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353X Series Instrumentation and process control Alexandre Labrie, jr. Eng. September 2012 Outline Overview - Introduction to process control - Design Description of 3531 - Pressure, Flow and Level - temperature Description of 3532 Description of 3539 SCADA Description of 3533 Calibration kit Options Typical Customer needs FAQ Selling tools What is process control? It is all about maintaining a parameter to a desired value despite disturbances This parameter can be almost anything: - Speed, acceleration -
353X Series Instrumentation and process control Alexandre Labrie, jr. Eng. September 2012 Outline Overview - Introduction to process control - Design Description of 3531 - Pressure, Flow and Level - temperature Description of 3532 Description of 3539 SCADA Description of 3533 Calibration kit Options Typical Customer needs FAQ Selling tools What is process control? It is all about maintaining a parameter to a desired value despite disturbances This parameter can be almost anything: - Speed, acceleration -
353X Series Instrumentation and process control Alexandre Labrie, jr. Eng. September 2012 Outline Overview - Introduction to process control - Design Description of 3531 - Pressure, Flow and Level - temperature Description of 3532 Description of 3539 SCADA Description of 3533 Calibration kit Options Typical Customer needs FAQ Selling tools What is process control? It is all about maintaining a parameter to a desired value despite disturbances This parameter can be almost anything: - Speed, acceleration -
Alexandre Labrie, jr. eng. September 2012 Outline Overview Introduction to ProcessControl Design Description of 3531 Pressure, Flow and Level Temperature Description of 3532 Description of 3539 SCADA Description of 3533 Calibration kit Options Typical Customer needs FAQ Selling tools What is process control? It is all about maintaining a parameter to a desired value despite disturbances This parameter can be almost anything: Speed, acceleration Pressure, flow, level Temperature pH and so on Concrete applications Some cars are equipped with a cruise control system that tries to maintain the speed despite hills or wind: Concrete applications An oven is a very simple household device that uses a basic form of process control called on/off control: Thetemperatureisroughlycontrolled.Precisionisnot important. Concrete applications Refineries use process control extensively: Theyhandlegases,liquidsanddifferent chemicalsinpipes,tanks,valves. Thepressurewithinatankorflowrate ofdifferentchemicalsmustbeprecisely controlledfortwomainreasons: 1) Consistencyofthefinalproducts 2) Preventaccidents Thetypeofcontrolusedwhen precisionisrequirediscalledPID control Petrochemical Industry Pulp& Paper Metallurgy: Iron, Copper, Aluminum Biotechnology, Pharmaceutical, Food Environment: Wastewater, Drinkingwater Electronics Power Plants Concrete applications Typical elements of a process control loop Maintaining the level of liquid in a vessel: MainGoalsofthe trainer: Tobuildvariousprocess loops Toadjusttheinstruments Tooperateandtunethe controllertogetadesired behavior Design Overview Main Goals of the trainer: To build various process loops To adjust the instruments To operate and tune the controller to get a desired behavior BRING THE PLANT TO THE CLASS Process Workstation Possibility to work on both sides (2 nd team Add-on for Pressure/Flow/Level). Solid mobile steel frame mountedon lockablecasters. StainlessSteel Driptrays. Power requirement: 120V-20A/230V-10A 1ph. or Power requirement: 208-20A/380-10A 3ph (2 circuits for Temperature) Up to four high capacitypumpswith750W three-phase motors. (75 lpm@186 kPa) Tworeservoirs(60 liters). Fast and convenient attachment system. Industrial quick-disconnect system. Wiring: Easy and fast wiring using banana jacks or realistic wiring using terminal blocks. Fault insertion capability on all the main components (electrical and pneumatic). Industrial PID Controllers and/or PLCs can be used. Possibility to add optional Touch Screen Terminals. High-speed Color Paperless Recorder permits data analysis. Instrumentation uses the latest communications protocols such as: Ethernet/IP, HART, Modbus, Foundation Fieldbus. (shown with optional equiment) Instrumentation Workstation Description of 353X The 353X series is composed of three Systems each covering different processes : 3531 : Pressure, Flow, Level and Temperature *include also few 3530 sub-systems 3532: PH and Conductivity 3533: Air Pressure and Flow 3539: Controllers Each System offer various sub-systems in order to offer an unlimited possibilities. Description 3531 The base of the system Two main versions available: Pressure, Flow, Level For one team of students Pressure, Flow, Level with Temperature For one team of students Description 3531 Two communication protocols are available: Hart The HART protocol enables