p01 06 Control Loop v9 Tud 0719 en

Learn-/Training Document | PA Module P01-06, Edition 02/2020 | Digital Industries, FA
Learn-/Training Document
Siemens Automation Cooperates with Education
(SCE) | As of Version V9 SP1
PA Module P01-06
SIMATIC PCS 7 – Control loop and other control
functions
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Table of contents
1 Goal ................................................................................................................................................. 5
2 Prerequisite...................................................................................................................................... 5
3 Required hardware and software ...................................................................................................... 6
4 Theory ............................................................................................................................................. 7
4.1 Theory in brief ..........................................................................................................................7
4.2 Introduction ..............................................................................................................................8
4.3 Suitability of loop controllers in industry.....................................................................................9
4.4 Expanded closed-loop control structures ................................................................................. 10
4.5 Interfacing to processes .......................................................................................................... 11
4.6 References ............................................................................................................................. 13
5 Task ............................................................................................................................................... 14
6 Planning......................................................................................................................................... 15
7 Learning objective .......................................................................................................................... 16
8 Structured step-by-step instructions................................................................................................ 17
8.1 Creating the manual control A1T2H008 .................................................................................. 17
8.2 Creating the A1T2T001 temperature control ........................................................................... 20
8.3 Manual control of A1T2T001 temperature control .................................................................... 26
8.4 Checklist – step-by-step instruction ......................................................................................... 29
9 Exercises ....................................................................................................................................... 30
9.1 Tasks ..................................................................................................................................... 30
9.2 Checklist – exercise ................................................................................................................ 32
10 Additional information ..................................................................................................................... 33

Control loop and other control functions

1 Goal
In this chapter, students become familiar with the essential components and requirements for a
block for continuous closed-loop control of process tags and can create and configure a
temperature control using the PIDConL and PULSEGEN blocks.
2 Prerequisite
This chapter builds on chapter 'Functional safety'. To implement this chapter, you can use an
existing project from the previous chapter or the archived project 'p01-05-exercise-r1905-en.zip'
provided by SCE. The download of the project(s) is stored on the SCE Internet for the respective
module.
The (optional) simulation for the SIMIT program can be retrieved from the file 'p01-04-plantsim-
v10-r1905-en.simarc'. It can be run in Demo mode.
3 Required hardware and software

1 Engineering station: Requirements include hardware and operating system
(for further information, see Readme on the PCS 7 installation DVD)
2 SIMATIC PCS 7 software V9 SP1 or higher
 Installed program packages (contained in SIMATIC PCS 7 Software Trainer
Package):
 Engineering  PCS 7 Engineering
 Engineering  BATCH Engineering
 Runtime  Single Station  OS Single Station
 Runtime  Single Station  BATCH Single Station
 Options  SIMATIC Logon
 Options  S7-PLCSIM V5.4 SP8
3 Demo Version SIMIT Simulation Platform V10
2 SIMATIC PCS 7
V9 SP1 or higher
1 Engineering Station
3 SIMIT V10 or higher
4 Theory
4.1 Theory in brief
In the process industry, certain process tags must be kept at a specific value despite
disturbances (disturbance response) and process tags must be adjusted to specified
setpoints in a stable manner (response to setpoint change). Control loops, as shown in
Figure 1, are used for this.
Disturbance
variables z
System Manipulated
deviation e variable y Process variable =
Loop controlled variable
Setpoint w System x
controller
+
-
Figure 1: Control loop
For the plant used in these training curriculums, the reactor temperature is set to a certain value
for controlling a reaction according to specification. Disturbance variables are the ambient
temperature and the raw materials with different temperatures. In order for the temperature to be
controlled, it first has to be measured. This measured value, which corresponds to the actual
value of the process tag, is then compared with the desired value (setpoint). The difference
between the actual value and setpoint is called the (control) deviation.
When the control deviation is known, it is possible to identify counter measures. In the case of
temperature control, the heater is switched on when the measured actual value is less than the
specified setpoint. For the process to react automatically, a loop controller is needed. A loop
controller that calculates the manipulated variable based solely on the current deviation is called
a proportional controller (or P controller for short).
In practice, so-called PID controllers, which can be used for a wide variety of processes with
the help of just a few parameters, have prevailed.
The PCS 7 Advanced Process Library V90 contains proven blocks that implement this
functionality. The PIDConL block will be used in the following.
4.2 Introduction
The above-mentioned P controller represents the simplest loop controller. It operates according
to the principle: the more the actual value differs from the setpoint, the larger the manipulated
variable will be. Its behavior is thus derived directly from the control deviation at the given
moment, which makes it fast and relatively dynamically favorable. However, certain disturbances
are not fully compensated for, which means there is a sustained control deviation.
Not every process tolerates a sustained control deviation so that additional measures have to be
taken. One possibility consists of adding an integral-action component, which turns the P
controller into a PI controller. The effect of the integral-action component is that a sustained
control deviation is added up. This means that manipulated variable becomes larger and larger
despite the constant control deviation.
If abrupt disturbances occur in a system, they can be counteracted quickly with an additional
derivative-action component. The derivative-action component calculates the manipulated
variable from the time derivative of the control deviation. However, this behavior also leads to an
increase of stochastic disturbances (noise). It is necessary to strike a balance here.
A controller that combines proportional, integral-action and derivative-action components is called

