MPS PA Workbook - festo-didactic.com · The MPS ®PA learning system

548591 EN 12/06

MPS®

PA

Workbook

2 © Festo Didactic GmbH & Co. KG • MPS®

PA

The Festo Didactic Learning System has been developed and produced solely for

vocational and further training purposes in the field of process automation and

technology. The company undertaking the training and/or the instructors is/are to

ensure that trainees observe the safety precautions specified in this workbook.

Festo Didactic herewith excludes any liability for damage or injury caused to

trainees, the training company and/or any third party, which may occur if the system

is in use for purposes other than purely for training; unless the said damage/injury

has been caused by Festo Didactic deliberately or through gross negligence.

Order No.:

Status:

Authors:

Editorial team:

Graphics:

548591

12/2006

J. Helmich, ADIRO

H. Kaufmann

M. Linn

V. Xhemajli, C. Green, T. Schwab, ADIRO

© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2013

Internet: www.festo-didactic.com

e-mail: [email protected]

The purchaser shall receive a single right of use which is non-exclusive, non-time-

limited and limited geographically to use at the purchaser's site/location as follows.

The purchaser shall be entitled to use the work to train his/her staff at the

purchaser's site/location and shall also be entitled to use parts of the copyright

material as the basis for the production of his/her own training documentation for

the training of his/her staff at the purchaser's site/location with acknowledgement

of source and to make copies for this purpose. In the case of schools/technical

colleges and training centres, the right of use shall also include use by school and

college students and trainees at the purchaser's site/location for teaching purposes.

The right of use shall in all cases exclude the right to publish the copyright material

or to make this available for use on intranet, Internet and LMS platforms and

databases such as Moodle, which allow access by a wide variety of users, including

those outside of the purchaser's site/location.

Entitlement to other rights relating to reproductions, copies, adaptations,

translations, microfilming and transfer to and storage and processing in electronic

systems, no matter whether in whole or in part, shall require the prior consent of

Festo Didactic GmbH & Co. KG.

Intended use

© Festo Didactic GmbH & Co. KG • MPS®

PA 3

Preface ___________________________________________________________ 7

Introduction__________________________________________________________ 8

Safety and operating instructions ________________________________________ 9

Learning system for process automation _________________________________ 10

Training aims and project work _________________________________________ 12

Allocation of training aims and exercises _________________________________ 14

MPS®

PA components _________________________________________________ 22

Allocation of components and exercises __________________________________ 27

Methodological training aid for the instructor______________________________ 31

Methodological structure of the exercises_________________________________ 32

Designation of equipment _____________________________________________ 33

Basic definition ______________________________________________________ 33

Electrical components_________________________________________________ 33

Pneumatic components _______________________________________________ 35

Process-engineering components _______________________________________ 36

CD-ROM contents ____________________________________________________ 40

Contents

Contents


PA

Fundamentals of closed-loop control technology __________________________ 41

1. What is a system? _____________________________________________ 43

2. Open and closed-loop control technology __________________________ 44

3. Basic terminology of closed-loop control technology _________________ 46

4. Controlled systems ____________________________________________ 48

5. Identification of the controlled system ____________________________ 49

5.1 Dynamic behaviour ____________________________________________ 50

6. Characterisation of the response behaviour ________________________ 51

6.1 Order of a system______________________________________________ 52

6.2 Time constant ________________________________________________ 52

6.3 The inflectional tangent model ___________________________________ 53

7. The controller_________________________________________________ 55

7.1 Control response ______________________________________________ 55

7.2 The two-position controller _____________________________________ 56

7.3 The time response of a controller ________________________________ 58

7.4 Technical details of controllers ___________________________________ 60

8. Mode of operation of various controller types_______________________ 61

8.1 The P-controller _______________________________________________ 61

8.2 The I-controller _______________________________________________ 62

8.3 The PI controller ______________________________________________ 63

8.4 The PD controller ______________________________________________ 64

8.5 The PID controller _____________________________________________ 65

9. Optimisation method for controller settings ________________________ 66

9.1 Manual tuning of control parameters without knowledge of the system

behaviour ___________________________________________________ 68

9.2 Tuning rules according to Ziegler/Nichols __________________________ 69

9.3 Tuning rules according to Chien/Hrones/Reswick____________________ 70

9.4 Tuning method according to the rate of rise ________________________ 71

10. Summary ____________________________________________________ 73

Contents


PA 5

Part A – Filtration station

Exercise 1.1: System analysis and appraisal

Exercise 1.1.1: Designation of process components_________________________A-5

Exercise 1.1.2: Completing the P&I diagram _______________________________A-7

Exercise 1.1.3: Completing the pneumatic circuit diagram____________________A-9

Exercise 1.1.4: Determining the technical data of a system __________________A-11

