onoff control froman external source (eg the Armfield PCT19BR PLC)or analogue control from an external source (eg theArmfield PCT20H PID) The source signals for bothpumps and the heater are individually selectable
Electrical faults may be introduced into any of thelow voltage measurement or control signals by a faultemulator installed in the electrical console Faultsmay be inserted individually or in combination to suitthe studentrsquos ability The quick release fittings usedthroughout the process enable faults to be introducedinto the process pipework
The unit comprises
bull Product feed pump speed control
bull Heating fluid pump speed controlbull Heater power measurement and control
bull Temperature (x 4) flow level ampconductivity measurement
bull Digital inputsoutputs(from switchesto solenoid valves)
bull Simultaneous connection of all signals to PCT19BRvia 50 way IDC connector or PC via USB port
bull Front panel sockets for connection to accessories inparticular industrial controllers and chart recorder
DESCRIPTION
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 38
Software data screen showing graph plotting facilities daggerSoftware process screen dagger
PCT23MkII Control console rear viewPCT23MkII Control console side switches
c) Software
Included in the basic equipment supply is an advancededucational software package which implementsthe control functions The software displays a realtime process mimic diagram and includes PIDcontrol algorithms with user control over thekey parameters A number of predefined studentexercises are implemented such as alarm actions andacknowledgements different single PID loops cascadeand multiple PID loops
Included in the software is a sophisticated datalogging and graphical display capability This capabilitycan be used even when the control signals are derivedexternally or manually The data can be saved andrecalled or exported in Microsoftreg Excel format
Other facilities included in the software are a series ofpresentation screens to aid in the setting up using theequipment analysing the results etc This is backed upby a comprehensive Help system
Advanced users may wish to produce their owncontrol software using packages such as LabVIEWtrade
MatLab or lsquoCrsquo This is possible using the USB interfaceon the PCT23 as the low level software driver (DLL) isaccessible and interfacing instructions are provided
For more advanced use an optional software packagehas been developed for use with the ArmfieldPCT19BR to demonstrate SCADA This package (ordercode PCT23SCADA) enables the PLC to control theprocess and extracts the data from the PLC via anRS232 connection The PLC data is then displayed onthe mimic diagram giving the PC the supervisory roleof the SCADA implementation
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 48
Heatedvessel
T2
Power
T1
T3
LL
HL
L1
C
SOL1
SOL3
SOL2
SOL5SOL4
V1
V3
PRV1
N2
T4
F1N1
Hot water
Holding tube
dead time
Alarm activated
valve
Diverted product
Recycle stream
Drain
Cold water
Finished product
Feed
Alarms
Washtreat
sequencing valves
Process flow diagram
The Armfield PCT23MkII Process Plant trainer is designed to cover course topics ranging from a first introduction to
the subject of process control through to demonstrations of the latest advanced techniques including the use of
on-line mathematical models
PRACTICAL TRAINING EXERCISES
PCT23MkII TRAINING EXERCISES
bull Plant monitoring using a PCbull Calibration of sensorsbull Process dynamics I - Direct heating - Indirect heat exchange - Dead time - Step changes - Heat losses efficiencybull Process dynamics II
- Interactions between loops - Heat regeneration - Indirect cooling - Understanding process duty
and its implicationsbull Direct Digital Control using a PC - PID control of level - PID control of flow - PID control of temperature - PID control of conductivity - Indirect PID control of temperature - Indirect PID control with dead time - PID control with alarm
driven disturbances - Controller optimisation - Controller optimisation with
dead time - Two loop cascade control - Two loop control and interactions - Three loop controlbull Fault finding and diagnostics
TRAINING EXERCISES USING
EXTERNAL CONTROLLERS
bull Using an external controller - Controller setup for level flow
temperature and conductivity - Onoff control - PID time-proportioned control - PID proportional control - Alarm functions - Comparison of control requirements
- Manual tuning of a PID controller - Automatic tuning of a PID controller - Introduction to SCADAbull PID control using a PLC - Introduction to ladder logic - One PID loop two PID loops alarmsbull Sequencing plant operation using a PLC
under SCADA
requires one Armfield PCT20H Industrial PID Controller
requires one Armfield PCT19BR Industrial PLC Unit
ADVANCED PROCESS CONTROL
The equipment is also ideal for more advancedprocess control topics and for both project andresearch work
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 58
Fig 3 Dual-loop control using Windows software
- Product temperature T1 controlling hot water circulation rate
- Hot water temperature T2 controlling heater power (PWR)
Note reaction between T1 T
2 and PWR as a result of setpoint change to T
1 (up 50C then down 50C)
T e m p e r a t u r e
0 C
Time in minutes
80
70
60
50
40
0 10 20 30 40 50 60
Change in T 1
setpoint
5160 to 566
0
Change in T 2
setpoint
5660 to 516
0
T 2
T 1
Fig 2 Controlling power consumption with and without a recycle-loop Product temperature T1
controlling power (PWR)
T e m p e r a t u r e
0 C
Time in minutes
75
70
65
60
55
50
45
PWR = 700W
PWR = 350W
0 10 20 30 40 50 60
Normal Divert (loss of regeneration)
Fig 1 Open-loop temperature responses to a step in change (in power) Use of a lsquoreaction curversquomethod to obtain optimum P+I+D settings for a process temperature (T
1 T
2 and T
4) to control the
power to the heater vessel
T1 = Process temperature after holding tube
T2 = Hot water circulating temperature
T3 = Process temperature before holding tube
T e m p e r a t u r e
0 C
Time in minutes
90
85
80
75
70
65
60
55
50
T 2
T 4
T 1
950W
Step in power
Dead time of holding tube750W
0 10 20 30 40 50
33
DETAILED PRACTICAL WORK ASSIGNMENTS
PCT23MkII Process Plant Trainer including LabVIEWtradesoftware with user provided PC 1a) Manual control with software performing data
acquisition and monitoring tasks only i) Gaining familiarity with screen based flow
sheet mimic diagrams for monitoringprocess variables level temperature flowconductivity and power
ii) Understanding how changing one processvariable (eg flow rate) affects the others (egtemperature)
iii) Measuring responses to step changeseg characterising the hot water tank
as a lsquofirst-order systemrsquo the holding tube aslsquodead timersquo and the plate heat exchanger asa combination of both types ofsystem (Fig1)
iv) Downloading data to a user providedspreadsheet for subsequent analysis
1b) Automatic control with software performing
control tasks setting up and studying i) Single-loop PID with hot water temperature
controlling the power to the heater ii) Single-loop PID with product
temperature controlling heater power iii) The effect of adding lsquodead timersquo of the
holding tube to the single control loopiv) The effect of recycling heated product
through the heat exchanger on controlaction (Fig 2)
v) The effect on control action of including analarm-activated diverter valve
vi) Cascade control whereby producttemperature controls the hot watertemperature setpoint which in turn
controls the heater power vii) Multi-variable control flow control ofthe product stream producttemperature controlling the hot waterflow rate hot water temperaturecontrolling the heater power (Fig 3)
viii) Fault simulation and diagnosis by theinstructor switching out selected signals
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 68
PCT23MkII Process Plant Trainer including LabVIEWtradesoftware with user provided PC
2a) All of the single-loop studies listed as1b) i) to v) with the control actions being setup and performed by the PCT20H controllerconnected to the front panel of the PCT23MkIIconsole (also onoff and time proportionedPID control)
The PCT23MkII software may be used to logsimultaneously the plant data to a PC (Fig 4)
2b) Supervision of the Industrial Controller (PCT20H)by PC based software - ie an introduction toSCADA with serial communications from the PC to
and from the controller2c) Alternative single-loops including levelflow and conductivity control alternativetemperature control loops
For each of the single control loops selectedfrom the above practical exercises on thefollowing topics are possible
gt Onoff control
gt Setting up
gt P I and D values
gt Tuning a controller for optimum performancegt Automanual transfer
gt Stability tests
PCT23MkII Process Plant Trainer with two PCT20HIndustrial PID Controllers3a) Cascade control as in 1b)vi) but using
the controllers connected to the plant in place ofdirect PC control
3b) Two input two output control with theproduct temperature controlling the
feed pump and the hot watercirculating temperature controlling theheater power Demonstration oflsquointeractingrsquo control is possible
3c) Feed forward control with product flowrate controlling the hot water circulating rate inaddition to heater power being controlled by hotwater temperature
PCT23MkII Process Plant Trainer with a single PCT19BRIndustrial PLC Unit
4a) Connecting a PLC to a process4b) Use of ladder logic to set up control
and monitoring tasks (requires a PC)4c) Single-loop onoff and PID control studies4d) Setting of alarms in conjunction with PID
control loops4e) Two-loop control strategies as in 3b)4f) Using digital inputs and outputs alarms and control
valve actionsAdditionally a SCADA software package is available(PCT23SCADA) which in conjunction with PCT23MkIIand PCT19BR enables studies ofg) lsquoPoint to pointrsquo SCADA operation via a user
provided PCh) Sequencing of plant operation a five-stage
sequence may be set up
gt Fill tanks
gt Preheating
gt Heat processing
gt Fill wash tank
gt WashThis sequence may be carried out by the PCT19BR
PLC alone or under SCADA operation from the PCwith mimic diagram display of the progress of thesequencing
Fig 4 Single closed loop response using PCT20H Industrial PID Controller Product temperatureleaving holding tube (T
1)
controlling heater power (PWR) (optimum P+I settings from Fig1)
T e m p e r a t u r e
0 C
75
70
65
60
55
50
45
PWR = 700W
PWR = 350W
0 10 20 30 40 50 60
Normal Divert (loss of regeneration)
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 78
TECHNICAL SPECIFICATION OPTIONAL ACCESSORIES
Flow rate rangesProduct stream 0-480mlminWashing reagent 0-480mlmin