a PID controller. In the process industry, 95% of applications are implemented with a PID
controller, because it is tuned with only three parameters (gain, integral-action time and
derivative-action time). These few parameters allow for a good adaptation to a many different
dynamic processes.
However, tuning the parameters requires knowledge of the system that is being controlled.
Knowledge of the system can be gained by experience, determined experimentally or calculated
by modeling the system. For a wide variety of processes that are not dominated by dead times
and that respond similarly to positive and negative changes of the manipulated variable
interventions, several practical tuning rules have been identified. Examples are the tuning rules
according to Chien, Hrones and Reswick [1], the Ziegler and Nichols method [2] and the T-sum
rule [3].
The process control system PCS 7 supports the tuning of parameters using a PID Tuner.
In the controller block PIDConL, the parameters for the gain, integral-action component and
derivative-action component are called GAIN, TI and TD, respectively. The times must be
specified in seconds in each case. The input variables of the controller are the process tag PV
and the setpoint SP, which yield the control deviation ER. The manipulated variable MV is the
output variable for the controlled system; it is calculated according to the following formula:
 
 
 1 TD  s   ER
MV  GAIN  1  
 TI  s TD 
 1 s
 DiffGain  .
4.3 Suitability of loop controllers in industry

For a loop controller to also work in everyday industrial applications, additional functions have to
be implemented. These include above all:
– Bumpless changeover
– Anti-reset windup
– Support of different closed-loop control structures
The purpose of bumpless changeover is to prevent an abrupt change of the manipulated variable
on a changeover between manual and automatic mode or between an internal and external
setpoint setting or when a parameter changes. A bumpless changeover between manual and
automatic mode is required, for example, when a process in the process industry runs semi-
automatically, i.e. startup is performed in manual mode and a switch is then made to automatic
mode during regular operation. In manual mode, the operator specifies the manipulated variable
directly; in automatic mode, the control algorithm calculates the manipulated variable.
The purpose of the anti-reset windup (ARW) function is to prevent the integral-action component
(reset) of the manipulated variable from continuing to increase (figuratively: windup), because
control deviation cannot be corrected due to the manipulated variable limitation, for example.
The support of different closed-loop control structures enables optimization of the loop controller
without having to replace the controller. Some of these closed-loop control structures are
explained in greater detail in section 'Expanded closed-loop control structures'. With PIDConL
from the SIMATIC PCS 7 Advanced Process Library V90, the following closed-loop
control structures can be implemented:
– Fixed setpoint control
– Cascade control
– Ratio control
– Feedforward control
– Split-range control
– Smith predicator control
– Override control
4.4 Expanded closed-loop control structures