Exercise 1.1.5: Drawing up the allocation list _____________________________A-13

Exercise 1.2: Measurement and open-loop control

Exercise 1.2.1: Characteristics of the prop. pressure valve/filter system _______A-17

Exercise 1.2.2: Logic operation ________________________________________A-21

Exercise 1.2.3: Operating range and operating point of a controlled system ____A-29

Exercise 1.2.4: Identifying a controlled system ____________________________A-33

Exercise 1.2.5: Ramped pressure stages ________________________________A-37

Exercise 1.3: Closed-loop control

Exercise 1.3.1: Two-position controller __________________________________A-39

Exercise 1.3.2: Closed-loop control using conti.-action controllers (P, I, PI) _____A-41

Exercise 1.3.3: Optimisation method according to Ziegler-Nichols ____________A-46

Part B – Mixing station


Exercise 2.1.1: Designation of process components_________________________B-5

Exercise 2.1.2: Preparing a P&I diagram __________________________________B-7

Exercise 2.1.3: Completing the pneumatic circuit diagram____________________B-9

Exercise 2.1.4: Determining the technical data of a system _________________ B-11

Exercise 2.1.5: Drawing up the allocation list ____________________________ B-13


Exercise 2.2.1: Characteristics of the piping-pump system _________________ B-17

Exercise 2.2.2: Logic operation _______________________________________ B-24

Exercise 2.2.3: Operating range and operating point of a controlled system ___ B-33

Exercise 2.2.4: Identifying a controlled system ___________________________ B-36

Exercise 2.2.5: Mixing according to quantity_____________________________ B-40


Exercise 2.3.1: Two-position controller _________________________________ B-43

Exercise 2.3.2: Closed-loop control using conti.-action controllers (P, I, PI) ____ B-45

Exercise 2.3.3: Manual tuning of controller parameters ___________________ B-50

Contents


PA

Part C – Reactor station


Exercise 3.1.1:Designation of process components _________________________C-5

Exercise 3.1.2: Completing the P&I diagram _______________________________C-7

Exercise 3.1.3: Not applicable – no pneumatic components

Exercise 3.1.4: Determining the technical data of the system _________________C-9

Exercise 3.1.5: Drawing up the allocation list _____________________________C-11


Exercise 3.2.1: Characteristics of the heating system medium _______________C-15

Exercise 3.2.2: Logic operation ________________________________________C-22

Exercise 3.2.3: Operating range and operating point of a controlled system ____C-29

Exercise 3.2.4: Identifying a controlled system ____________________________C-32


Exercise 3.3.1: Two-position controller __________________________________C-36

Exercise 3.3.2: Closed-loop control using conti.-action controllers (P, I, PI) _____C-38

Exercise 3.3.3: Tuning method according to the rate of rise _________________C-42

Part D – Bottling station


Exercise 4.1.1: Designation of process components________________________ D-5

Exercise 4.1.2: Completing the P&I diagram ______________________________ D-7

Exercise 4.1.3: Completing the pneumatic circuit diagram___________________ D-9

Exercise 4.1.4: Determining the technical data of a system _________________ D-11

Exercise 4.1.5: Drawing up the allocation list ____________________________ D-13


Exercise 4.2.1: Characteristics of the metering tank/pump system___________ D-17

Exercise 4.2.2: Logic operation _______________________________________ D-22

Exercise 4.2.3: Operating range and operating point of a controlled system ___ D-29

Exercise 4.2.4: Identifying a controlled system ___________________________ D-33

Exercise 4.2.5: Inlet and outlet behaviour of the metering tank______________ D-37


Exercise 4.3.1: Two-position controller _________________________________ D-43

Exercise 4.3.2: Closed-loop control using continuous-action controllers (P, I, PI) D-45

Exercise 4.3.3: Optimisation method according to Chien-Hrones-Reswick (CHR) D-50


PA 7

The Festo Didactic Learning System for process automation and technology is

designed to meet a number of different training and vocational requirements. The

systems and stations of the modular production system for Process Automation

(MPS®

PA) facilitate vocational and further training in line with industrial practice.

