National Polytechnic Institute

ESIQIE

MULTI-LOOP CONTROL MODULE

OF INDUSTRIAL PROCESSES

PRACTICE MANUAL
NOVEMBER 2012
 MEXICAN ENGINEERING SPECIALIZED IN

INDUSTRIAL PROJECTS

Galileo Galilei 3865-1C Zapopan Jalisco Mexico

Tels/Fax 3631-5011
IMEPI SA de CV
[email protected] www.imepi.com.mx

IMEPI SA de CV collaborators for him

development of these practices.

Eng. José Antonio Neri Olvera.

Eng. Javier Enriquez Rodríguez.

Eng. Daniel Ramos Plasencia.

Eng. Jesus Neri Quiroz.

Eng. Oscar Arturo Sandoval Martínez.

“Teamwork and leadership are essential for the development of

any project, they will always achieve the goals regardless of the
difficulties that arise
 IMEPI SA de CV
National Polytechnic Institute

"CONTROL MODULE
MULTI-LOOK OF PROCESSES
INDUSTRIAL”
Understanding the System

"The acquisition of any knowledge is always useful to the intellect, which will know how
to discard
the bad and preserve the good.” Leonardo da Vinci
 MEXICAN ENGINEERING SPECIALIZED IN

INDUSTRIAL PROJECTS
Galileo Galilei 3865-1C Zapopan Jalisco
Mexico
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx

Content
National Polytechnic Institute...............................................................................................1
ESIQIE..................................................................................................................................1
IMEPI SA de CV collaborators for him development of these practices....................3
National Polytechnic Institute....................................................................................4
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”................4
Understanding the System.............................................................................................4
1.1 Goals...........................................................................................................8
1.1.1 Generals...................................................................................................8
1.1.2 Specific....................................................................................................8
1.2 Understanding the system.........................................................................10
1.2.1 Closed Control Loop or Closed Flow Control Circuit..........................10
1.2.2 Closed Control Loop or Closed Level Control Circuit...............................13
1.2.3 Closed Control Loop or Closed Pressure Control Circuit.....................15
1.2.4 Closed Control Loop or Closed Circuit Temperature Control..............17
1.4 Control of 3 process variables...................................................................27
1.4.1 Flow-Level-Pressure.............................................................................27
1.5 Questionnaire............................................................................................28
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..............38
National Polytechnic Institute..................................................................................41
3.2 Theoretical framework:.............................................................................42
3.2.1 What is a transmitter?............................................................................42
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3.2.2 Digital electronic transmitters...............................................................49
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3.2.3 Differential pressure transmitter............................................................53
National Polytechnic Institute..................................................................................54
3.2.3.1 Yokogawa brand differential pressure transmitter................................55

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Galileo Galilei 3865-1C Zapopan Jalisco
National Polytechnic Institute..................................................................................56
Mexico
3.2.3.2 Tube installation....................................................................................57
Tel/Fax 3631-5011
3.2.3.3 [email protected]
IMEPI SA de CV of the transmitter for closed www.imepi.com.mx
tank........................................57
National Polytechnic Institute..................................................................................58
3.2.3.4 Wiring....................................................................................................59
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3.3 Equipment used.........................................................................................61
3.4.1 Construction of the calibration curve for the LIT-2 level differential
pressure transmitter..............................................................................................61
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3.4.2 HART communication protocol for smart transmitters........................65
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3.16 3 PACTware software for configuring intelligent transmitters with HART
protocol................................................................................................................71
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3.5 Material:....................................................................................................73
3.6 Development.............................................................................................73
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1 .7 Questionnaire............................................................................................88
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"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..............66
National Polytechnic Institute..................................................................................69
4.1 Aim............................................................................................................70
4.2 Theoretical framework..............................................................................70
4.2.1 Flow Indicator Controller FIC-1 Brand ABB. (receiver)......................70
National Polytechnic Institute..................................................................................71
National Polytechnic Institute..................................................................................73