communication between devices by superimposing digital signals on top of the existing 4-20 mA outputs Foundation Fieldbus The Fieldbus protocol is like a Local Area Network (LAN) for smart devices. Description 3531 The available Add-on systems are : BASIC PRESSURE/FLOW/LEVEL PROCESS SECOND TEAMADD-ON PRESSURE/FLOW/LEVEL ADVANCEDPROCESS CONTROL ADD-ON ADVANCEDTEMPERATURE PROCESS ADD-ON BOILER SIMULATION (WATER/AIR) ADD-ON TEMPERATURE PROCESS ADD-ON Only for system without temperature PRESSURE/FLOW AIR PROCESS ADD-ON, Only for system without Pressure, Flow and Level Description 3531 All Add-on system are available in four version depending of The basic system selected The communication protocoleselected Please use the Custom System builder in order to select the right version of each add-on. 3531 Selection Chart BasicPressure/Flow/Level TrainingSystem Scenario2:ThecustomerwantstopurchasePressure/Flow/LevelProcessesbutnotimmediatelytheTemperatureProcess. 3531A0 HartProtocol 3530K0 2 nd Team Pressure/Flow/Level AddOn 3533A0 AirProcess Pressure/Flow Addon 3530M0 Advanced Pressure/Flow/Level Addon 3531K0 BoilerSimulation Addon (ifnoTemperature) 3531C0 Basic Temperature &Heat Exchanger AddOn 353120 Advanced Temperature &Heat Exchanger Addon 3531M0 BoilerSimulation Addon 3531B0 Foundation Fieldbus 3530L0 2 nd Team Pressure/Flow/Level AddOn 3533A0 AirProcess Pressure/Flow Addon 3530M0 Advanced Pressure/Flow/Level Addon 3531L0 BoilerSimulation Addon (ifnoTemperature) 3531D0 Basic Temperature &Heat Exchanger AddOn 353130 Advanced Temperature &Heat Exchanger Addon 3531N0 BoilerSimulation Addon 3539Controller(Appropriate controller selection is required) 3531 Selection Chart BasicTemperature &Heat Exchanger TrainingSystem Scenario1:ThecustomerwantstopurchasetheTemperatureProcessandconsidersotheroptionalprocesses. 353100 HartProtocol 353120 Advanced Temperature &Heat exchanger AddOn 3530F0 Pressure/Flow/Level Addon 3530H0 2 nd Team Pressure/Flow/Level Add on 3533A0 AirProcess Pressure/Flow Addon 3530M0 Advanced Pressure/Flow/Level Addon 3531M0 BoilerSimulation Addon 353110 Foundation Fieldbus 353130 Advanced Temperature &Heat exchanger AddOn 3530G0 Pressure/Flow/Level Addon 3530J0 2 nd Team Pressure/Flow/Level Add on 3533A0 AirProcess Pressure/Flow Addon 3530M0 Advanced Pressure/Flow/Level Addon 3531N0 BoilerSimulation Addon 3539Controller(Appropriate controller selection is required) Learning Path Manuals included in each add-on and sub system follow the following path. Learning Path As example : For Pressure, Flow and Level Sub-system Measurement - Pressure/Flow/Level Student Manual Measurement - Pressure/Flow/Level Instructor Guide Process Control - Pressure/Flow/Level Student Manual Process Control - Pressure/Flow/Level Instructor Guide For Advance Pressure, flow and Level Advanced Process Control - Pressure/Flow/Level Student Manual Advanced Process Control - Pressure/Flow/Level Instructor Guide Same for structure for Temperature, PH , Conductivity and Air Process Learning Path - Ex Familiarisation and Specific equipment User Guides Example Measuring Pressure; From Measuring Manual From Familiarisation manual Pressure, Flow, Level Level Control Pressure, Flow & Level - Topics Advanced P/F/L - Topics PFL - Key Features Clear acrylic plastic, large, watertight process column with a capacity of 8.025 gal (30.4 litters) and an industrial flange that can house one of many optional level sensors. All Modules featuring hardwired input and output to both banana jacks and terminal blocks on the module front panel. One High and One low Deltabar S DP transmitter from Endress& Hauser Fisher Baumann industrial bronze control globe valve Allowunlimited configurations. Trend recorder MemographM from Endressand Hauser for data recording. Ability to do screen captures of the trends. Ability to record the data acquired in the internal memory of the apparatus and transfer it to a USB stick for archival or transfer to a PC using an Ethernet port (TCP/IP). Temperature Two loops controlled by the heating/cooling unit The Heat is exchanged from these two loop. Students control the flow of each loop in order to obtain a specific temperature at an output of the heat exchanger. Topics - Temperature Topics Advanced Temp. Temp. Key Feature (1) Endress& Hauser galvanic isolated temperature transmitter with capacity to display the temperature measured by up to two devices such as RTDs and thermocouples. One (1) 3-way diverting by Fisher Baumann industrial control globe valve that can be used in mixing mode with a Input of 4-20 mA and a bench range of 5 to 13 psi. Temp. Key Feature Capacity of 2 tons, (24000 BTU/hour, or 7 kW) of heating and two (2) tons, (24000 BTU/hour, or 7 kW) of cooling to maintain the temperature. Because the system exchange heat between two tanks of water, there is only a very small portion of heat which is release in class. (No heating element) Heat exchanger