In some applications, single-loop control loops are inadequate, so that expanded closed-loop
control structures must be used to reach the desired goal.
If the response to setpoint changes and the disturbance response is not simultaneously
optimized satisfactorily for a process tag, a feedforward control/auxiliary value injection or a
cascade control can be used.
If the disturbance is measured and its point of application is known, there is the option to apply
feedforward compensation for disturbances at the controller input or controller output.
Feedforward control can be used to fully compensate the disturbance variable, so that the
controller can be tuned for optimal response to setpoint changes.
Disturbance
variables z
Compensation
(1) (2)
System Manipulated
deviation e variable y
- -
Process variable
Loop = Controlled
Setpoint w System
controller variable x
+
-
Figure 2: Feedforward control at the controller input (1) or controller output (2)
If the disturbance variable cannot be measured, but another variable in the system can be
measured in its place, this auxiliary variable is fed to the controller input with a loop controller.
The auxiliary variable injection reduces the effect of the disturbance variable but does not
compensate for it completely.
Auxiliarx
variable x2
Compensation
Disturbance
variables z
System Manipulated
deviation e variable y
-
Process variable
Loop
Setpoint w Subsystem Subsystem = controlled
controller
+ variable x1
-
Figure 3: Auxiliary variable injection
If the auxiliary variable is injected at the controller input, the compensation and the loop controller
do not act independently of each other. This means that if the controller parameters are adjusted,
the compensation has to be adjusted as well.
If the feedforward control and auxiliary value injection are inadequate, the point of application of
the disturbance variables cannot be determined with sufficient accuracy or the subsystems
cannot be modeled with sufficient accuracy, a two-loop or multi-loop cascade control is used.
When designing a cascade control, it is assumed that the lower-level control loops (Loop
controller 2 in Figure 4 – a so-called follower controller) respond faster in each case than the
higher-level control loops (Loop controller 1 in Figure 4 – a so-called master controller). The
closed-loop control system is thus always optimized from the inside out.
The cascade control reduces the effect of the disturbance variable and speeds up control of the
setpoint. In order for the cascade control to be used, measurable variables appropriate for this
type of control must exist.
e1 y1 = w2 e2 y2 x2
Loop Loop
w1 Subsytem Subsystem
controller 1 controller 2
+
- - x1
Figure 4: Cascade control with two loops
Ratio control is used if the process tag is determined in dependence on another variable, e.g.
ratio control of two liquid flows that are to be mixed. This means closed-loop control of the
composition of the mixture or ratio control of combustion gas and fresh air in a gas burner for
optimal combustion. The setpoint of the process tag w2 is calculated from the ratio Vw and the
process tag x1.
rw w2 e2 y2 x2
Loop
System 2
controller 2
-
e1 Loop y1
w1 System 1 x1
controller 1
+ -
Figure 5: Ratio control
4.5 Interfacing to processes