The hardware is comprised of didactically prepared industrial components.

The MPS®

PA stations provide you with an appropriate system whereby the following

key qualifications can be taught in a practice-related form

• Social competence

• Technical competence

• Methodological competence

In addition to this, team work, willingness to cooperate and organisational skills can

also be practised.

Actual project phases can be taught in training projects which include:

• Planning

• Assembly

• Programming

• Commissioning

• Operation

• Optimisation of control parameters

• Maintenance

• Fault finding

Preface


PA

This workbook is a component part of the learning system for process automation

and technology of Festo Didactic GmbH & Co. KG. The system represents a sound

basis for practice-oriented vocational and further training and facilitates a quick and

practice-related introduction to the technologies such as measuring and open and

closed-loop control of process-related variables.

First comes „learning by doing“ and understanding the effective relationships within

a control loop. Based on this you will gain the necessary knowledge regarding

formulas and calculation.

The control loops and control functions of the MPS®

PA stations replicate actual

processes:

Mixing, tempering, filtration and bottling as performed in industry.

The MPS®

PA learning system meets the multifaceted training requirements in a wide

range of different branches of industry, e.g.:

• Water supply and

• Waste water disposal

• Food industry

• Bulk material industry

• Chemical and petrochemical industry

• Bio/Pharmaceutical industry

• Paper industry

Reducing process costs, improving system reliability, preventing component wear

and tear, e.g. process-optimised operation of pumps, evaluating diagnostic data,

these are current topics which can be optimally pursued with the MPS®

PA learning

system.

• Modular – suitable for use as individual stations or in combination in the form of

a complete system.

• Safe – learning and working in a safe environment.

• Flexible – convertible in the blink of eye for different control variants.

Introduction

Practice-oriented

qualification

Clear trend:

From open to closed-loop

control


PA 9

In the interest of your own safety you should follow the safety instructions in the

manuals of the MPS®

PA stations.

General

• Trainees must only work on the MPS®

PA stations under the supervision of an

instructor.

• Observe the data sheets referring to the individual components, in particular all

notes regarding safety!

Safety and operating instructions


PA

The learning system for process automation is comprised of a wide range of

individual training media and courses.

• Assembled and adjusted MPS®

PA station

• Control

– Simulation box, digital/analogue with connecting cables

– Software Fluid Lab®

-PA with EasyPort digital/analogue PC interface,

connecting cable and PC

– PLC board or EduTrainer with touch panel

• PC with installed PLC programming software

• Power supply unit

• Optional training media

• Tools

• Complete laboratory installations

Training documentation

Textbooks Fundamentals of pneumatic control technology

Maintenance of pneumatic devices and systems

Programmable logic controllers, basic level

Workbooks Programmable logic controllers, basic level

Regulation of temperature, flow and fill level

Optional teachware WBT Fundamentals of electropneumatics

FluidSIM® 4.0 Pneumatics

WBT Fundamentals of open and closed-loop control

Learning system for process automation

Important elements of

MPS®

PA

Learning system for process automation


PA 11

Courses

P111 Introduction to pneumatics

P121 Advanced pneumatic

MCR Fundamentals of closed-loop control technology

E311 Introduction to programmable logic controllers

Venues, dates and prices can be found in the current course planner.

Further training media is detailed in our catalogues and on the Internet. The learning

system for process automation is continually updated and expanded. The

transparency sets, films, CD-ROMs and DVDs as well as technical books are available

in several languages.