Heating fluid 0-600mlminMax temperatureof heating fluid 80degCHeat exchanger Plate typeFeed and reagentvessel capacities 57 litres (each)Heating vessel capacity 37 litresSignal voltages 0-5VLevel sensor range 0-250mmFlow sensor range 0-500mlminTemperature sensor range 0-100degC(all 0-5V dc output) PCT19BR Industrial PLC Unit
Safety features
RCD in the console all circuits protected by MCBrsquos 24Vdc operation of solenoid valves and pump motorsHeating vesselbull Thermostat limiting max tempbull Low level switchbull Vent to avoid pressurisation
ESSENTIAL ACCESSORIES
PC computerThe customer needs to provide a PC running Windows7 8 98 2000 ME or XP with a spare USB port
(Not supplied)
Ordering Codes
PCT19BR Industrial PLC Unit
PLC unit incorporating Allen Bradley SLC500 complete
with proprietary ladder logic set-up program (requiringuser supplied PC)This program is initially configured by Armfield fortwo analog inputoutput control loops suited to thePCT23MkII Process Plant Trainer unit but may bereconfigured by users via their PC
PCT23SCADA SCADA SoftwareThis software contains the facilities required todemonstrate SCADA using the Armfield PCT23MkIIand PCT19BR
It includesbull SLC500 ladder logic routines written specifically for
the PCT23MkIIbull The communications facilities to enable the
PCT23MkII software to display and data log theSLC500 parameters
bull The additional exercises for the PCT23MkIIenabling SCADA to be demonstrated in thesame manner as the other exercises
PCT20H Industrial PID Controller
PID controller incorporating a Honeywell UDC3200series unit with voltagemA input and output forsingle-loop control and alarm configurations Asoftware package is supplied on disk to demonstratethe basic principles of SCADA whereby a user suppliedPC can address the PID controller directly
PCT19BR Industrial PLC Unit
PCT19BR Industrial PLC Unit
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 88
FOR FURTHER INFORMATION ON THE ADVANCED FEATURES OF THESOPHISTICATED ARMFIELD SOFTWARE VISIT
wwwdiscoverarmfieldcoukdataarmsoft
REQUIREMENTS
Electrical supply PCT23MkII-A 220-240V1ph50Hz
PCT23MkII-B 120V1ph60HzPCT23MkII-G 220V1ph60Hz
Cold water supply 4 lmin 2 bar
PC computer (not supplied by Armfield)See Essential Accessories for minimum specification
OVERALL DIMENSIONS
Process unit Console Height 0550m 0280mWidth 1000m 0425mDepth 0530m 0400m
SHIPPING DIMENSIONS
Volume 12msup3Gross weight 167kg
ORDERING SPECIFICATION
bull A bench mounted process plant trainerwith multiple streams both interacting andnoninteracting The process plant incorporates aminiature three-stage plate heat exchanger heatedfrom a hot water circulator two independent feedtanks a holding tube with product divert valve andtwo variable-speed peristaltic pumps
bull Temperature level flow and conductivity controlloops can be implemented
bull Manual control single feedback loops through
to sophisticated cascade loops and distributed
supervisory control of the whole process by a
remotely located computer can be demonstrated
bull The effect of lsquodead timersquo and heat recycle canbe demonstrated
bull An electrical console provides measurement andcontrol of the process plant and enables a varietyof control techniques including manual operationonoff control control from an external signal andcontrol from a PC or PLC
bull The equipment incorporates electrical faultsimulation and control data logging software and aUSB computer interface
ltEXTENDEDgt
WARRANTY
2 years
copy2011 Armfield Ltd All R ights Reser ved
Head Office Armfield LimitedBridge House West Street
Ringwood HampshireBH24 1DY England
Telephone +44 1425 478781Fax +44 1425 470916E-mail salesarmfieldcouk
US Office Armfield Inc436 West Commodore Blvd (2)
Jackson NJ 08527
Telephone (732) 928 3332Fax (732) 928 3542E-mail infoarmfieldinccom
An ISO 9001 Company
Innovators in Engineering Teaching Equipment
f
Scan QR code to visit our website Scan with smartphone with
QR code scanning software installed
Find us on YouTubewwwyoutubecomuserarmfieldUK
Follow us on Twitter FacebookLinkedIn and
dP
Head Office Armfield LimitedBridge House West Street
Ringwood HampshireBH24 1DY England
Telephone +44 1425 478781Fax +44 1425 470916E-mail salesarmfieldcouk
US Office Armfield Inc9 Trenton - Lakewood Road
Clarksburg NJ 08510TelFax (609) 208-2800E-mail infoarmfieldinccom
An ISO 9001 Company
Innovators in Engineering Teaching Equipment
l armfield co k
Find us on YouTubewwwyoutubecomuserarmfieldUK
Follow us on Twitter FacebookLinkedIn andWordPress
Scan QR code to visit our website Scan with smartphone with
QR code scanning software installed
copy 2014 Armfield Ltd A ll Rights Rese rved
W th i ht t d th ifi ti ith t i ti EampOE 07143k
ExcludingDLMxrange
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 28
PCT23MkII Control console
The PCT23MkII is a bench top process controlsystem comprising a process unit mounted
on an ABS plinth an electrical control consoleand control software which can be run onany Windows PC with a spare USB port
a) Process Unit
The process is modelled on an industrial hightemperature short time (HTST) pasteurisation processIn this process the product stream has to be kept ata predetermined temperature for a minimum timeusually for bacteriological purposes This is effectedby the use of a holding tube which delays theproduct stream thus posing particular process controlproblems and introducing the concept of lsquodead timersquo
Other reasons why the HTST process is a particularlysuitable basis for teaching process control are theuse of a three stage heat exchanger (recycle heatingand cooling) and the use of a divert valve to rejectinadequately treated product Again these importantindustrial principles pose real process controlproblems and help maintain the studentsrsquo interest
Further process control problems are illustrated by theuse of two feed tanks with different level sensor types
Solenoid driven valves control the filling and emptyingof these tanks These enable different level controlstrategies to be developed and provide startup andshutdown operational sequencing capability
The unit includes a wide range of instrumentation fortemperature and flow measurement It also includesa conductivity sensor enabling simple processconcentration experiments to be performed
The unit comprises
bull Feed system with peristaltic pump
bull Water heating unit with peristaltic pumpbull Water cooling system
bull Plate heat exchanger with holding tube
bull Flow sensor in feed line
bull Conductivity sensor
bull Four temperature sensors
bull Level sensor in product tank
bull Highlow level switches in washingreagent tank
bull 2-way solenoid valves for filling feed tanks andcooling water to exchanger
bull 3-way solenoid valves for selectingfeed tank and diverting waste product
bull Connections to the electrical console
b) Control Console
The control console provides the electrical interfaceand signal conditioning for the process module It alsoincludes a USB interface for a Windowsreg computerThe process module sensor outputs can be displayedin engineering units on an integral LED display Theoutputs are also available for external monitoring
The drive signals to the process module can beselected as either manual control from the front panelcontrol from a PC via the USB bus onoff control froman external source (eg the Armfield PCT19BR PLC)or analogue control from an external source (eg theArmfield PCT20H PID) The source signals for bothpumps and the heater are individually selectable
Electrical faults may be introduced into any of thelow voltage measurement or control signals by a faultemulator installed in the electrical console Faultsmay be inserted individually or in combination to suitthe studentrsquos ability The quick release fittings usedthroughout the process enable faults to be introducedinto the process pipework
The unit comprises
bull Product feed pump speed control
bull Heating fluid pump speed controlbull Heater power measurement and control
bull Temperature (x 4) flow level ampconductivity measurement
bull Digital inputsoutputs(from switchesto solenoid valves)
bull Simultaneous connection of all signals to PCT19BRvia 50 way IDC connector or PC via USB port
bull Front panel sockets for connection to accessories inparticular industrial controllers and chart recorder
DESCRIPTION
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 38
Software data screen showing graph plotting facilities daggerSoftware process screen dagger
PCT23MkII Control console rear viewPCT23MkII Control console side switches
c) Software
Included in the basic equipment supply is an advancededucational software package which implementsthe control functions The software displays a realtime process mimic diagram and includes PIDcontrol algorithms with user control over thekey parameters A number of predefined studentexercises are implemented such as alarm actions andacknowledgements different single PID loops cascadeand multiple PID loops
Included in the software is a sophisticated datalogging and graphical display capability This capabilitycan be used even when the control signals are derivedexternally or manually The data can be saved andrecalled or exported in Microsoftreg Excel format
Other facilities included in the software are a series ofpresentation screens to aid in the setting up using theequipment analysing the results etc This is backed upby a comprehensive Help system
Advanced users may wish to produce their owncontrol software using packages such as LabVIEWtrade
MatLab or lsquoCrsquo This is possible using the USB interfaceon the PCT23 as the low level software driver (DLL) isaccessible and interfacing instructions are provided
For more advanced use an optional software packagehas been developed for use with the ArmfieldPCT19BR to demonstrate SCADA This package (ordercode PCT23SCADA) enables the PLC to control theprocess and extracts the data from the PLC via anRS232 connection The PLC data is then displayed onthe mimic diagram giving the PC the supervisory roleof the SCADA implementation
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 48
Heatedvessel
T2
Power
T1
T3
LL
HL
L1
C
SOL1
SOL3
SOL2
SOL5SOL4
V1
V3
PRV1
N2
T4
F1N1
Hot water
Holding tube
dead time
Alarm activated
valve
Diverted product
Recycle stream
Drain
Cold water
Finished product
Feed
Alarms
Washtreat
sequencing valves
Process flow diagram
The Armfield PCT23MkII Process Plant trainer is designed to cover course topics ranging from a first introduction to
the subject of process control through to demonstrations of the latest advanced techniques including the use of
on-line mathematical models
PRACTICAL TRAINING EXERCISES
PCT23MkII TRAINING EXERCISES
bull Plant monitoring using a PCbull Calibration of sensorsbull Process dynamics I - Direct heating - Indirect heat exchange - Dead time - Step changes - Heat losses efficiencybull Process dynamics II