National Polytechnic
Institute
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INDUSTRIAL PROJECTS
Galileo Galilei 3865-1C Zapopan Jalisco
National Polytechnic Institute..................................................................................75
Mexico
National Polytechnic Institute..................................................................................77
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx
National Polytechnic Institute..................................................................................79
4.2.2 Key functions and entry to the ABB Flow controller display...............80
National Polytechnic Institute..................................................................................81
4.2.3 ABB Controller Configuration Menu Map...........................................82
4.3 Material Used.................................................................................................82
National Polytechnic Institute..................................................................................83
4.4 Development..................................................................................................84
4.4.1 Configuration of levels 5 and 6 of the ABB controller.........................84
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4.4.2 Identification of receiver errors (FIC-1 Flow Indicator Controller, ABB
brand)...................................................................................................................89
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4.5 questionnaire..................................................................................................97
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National Polytechnic Institute................................................................................100
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..............84
Orifice Plate.................................................................................................................84
National Polytechnic Institute..................................................................................87
5.2 Theoretical framework..............................................................................88
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National Polytechnic Institute................................................................................106
5.2.1 How an Orifice Plate Works...............................................................107

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National Polytechnic Institute................................................................................108
Mexico
5.2.2 InstallationTel/Fax
of an intelligent
3631-5011 differential pressure transmitter to measure
flow
IMEPI SAwith an orifice [email protected]
de CV plate...................................................................................109
www.imepi.com.mx
National Polytechnic Institute................................................................................110
5.3. Material and equipment used......................................................................111
National Polytechnic Institute................................................................................112
5.4 Development................................................................................................113
National Polytechnic Institute................................................................................114
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National Polytechnic Institute................................................................................133
5.5 Calculations..................................................................................................134
National Polytechnic Institute................................................................................135
5.6. Questionnaire..........................................................................................136
National Polytechnic Institute................................................................................137
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”............112
National Polytechnic Institute................................................................................116
6.2 Theoretical framework............................................................................117
National Polytechnic Institute................................................................................120
National Polytechnic Institute................................................................................124
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6.3 Material used................................................................................................129
National Polytechnic Institute................................................................................130
6.4. Development...........................................................................................131
National Polytechnic Institute................................................................................131
National Polytechnic Institute................................................................................133
6.4 Questionnaire...............................................................................................134
National Polytechnic Institute................................................................................135
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”............124

National Polytechnic
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Galileo Galilei 3865-1C Zapopan Jalisco
Proportional Band......................................................................................................124
Mexico
National Polytechnic Institute................................................................................127
Tel/Fax 3631-5011
IMEPI
7.1 SA de CV [email protected] www.imepi.com.mx
Aim..........................................................................................................128
7.2 Theoretical framework............................................................................128
7.2.1 Proportional control.............................................................................128
National Polytechnic Institute................................................................................129
National Polytechnic Institute................................................................................131
National Polytechnic Institute................................................................................133
National Polytechnic Institute................................................................................135
National Polytechnic Institute................................................................................137
7.2.2 Summary of the characteristics of proportional control......................138
National Polytechnic Institute................................................................................139
7.2.3 Operation of a proportional band controller........................................140
7.3 Used material..........................................................................................140
National Polytechnic Institute................................................................................141
7.4. Development...............................................................................................142
National Polytechnic Institute................................................................................143
7.4.1. Table and data to build the graph........................................................144
National Polytechnic Institute................................................................................145
7.5 Questionnaire...............................................................................................146
National Polytechnic Institute................................................................................147
National Polytechnic Institute................................................................................144
8.2.1 Types of final control elements...........................................................145
8.2.2 Pneumatic actuator..............................................................................145
National Polytechnic Institute................................................................................146
National Polytechnic Institute................................................................................148
National Polytechnic Institute................................................................................150
8.2.3 Valve body..........................................................................................151
National Polytechnic Institute................................................................................152
National Polytechnic Institute................................................................................154
National Polytechnic Institute................................................................................156
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8.2.4 Characteristic of a valve......................................................................159
National Polytechnic Institute................................................................................159
National Polytechnic Institute................................................................................161
National Polytechnic Institute................................................................................163
8.2.5 Calculation of valve flow coefficient..................................................164

