Armfield Process Plant Trainer

8
7/24/2019 Armfield Process Plant Trainer http://slidepdf.com/reader/full/armfield-process-plant-trainer 1/8   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 > Multiple inputs, multiple sensors, multiple control strategies - Manual control, single feedback loops, through to sophisticated cascade loops > Temperature, level, flow and conductivity control loops can be implemented > Effects of ‘dead time’ > Operational sequencing, including startup and shutdown > Recycle implications on process control > On/off, proportioning, PID, PLC, SCADA > Fault simulation and diagnosis > Includes computer interface (USB) plus sophisticated LabVIEW™ based educational and data logging software ISSUE 4 The latest version of this data sheet is available at:  www.armfield.co.uk/pct23mkii PROCESS PLANT TRAINER PCT23MKII PCT SERIES: PROCESS CONTROL TECHNOLOGY * *ExcludingDLMxrange

Transcript of Armfield Process Plant Trainer

Page 1: 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

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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

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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

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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

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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

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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)

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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

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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

Page 2: Armfield Process Plant Trainer

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

Page 3: Armfield Process Plant Trainer

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

Page 4: Armfield Process Plant Trainer

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

Page 5: Armfield Process Plant Trainer

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

Page 6: Armfield Process Plant Trainer

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

Page 7: Armfield Process Plant Trainer

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

Page 8: Armfield Process Plant Trainer

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

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