- Interactions between loops - Heat regeneration - Indirect cooling - Understanding process duty
and its implicationsbull Direct Digital Control using a PC - PID control of level - PID control of flow - PID control of temperature - PID control of conductivity - Indirect PID control of temperature - Indirect PID control with dead time - PID control with alarm
driven disturbances - Controller optimisation - Controller optimisation with
dead time - Two loop cascade control - Two loop control and interactions - Three loop controlbull Fault finding and diagnostics
TRAINING EXERCISES USING
EXTERNAL CONTROLLERS
bull Using an external controller - Controller setup for level flow
temperature and conductivity - Onoff control - PID time-proportioned control - PID proportional control - Alarm functions - Comparison of control requirements
- Manual tuning of a PID controller - Automatic tuning of a PID controller - Introduction to SCADAbull PID control using a PLC - Introduction to ladder logic - One PID loop two PID loops alarmsbull Sequencing plant operation using a PLC
under SCADA
requires one Armfield PCT20H Industrial PID Controller
requires one Armfield PCT19BR Industrial PLC Unit
ADVANCED PROCESS CONTROL
The equipment is also ideal for more advancedprocess control topics and for both project andresearch work
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 58
Fig 3 Dual-loop control using Windows software
- Product temperature T1 controlling hot water circulation rate
- Hot water temperature T2 controlling heater power (PWR)
Note reaction between T1 T
2 and PWR as a result of setpoint change to T
1 (up 50C then down 50C)
T e m p e r a t u r e
0 C
Time in minutes
80
70
60
50
40
0 10 20 30 40 50 60
Change in T 1
setpoint
5160 to 566
0
Change in T 2
setpoint
5660 to 516
0
T 2
T 1
Fig 2 Controlling power consumption with and without a recycle-loop Product temperature T1
controlling power (PWR)
T e m p e r a t u r e
0 C
Time in minutes
75
70
65
60
55
50
45
PWR = 700W
PWR = 350W
0 10 20 30 40 50 60
Normal Divert (loss of regeneration)
Fig 1 Open-loop temperature responses to a step in change (in power) Use of a lsquoreaction curversquomethod to obtain optimum P+I+D settings for a process temperature (T
1 T
2 and T
4) to control the
power to the heater vessel
T1 = Process temperature after holding tube
T2 = Hot water circulating temperature
T3 = Process temperature before holding tube
T e m p e r a t u r e
0 C
Time in minutes
90
85
80
75
70
65
60
55
50
T 2
T 4
T 1
950W
Step in power
Dead time of holding tube750W
0 10 20 30 40 50
33
DETAILED PRACTICAL WORK ASSIGNMENTS
PCT23MkII Process Plant Trainer including LabVIEWtradesoftware with user provided PC 1a) Manual control with software performing data
acquisition and monitoring tasks only i) Gaining familiarity with screen based flow
sheet mimic diagrams for monitoringprocess variables level temperature flowconductivity and power
ii) Understanding how changing one processvariable (eg flow rate) affects the others (egtemperature)
iii) Measuring responses to step changeseg characterising the hot water tank
as a lsquofirst-order systemrsquo the holding tube aslsquodead timersquo and the plate heat exchanger asa combination of both types ofsystem (Fig1)
iv) Downloading data to a user providedspreadsheet for subsequent analysis
1b) Automatic control with software performing
control tasks setting up and studying i) Single-loop PID with hot water temperature
controlling the power to the heater ii) Single-loop PID with product
temperature controlling heater power iii) The effect of adding lsquodead timersquo of the
holding tube to the single control loopiv) The effect of recycling heated product
through the heat exchanger on controlaction (Fig 2)
v) The effect on control action of including analarm-activated diverter valve
vi) Cascade control whereby producttemperature controls the hot watertemperature setpoint which in turn
controls the heater power vii) Multi-variable control flow control ofthe product stream producttemperature controlling the hot waterflow rate hot water temperaturecontrolling the heater power (Fig 3)
viii) Fault simulation and diagnosis by theinstructor switching out selected signals
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 68
PCT23MkII Process Plant Trainer including LabVIEWtradesoftware with user provided PC
2a) All of the single-loop studies listed as1b) i) to v) with the control actions being setup and performed by the PCT20H controllerconnected to the front panel of the PCT23MkIIconsole (also onoff and time proportionedPID control)
The PCT23MkII software may be used to logsimultaneously the plant data to a PC (Fig 4)
2b) Supervision of the Industrial Controller (PCT20H)by PC based software - ie an introduction toSCADA with serial communications from the PC to
and from the controller2c) Alternative single-loops including levelflow and conductivity control alternativetemperature control loops
For each of the single control loops selectedfrom the above practical exercises on thefollowing topics are possible
gt Onoff control
gt Setting up
gt P I and D values
gt Tuning a controller for optimum performancegt Automanual transfer
gt Stability tests
PCT23MkII Process Plant Trainer with two PCT20HIndustrial PID Controllers3a) Cascade control as in 1b)vi) but using
the controllers connected to the plant in place ofdirect PC control
3b) Two input two output control with theproduct temperature controlling the
feed pump and the hot watercirculating temperature controlling theheater power Demonstration oflsquointeractingrsquo control is possible
3c) Feed forward control with product flowrate controlling the hot water circulating rate inaddition to heater power being controlled by hotwater temperature
PCT23MkII Process Plant Trainer with a single PCT19BRIndustrial PLC Unit
4a) Connecting a PLC to a process4b) Use of ladder logic to set up control
and monitoring tasks (requires a PC)4c) Single-loop onoff and PID control studies4d) Setting of alarms in conjunction with PID
control loops4e) Two-loop control strategies as in 3b)4f) Using digital inputs and outputs alarms and control
valve actionsAdditionally a SCADA software package is available(PCT23SCADA) which in conjunction with PCT23MkIIand PCT19BR enables studies ofg) lsquoPoint to pointrsquo SCADA operation via a user
provided PCh) Sequencing of plant operation a five-stage
sequence may be set up
gt Fill tanks
gt Preheating
gt Heat processing
gt Fill wash tank
gt WashThis sequence may be carried out by the PCT19BR
PLC alone or under SCADA operation from the PCwith mimic diagram display of the progress of thesequencing
Fig 4 Single closed loop response using PCT20H Industrial PID Controller Product temperatureleaving holding tube (T
1)
controlling heater power (PWR) (optimum P+I settings from Fig1)
T e m p e r a t u r e
0 C
75
70
65
60
55
50
45
PWR = 700W
PWR = 350W
0 10 20 30 40 50 60
Normal Divert (loss of regeneration)
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 78
TECHNICAL SPECIFICATION OPTIONAL ACCESSORIES
Flow rate rangesProduct stream 0-480mlminWashing reagent 0-480mlmin
Heating fluid 0-600mlminMax temperatureof heating fluid 80degCHeat exchanger Plate typeFeed and reagentvessel capacities 57 litres (each)Heating vessel capacity 37 litresSignal voltages 0-5VLevel sensor range 0-250mmFlow sensor range 0-500mlminTemperature sensor range 0-100degC(all 0-5V dc output) PCT19BR Industrial PLC Unit
Safety features
RCD in the console all circuits protected by MCBrsquos 24Vdc operation of solenoid valves and pump motorsHeating vesselbull Thermostat limiting max tempbull Low level switchbull Vent to avoid pressurisation
ESSENTIAL ACCESSORIES
PC computerThe customer needs to provide a PC running Windows7 8 98 2000 ME or XP with a spare USB port
(Not supplied)
Ordering Codes
PCT19BR Industrial PLC Unit
PLC unit incorporating Allen Bradley SLC500 complete
with proprietary ladder logic set-up program (requiringuser supplied PC)This program is initially configured by Armfield fortwo analog inputoutput control loops suited to thePCT23MkII Process Plant Trainer unit but may bereconfigured by users via their PC
PCT23SCADA SCADA SoftwareThis software contains the facilities required todemonstrate SCADA using the Armfield PCT23MkIIand PCT19BR
It includesbull SLC500 ladder logic routines written specifically for
the PCT23MkIIbull The communications facilities to enable the
PCT23MkII software to display and data log theSLC500 parameters
bull The additional exercises for the PCT23MkIIenabling SCADA to be demonstrated in thesame manner as the other exercises
PCT20H Industrial PID Controller
PID controller incorporating a Honeywell UDC3200series unit with voltagemA input and output forsingle-loop control and alarm configurations Asoftware package is supplied on disk to demonstratethe basic principles of SCADA whereby a user suppliedPC can address the PID controller directly
PCT19BR Industrial PLC Unit
PCT19BR Industrial PLC Unit
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 88
FOR FURTHER INFORMATION ON THE ADVANCED FEATURES OF THESOPHISTICATED ARMFIELD SOFTWARE VISIT
wwwdiscoverarmfieldcoukdataarmsoft
REQUIREMENTS
Electrical supply PCT23MkII-A 220-240V1ph50Hz
PCT23MkII-B 120V1ph60HzPCT23MkII-G 220V1ph60Hz
Cold water supply 4 lmin 2 bar
PC computer (not supplied by Armfield)See Essential Accessories for minimum specification
OVERALL DIMENSIONS
Process unit Console Height 0550m 0280mWidth 1000m 0425mDepth 0530m 0400m
SHIPPING DIMENSIONS
Volume 12msup3Gross weight 167kg
ORDERING SPECIFICATION
bull A bench mounted process plant trainerwith multiple streams both interacting andnoninteracting The process plant incorporates aminiature three-stage plate heat exchanger heatedfrom a hot water circulator two independent feedtanks a holding tube with product divert valve andtwo variable-speed peristaltic pumps
bull Temperature level flow and conductivity controlloops can be implemented
bull Manual control single feedback loops through
to sophisticated cascade loops and distributed
supervisory control of the whole process by a
remotely located computer can be demonstrated
bull The effect of lsquodead timersquo and heat recycle canbe demonstrated
bull An electrical console provides measurement andcontrol of the process plant and enables a varietyof control techniques including manual operationonoff control control from an external signal andcontrol from a PC or PLC
bull The equipment incorporates electrical faultsimulation and control data logging software and aUSB computer interface
ltEXTENDEDgt
WARRANTY
2 years
copy2011 Armfield Ltd All R ights Reser ved
Head Office Armfield LimitedBridge House West Street
Ringwood HampshireBH24 1DY England
Telephone +44 1425 478781Fax +44 1425 470916E-mail salesarmfieldcouk