National Polytechnic
Institute
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 MEXICAN ENGINEERING SPECIALIZED IN

INDUSTRIAL PROJECTS
Galileo Galilei 3865-1C Zapopan Jalisco
National Polytechnic Institute................................................................................165
Mexico
National Polytechnic Institute................................................................................167
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx
National Polytechnic Institute................................................................................169
National Polytechnic Institute................................................................................171
National Polytechnic Institute................................................................................173
National Polytechnic Institute................................................................................175
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”............154
Cascade Control........................................................................................................154
9.1 Aim..........................................................................................................158
9.2 Theoretical framework............................................................................158
9.2.1 Cascade control...................................................................................158
9.2.2 Cascade control of the Multiloop Control Module.............................159
9.3 Used material..........................................................................................160
9.4 Development................................................................................................160
9.5 Questionnaire...............................................................................................168
1.1

Understanding the System

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Galileo Galilei 3865-1C Zapopan Jalisco
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Tel/Fax 3631-5011
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1.1 Goals.

1.1.1 Generals.
The student will understand the correct operation of the system.
1.1.2 Specific.
1) It will identify the elements that make up the closed control loops of each of the process
variables, as well as the on and off procedure of the entire system.
2) You will understand the interrelationship that exists between the different elements that
make up the closed control loops of each of the process variables based on the system
engineering diagrams.

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Galileo Galilei 3865-1C
Understanding theZapopan
System Jalisco
Mexico
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx

National Polytechnic
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 MEXICAN ENGINEERING SPECIALIZED IN

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Galileo Galilei 3865-1C Zapopan Jalisco
Mexico
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx

1.2 Understanding the system.

The Multiloop Control Module for Industrial Processes will control 4 process variables: Flow,
Level, Temperature and Pressure. The module has a closed control loop for each variable,
allowing the field instruments used to be calibrated, as well as tuning each closed loop with its
control modes: P, P+I, P+I+D.

The operation is versatile and flexible in such a way that each closed loop can be controlled on its
own in automatic mode and also interact with the other process variables at the same time. The
control strategy is described below.

1.2.1 Closed Control Loop or Closed Flow Control Circuit.

The control circuit consists of a primary flow element type FE-1 Orifice Plate, installed in 1”
diameter pipe; a secondary element or differential pressure indicator transmitter FIT-1, with
HART communication; a final control element, in this case, a control valve with FV-1 intelligent
positioner, also with HART communication.

The flow measurement begins when the water flow passes through the orifice plate, which causes
a pressure drop, generating a differential pressure that is detected by the FIT-1 differential pressure
transmitter, this instrument sends at the same time an electrical signal of 4-20 mA to the universal
type digital electronic controller FIC-1, located in front of the control cabinet and to the FIRC-1
controller located in the programmable logic controller, also known as “PLC”. The closed loop
flow control is carried out with the FIC-1 controller or in the FIRC-1 controller from the operating
station, it should only be selected with the selector installed on the front of the control board, if the
control is It will be carried out with the controller “C” or from the “PLC”. The controller selected
through said selector will manipulate the FV-1 control valve to maintain the flow at the desired
value of the process variable (Set Point) by configuring and adjusting the P+I+D tuning
parameters.

The Flow circuit (see figure E.1) is located in the T1 tank of 300 liters capacity, water is
recirculated by aligning the manual valve HV-3 of the discharge and the T1 pipe on its return,
opening with the station of operation the two-position ball valve V1, once verifying that the circuit
is aligned, the pump B1 is started from the control panel (BA1) on the panel or from the virtual
control panel on the operating station (with the Aurora HMI SCADA software ), to start the water
circulation.

Pump B1 can be stopped by its own button panel (BP1) located in the cabinet or from the
operation console.