The continuous output signal of the loop controller is not always output directly to the process.
Especially when large forces or flows are involved, this direct output is not advisable, and a
binary interface is therefore implemented. To this end, the analog signal is converted into a
binary signal by means of pulse width modulation. The elementary block PULSEGEN [4] is
available in the CFC Library for this.
The PULSEGEN function uses pulse width modulation to transform the input variable INV (=
LMN manipulated variable of the PID controller) into a pulse train with a constant period. It
corresponds to the cycle time used to update the input variable and must be assigned in
PER_TM.
The duration of a pulse per period is proportional to the input variable. The cycle assigned with
PER_TM is not identical to the processing cycle of the PULSEGEN function block. As shown in
Figure 6, a PER_TM cycle consists of several processing cycles of the function block
PULSEGEN. In this context, the number of PULSEGEN calls per PER_TM cycle provides a
measure of the precision of the pulse width modulation.
Figure 6: Timing diagram of input INV and output QPOS_P of PULSEGEN [4]
An input variable of 30% with 10 PULSEGEN calls per PER_TM means the following:
– 1 at output QPOS for the first three calls of PULSEGEN (30% of 10 calls)
– 0 at output QPOS for the remaining seven calls of PULSEGEN (70% of 10 calls)
The pulse width is recalculated at the beginning of each period. Through a sampling ratio of 1:10
(CTRL_PID calls to PULSEGEN calls), the manipulated value precision is limited in this example
to 10%. Specified input values INV can only be mapped to a pulse width at the QPOS output in a
grid of 10%. Correspondingly, the precision increases with the number of PULSEGEN calls per
PIDConL call. If PULSEGEN is called 100 times and PIDConL only once, a resolution of 1% of
the manipulated variable range is achieved.
Note:
– You must program the reduction ratio of the call frequency yourself.
4.6 References
[1] Chien, Kun Li; Hrones, J. A.; Reswick, J. B. (1952): On the Automatic Control of
Generalized Passive Systems. In: Transactions of the American Society of Mechanical
Engineers, Vol. 74, Cambridge (Mass.), pg. 175-185.
[2] Ziegler, J. G. and Nichols, N. B (1942): Optimum settings for automatic controllers. In:
Trans. ASME, 64, pg. 759-768.
[3] Kuhn, U.: Eine praxisnahe Einstellregel für PID-Regler: Die T-Summen-Regel.
Automatisierungstechnische Praxis, Nr. 5, 1995, pg. 10-16.
[4] SIEMENS (2017): Process Control System PCS 7: CFC Elementary Blocks.
A5E41367308-AB. (support.automation.siemens.com/WW/view/en/109755019)
5 Task
In accordance with the specifications in chapter 'Process Description', the temperature control
and the associated manual control of Reactor R001 is to be added to the CFCs from chapter
'Functional safety'. The heating of the reactor will be implemented using a PID controller with
downstream pulse generator.
The following CFCs will be created here:
– A1T2H008 (manual local control for heating reactor R001)
– A1T2T001 (temperature control reactor R001)
When implementing the temperature control, the following interlock conditions must be taken into
account in the CFC.
– An actuator may only be operated when the main switch of the plant is switched on and the
Emergency Stop switch is unlocked.
– The temperatures in the two reactors must not exceed 60 °C.
– The heaters of the two reactors may only be started up if they are covered with liquid (here: a
minimum of 200 ml in the reactor).
6 Planning
The manual control A1T2H008 (see Figure 8) for controlling the heating consists of three parts:
– A digital input for the Start command: 'A1.T2.A1T2H008.HS+.START' / I7.0
– A digital input for the Stop command: 'A1.T2.A1T2H008.HS-.STOP' / I7.1
– A digital output for the status feedback: 'A1.T2.A1T2H008.HO+-.0+' / Q4.1
An analog measured value is available for the temperature measurement:
– 'A1.T2.A1T2T001.TIC.M' / IW76 / actual temperature value R001
A digital output is available for the heating control:
– 'A1.T2.A1T2T001.TV.S' / Q4.
The signals are already contained in the symbol table and only still have to be linked.
The analog measured value must still be scaled to an actual temperature. For this, the user
specifies the high limit 100°C and low limit 0°C of the measured value.
The manual control influences the A1T2T001 temperature control (see also Figure 7), which must
be expanded accordingly.
The interlocks mentioned in the task description can all be implemented with previously created
sensors and actuators.
Figure 7: Portion of the P&ID flow chart to be programmed
Figure 8: Local operator station
7 Learning objective
In this chapter, students gain the following:
– Knowledge of how to program a continuous loop controller with pulse output and interlocks
8 Structured step-by-step instructions

8.1 Creating the manual control A1T2H008
1. First, insert a new CFC in the reactor R001 folder. You will implement the manual control for
the heating in this folder.
2. The newly created chart is renamed A1T2H008.
3. The interconnections of A1T2H008 differ from those of A1T2H011 only in the input and
output signals (Pcs7DiIn and Pcs7DiOu) and in the last two reset conditions (block 'Or08').
The conditions relate to the minimum level of 200.0 ml and the maximum temperature of
60.0 °C.
Block: Catalog/Folder:
Pcs7DiIn (2x) Blocks/Channel
Or08 Blocks/LogicDi
CompAn02 (2x) Blocks/LogicAn
FlipFlop Blocks/LogicDi
Pcs7DiOu Blocks/Channel
Table 1: New blocks in chart 'A1T2H008'
Input: Interconnection to: Inverted
Pcs7DiIn.HS+.PV_In 'A1.T2.A1T2H008.HS+.START' / I7.0 / reactor R001 No