US Office Armfield Inc436 West Commodore Blvd (2)
Jackson NJ 08527
Telephone (732) 928 3332Fax (732) 928 3542E-mail infoarmfieldinccom
An ISO 9001 Company
Innovators in Engineering Teaching Equipment
f
Scan QR code to visit our website Scan with smartphone with
QR code scanning software installed
Find us on YouTubewwwyoutubecomuserarmfieldUK
Follow us on Twitter FacebookLinkedIn and
dP
Head Office Armfield LimitedBridge House West Street
Ringwood HampshireBH24 1DY England
Telephone +44 1425 478781Fax +44 1425 470916E-mail salesarmfieldcouk
US Office Armfield Inc9 Trenton - Lakewood Road
Clarksburg NJ 08510TelFax (609) 208-2800E-mail infoarmfieldinccom
An ISO 9001 Company
Innovators in Engineering Teaching Equipment
l armfield co k
Find us on YouTubewwwyoutubecomuserarmfieldUK
Follow us on Twitter FacebookLinkedIn andWordPress
Scan QR code to visit our website Scan with smartphone with
QR code scanning software installed
copy 2014 Armfield Ltd A ll Rights Rese rved
W th i ht t d th ifi ti ith t i ti EampOE 07143k
ExcludingDLMxrange
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 38
Software data screen showing graph plotting facilities daggerSoftware process screen dagger
PCT23MkII Control console rear viewPCT23MkII Control console side switches
c) Software
Included in the basic equipment supply is an advancededucational software package which implementsthe control functions The software displays a realtime process mimic diagram and includes PIDcontrol algorithms with user control over thekey parameters A number of predefined studentexercises are implemented such as alarm actions andacknowledgements different single PID loops cascadeand multiple PID loops
Included in the software is a sophisticated datalogging and graphical display capability This capabilitycan be used even when the control signals are derivedexternally or manually The data can be saved andrecalled or exported in Microsoftreg Excel format
Other facilities included in the software are a series ofpresentation screens to aid in the setting up using theequipment analysing the results etc This is backed upby a comprehensive Help system
Advanced users may wish to produce their owncontrol software using packages such as LabVIEWtrade
MatLab or lsquoCrsquo This is possible using the USB interfaceon the PCT23 as the low level software driver (DLL) isaccessible and interfacing instructions are provided
For more advanced use an optional software packagehas been developed for use with the ArmfieldPCT19BR to demonstrate SCADA This package (ordercode PCT23SCADA) enables the PLC to control theprocess and extracts the data from the PLC via anRS232 connection The PLC data is then displayed onthe mimic diagram giving the PC the supervisory roleof the SCADA implementation
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 48
Heatedvessel
T2
Power
T1
T3
LL
HL
L1
C
SOL1
SOL3
SOL2
SOL5SOL4
V1
V3
PRV1
N2
T4
F1N1
Hot water
Holding tube
dead time
Alarm activated
valve
Diverted product
Recycle stream
Drain
Cold water
Finished product
Feed
Alarms
Washtreat
sequencing valves
Process flow diagram
The Armfield PCT23MkII Process Plant trainer is designed to cover course topics ranging from a first introduction to
the subject of process control through to demonstrations of the latest advanced techniques including the use of
on-line mathematical models
PRACTICAL TRAINING EXERCISES
PCT23MkII TRAINING EXERCISES
bull Plant monitoring using a PCbull Calibration of sensorsbull Process dynamics I - Direct heating - Indirect heat exchange - Dead time - Step changes - Heat losses efficiencybull Process dynamics II
- Interactions between loops - Heat regeneration - Indirect cooling - Understanding process duty
and its implicationsbull Direct Digital Control using a PC - PID control of level - PID control of flow - PID control of temperature - PID control of conductivity - Indirect PID control of temperature - Indirect PID control with dead time - PID control with alarm
driven disturbances - Controller optimisation - Controller optimisation with
dead time - Two loop cascade control - Two loop control and interactions - Three loop controlbull Fault finding and diagnostics
TRAINING EXERCISES USING
EXTERNAL CONTROLLERS
bull Using an external controller - Controller setup for level flow
temperature and conductivity - Onoff control - PID time-proportioned control - PID proportional control - Alarm functions - Comparison of control requirements
- Manual tuning of a PID controller - Automatic tuning of a PID controller - Introduction to SCADAbull PID control using a PLC - Introduction to ladder logic - One PID loop two PID loops alarmsbull Sequencing plant operation using a PLC
under SCADA
requires one Armfield PCT20H Industrial PID Controller
requires one Armfield PCT19BR Industrial PLC Unit
ADVANCED PROCESS CONTROL
The equipment is also ideal for more advancedprocess control topics and for both project andresearch work
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 58
Fig 3 Dual-loop control using Windows software
- Product temperature T1 controlling hot water circulation rate
- Hot water temperature T2 controlling heater power (PWR)
Note reaction between T1 T
2 and PWR as a result of setpoint change to T
1 (up 50C then down 50C)
T e m p e r a t u r e
0 C
Time in minutes
80
70
60
50
40
0 10 20 30 40 50 60
Change in T 1
setpoint
5160 to 566
0
Change in T 2
setpoint
5660 to 516
0
T 2
T 1
Fig 2 Controlling power consumption with and without a recycle-loop Product temperature T1
controlling power (PWR)
T e m p e r a t u r e
0 C
Time in minutes
75
70
65
60
55
50
45
PWR = 700W
PWR = 350W
0 10 20 30 40 50 60
Normal Divert (loss of regeneration)
Fig 1 Open-loop temperature responses to a step in change (in power) Use of a lsquoreaction curversquomethod to obtain optimum P+I+D settings for a process temperature (T
1 T
2 and T
4) to control the
power to the heater vessel
T1 = Process temperature after holding tube
T2 = Hot water circulating temperature
T3 = Process temperature before holding tube
T e m p e r a t u r e
0 C
Time in minutes
90
85
80
75
70
65
60
55
50
T 2
T 4
T 1
950W
Step in power
Dead time of holding tube750W
0 10 20 30 40 50
33
DETAILED PRACTICAL WORK ASSIGNMENTS
PCT23MkII Process Plant Trainer including LabVIEWtradesoftware with user provided PC 1a) Manual control with software performing data
acquisition and monitoring tasks only i) Gaining familiarity with screen based flow
sheet mimic diagrams for monitoringprocess variables level temperature flowconductivity and power
ii) Understanding how changing one processvariable (eg flow rate) affects the others (egtemperature)
iii) Measuring responses to step changeseg characterising the hot water tank
as a lsquofirst-order systemrsquo the holding tube aslsquodead timersquo and the plate heat exchanger asa combination of both types ofsystem (Fig1)
iv) Downloading data to a user providedspreadsheet for subsequent analysis
1b) Automatic control with software performing
control tasks setting up and studying i) Single-loop PID with hot water temperature
controlling the power to the heater ii) Single-loop PID with product
temperature controlling heater power iii) The effect of adding lsquodead timersquo of the
holding tube to the single control loopiv) The effect of recycling heated product
through the heat exchanger on controlaction (Fig 2)
v) The effect on control action of including analarm-activated diverter valve
vi) Cascade control whereby producttemperature controls the hot watertemperature setpoint which in turn
controls the heater power vii) Multi-variable control flow control ofthe product stream producttemperature controlling the hot waterflow rate hot water temperaturecontrolling the heater power (Fig 3)
viii) Fault simulation and diagnosis by theinstructor switching out selected signals
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 68
PCT23MkII Process Plant Trainer including LabVIEWtradesoftware with user provided PC
2a) All of the single-loop studies listed as1b) i) to v) with the control actions being setup and performed by the PCT20H controllerconnected to the front panel of the PCT23MkIIconsole (also onoff and time proportionedPID control)
The PCT23MkII software may be used to logsimultaneously the plant data to a PC (Fig 4)
2b) Supervision of the Industrial Controller (PCT20H)by PC based software - ie an introduction toSCADA with serial communications from the PC to
and from the controller2c) Alternative single-loops including levelflow and conductivity control alternativetemperature control loops
For each of the single control loops selectedfrom the above practical exercises on thefollowing topics are possible
gt Onoff control
gt Setting up
gt P I and D values
gt Tuning a controller for optimum performancegt Automanual transfer
gt Stability tests
PCT23MkII Process Plant Trainer with two PCT20HIndustrial PID Controllers3a) Cascade control as in 1b)vi) but using
the controllers connected to the plant in place ofdirect PC control
3b) Two input two output control with theproduct temperature controlling the
feed pump and the hot watercirculating temperature controlling theheater power Demonstration oflsquointeractingrsquo control is possible
3c) Feed forward control with product flowrate controlling the hot water circulating rate inaddition to heater power being controlled by hotwater temperature
PCT23MkII Process Plant Trainer with a single PCT19BRIndustrial PLC Unit
4a) Connecting a PLC to a process4b) Use of ladder logic to set up control
and monitoring tasks (requires a PC)4c) Single-loop onoff and PID control studies4d) Setting of alarms in conjunction with PID
control loops4e) Two-loop control strategies as in 3b)4f) Using digital inputs and outputs alarms and control
valve actionsAdditionally a SCADA software package is available(PCT23SCADA) which in conjunction with PCT23MkIIand PCT19BR enables studies ofg) lsquoPoint to pointrsquo SCADA operation via a user
provided PCh) Sequencing of plant operation a five-stage
sequence may be set up
gt Fill tanks
gt Preheating
gt Heat processing
gt Fill wash tank
gt WashThis sequence may be carried out by the PCT19BR
PLC alone or under SCADA operation from the PCwith mimic diagram display of the progress of thesequencing
Fig 4 Single closed loop response using PCT20H Industrial PID Controller Product temperatureleaving holding tube (T
1)
controlling heater power (PWR) (optimum P+I settings from Fig1)
T e m p e r a t u r e
0 C
75
70
65
60
55
50
45
PWR = 700W
PWR = 350W
0 10 20 30 40 50 60
Normal Divert (loss of regeneration)
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 78
TECHNICAL SPECIFICATION OPTIONAL ACCESSORIES
Flow rate rangesProduct stream 0-480mlminWashing reagent 0-480mlmin