Pump B1 also stops due to the following safety conditions:

-Low level LSL-1 in tank T1, which will illuminate a low level pilot light (LAL-1) on the control
board.

-High level LSH-2 in tank T2, which will light a pilot light (LAH-2) installed on the control board.

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Galileo Galilei 3865-1C
Understanding Zapopan Jalisco
the System
Mexico
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx

National Polytechnic
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Galileo Galilei 3865-1C Zapopan Jalisco
Mexico
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx

- Emergency Stop Button located on the control panel.

- Virtual Emergency Stop button located on the operating station.
- Pump B1 motor overload.
- Electric power failure.

The 2-position ball valves, with identifications V1, V2, V3, V4, V5 and V6, have a pneumatic
actuator with spring return, are normally closed (NC), which means that they require air pressure
to open and are missing of the same the valve closes.

These valves can be opened and closed directly manually from the solenoid valves located inside
the G2 cabinet or with the operation station (with the Aurora HMI SCADA software), that is, from
the PLC.

These valves have 2 contacts or position switches (ZSL and ZSH), to sense when they are open or
closed. In addition, at the operating station the colors of the valves change when they are in a
certain position.

Figure E.1 Flow control loop.

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Mexico
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IMEPI SA de CV [email protected] www.imepi.com.mx

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Galileo Galilei 3865-1C Zapopan Jalisco
Mexico
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx

1.2.2 Closed Control Loop or Closed Level Control Circuit.

The control circuit consists of a LIT-2 differential pressure type level transmitter sensor, with
HART communication, which sends an electrical signal of 4-20 mA to a universal type digital
electronic controller LIC-2 or the LIRC-2 of the PLC. , which after configuring and adjusting the
PID parameters, will manipulate an LV-2 control valve to maintain the level at the desired value
of the process variable (Set Point).

The green level circuit shown in figure E.3 is located in tank T2 of 300 liters capacity, water will
be recirculated by aligning the discharge pipe from tank T2 to the return of tank T1, with the
selector located in front of the control board in level control position or from the operation console
with the virtual selector “Selector 2” of the operation station in level control position “LIC2”, it
must automatically open valve V5 and close the valve V3 and V4, once this operation has been
verified with the valve position switches (ZSH and ZSL), pump B2 is started to start water
circulation. The B2 pump can be stopped by its own keypad located on the control panel or from
the virtual keypad on the operating station.

Pump B2 also stops due to the following safety conditions:

-Low level LSL-2 in tank T2, which will illuminate a low level pilot light (LAL-2) on the control
board.

-High level LSH-1 in tank T1, which will illuminate a high level pilot light (LAH-1) on the control
board.

- Emergency Stop Button located on the control cabinet.

- Virtual Emergency Stop button located on the operating station.

- Electric power failure.

- Pump B2 motor overload.

To cause disturbances in the level control, the power flow with the FIC-1 must be reduced, so that
when the LIT-2 senses a lower level, the LIC-2 or LIRC-2 control of the PLC will order it to close
automatically. proportional the control valve LV-2 and thus maintain the level at the desired value
of the process variable. The same procedure can be carried out by increasing the feed flow with
the FIC-1, so now the closed control loop, also known as the control circuit, will perform the work
in reverse.

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Mexico
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx

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Galileo Galilei 3865-1C Zapopan Jalisco
Mexico
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx

Figure E.2 Level Control Loop.

1.2.3 Closed Control Loop or Closed Pressure Control Circuit.

The control circuit consists of a PIT-2 gauge pressure transmitter sensor, with HART
communication, which sends a 4-20 mA signal to a universal type digital electronic controller
PIC-2 or the PIRC-2 of the PLC, which After configuring and adjusting the PID parameters, it will
manipulate the control valves PV-2A and PV-2B to maintain the pressure at the desired value of
the process variable (Set Point). The installed pressure control circuit is considered as a compound
control loop and is known as a split-range control loop, since a single output signal from the
controller manipulates 2 final control elements, that is, it manipulates 2 modulating control valves
PV-2 and PV-2B.