PA

Training contents from the following areas can be carried out:

• Mechanics

– Mechanical construction of a station

• Process engineering

– Reading and preparation of flow diagrams and documentation

– Piping up of process engineering components

– System analysis

• Pneumatics

– Piping up of pneumatic components

• Electrotechnology

– Correct wiring of electrical components

• Sensor technology

– Correct use of sensors

– Measurement of non-electrical, process engineering and closed-loop control

variables

• Closed-loop control technology

– Fundamentals of closed-loop control technology

– Expansion of measuring chains into closed control loops

– Analysis of controlled systems

– Use of controllers

• PLC

– Programming and use of a PLC

– Structure of a PLC program

• Commissioning

– Commissioning of a process engineering system

– Commissioning of a control loop

• Fault finding

– Systematic fault finding on a process engineering system

– Inspecting, maintaining and servicing of process engineering systems

Training aims and project tasks

Training contents

Training aims and project tasks


PA 13

Project tasks covering the following topics can be carried out:

• Closed-loop control technology

– Controlled system for pressure control

– Flow rate control

– Temperature control

– Controlled system with compensation and large time constant

– Level control

• Safety monitoring of containers

– Use of a float switch

• Sensor technology

– Pressure measurement with pressure sensor and pressure gauge

– Flow sensor and display of fluids

– Use of level sensors

– Connection of a temperature sensor, signal conversion

– Level sensor for level detection

• Planning, implementing and documenting conversions

The hardware is comprised of didactically prepared industrial components and

systems.

The didactic methodological format of the teachware is harmonised for use with the

training hardware. The teachware includes the following:

• The workbook (with practical exercises, supplementary notes and solutions)

• The textbook (with fundamentals)

The tuition and training media is available in several languages and is designed both

for use in the classroom and self-tuition.

In terms of software, computer training programs and programming software are

available for programmable logic controllers.

A comprehensive range of courses covering the contents of the technology packages

completes the range of vocational and further training programmes.

Topics for project tasks


PA

MPS®

PA Filtration station

Training aims Ex

erc

ise

s

1.1

.1

1.1

.2

1.1

.3

1.1

.4

1.1

.5

1.2

.1

1.2

.2

1.2

.3

1.2

.4

1.2

.5

1.3

.1

1.3

.2

1.3

.3

System overview and components

To familiarise yourself with the

design and mode of operation of the

filtration station.

•

To be able to evaluate information

from data sheets • • • •

Functional description

To be able to read and amend flow

diagrams. •

To be able to read electrical circuit

diagrams. • • • • •

To be able to read and amend

pneumatic circuit diagrams. •


design and mode of operation of a

pump.

• • • • • • • • •


design and mode of operation of a

pressure sensor.

•


design and mode of operation of

process valves.

• • • • • •


design and mode of operation of limit

switches.

• • • •

To be able to establish the allocation

of the sensors and actuators of the

station and represent these in an

allocation list.

• •

Allocation of training aims and exercise


PA A-1

Part A – Filtration station _____________________________________________A-1


Exercise 1.1.1: Designation of process components_________________________A-5

Exercise 1.1.2: Completing the P&I diagram _______________________________A-7

Exercise 1.1.3: Completing the pneumatic circuit diagram____________________A-9

Exercise 1.1.4: Determining the technical data of a system __________________A-11

Exercise 1.1.5: Drawing up the allocation list _____________________________A-13

Exercise 1.2: Measurement and control

Exercise 1.2.1: Characteristics of the prop. pressure regulator/filter system ____A-17

Exercise 1.2.2: Logic operation ________________________________________A-21

Exercise 1.2.3: Operating range and operating point of a controlled system ____A-29

Exercise 1.2.4: Identifying the controlled system __________________________A-32

Exercise 1.2.5: Ramped pressure stages ________________________________A-36


Exercise 1.3.1: Two-position controller __________________________________A-39

Exercise 1.3.2: Closed-loop control using conti.-action controllers (P, I, PI) _____A-41

Exercise 1.3.3: Optimisation method according to Ziegler-Nichols ____________A-46

Contents

Contents

A-2 © Festo Didactic GmbH & Co. KG • MPS®

PA


PA A-3

• To familiarise yourself with the design and mode of operation of the filtration

station.

• To be able to read and amend flow diagrams.

• To be able to read and amend pneumatic circuit diagrams.