Heating fluid 0-600mlminMax temperatureof heating fluid 80degCHeat exchanger Plate typeFeed and reagentvessel capacities 57 litres (each)Heating vessel capacity 37 litresSignal voltages 0-5VLevel sensor range 0-250mmFlow sensor range 0-500mlminTemperature sensor range 0-100degC(all 0-5V dc output) PCT19BR Industrial PLC Unit
Safety features
RCD in the console all circuits protected by MCBrsquos 24Vdc operation of solenoid valves and pump motorsHeating vesselbull Thermostat limiting max tempbull Low level switchbull Vent to avoid pressurisation
ESSENTIAL ACCESSORIES
PC computerThe customer needs to provide a PC running Windows7 8 98 2000 ME or XP with a spare USB port
(Not supplied)
Ordering Codes
PCT19BR Industrial PLC Unit
PLC unit incorporating Allen Bradley SLC500 complete
with proprietary ladder logic set-up program (requiringuser supplied PC)This program is initially configured by Armfield fortwo analog inputoutput control loops suited to thePCT23MkII Process Plant Trainer unit but may bereconfigured by users via their PC
PCT23SCADA SCADA SoftwareThis software contains the facilities required todemonstrate SCADA using the Armfield PCT23MkIIand PCT19BR
It includesbull SLC500 ladder logic routines written specifically for
the PCT23MkIIbull The communications facilities to enable the
PCT23MkII software to display and data log theSLC500 parameters
bull The additional exercises for the PCT23MkIIenabling SCADA to be demonstrated in thesame manner as the other exercises
PCT20H Industrial PID Controller
PID controller incorporating a Honeywell UDC3200series unit with voltagemA input and output forsingle-loop control and alarm configurations Asoftware package is supplied on disk to demonstratethe basic principles of SCADA whereby a user suppliedPC can address the PID controller directly
PCT19BR Industrial PLC Unit
PCT19BR Industrial PLC Unit
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 88
FOR FURTHER INFORMATION ON THE ADVANCED FEATURES OF THESOPHISTICATED ARMFIELD SOFTWARE VISIT
wwwdiscoverarmfieldcoukdataarmsoft
REQUIREMENTS
Electrical supply PCT23MkII-A 220-240V1ph50Hz
PCT23MkII-B 120V1ph60HzPCT23MkII-G 220V1ph60Hz
Cold water supply 4 lmin 2 bar
PC computer (not supplied by Armfield)See Essential Accessories for minimum specification
OVERALL DIMENSIONS
Process unit Console Height 0550m 0280mWidth 1000m 0425mDepth 0530m 0400m
SHIPPING DIMENSIONS
Volume 12msup3Gross weight 167kg
ORDERING SPECIFICATION
bull A bench mounted process plant trainerwith multiple streams both interacting andnoninteracting The process plant incorporates aminiature three-stage plate heat exchanger heatedfrom a hot water circulator two independent feedtanks a holding tube with product divert valve andtwo variable-speed peristaltic pumps
bull Temperature level flow and conductivity controlloops can be implemented
bull Manual control single feedback loops through
to sophisticated cascade loops and distributed
supervisory control of the whole process by a
remotely located computer can be demonstrated
bull The effect of lsquodead timersquo and heat recycle canbe demonstrated
bull An electrical console provides measurement andcontrol of the process plant and enables a varietyof control techniques including manual operationonoff control control from an external signal andcontrol from a PC or PLC
bull The equipment incorporates electrical faultsimulation and control data logging software and aUSB computer interface
ltEXTENDEDgt
WARRANTY
2 years
copy2011 Armfield Ltd All R ights Reser ved
Head Office Armfield LimitedBridge House West Street
Ringwood HampshireBH24 1DY England
Telephone +44 1425 478781Fax +44 1425 470916E-mail salesarmfieldcouk
US Office Armfield Inc436 West Commodore Blvd (2)
Jackson NJ 08527
Telephone (732) 928 3332Fax (732) 928 3542E-mail infoarmfieldinccom
An ISO 9001 Company
Innovators in Engineering Teaching Equipment
f
Scan QR code to visit our website Scan with smartphone with
QR code scanning software installed
Find us on YouTubewwwyoutubecomuserarmfieldUK
Follow us on Twitter FacebookLinkedIn and
dP
Head Office Armfield LimitedBridge House West Street
Ringwood HampshireBH24 1DY England
Telephone +44 1425 478781Fax +44 1425 470916E-mail salesarmfieldcouk
US Office Armfield Inc9 Trenton - Lakewood Road
Clarksburg NJ 08510TelFax (609) 208-2800E-mail infoarmfieldinccom
An ISO 9001 Company
Innovators in Engineering Teaching Equipment
l armfield co k
Find us on YouTubewwwyoutubecomuserarmfieldUK
Follow us on Twitter FacebookLinkedIn andWordPress
Scan QR code to visit our website Scan with smartphone with
QR code scanning software installed
copy 2014 Armfield Ltd A ll Rights Rese rved
W th i ht t d th ifi ti ith t i ti EampOE 07143k
ExcludingDLMxrange
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 48
Heatedvessel
T2
Power
T1
T3
LL
HL
L1
C
SOL1
SOL3
SOL2
SOL5SOL4
V1
V3
PRV1
N2
T4
F1N1
Hot water
Holding tube
dead time
Alarm activated
valve
Diverted product
Recycle stream
Drain
Cold water
Finished product
Feed
Alarms
Washtreat
sequencing valves
Process flow diagram
The Armfield PCT23MkII Process Plant trainer is designed to cover course topics ranging from a first introduction to
the subject of process control through to demonstrations of the latest advanced techniques including the use of
on-line mathematical models
PRACTICAL TRAINING EXERCISES
PCT23MkII TRAINING EXERCISES
bull Plant monitoring using a PCbull Calibration of sensorsbull Process dynamics I - Direct heating - Indirect heat exchange - Dead time - Step changes - Heat losses efficiencybull Process dynamics II
- Interactions between loops - Heat regeneration - Indirect cooling - Understanding process duty
and its implicationsbull Direct Digital Control using a PC - PID control of level - PID control of flow - PID control of temperature - PID control of conductivity - Indirect PID control of temperature - Indirect PID control with dead time - PID control with alarm
driven disturbances - Controller optimisation - Controller optimisation with
dead time - Two loop cascade control - Two loop control and interactions - Three loop controlbull Fault finding and diagnostics
TRAINING EXERCISES USING
EXTERNAL CONTROLLERS
bull Using an external controller - Controller setup for level flow
temperature and conductivity - Onoff control - PID time-proportioned control - PID proportional control - Alarm functions - Comparison of control requirements
- Manual tuning of a PID controller - Automatic tuning of a PID controller - Introduction to SCADAbull PID control using a PLC - Introduction to ladder logic - One PID loop two PID loops alarmsbull Sequencing plant operation using a PLC
under SCADA
requires one Armfield PCT20H Industrial PID Controller
requires one Armfield PCT19BR Industrial PLC Unit
ADVANCED PROCESS CONTROL
The equipment is also ideal for more advancedprocess control topics and for both project andresearch work
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 58
Fig 3 Dual-loop control using Windows software
- Product temperature T1 controlling hot water circulation rate
- Hot water temperature T2 controlling heater power (PWR)
Note reaction between T1 T
2 and PWR as a result of setpoint change to T
1 (up 50C then down 50C)
T e m p e r a t u r e
0 C
Time in minutes
80
70
60
50
40
0 10 20 30 40 50 60
Change in T 1
setpoint
5160 to 566
0
Change in T 2
setpoint
5660 to 516
0
T 2
T 1
Fig 2 Controlling power consumption with and without a recycle-loop Product temperature T1
controlling power (PWR)
T e m p e r a t u r e
0 C
Time in minutes
75
70
65
60
55
50
45
PWR = 700W
PWR = 350W
0 10 20 30 40 50 60
Normal Divert (loss of regeneration)
Fig 1 Open-loop temperature responses to a step in change (in power) Use of a lsquoreaction curversquomethod to obtain optimum P+I+D settings for a process temperature (T
1 T
2 and T
4) to control the
power to the heater vessel
T1 = Process temperature after holding tube
T2 = Hot water circulating temperature
T3 = Process temperature before holding tube
T e m p e r a t u r e
0 C
Time in minutes
90
85
80
75
70
65
60
55
50
T 2
T 4
T 1
950W
Step in power
Dead time of holding tube750W
0 10 20 30 40 50
33
DETAILED PRACTICAL WORK ASSIGNMENTS
PCT23MkII Process Plant Trainer including LabVIEWtradesoftware with user provided PC 1a) Manual control with software performing data
acquisition and monitoring tasks only i) Gaining familiarity with screen based flow
sheet mimic diagrams for monitoringprocess variables level temperature flowconductivity and power
ii) Understanding how changing one processvariable (eg flow rate) affects the others (egtemperature)
iii) Measuring responses to step changeseg characterising the hot water tank
as a lsquofirst-order systemrsquo the holding tube aslsquodead timersquo and the plate heat exchanger asa combination of both types ofsystem (Fig1)
iv) Downloading data to a user providedspreadsheet for subsequent analysis
1b) Automatic control with software performing
control tasks setting up and studying i) Single-loop PID with hot water temperature
controlling the power to the heater ii) Single-loop PID with product
temperature controlling heater power iii) The effect of adding lsquodead timersquo of the
holding tube to the single control loopiv) The effect of recycling heated product
through the heat exchanger on controlaction (Fig 2)
v) The effect on control action of including analarm-activated diverter valve
vi) Cascade control whereby producttemperature controls the hot watertemperature setpoint which in turn
controls the heater power vii) Multi-variable control flow control ofthe product stream producttemperature controlling the hot waterflow rate hot water temperaturecontrolling the heater power (Fig 3)
viii) Fault simulation and diagnosis by theinstructor switching out selected signals
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 68
PCT23MkII Process Plant Trainer including LabVIEWtradesoftware with user provided PC
2a) All of the single-loop studies listed as1b) i) to v) with the control actions being setup and performed by the PCT20H controllerconnected to the front panel of the PCT23MkIIconsole (also onoff and time proportionedPID control)
The PCT23MkII software may be used to logsimultaneously the plant data to a PC (Fig 4)
2b) Supervision of the Industrial Controller (PCT20H)by PC based software - ie an introduction toSCADA with serial communications from the PC to
and from the controller2c) Alternative single-loops including levelflow and conductivity control alternativetemperature control loops
For each of the single control loops selectedfrom the above practical exercises on thefollowing topics are possible
gt Onoff control
gt Setting up
gt P I and D values
gt Tuning a controller for optimum performancegt Automanual transfer
gt Stability tests
PCT23MkII Process Plant Trainer with two PCT20HIndustrial PID Controllers3a) Cascade control as in 1b)vi) but using
the controllers connected to the plant in place ofdirect PC control