made with eight (8) copper brazed, stainless steel plates One T-shaped connector with one (1) Endress& Hauser Thermowell, which shall be installed anywhere on a set up. One (1) T-shaped connector with one (1) Endress& Hauser Thermowell which shall be installed anywhere on a set up. High temperaturedifferential (upto10C@11lpm). Accurate flowrates. Realtimeenergytransfercalculation. Four typesofHeat exhangers available: Brazed plates Plateswith gasket Onepass tubes&shell Fourpass tubes&shell Advanced Temp. Key Feature Boiler Recreates the same behaviour as seen in a real boiler. Experiments performed in a safe environment: low pressure and low temperature. As soon we increase the steam demand, we see more bubbles and the level increasing. The controller then works to maintain the level. 3 elements process control Boiler - Topics Introduction A Short Introduction to Boilers What is a boiler? Go through fire and water. Dissection of aboiler system. Safety. Exercise 1 Single-Element Control Final control elements in a boiler. On the importance of level control. Instruments used in level control. Perturbations in level control. Single-element level control. Simulation of the evaporation and heating processes. Exercise 2 Two-Element Control Short comings of the single-element control scheme. Two element level control. Exercise 3 Three-Element Control Shortcomings of the two-element control scheme. Threeelement level control. 3539 - Description Controllers Intouch Development Studio by Wonderware Models46968&46969:ProcessControlSCADASoftware FactoryTalkViewStudiobyRockwell SCADA 3532 - Description Series 3532 is designed to introduce students to pH and conductivity industrial processes and their associated instruments and control. StandAloneversion Addonversion 3532 - Description Available Sub-Systems: pH Control Conductivity Add-on pH required. Available as Add-on or stand-alone and for hart or Foundation fieldbudcommunication protocole. Please use the Custom System builder in order to select the right version of each add-on. 3532 Key features Transmitter pH Conductivity Clear plastic tube Hard wire and banana jacks Hart or Foundation Fieldbus 3532 Key Feature The Metering Pump is used to dispense chemicals to the process at an adjustable and precise rate. It features an LCD, a stroke length adjustment knob and a six- button touchpad. The pump can operate in a fixed rate mode or it can be commanded by an external 4-20 mA signal. A contact relay is also featured on this model. 3533 - Description Introduces students to process instruments and control performed on air processes Available as stand-alone or add-on module. 3533 Description Measurement and control of : Air Pressure Air Flow Calibration kit Calibration kit is required. Note that most I&C potential customer may already have their own calibration kit. The following calibration kit are available: Calibration Kit- 46980-00 Calibration Kit with Pressure Modules- 46980-A0 Calibration Kit (HART)- 46981-00 Calibration Kit (HART and FOUNDATION Fieldbus)- 46981-A0 HART Software Configurator- 46982-00 FOUNDATION Fieldbus Software Configurator- 46982-A0 HART/FOUNDATION Fieldbus Software Configurator - 46982-B0 Please refer to 353X for complete description of available calibration. Options - Transmitters Options - Valves Options - Others Typical Customer 353X offer unlimited possiblities. Some customer have the same needs; Process Operator program Instrumentation and Process Control Technicien Research Industrial Company Military Typical Customer General request from all customer: Safety. Lockout/tagout procedures, emergency-stop button, very clear indications in the manuals when a danger is present. Industrial grade Modular and highly customizable Extensive curriculum 35 manuals Covers a wide range if skills Typical Customer Process Operator program Person who will monitored, maintain and tune the process. Mainly interested in: Calibration Measurement Understanding basic of PID Ability to work with HMI Connection between instrument for troubleshooting Insist on : Faults switches on each module Courseware Students autonomy P&ID Learning Path Program already made for HMI and PLC Work with real components Measurement devices Typical Customer Instrumentation and Process Control Technician Person who will design the process, select the components and program the controllers. Mainly interested in: Tuning Loop adjusting the variable P,I,D PLC Programing Learning various control strategy Insist on: Trend recording using trend recorder Trend view using HMI SCADA Advanced Process Control courseware, Choice of PLC Possibility to create a complete process from scratch Pick experiments from more than 35 available manuals to suit your specific courses. Typical Customer Researcher University Person who develop new control algorithm Mainly interested in: PLC Programming Capability to interacwith Matlaband Labview Client