• To familiarise yourself with the design and mode operation of a filter.

• To familiarise yourself with the design and mode of operation of a pump.

• To familiarise yourself with the design and mode of operation of a pressure

sensor.

• To familiarise yourself with the design and mode of operation of a process valve

• To familiarise yourself with the design and mode of operation of a limit switch.

• To be able to establish the allocation of the sensors and actuators of the station

and represent these in an allocation list.

• To be able to plot and analyse characteristic curves.

• To be able to create a program.

• To be able to determine the operating range and operating point of a controlled

system.

• To be able to identify a controlled system and determine the order of a system.

• To be able to configure a two-position controller and evaluate the control

response.

• To be able to configure continuous-action controllers (P, PI, PID) and evaluate the

control response.

• To be able to parameterise continuous-action controllers (P, PI, PID) according to

the Ziegler-Nichols tuning method.

The filtration station is to be used for the partial automation of a production process

in your company. In order to commission the station at a later stage, you are to

familiarise yourself with the functioning of the station and the most important

process components.

• For the analysis of the station you can use the digital/analogue simulation box;

digital/analogue EasyPort with FluidLab®

PA or PLC with touch panel.

• You will find information regarding the station and process components in the

station manual, operating instructions and data sheets.

1. Answer the questions and solve the exercises regarding the fundamentals of the

training contents mentioned.

2. Analyse and amend the circuit diagrams.

3. Draw up the allocation list.

4. Determine the characteristics of the components and then evaluate the

components.

5. Create the logic program.

6. Check the circuit sequence.

7. Determine the operating point of the controlled system.

8. Identify the controlled system and determine the order of the system.

Exercises MPS• PA Filtration station

Training aims

Information

Project assignment

Exercises MPS® PA Filtration station


PA

9. Set discontinuous-action and continuous-action controllers and evaluate their

behaviour.



PA A-5

Exercise 1.1: Filtration station – system analysis and appraisal

Name: Date:

1.1.1 Designation of process components Sheet 1 of 2

The filtration station filters a liquid which is pumped through the filter from the

waste water tank via a gate valve. The filtered liquid reaches the pure water tank via

a butterfly valve. The filter can be back-flushed by means of a flushing program. To

remove deposits, controlled compressed air is additionally blasted through the filter

to remove any particles.

You will find the necessary information in the manual of the MPS®

PA filtration

station.

The component designations can be found in the electrical circuit diagram and in the

P&I diagram of the station.

– Determine and complete the designations of the process components in the

system photo below.

3

1

2

4

Designation of process components

Information

Planning

Implementation



PA

Exercise1.1: Filtration station – system analysis and appraisal

Name: Date:

1.1.1 Designation of process components Sheet 2 of 2

– Complete the table.

No. Designation Meaning or function

1

Pressure sensor

2 F101

3

Gate valve

4 V103

5

3-way ball valve

You will find two different inscriptions for the gate valve in the electrical circuit

diagram or P&I diagram.

– Explain the difference.

Comprehension questions

Designation of

process components

Evaluation



PA A-7


Name: Date:

1.1.2 Completing the P&I diagram Sheet 1 of 2

The P&I diagram is a technical drawing used in process technology. It represents the

process steps in schematic form. The P&I diagram expresses the geometric course of

the piping and also represents the open and closed-loop control components

according to DIN 10628. Measured variables are also referred to as

EMCS points in accordance with DIN 19227-1 (EMSR points).


PA filtration

station.

The designations and symbols of the components can be found in the workbook

introduction.

– Collect the information regarding the correct designation and symbols and

complete the P&I diagram for the filtration station.

P&I diagram

The designation of components in the P&I diagram enables you to analyse the

functioning of the system.

Information

Planning

Implementation



PA


Name: Date:

1.1.2 Completing the P&I diagram Sheet 2 of 2


– Describe the meaning or function of the designations below.

Designation Meaning or function

Filter

LS-

LA+

Digital pump

V

– State the difference between the designations of the measuring points

LA+ and LS+?


Functional description of

components

Evaluation



PA A-9


Name: Date:

1.1.3 Completing the pneumatic circuit diagram Sheet 1 of 2

The allocation of pneumatic components in a circuit diagram is the differentiating

factor for the allocation of these components into their respective component

groups.