3b) Two input two output control with theproduct temperature controlling the
feed pump and the hot watercirculating temperature controlling theheater power Demonstration oflsquointeractingrsquo control is possible
3c) Feed forward control with product flowrate controlling the hot water circulating rate inaddition to heater power being controlled by hotwater temperature
PCT23MkII Process Plant Trainer with a single PCT19BRIndustrial PLC Unit
4a) Connecting a PLC to a process4b) Use of ladder logic to set up control
and monitoring tasks (requires a PC)4c) Single-loop onoff and PID control studies4d) Setting of alarms in conjunction with PID
control loops4e) Two-loop control strategies as in 3b)4f) Using digital inputs and outputs alarms and control
valve actionsAdditionally a SCADA software package is available(PCT23SCADA) which in conjunction with PCT23MkIIand PCT19BR enables studies ofg) lsquoPoint to pointrsquo SCADA operation via a user
provided PCh) Sequencing of plant operation a five-stage
sequence may be set up
gt Fill tanks
gt Preheating
gt Heat processing
gt Fill wash tank
gt WashThis sequence may be carried out by the PCT19BR
PLC alone or under SCADA operation from the PCwith mimic diagram display of the progress of thesequencing
Fig 4 Single closed loop response using PCT20H Industrial PID Controller Product temperatureleaving holding tube (T
1)
controlling heater power (PWR) (optimum P+I settings from Fig1)
T e m p e r a t u r e
0 C
75
70
65
60
55
50
45
PWR = 700W
PWR = 350W
0 10 20 30 40 50 60
Normal Divert (loss of regeneration)
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 78
TECHNICAL SPECIFICATION OPTIONAL ACCESSORIES
Flow rate rangesProduct stream 0-480mlminWashing reagent 0-480mlmin
Heating fluid 0-600mlminMax temperatureof heating fluid 80degCHeat exchanger Plate typeFeed and reagentvessel capacities 57 litres (each)Heating vessel capacity 37 litresSignal voltages 0-5VLevel sensor range 0-250mmFlow sensor range 0-500mlminTemperature sensor range 0-100degC(all 0-5V dc output) PCT19BR Industrial PLC Unit
Safety features
RCD in the console all circuits protected by MCBrsquos 24Vdc operation of solenoid valves and pump motorsHeating vesselbull Thermostat limiting max tempbull Low level switchbull Vent to avoid pressurisation
ESSENTIAL ACCESSORIES
PC computerThe customer needs to provide a PC running Windows7 8 98 2000 ME or XP with a spare USB port
(Not supplied)
Ordering Codes
PCT19BR Industrial PLC Unit
PLC unit incorporating Allen Bradley SLC500 complete
with proprietary ladder logic set-up program (requiringuser supplied PC)This program is initially configured by Armfield fortwo analog inputoutput control loops suited to thePCT23MkII Process Plant Trainer unit but may bereconfigured by users via their PC
PCT23SCADA SCADA SoftwareThis software contains the facilities required todemonstrate SCADA using the Armfield PCT23MkIIand PCT19BR
It includesbull SLC500 ladder logic routines written specifically for
the PCT23MkIIbull The communications facilities to enable the
PCT23MkII software to display and data log theSLC500 parameters
bull The additional exercises for the PCT23MkIIenabling SCADA to be demonstrated in thesame manner as the other exercises
PCT20H Industrial PID Controller
PID controller incorporating a Honeywell UDC3200series unit with voltagemA input and output forsingle-loop control and alarm configurations Asoftware package is supplied on disk to demonstratethe basic principles of SCADA whereby a user suppliedPC can address the PID controller directly
PCT19BR Industrial PLC Unit
PCT19BR Industrial PLC Unit
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 88
FOR FURTHER INFORMATION ON THE ADVANCED FEATURES OF THESOPHISTICATED ARMFIELD SOFTWARE VISIT
wwwdiscoverarmfieldcoukdataarmsoft
REQUIREMENTS
Electrical supply PCT23MkII-A 220-240V1ph50Hz
PCT23MkII-B 120V1ph60HzPCT23MkII-G 220V1ph60Hz
Cold water supply 4 lmin 2 bar
PC computer (not supplied by Armfield)See Essential Accessories for minimum specification
OVERALL DIMENSIONS
Process unit Console Height 0550m 0280mWidth 1000m 0425mDepth 0530m 0400m
SHIPPING DIMENSIONS
Volume 12msup3Gross weight 167kg
ORDERING SPECIFICATION
bull A bench mounted process plant trainerwith multiple streams both interacting andnoninteracting The process plant incorporates aminiature three-stage plate heat exchanger heatedfrom a hot water circulator two independent feedtanks a holding tube with product divert valve andtwo variable-speed peristaltic pumps
bull Temperature level flow and conductivity controlloops can be implemented
bull Manual control single feedback loops through
to sophisticated cascade loops and distributed
supervisory control of the whole process by a
remotely located computer can be demonstrated
bull The effect of lsquodead timersquo and heat recycle canbe demonstrated
bull An electrical console provides measurement andcontrol of the process plant and enables a varietyof control techniques including manual operationonoff control control from an external signal andcontrol from a PC or PLC
bull The equipment incorporates electrical faultsimulation and control data logging software and aUSB computer interface
ltEXTENDEDgt
WARRANTY
2 years
copy2011 Armfield Ltd All R ights Reser ved
Head Office Armfield LimitedBridge House West Street
Ringwood HampshireBH24 1DY England
Telephone +44 1425 478781Fax +44 1425 470916E-mail salesarmfieldcouk
US Office Armfield Inc436 West Commodore Blvd (2)
Jackson NJ 08527
Telephone (732) 928 3332Fax (732) 928 3542E-mail infoarmfieldinccom
An ISO 9001 Company
Innovators in Engineering Teaching Equipment
f
Scan QR code to visit our website Scan with smartphone with
QR code scanning software installed
Find us on YouTubewwwyoutubecomuserarmfieldUK
Follow us on Twitter FacebookLinkedIn and
dP
Head Office Armfield LimitedBridge House West Street
Ringwood HampshireBH24 1DY England
Telephone +44 1425 478781Fax +44 1425 470916E-mail salesarmfieldcouk
US Office Armfield Inc9 Trenton - Lakewood Road
Clarksburg NJ 08510TelFax (609) 208-2800E-mail infoarmfieldinccom
An ISO 9001 Company
Innovators in Engineering Teaching Equipment
l armfield co k
Find us on YouTubewwwyoutubecomuserarmfieldUK
Follow us on Twitter FacebookLinkedIn andWordPress
Scan QR code to visit our website Scan with smartphone with
QR code scanning software installed
copy 2014 Armfield Ltd A ll Rights Rese rved
W th i ht t d th ifi ti ith t i ti EampOE 07143k
ExcludingDLMxrange
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 58
Fig 3 Dual-loop control using Windows software
- Product temperature T1 controlling hot water circulation rate
- Hot water temperature T2 controlling heater power (PWR)
Note reaction between T1 T
2 and PWR as a result of setpoint change to T
1 (up 50C then down 50C)
T e m p e r a t u r e
0 C
Time in minutes
80
70
60
50
40
0 10 20 30 40 50 60
Change in T 1
setpoint
5160 to 566
0
Change in T 2
setpoint
5660 to 516
0
T 2
T 1
Fig 2 Controlling power consumption with and without a recycle-loop Product temperature T1
controlling power (PWR)
T e m p e r a t u r e
0 C
Time in minutes
75
70
65
60
55
50
45
PWR = 700W
PWR = 350W
0 10 20 30 40 50 60
Normal Divert (loss of regeneration)
Fig 1 Open-loop temperature responses to a step in change (in power) Use of a lsquoreaction curversquomethod to obtain optimum P+I+D settings for a process temperature (T
1 T
2 and T
4) to control the
power to the heater vessel
T1 = Process temperature after holding tube
T2 = Hot water circulating temperature
T3 = Process temperature before holding tube
T e m p e r a t u r e
0 C
Time in minutes
90
85
80
75
70
65
60
55
50
T 2
T 4
T 1
950W
Step in power
Dead time of holding tube750W
0 10 20 30 40 50
33
DETAILED PRACTICAL WORK ASSIGNMENTS
PCT23MkII Process Plant Trainer including LabVIEWtradesoftware with user provided PC 1a) Manual control with software performing data
acquisition and monitoring tasks only i) Gaining familiarity with screen based flow
sheet mimic diagrams for monitoringprocess variables level temperature flowconductivity and power
ii) Understanding how changing one processvariable (eg flow rate) affects the others (egtemperature)
iii) Measuring responses to step changeseg characterising the hot water tank
as a lsquofirst-order systemrsquo the holding tube aslsquodead timersquo and the plate heat exchanger asa combination of both types ofsystem (Fig1)
iv) Downloading data to a user providedspreadsheet for subsequent analysis
1b) Automatic control with software performing
control tasks setting up and studying i) Single-loop PID with hot water temperature
controlling the power to the heater ii) Single-loop PID with product
temperature controlling heater power iii) The effect of adding lsquodead timersquo of the
holding tube to the single control loopiv) The effect of recycling heated product
through the heat exchanger on controlaction (Fig 2)
v) The effect on control action of including analarm-activated diverter valve
vi) Cascade control whereby producttemperature controls the hot watertemperature setpoint which in turn
controls the heater power vii) Multi-variable control flow control ofthe product stream producttemperature controlling the hot waterflow rate hot water temperaturecontrolling the heater power (Fig 3)
viii) Fault simulation and diagnosis by theinstructor switching out selected signals
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 68
PCT23MkII Process Plant Trainer including LabVIEWtradesoftware with user provided PC
2a) All of the single-loop studies listed as1b) i) to v) with the control actions being setup and performed by the PCT20H controllerconnected to the front panel of the PCT23MkIIconsole (also onoff and time proportionedPID control)
The PCT23MkII software may be used to logsimultaneously the plant data to a PC (Fig 4)
2b) Supervision of the Industrial Controller (PCT20H)by PC based software - ie an introduction toSCADA with serial communications from the PC to
and from the controller2c) Alternative single-loops including levelflow and conductivity control alternativetemperature control loops
For each of the single control loops selectedfrom the above practical exercises on thefollowing topics are possible
gt Onoff control
gt Setting up
gt P I and D values
gt Tuning a controller for optimum performancegt Automanual transfer
gt Stability tests
PCT23MkII Process Plant Trainer with two PCT20HIndustrial PID Controllers3a) Cascade control as in 1b)vi) but using
the controllers connected to the plant in place ofdirect PC control
3b) Two input two output control with theproduct temperature controlling the
feed pump and the hot watercirculating temperature controlling theheater power Demonstration oflsquointeractingrsquo control is possible