have to supply interface (4-20ma I/O) Capacity to reproduce almost any process Insist on : PLC Rslogix500 or 5000 SCADA Communication protocol Advanced process Fuzzy logic module also available Typical Customer Military Water treatment technician PLC training Mainly Interested in : Water treatment process PLC programing Insist on : pH add-on Conductivity PLC Optional equipments HMI Typical Customer Industries Train workers on industry recognized brands: Allen-Bradley PLC and drives Honeywell and Foxboro controllers Fisher valves HART and Foundation Fieldbus communication protocols Industrial customers Introduce typical faults to get workers used to troubleshooting procedures: Physical fault switch on most equipment Possible to introduce software faults as well on some controllers Industrial customers Change setups rapidly: Modular approach makes it easy to modify a setup Quick-connect mechanism for plumbing and banana jack connection available for wiring In-depth and well-written curriculum: Step-by-step procedures make it possible for employees to work on their own or in teams on various schedules Industrial customers Covers various levels of learning: Operators learn to read ISA industry-standard piping and instrumentation diagrams (P&ID). They learn to connect electrical wires as well as the plumbing for each loop. Engineers and technicians can develop an in-depth understanding of the PID algorithmand test various configurations. Industrial customers Easily replicate parts of your loops: Operators can be trained on a copy of the actual loop. Engineers and technicians can test changes without interfering with the plant process. Industrial customers In short, it covers all aspects of process loops from building them up to fine tuning the controllers as well as troubleshooting Example of industrial customer With30locationsacrosstheU.S.andMexico, theymanufacturehighqualityproductsused forawidevarietyofpackagingandlabeling applications. Example of industrial customer Weworkedcloselywiththemtoreplicateone oftheirprocessloop.Wecustomizedthe systemandsentanengineeronsitetobuildit. Colleges and universities Can adapt to a wide range of coursesin variousfieldsof learning. Amongothers: Chemical, industrial, mechatronics(automation) Suitable for students training to become: Operators, maintenance technicians, supervisors, engineers Colleges and universities Safety is our priority Lockout/tagout procedures, emergency-stop button, very clear indications in the manuals when a danger is present. Equipment protection Fast-acting electrical protections means student can make bad connection without putting the system at risk. FAQ Q: What does the basic system cover? A: Pressure, flow and level loops. Temperature, pH and conductivity are optional. Q: Can I use a medium other than water with this system? A: Yes. It is possible to select a version of the system that uses air instead of water. Obviously, level, pH and conductivity are not available if air is selected. Q: If I decide to cover only pressure, flow and level for the moment, will I be able to add components to cover the other ones later? A: Yes. The 3531 is made so that you can start with a basic system and add other components over time. FAQ Q: Should I have three-phase available if I plan to purchase the temperature option? A: Yes. When (and only when) temperature is selected, two outlets of 3-phase are required. Contact services for the exact requirements. Q: Does the 3531 require compressed air? A: Yes. Compressed air is required to operate the pneumatic control valves among other things. Q: I would like a Lab-Volt representative to train us on this equipment. How long will it take to cover, pressure, flow, level, temperature and pH? A: Two days are sufficient to cover all parameters. FAQ Q: Can I use a 4-20 mA compatible controller I already own? A: Yes. As long as you are willing to take the time to program a PID algorithm yourself which can be time-consuming. Q: Can I use transmitters I already own? A: Most probably. You'll have to make sure they are compatible with the controller you will use. Q: Most of my students will work as operators or maintenance technicians after their studies. Is the 3531 the right choice? A: Yes. The 3531 is focused on using industrial components rather than custom-made ones. What the trainees will use on the system is what they will see in the plant. Q: I would like to build a loop that is very common in plants in my area. Is it possible? A: Most probably. The 3531 is modular and a wide variety of optional transmitters and controllers are available. Selling Tools Video http://www.youtube.com/watch?v=laIkUPQ9Gfs Sell Sheet and Courseware sample http://www.labvolt.com/products/instrumentation- and-process-control/computer-control- instrumentation-and-process/instrumentation-and- process-control-training-system-3531/download Custom system builder See Dealer access