The Pressure circuit in yellow color shown in figure E.4 is located in tank T2 of 300 liters
capacity, pressurized air is supplied to tank T2 through valve PV-2A and pressure is released in
tank T2. opening the PV-2B vent control valve. The PLC must open valve PV-2A to introduce
pressurized air to tank T2, so that the pressure at T2 increases, and it must open valve PV-2B to
release air contained in the tank, reducing the pressure at T2.

The pressure control loop is known as a composite control because 2 control valves are
manipulated from a single control output. This is done as follows:

The PIC-2 pressure control located on the control board or the PIRC-2 control of the PLC sends a
4-20 mA signal to the two control valves PV-2A and PV-2B, the first is normally closed and is
which supplies air to tank T2, operates in the range of 12 to 20 mA. The second valve is normally
open and releases air from tank T2, operating at 4-12 mA. In such a way that when the process
variable is less than the Set Point of the controller, then the control output will send a signal above
12 mA, which will allow the opening of the PV valve.

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Mexico
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IMEPI SA de CV [email protected] www.imepi.com.mx

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2A and of course since the signal is greater than 12 mA the vent control valve PV-2B remains
closed. On the contrary, when the process variable is greater than the Set Point of the controller,
then the control output will send a signal below 12 mA, which closes the air supply valve PV-2A
and opens the air supply valve. PV-2B vent.

Figure E.3 Pressure Control Loop.

1.2.4 Closed Control Loop or Closed Circuit Temperature Control.

The control circuit consists of a primary temperature element type RTD TE-2, installed in tank T2;
a secondary element or temperature indicator transmitter TIT-2, with HART communication and
the final control element, in this case for heating it is an electric heat exchanger CE1 and for
cooling it is the supply of cold water through the valves solenoid TY-1 and TY-2.

The control circuit consists of an RTD type temperature sensor identified as TE-2, which detects
the water temperature in tank T2 through resistance changes in the sensor (RTD), these changes
are received by the indicator transmitter. temperature TIT-2 and at the same time an electrical
signal of 4-20 mA to the universal type digital electronic controller TIC-2 and to the TIRC of the
PLC. The closed loop temperature control is carried out with the TIC-2 controller or with the
TIRC-2 controller from the operating station, it must only be selected with the selector installed in
front of the control board, if the control will be carried out with the controller “C” or from the
“PLC”.

The controller selected through said selector will manipulate the final control element, which in
this case are two devices called relays, one of them allows the heating to be activated or
deactivated indirectly with the electric heat exchanger and the second relay allows the heating to
be activated or deactivated indirectly. The cooling is activated or deactivated indirectly with the
cold water supply by opening and closing the solenoid valves TY-1 and TY-2, maintaining the

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IMEPI SA de CV [email protected] www.imepi.com.mx

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in the desired value of the process variable (Set Point), through previously configuring and
adjusting the tuning parameters of the PID controller.

The temperature circuit in red shown in figure E.2 is located in tank T2 with a 300 liter capacity.
Water will be recirculated by aligning the discharge pipe from T2 to its return, opening the valves
with the operating station. ON-OFF V3 and V4, and closing the ON-OFF valve V5, the latter is
easily done with the selector located in front of the control panel in the temperature control
position or from the operation console with the virtual selector “Selector 2” of the operating
station in temperature control position “TIC2”, once selected, verify on the screen that it is
confirmed with the position switches (ZSH and ZSL) that the valves are open and closed
respectively. Once it is confirmed that the pipe is aligned, then pump B2 is started, from the
control panel keypad or from the operation station (with Aurora HMI SCADA software), to start
water circulation.

The B2 pump can be stopped by its own button located in the cabinet or from the operation
console.

Pump B2 also stops due to the following safety conditions:

-Low level LSL-2 in tank T2, which will illuminate a low level pilot light (LAL-2) on the control
board.