3c) Feed forward control with product flowrate controlling the hot water circulating rate inaddition to heater power being controlled by hotwater temperature
PCT23MkII Process Plant Trainer with a single PCT19BRIndustrial PLC Unit
4a) Connecting a PLC to a process4b) Use of ladder logic to set up control
and monitoring tasks (requires a PC)4c) Single-loop onoff and PID control studies4d) Setting of alarms in conjunction with PID
control loops4e) Two-loop control strategies as in 3b)4f) Using digital inputs and outputs alarms and control
valve actionsAdditionally a SCADA software package is available(PCT23SCADA) which in conjunction with PCT23MkIIand PCT19BR enables studies ofg) lsquoPoint to pointrsquo SCADA operation via a user
provided PCh) Sequencing of plant operation a five-stage
sequence may be set up
gt Fill tanks
gt Preheating
gt Heat processing
gt Fill wash tank
gt WashThis sequence may be carried out by the PCT19BR
PLC alone or under SCADA operation from the PCwith mimic diagram display of the progress of thesequencing
Fig 4 Single closed loop response using PCT20H Industrial PID Controller Product temperatureleaving holding tube (T
1)
controlling heater power (PWR) (optimum P+I settings from Fig1)
T e m p e r a t u r e
0 C
75
70
65
60
55
50
45
PWR = 700W
PWR = 350W
0 10 20 30 40 50 60
Normal Divert (loss of regeneration)
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 78
TECHNICAL SPECIFICATION OPTIONAL ACCESSORIES
Flow rate rangesProduct stream 0-480mlminWashing reagent 0-480mlmin
Heating fluid 0-600mlminMax temperatureof heating fluid 80degCHeat exchanger Plate typeFeed and reagentvessel capacities 57 litres (each)Heating vessel capacity 37 litresSignal voltages 0-5VLevel sensor range 0-250mmFlow sensor range 0-500mlminTemperature sensor range 0-100degC(all 0-5V dc output) PCT19BR Industrial PLC Unit
Safety features
RCD in the console all circuits protected by MCBrsquos 24Vdc operation of solenoid valves and pump motorsHeating vesselbull Thermostat limiting max tempbull Low level switchbull Vent to avoid pressurisation
ESSENTIAL ACCESSORIES
PC computerThe customer needs to provide a PC running Windows7 8 98 2000 ME or XP with a spare USB port
(Not supplied)
Ordering Codes
PCT19BR Industrial PLC Unit
PLC unit incorporating Allen Bradley SLC500 complete
with proprietary ladder logic set-up program (requiringuser supplied PC)This program is initially configured by Armfield fortwo analog inputoutput control loops suited to thePCT23MkII Process Plant Trainer unit but may bereconfigured by users via their PC
PCT23SCADA SCADA SoftwareThis software contains the facilities required todemonstrate SCADA using the Armfield PCT23MkIIand PCT19BR
It includesbull SLC500 ladder logic routines written specifically for
the PCT23MkIIbull The communications facilities to enable the
PCT23MkII software to display and data log theSLC500 parameters
bull The additional exercises for the PCT23MkIIenabling SCADA to be demonstrated in thesame manner as the other exercises
PCT20H Industrial PID Controller
PID controller incorporating a Honeywell UDC3200series unit with voltagemA input and output forsingle-loop control and alarm configurations Asoftware package is supplied on disk to demonstratethe basic principles of SCADA whereby a user suppliedPC can address the PID controller directly
PCT19BR Industrial PLC Unit
PCT19BR Industrial PLC Unit
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 88
FOR FURTHER INFORMATION ON THE ADVANCED FEATURES OF THESOPHISTICATED ARMFIELD SOFTWARE VISIT
wwwdiscoverarmfieldcoukdataarmsoft
REQUIREMENTS
Electrical supply PCT23MkII-A 220-240V1ph50Hz
PCT23MkII-B 120V1ph60HzPCT23MkII-G 220V1ph60Hz
Cold water supply 4 lmin 2 bar
PC computer (not supplied by Armfield)See Essential Accessories for minimum specification
OVERALL DIMENSIONS
Process unit Console Height 0550m 0280mWidth 1000m 0425mDepth 0530m 0400m
SHIPPING DIMENSIONS
Volume 12msup3Gross weight 167kg
ORDERING SPECIFICATION
bull A bench mounted process plant trainerwith multiple streams both interacting andnoninteracting The process plant incorporates aminiature three-stage plate heat exchanger heatedfrom a hot water circulator two independent feedtanks a holding tube with product divert valve andtwo variable-speed peristaltic pumps
bull Temperature level flow and conductivity controlloops can be implemented
bull Manual control single feedback loops through
to sophisticated cascade loops and distributed
supervisory control of the whole process by a
remotely located computer can be demonstrated
bull The effect of lsquodead timersquo and heat recycle canbe demonstrated
bull An electrical console provides measurement andcontrol of the process plant and enables a varietyof control techniques including manual operationonoff control control from an external signal andcontrol from a PC or PLC
bull The equipment incorporates electrical faultsimulation and control data logging software and aUSB computer interface
ltEXTENDEDgt
WARRANTY
2 years
copy2011 Armfield Ltd All R ights Reser ved
Head Office Armfield LimitedBridge House West Street
Ringwood HampshireBH24 1DY England
Telephone +44 1425 478781Fax +44 1425 470916E-mail salesarmfieldcouk
US Office Armfield Inc436 West Commodore Blvd (2)
Jackson NJ 08527
Telephone (732) 928 3332Fax (732) 928 3542E-mail infoarmfieldinccom
An ISO 9001 Company
Innovators in Engineering Teaching Equipment
f
Scan QR code to visit our website Scan with smartphone with
QR code scanning software installed
Find us on YouTubewwwyoutubecomuserarmfieldUK
Follow us on Twitter FacebookLinkedIn and
dP
Head Office Armfield LimitedBridge House West Street
Ringwood HampshireBH24 1DY England
Telephone +44 1425 478781Fax +44 1425 470916E-mail salesarmfieldcouk
US Office Armfield Inc9 Trenton - Lakewood Road
Clarksburg NJ 08510TelFax (609) 208-2800E-mail infoarmfieldinccom
An ISO 9001 Company
Innovators in Engineering Teaching Equipment
l armfield co k
Find us on YouTubewwwyoutubecomuserarmfieldUK
Follow us on Twitter FacebookLinkedIn andWordPress
Scan QR code to visit our website Scan with smartphone with
QR code scanning software installed
copy 2014 Armfield Ltd A ll Rights Rese rved
W th i ht t d th ifi ti ith t i ti EampOE 07143k
ExcludingDLMxrange
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 68
PCT23MkII Process Plant Trainer including LabVIEWtradesoftware with user provided PC
2a) All of the single-loop studies listed as1b) i) to v) with the control actions being setup and performed by the PCT20H controllerconnected to the front panel of the PCT23MkIIconsole (also onoff and time proportionedPID control)
The PCT23MkII software may be used to logsimultaneously the plant data to a PC (Fig 4)
2b) Supervision of the Industrial Controller (PCT20H)by PC based software - ie an introduction toSCADA with serial communications from the PC to
and from the controller2c) Alternative single-loops including levelflow and conductivity control alternativetemperature control loops
For each of the single control loops selectedfrom the above practical exercises on thefollowing topics are possible
gt Onoff control
gt Setting up
gt P I and D values
gt Tuning a controller for optimum performancegt Automanual transfer
gt Stability tests
PCT23MkII Process Plant Trainer with two PCT20HIndustrial PID Controllers3a) Cascade control as in 1b)vi) but using
the controllers connected to the plant in place ofdirect PC control
3b) Two input two output control with theproduct temperature controlling the
feed pump and the hot watercirculating temperature controlling theheater power Demonstration oflsquointeractingrsquo control is possible
3c) Feed forward control with product flowrate controlling the hot water circulating rate inaddition to heater power being controlled by hotwater temperature
PCT23MkII Process Plant Trainer with a single PCT19BRIndustrial PLC Unit
4a) Connecting a PLC to a process4b) Use of ladder logic to set up control
and monitoring tasks (requires a PC)4c) Single-loop onoff and PID control studies4d) Setting of alarms in conjunction with PID
control loops4e) Two-loop control strategies as in 3b)4f) Using digital inputs and outputs alarms and control
valve actionsAdditionally a SCADA software package is available(PCT23SCADA) which in conjunction with PCT23MkIIand PCT19BR enables studies ofg) lsquoPoint to pointrsquo SCADA operation via a user
provided PCh) Sequencing of plant operation a five-stage
sequence may be set up
gt Fill tanks
gt Preheating
gt Heat processing
gt Fill wash tank
gt WashThis sequence may be carried out by the PCT19BR
PLC alone or under SCADA operation from the PCwith mimic diagram display of the progress of thesequencing
Fig 4 Single closed loop response using PCT20H Industrial PID Controller Product temperatureleaving holding tube (T
1)
controlling heater power (PWR) (optimum P+I settings from Fig1)
T e m p e r a t u r e
0 C
75
70
65
60
55
50
45
PWR = 700W
PWR = 350W
0 10 20 30 40 50 60
Normal Divert (loss of regeneration)
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 78
TECHNICAL SPECIFICATION OPTIONAL ACCESSORIES
Flow rate rangesProduct stream 0-480mlminWashing reagent 0-480mlmin
Heating fluid 0-600mlminMax temperatureof heating fluid 80degCHeat exchanger Plate typeFeed and reagentvessel capacities 57 litres (each)Heating vessel capacity 37 litresSignal voltages 0-5VLevel sensor range 0-250mmFlow sensor range 0-500mlminTemperature sensor range 0-100degC(all 0-5V dc output) PCT19BR Industrial PLC Unit
Safety features
RCD in the console all circuits protected by MCBrsquos 24Vdc operation of solenoid valves and pump motorsHeating vesselbull Thermostat limiting max tempbull Low level switchbull Vent to avoid pressurisation
ESSENTIAL ACCESSORIES
PC computerThe customer needs to provide a PC running Windows7 8 98 2000 ME or XP with a spare USB port
(Not supplied)
Ordering Codes
PCT19BR Industrial PLC Unit
PLC unit incorporating Allen Bradley SLC500 complete
with proprietary ladder logic set-up program (requiringuser supplied PC)This program is initially configured by Armfield fortwo analog inputoutput control loops suited to thePCT23MkII Process Plant Trainer unit but may bereconfigured by users via their PC
PCT23SCADA SCADA SoftwareThis software contains the facilities required todemonstrate SCADA using the Armfield PCT23MkIIand PCT19BR
It includesbull SLC500 ladder logic routines written specifically for
the PCT23MkIIbull The communications facilities to enable the
PCT23MkII software to display and data log theSLC500 parameters
bull The additional exercises for the PCT23MkIIenabling SCADA to be demonstrated in thesame manner as the other exercises
PCT20H Industrial PID Controller
PID controller incorporating a Honeywell UDC3200series unit with voltagemA input and output forsingle-loop control and alarm configurations Asoftware package is supplied on disk to demonstratethe basic principles of SCADA whereby a user suppliedPC can address the PID controller directly