heating start
Pcs7DiIn.HS-.PV_In 'A1.T2.A1T2H008.HS-.STOP' / I7.1 / reactor R001 heating No

stop
Or08.In4 A1H001(A,1) / A1H001 PV_Out Process value incl. ST Yes
CompAn02.T.In2 60.0
CompAn02.L.In1 A1T2L001(A,1) / Level_A1T2L001 PV_Out Process value

incl. ST
CompAn02.L.In2 200.0
FlipFlop.Mode 1
Table 2: Input interconnections in chart 'A1T2H008'
Input: Output: Inverted
FlipFlop.SetLi Pcs7DiIn.HS+.PV_Out No
FlipFlop.RstLi Or08.Out No
Or08.In3 Pcs7DiIn.HS-.PV_Out No
Or08.In7 CompAn02.T.GT No
Or08.In8 CompAn02.L.LT No
Pcs7DiOu.PV_In FlipFlop.Out No
Table 3: Block interconnections in chart 'A1T2H008'
Output: Interconnection to: Inverted
Pcs7DiOu.PV_Out 'A1.T2.A1T2H008.HO+-.0+' / Q4.1 / reactor R001 heating No

status value
Table 4: Output interconnections in chart 'A1T2H008'
8.2 Creating the A1T2T001 temperature control

1. First, a new CFC named 'A1T2T001' is created. In this chart, you will implement the actual
closed-loop control of the heating of reactor R001.
2. Add the following blocks and name them appropriately.
Pcs7AnIn Blocks/Channel
PIDConL Libraries/PCS7 APL V90/ Blocks + Templates\

Blocks/Control
PULSEGEN Libraries/CFC Library/ELEM400\Blocks/CONTROL
Pcs7DiOu Blocks/Channel
Table 5: New blocks in chart 'A1T2T001'
3. Next, implement the basic interconnections as shown in the table below. Compare your result
with the figure.
Pcs7AnIn.PV_In 'A1.T2.A1T2T001.TIC.M' / IW76 / actual temperature

value R001
Pcs7AnIn.Scale High value = 100.0, Low value = 0.0
Table 6: Input interconnections in chart 'A1T2T001'
PIDConL.PV Pcs7AnIn.PV_Out
PULSEGEN.INV PIDConL.MV
Pcs7DiOu.PV_In PULSEGEN.QPOS_P No
Table 7: Block interconnections in chart 'A1T2T001'
Output: Interconnection to: Inverted
Pcs7DiOu.PV_Out 'A1.T2.A1T2T001.TV.S’ / Q4.5 / temperature reactor R001 No

control signal
Table 8: Output interconnections in chart 'A1T2T001'
4. Now, configure the gains and the integral-action time of the PID controller by setting
PIDConL.Gain = 2 and TI = 10.0.
5. Change to Sheet 2 and create the interlocks shown below:
Or04 Blocks/LogicDi
CompAn02 (2x) Blocks/LogicAn
Table 9: New blocks in chart 'A1T2T001/Sheet2'
CompAn02.T.In1 A1T2T001(A,1) / In_A1T2T001 PV_Out Process value

incl. ST
CompAn02.T.In2 60.0
CompAn02.L.In1 A1T2L001(A,1) / Level_A1T2L001 PV_Out Process value

incl. ST
CompAn02.L.In1 200.0
Table 10: Input interconnections in chart 'A1T2T001/Sheet2'
Or04.In3 CompAn02.T.GT
Or04.In4 CompAn02.L.LT
Table 11: Block interconnections in chart 'A1T2T001'
6. Now, interconnect output 'Out' of block 'Or04' with input 'MV_ForOn' of block 'PIDConL' and
check that 'MV_Force' = 0.0. As a result of this, the value 'MV_Force' will be applied at output
'MV' of the PID controller (manipulated variable of controller) as soon as the interlocking
conditions are met.
8.3 Manual control of A1T2T001 temperature control