-Under flow FSL-2, of the water circulating from B2 to the heat exchanger, a pilot light (FAL-2)
installed on the control board will also light up.
-High LSH-1 level in tank T1, which will light a pilot light (LAH-1) installed on the control board.

- Emergency Stop Button located on the control cabinet.

- Virtual Emergency Stop button located on the operating station.

- Electric power failure.

- Pump B2 motor overload.

The water heating system will be operating in a closed circuit so each passage of the water through
the electric heat exchanger will increase its temperature. When the water is required to be cooled,
the solenoid valves TY-1 and TY-2 are opened to feed cold water from the general water supply.
Excess water in T2 is sent to drain to maintain the same amount of water in the system.
To cause disturbances in the temperature control, cold water must be supplied to the system and
the temperature control must maintain the desired value of the process variable.

Understanding the System

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Figure E.4 Temperature Control Loop

Understanding the System

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1.3 Control of 2 process variables.

1.3.1 Flow-Level.

Figure E.5 shows the flow and level circuit in green. The first step is to stabilize the Flow and
Level control, subsequently disturbances can be caused with the flow controller, increasing or
decreasing the flow Set Point value, so that the level control will automatically perform its control
in proportion to the changes caused.

Figure E.5 Flow and Level Control Loop.

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Galileo Galilei 3865-1C Zapopan Jalisco
Mexico
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx

1.3.2 Flow-Temperature.

Figure E.6 shows the flow and temperature circuit in blue and red respectively. The first step is to
stabilize the Temperature control, subsequently disturbances can be caused with the flow controller,
supplied with cold water from tank T1, so that the temperature control will automatically carry out
the control in proportion to the changes caused.

Figure E.6. Flow and Temperature Control Loop.

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GalileoUnderstanding
Galilei 3865-1C Zapopan Jalisco
the System
Mexico
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx

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INDUSTRIAL PROJECTS
Galileo Galilei 3865-1C Zapopan Jalisco
Mexico
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx

1.3.3 Level-Pressure.

Figure E.7 shows the Level and Pressure control circuit in green and yellow. The first step is to
stabilize the Level control, so that the pressure control can then be stabilized, ensuring that a constant
input flow is maintained at T2, later disturbances can be caused with the level control, increasing or
decreasing the value. of level Set Point, with which the pressure control will automatically carry out
its control in proportion to the changes caused.

Figure E.7 Level and Pressure Control Loop.

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INDUSTRIAL PROJECTS
Galileo Galilei 3865-1Cthe
Understanding Zapopan
System Jalisco
Mexico
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx

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 MEXICAN ENGINEERING SPECIALIZED IN

INDUSTRIAL PROJECTS
Galileo Galilei 3865-1C Zapopan Jalisco
Mexico
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx

1.4 Control of 3 process variables.

1.4.1 Flow-Level-Pressure.

Figure E.8 shows the Flow, Level and Pressure control circuit in Blue, Green and Yellow
respectively. The first step is to stabilize the flow control, it is suggested at 60 LPM, this will
allow the level control and pressure control to be stabilized, subsequently disturbances can be
caused with the flow controller, increasing or decreasing the Set Flow point (suggested between
50 and 70 LPM), with which the level control will automatically carry out its control in proportion
to the changes caused, and the pressure control will also carry out its control according to the
changes caused.

Once the flow is stabilized at 60 LPM, the level Set Point can be changed (60 to 75% is
suggested), so that the flow and pressure control will make the necessary changes to stabilize the
operation automatically.

Once the flow is stabilized at 60 LPM, the pressure Set Point can be changed (7 to 14 PSI is
suggested), so that the flow and level control will make the necessary changes to stabilize the
operation automatically.

The Industrial Process Multiloop Control Module has the following switches:
• LSL-1 Low Level in tank T1. For Pump B1
• LSH-1 High Level in tank T1. For Pump B2.
• LSL-2 Low Level in tank T2. Stop Pump B2 and Deactivate the electric heater.
• LSH-2 High Level in tank T2. For Pump B1
• FSL-2 Low Flow in T2 tank discharge. Deactivates the heating system, For pump
B2.
• PSH-2 High pressure in tank T2. For Pump B1

All these signals will be sent to the PLC to indicate alarms on the operation screen. They are also
safety systems for equipment and operators.