PCT19BR Industrial PLC Unit
PCT19BR Industrial PLC Unit
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 88
FOR FURTHER INFORMATION ON THE ADVANCED FEATURES OF THESOPHISTICATED ARMFIELD SOFTWARE VISIT
wwwdiscoverarmfieldcoukdataarmsoft
REQUIREMENTS
Electrical supply PCT23MkII-A 220-240V1ph50Hz
PCT23MkII-B 120V1ph60HzPCT23MkII-G 220V1ph60Hz
Cold water supply 4 lmin 2 bar
PC computer (not supplied by Armfield)See Essential Accessories for minimum specification
OVERALL DIMENSIONS
Process unit Console Height 0550m 0280mWidth 1000m 0425mDepth 0530m 0400m
SHIPPING DIMENSIONS
Volume 12msup3Gross weight 167kg
ORDERING SPECIFICATION
bull A bench mounted process plant trainerwith multiple streams both interacting andnoninteracting The process plant incorporates aminiature three-stage plate heat exchanger heatedfrom a hot water circulator two independent feedtanks a holding tube with product divert valve andtwo variable-speed peristaltic pumps
bull Temperature level flow and conductivity controlloops can be implemented
bull Manual control single feedback loops through
to sophisticated cascade loops and distributed
supervisory control of the whole process by a
remotely located computer can be demonstrated
bull The effect of lsquodead timersquo and heat recycle canbe demonstrated
bull An electrical console provides measurement andcontrol of the process plant and enables a varietyof control techniques including manual operationonoff control control from an external signal andcontrol from a PC or PLC
bull The equipment incorporates electrical faultsimulation and control data logging software and aUSB computer interface
ltEXTENDEDgt
WARRANTY
2 years
copy2011 Armfield Ltd All R ights Reser ved
Head Office Armfield LimitedBridge House West Street
Ringwood HampshireBH24 1DY England
Telephone +44 1425 478781Fax +44 1425 470916E-mail salesarmfieldcouk
US Office Armfield Inc436 West Commodore Blvd (2)
Jackson NJ 08527
Telephone (732) 928 3332Fax (732) 928 3542E-mail infoarmfieldinccom
An ISO 9001 Company
Innovators in Engineering Teaching Equipment
f
Scan QR code to visit our website Scan with smartphone with
QR code scanning software installed
Find us on YouTubewwwyoutubecomuserarmfieldUK
Follow us on Twitter FacebookLinkedIn and
dP
Head Office Armfield LimitedBridge House West Street
Ringwood HampshireBH24 1DY England
Telephone +44 1425 478781Fax +44 1425 470916E-mail salesarmfieldcouk
US Office Armfield Inc9 Trenton - Lakewood Road
Clarksburg NJ 08510TelFax (609) 208-2800E-mail infoarmfieldinccom
An ISO 9001 Company
Innovators in Engineering Teaching Equipment
l armfield co k
Find us on YouTubewwwyoutubecomuserarmfieldUK
Follow us on Twitter FacebookLinkedIn andWordPress
Scan QR code to visit our website Scan with smartphone with
QR code scanning software installed
copy 2014 Armfield Ltd A ll Rights Rese rved
W th i ht t d th ifi ti ith t i ti EampOE 07143k
ExcludingDLMxrange
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 78
TECHNICAL SPECIFICATION OPTIONAL ACCESSORIES
Flow rate rangesProduct stream 0-480mlminWashing reagent 0-480mlmin
Heating fluid 0-600mlminMax temperatureof heating fluid 80degCHeat exchanger Plate typeFeed and reagentvessel capacities 57 litres (each)Heating vessel capacity 37 litresSignal voltages 0-5VLevel sensor range 0-250mmFlow sensor range 0-500mlminTemperature sensor range 0-100degC(all 0-5V dc output) PCT19BR Industrial PLC Unit
Safety features
RCD in the console all circuits protected by MCBrsquos 24Vdc operation of solenoid valves and pump motorsHeating vesselbull Thermostat limiting max tempbull Low level switchbull Vent to avoid pressurisation
ESSENTIAL ACCESSORIES
PC computerThe customer needs to provide a PC running Windows7 8 98 2000 ME or XP with a spare USB port
(Not supplied)
Ordering Codes
PCT19BR Industrial PLC Unit
PLC unit incorporating Allen Bradley SLC500 complete
with proprietary ladder logic set-up program (requiringuser supplied PC)This program is initially configured by Armfield fortwo analog inputoutput control loops suited to thePCT23MkII Process Plant Trainer unit but may bereconfigured by users via their PC
PCT23SCADA SCADA SoftwareThis software contains the facilities required todemonstrate SCADA using the Armfield PCT23MkIIand PCT19BR
It includesbull SLC500 ladder logic routines written specifically for
the PCT23MkIIbull The communications facilities to enable the
PCT23MkII software to display and data log theSLC500 parameters
bull The additional exercises for the PCT23MkIIenabling SCADA to be demonstrated in thesame manner as the other exercises
PCT20H Industrial PID Controller
PID controller incorporating a Honeywell UDC3200series unit with voltagemA input and output forsingle-loop control and alarm configurations Asoftware package is supplied on disk to demonstratethe basic principles of SCADA whereby a user suppliedPC can address the PID controller directly
PCT19BR Industrial PLC Unit
PCT19BR Industrial PLC Unit
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 88
FOR FURTHER INFORMATION ON THE ADVANCED FEATURES OF THESOPHISTICATED ARMFIELD SOFTWARE VISIT
wwwdiscoverarmfieldcoukdataarmsoft
REQUIREMENTS
Electrical supply PCT23MkII-A 220-240V1ph50Hz
PCT23MkII-B 120V1ph60HzPCT23MkII-G 220V1ph60Hz
Cold water supply 4 lmin 2 bar
PC computer (not supplied by Armfield)See Essential Accessories for minimum specification
OVERALL DIMENSIONS
Process unit Console Height 0550m 0280mWidth 1000m 0425mDepth 0530m 0400m
SHIPPING DIMENSIONS
Volume 12msup3Gross weight 167kg
ORDERING SPECIFICATION
bull A bench mounted process plant trainerwith multiple streams both interacting andnoninteracting The process plant incorporates aminiature three-stage plate heat exchanger heatedfrom a hot water circulator two independent feedtanks a holding tube with product divert valve andtwo variable-speed peristaltic pumps
bull Temperature level flow and conductivity controlloops can be implemented
bull Manual control single feedback loops through
to sophisticated cascade loops and distributed
supervisory control of the whole process by a
remotely located computer can be demonstrated
bull The effect of lsquodead timersquo and heat recycle canbe demonstrated
bull An electrical console provides measurement andcontrol of the process plant and enables a varietyof control techniques including manual operationonoff control control from an external signal andcontrol from a PC or PLC
bull The equipment incorporates electrical faultsimulation and control data logging software and aUSB computer interface
ltEXTENDEDgt
WARRANTY
2 years
copy2011 Armfield Ltd All R ights Reser ved
Head Office Armfield LimitedBridge House West Street
Ringwood HampshireBH24 1DY England
Telephone +44 1425 478781Fax +44 1425 470916E-mail salesarmfieldcouk
US Office Armfield Inc436 West Commodore Blvd (2)
Jackson NJ 08527
Telephone (732) 928 3332Fax (732) 928 3542E-mail infoarmfieldinccom
An ISO 9001 Company
Innovators in Engineering Teaching Equipment
f
Scan QR code to visit our website Scan with smartphone with
QR code scanning software installed
Find us on YouTubewwwyoutubecomuserarmfieldUK
Follow us on Twitter FacebookLinkedIn and
dP
Head Office Armfield LimitedBridge House West Street
Ringwood HampshireBH24 1DY England
Telephone +44 1425 478781Fax +44 1425 470916E-mail salesarmfieldcouk
US Office Armfield Inc9 Trenton - Lakewood Road
Clarksburg NJ 08510TelFax (609) 208-2800E-mail infoarmfieldinccom
An ISO 9001 Company
Innovators in Engineering Teaching Equipment
l armfield co k
Find us on YouTubewwwyoutubecomuserarmfieldUK
Follow us on Twitter FacebookLinkedIn andWordPress
Scan QR code to visit our website Scan with smartphone with
QR code scanning software installed
copy 2014 Armfield Ltd A ll Rights Rese rved
W th i ht t d th ifi ti ith t i ti EampOE 07143k
ExcludingDLMxrange
7242019 Armfield Process Plant Trainer
httpslidepdfcomreaderfullarmfield-process-plant-trainer 88
FOR FURTHER INFORMATION ON THE ADVANCED FEATURES OF THESOPHISTICATED ARMFIELD SOFTWARE VISIT
wwwdiscoverarmfieldcoukdataarmsoft
REQUIREMENTS
Electrical supply PCT23MkII-A 220-240V1ph50Hz
PCT23MkII-B 120V1ph60HzPCT23MkII-G 220V1ph60Hz
Cold water supply 4 lmin 2 bar
PC computer (not supplied by Armfield)See Essential Accessories for minimum specification
OVERALL DIMENSIONS
Process unit Console Height 0550m 0280mWidth 1000m 0425mDepth 0530m 0400m
SHIPPING DIMENSIONS
Volume 12msup3Gross weight 167kg
ORDERING SPECIFICATION
bull A bench mounted process plant trainerwith multiple streams both interacting andnoninteracting The process plant incorporates aminiature three-stage plate heat exchanger heatedfrom a hot water circulator two independent feedtanks a holding tube with product divert valve andtwo variable-speed peristaltic pumps
bull Temperature level flow and conductivity controlloops can be implemented
bull Manual control single feedback loops through
to sophisticated cascade loops and distributed
supervisory control of the whole process by a
remotely located computer can be demonstrated
bull The effect of lsquodead timersquo and heat recycle canbe demonstrated
bull An electrical console provides measurement andcontrol of the process plant and enables a varietyof control techniques including manual operationonoff control control from an external signal andcontrol from a PC or PLC
bull The equipment incorporates electrical faultsimulation and control data logging software and aUSB computer interface
ltEXTENDEDgt
WARRANTY
2 years
copy2011 Armfield Ltd All R ights Reser ved
Head Office Armfield LimitedBridge House West Street
Ringwood HampshireBH24 1DY England
Telephone +44 1425 478781Fax +44 1425 470916E-mail salesarmfieldcouk
US Office Armfield Inc436 West Commodore Blvd (2)
Jackson NJ 08527
Telephone (732) 928 3332Fax (732) 928 3542E-mail infoarmfieldinccom
An ISO 9001 Company
Innovators in Engineering Teaching Equipment
f
Scan QR code to visit our website Scan with smartphone with
QR code scanning software installed
Find us on YouTubewwwyoutubecomuserarmfieldUK
Follow us on Twitter FacebookLinkedIn and
dP
Head Office Armfield LimitedBridge House West Street
Ringwood HampshireBH24 1DY England
Telephone +44 1425 478781Fax +44 1425 470916E-mail salesarmfieldcouk
US Office Armfield Inc9 Trenton - Lakewood Road
Clarksburg NJ 08510TelFax (609) 208-2800E-mail infoarmfieldinccom
An ISO 9001 Company
Innovators in Engineering Teaching Equipment
l armfield co k
Find us on YouTubewwwyoutubecomuserarmfieldUK
Follow us on Twitter FacebookLinkedIn andWordPress
Scan QR code to visit our website Scan with smartphone with
QR code scanning software installed
copy 2014 Armfield Ltd A ll Rights Rese rved
W th i ht t d th ifi ti ith t i ti EampOE 07143k
ExcludingDLMxrange