1. Now you will assign parameters for local control. You will use programming mode for this.
Programming mode is enabled using the 'AdvCoEn' input and activated using 'AdvCoMst'.
Set the 'AdvCoMod' parameter to '0' so that in local mode the 'AdvCoMV' input is interpreted
as the manipulated variable and not as the setpoint. Make 'AdvCoMV' visible and set it to
100. As a result of this, the heating will be controlled in local mode without closed-loop
control.
PIDConL.AdvCoEn A1H003(A,1) / A1H003 No

PV_Out Process value
including ST
PIDConL.AdvCoMod 0
PIDConL.AdvCoMst A1T2H008(A,1) / A1T2H008 No

Out Output
PIDConL.AdvCoMV 100.0
Table 12: Input interconnections in chart 'A1T2T001/Sheet1'
2. With parameter assignment of OS_Perm (bits 0 to 31) of the PIDConL block, operator
authorizations can be restricted. Set Bit 4 and Bit 7 to zero, so that the operator cannot
enable programming mode and cannot change the manual setting for the manipulated
variable ('Man').
3. Finally, you can interconnect chart 'A1T2H008' and chart 'A1T2T001' as follows.
CompAn02.T.In1 A1T2T001(A,1) /
In_A1T2T001 PV_Out
Process value incl. ST
Table 13: Block interconnections between chart 'A1T2H008/Sheet1' and 'A1T2T001/Sheet1'
8.4 Checklist – step-by-step instruction

The following checklist helps students to independently check whether all steps of the step-by-
step instruction have been carefully completed and enables them to successfully complete the
module on their own.
No. Description Checked
1 Manual control A1T2H008 created and completely interconnected
2 Temperature control A1T2T001 created, configured and interlocked
3 Manual control A1T2H008 combined with the A1T2T001 temperature

control
4 Interlocks and manual control successfully tested (optional)
5 Project successfully archived
Table 14: Checklist for step-by-step instructions
9 Exercises
In the exercises, you apply what you learned in the theory section and in the step-by-step
instructions. The existing multiproject from the step-by-step instructions (p01-06-project-r1905-
en.zip) is to be used and expanded for this. The download of the project is stored as zip file
"Projects" on the SCE Internet for the respective module.
To prepare for the next chapter, you will implement the final missing function of reactor R001 –
the stirrer and the manual control of the stirrer. The interlock conditions are as follows:
– An actuator may only be operated when the main switch of the plant is switched on and the
Emergency Stop switch is unlocked.
– The stirrers of the two reactors should only be started up when they are in contact with liquid
(here: a minimum of 300 ml in the reactor).
In addition, you can learn more about the PID controller, how it works and what parameters can
be set. However, this is not needed here for the functionality of the control.
9.1 Tasks
1. Implement stirrer A1T2S001 in the chart folder 'reactor R001'. Use the same process tag
type for the stirrer as for the pumps. Connect the feedback signal and actuating signal.
Assign appropriate names to the blocks. Then add the interlocks as explained above.
2. Then implement the manual control A1T2H007 for the stirrer you just created. Implement the
interlocking conditions here as reset conditions.
3. Inform yourself about the inputs 'ModLiOp', 'AutModLi' and 'ManModLi' of the 'PIDConL'
block. To do so, open the help of the 'PIDConL' block with the 'F1' key. Select 'PIDConL
operating modes' and then manual mode or automatic mode.
4. If you want to learn more about the inputs 'SP_LiOp', 'SP_ExtLi', 'SP_IntLi', etc., enter
setpoint setting in the 'Search' tab of the help. You will receive information under the
suggested title 'Setpoint setting – Internal/external'.
5. What is the purpose of parameters MV_HiLim and MV_LoLim? Search for information on
these inputs in the help on your own.
Figure 9: Excerpt from the local operator station
Figure 10: Excerpt from P&ID flowchart
9.2 Checklist – exercise

The following checklist helps students to independently check whether all steps of the exercise
have been carefully completed and enables them to successfully complete the module on their
own.
No. Description Checked
1 Stirrer 'Reactor R001\A1T2S001' created, configured and interlocked
2 Manual control 'Reactor R001\A1T2H007' created and configured
3 Manual control A1T2H007 combined with temperature control