PA filtration

station.

The circuit diagrams, designations and symbols of components can be found in the

workbook introduction, the technical documentation of the MPS®

PA station and in

FluidSIM®

Pneumatics.

– Collect the information regarding the correct designation and symbols of

pneumatic components and complete the pneumatic circuit diagram for the

filtration station.

Information

Planning

Implementation

Pneumatic circuit diagram



PA


Name: Date:

1.1.3 Completing the pneumatic circuit diagram Sheet 2 of 2


– Describe the meaning or function of the designations below.

Symbol Meaning or function

5/2-way valve

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

– What is the function of an exhaust air flow control on a pneumatic cylinder?


Functional description of

pneumatic components

Evaluation



PA A-11


Name: Date:

1.1.4 Determining the technical data of a system Sheet 1 of 2

Different process components are used in the MPS®

PA filtration station. The

technical data regarding the function of components within the station are of major

significance.


PA Filtration

station.

The data sheets and circuit diagrams of process components can be found in the

technical documentation of the MPS®

PA station.

– Look through the documentation and complete the table.

Component Designation in

flow diagram

Function Characteristics

Pump P201

Voltage [V] ______

Electric power [W] ______

Max. throughput [l/min]

______

Proportional-

pressure

regulator

Setpoint voltage [V] ______

Pressure range [bar] ______

3-way ball

valve

Min. pneum. pressure [bar] ______

Max. current intensity [mA]

______

Pressure

sensor

Pressure range [bar] ______

Sensor signal [V] ______

Limit switch

up

Filling amount up to contact [l] ______

Type (normally open/normally closed

contact) ______

Limit switch

down

Filling amount up to contact [l] ______

Type (normally open/normally closed

contact) ______

Information

Planning

Implementation

Technical data



PA


Name: Date:

1.1.4 Determining the technical data of a system Sheet 2 of 2

– Describe the design and function of the proportional pressure regulator.


Evaluation



PA A-13


Name: Date:

1.1.5 Drawing up the allocation list Sheet 1 of 3

In order to analyse the function of the MPS®

PA filtration station, the station is to be

controlled by means of the digital/analogue simulation box; digital/analogue

EasyPort with FluidLab®

-PA or PLC with touch panel. This enables you to allocate the

output and input signals. The allocation list forms the basis of programming a

process sequence of the station.


PA filtration

station.

The data sheets and circuit diagrams of process components can be found in the

technical documentation of the MPS®

PA station.

– Fill the waste water tank with approx. 7 l of water.

– Connect the digital/analogue simulation box, digital/analogue EasyPort with

FluidLab®

-PA or the PLC with touch panel to the I/O terminal and the analogue

terminal of the station.

– Operate the pumps and valve and observe the system and LED statuses on the

I/O terminal of the system.

– Complete the allocation lists.

Symbol EasyPort/

Simbox address

PLC address Description Check

1B1 DI 0 Air jet pressure

DI 1

DI 2

1B4 DI 3 Tank B102 top

DI 4

DI 5

DI 6

DI 7

Symbol EasyPort/

Simubox

address


1PV1 AI0 Actual value X (pressure)

Information

Planning

Implementation

Allocation list of

digital inputs

Allocation list of

analogue inputs



PA


Name: Date:


Symbol EasyPort/

Simubox

address


DO 0

1M2 DO 1 Pump P101 – waste water

DO 2

DO 3

DO 4

DO 5

DO 6

DO 7

Symbol EasyPort/

Simubox

address


1CO1 AO 0 Manipulated variable Y,

Proportional pressure regulator

Observe the status of all inputs and outputs and enter the result in the table.

Compare the input/output signal with the status displays on the digital/analogue

simulation box, digital/analogue EasyPort with FluidLab®

-PA or PLC with touch

panel.

Allocation list of digital

outputs

Allocation list of analogue

outputs

Check



PA A-15


Name: Date:


– Describe the behaviour of the analogue final control element (proportional

pressure regulator) when actuated via analogue signal.


Evaluation

Documents

MPS PA Workbook - festo-didactic.com · The MPS ®PA learning system