A1T2S001
4 The functionality of operating modes and setpoint setting in the

PIDConL block is known.
5 Function of the manipulated variable limitation in the PIDConL block is

known
6 New elements successfully tested (optional)
7 Project successfully archived
Table 15: Checklist for exercises
10 Additional information
More information for further practice and consolidation is available as orientation, for example:
Getting Started, videos, tutorials, apps, manuals, programming guidelines and trial software/
firmware, under the following link:
siemens.com/sce/pcs7
Preview "Additional information"
Further Information
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Learn-/Training Document | PA Module P01-06, Edition 02/2020 | Digital Industries, FA

Matching SCE Trainer Packages for this Learn-/Training Document

• SIMATIC PCS 7 Software Package V9.0 (set of 3)

Additional information regarding SCE

Information regarding use

3 Required hardware and software ...................................................................................................... 6

4.1 Theory in brief ..........................................................................................................................7

4.2 Introduction ..............................................................................................................................8

4.3 Suitability of loop controllers in industry.....................................................................................9

4.4 Expanded closed-loop control structures ................................................................................. 10

4.5 Interfacing to processes .......................................................................................................... 11

4.6 References ............................................................................................................................. 13

7 Learning objective .......................................................................................................................... 16

8 Structured step-by-step instructions................................................................................................ 17

8.1 Creating the manual control A1T2H008 .................................................................................. 17

8.2 Creating the A1T2T001 temperature control ........................................................................... 20

8.3 Manual control of A1T2T001 temperature control .................................................................... 26

8.4 Checklist – step-by-step instruction ......................................................................................... 29

9.1 Tasks ..................................................................................................................................... 30

9.2 Checklist – exercise ................................................................................................................ 32

10 Additional information ..................................................................................................................... 33

Control loop and other control functions

3 Required hardware and software

3 SIMIT V10 or higher

Figure 1: Control loop

A controller that combines proportional, integral-action and derivative-action components is called

4.3 Suitability of loop controllers in industry

– Support of different closed-loop control structures

– Fixed setpoint control

– Smith predicator control

4.4 Expanded closed-loop control structures

Figure 3: Auxiliary variable injection

Figure 4: Cascade control with two loops

Figure 5: Ratio control

4.5 Interfacing to processes

The following CFCs will be created here:

– A1T2H008 (manual local control for heating reactor R001)

– A1T2T001 (temperature control reactor R001)

– The temperatures in the two reactors must not exceed 60 °C.

– A digital input for the Start command: 'A1.T2.A1T2H008.HS+.START' / I7.0

– A digital input for the Stop command: 'A1.T2.A1T2H008.HS-.STOP' / I7.1

– A digital output for the status feedback: 'A1.T2.A1T2H008.HO+-.0+' / Q4.1

An analog measured value is available for the temperature measurement:

– 'A1.T2.A1T2T001.TIC.M' / IW76 / actual temperature value R001

A digital output is available for the heating control:

Figure 7: Portion of the P&ID flow chart to be programmed

Figure 8: Local operator station

8 Structured step-by-step instructions

2. The newly created chart is renamed A1T2H008.

Pcs7DiIn (2x) Blocks/Channel

CompAn02 (2x) Blocks/LogicAn

Table 1: New blocks in chart 'A1T2H008'

Input: Interconnection to: Inverted

Pcs7DiIn.HS+.PV_In 'A1.T2.A1T2H008.HS+.START' / I7.0 / reactor R001 No

Pcs7DiIn.HS-.PV_In 'A1.T2.A1T2H008.HS-.STOP' / I7.1 / reactor R001 heating No

Or08.In4 A1H001(A,1) / A1H001 PV_Out Process value incl. ST Yes

Or08.In5 A1H002(A,1) / A1H002 PV_Out Process value incl. ST Yes

Or08.In6 A1H003(A,1) / A1H003 PV_Out Process value incl. ST Yes

CompAn02.L.In1 A1T2L001(A,1) / Level_A1T2L001 PV_Out Process value