Pumps B1 and B2 can be started and stopped with the control panel buttons and/or with the
operating station, that is, from the PLC. In this way you can view the operation of the pumps on
the operation screen. Likewise, there are confirmation contacts from the pumps to the PLC.

The tuning of the universal controllers is carried out in a conventional way and the PLC controls
are carried out from the tuning screen where each of the controls and their PI D parameters are
displayed.

To facilitate tuning, graphs of the process variables can be displayed through the operation trends
that are displayed on the operation screen with the AURORA HMI SCADA SOFTWARE.

Understanding the System

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Figure E.8 Piping and Instrumentation Diagram.

1.5 Questionnaire.

1 .- How many variables can the Industrial Process Multiloop control module control?
2 .- How many and what variables can be controlled simultaneously in the Multiloop Control
Module for Industrial Processes?
3 .- What are the instruments that make up the closed Flow control loop?
4 .- Locate the instruments that make up the Flow control Loop in the Piping and Instrument
Diagram (DTI) and physically.
5 .- Locate the graphics that represent the Flow control loop on the Aurora HMI SCADA Software
screen of the operation station.
6 .- What are the instruments that make up the closed Level control loop?
7 .- Locate the instruments that make up the Level control loop in the Pipe and Instrument Diagram
(DTI) and physically.
8 .- Locate the graphics that represent the Level control loop on the Aurora HMI SCADA Software
screen of the operation station.
9 .- What are the instruments that make up the closed pressure control loop?
10 .- Locate the instruments that make up the Pressure control loop in the Piping and Instrument
Diagram (DTI) and physically.
11 .- Locate the graphics that represent the Pressure control loop on the Aurora HMI SCADA
Software screen of the operating station.
12 .- What are the instruments that make up the closed loop temperature control?
13 .- Locate the instruments that make up the Temperature control loop in the Piping and Instrument
Diagram (DTI) and physically.
14 .- Locate the graphics that represent the Temperature control loop on the Aurora HMI SCADA

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Galileo Galilei
Software screen of the operating station. 3865-1C Zapopan Jalisco
Mexico of Pump B1?
15 .- What are the safety conditions
Tel/Fax 3631-5011
IMEPI SA de CV [email protected]
Understanding www.imepi.com.mx
the System

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Mexico
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx

16 .- What are the safety conditions of the B2 pump?

17 .- How many and which are the two-position ball valves (On – Off) of the Multiloop Control
Module for Industrial Processes?
18 .- What are the switches contained in the Multiloop Control Module for Industrial Processes and
what are they for?
19 .- What are the position switches of two-position ball valves used for?
20 .- What are the ways to open or close two-position valves?
21 .- The Multiloop Control Module for Industrial Processes is designed to control variables
through two control systems. Mention what they are and what is done to select one control
system or another?
22 .-Identify where the set point of any variable is changed on the screen or in the ABB brand C250
controllers.
23 .- How many and what screens does the operating station have?
24 .- Control tuning is carried out through the operation screen (Aurora HMI SCADA) and from
conventional controllers. Locate the tuning screen and tuning menu on the controllers.
25 .- Identify which are the trend graph screens for the 4 variables in the operating station.

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Understanding theZapopan
System Jalisco
Mexico
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IMEPI SA de CV [email protected] www.imepi.com.mx

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 IMEPI SA de CV

"CONTROL MODULE
MULTI-LOOK OF PROCESSES
INDUSTRIAL”

Operation manual

"They explained it to me and I forgot it, I read it and understood it, I did it
and I learned it"
 MEXICAN ENGINEERING SPECIALIZED IN

INDUSTRIAL PROJECTS
Galileo Galilei 3865-1C Zapopan Jalisco Mexico
Tel/Fax 3631-5011
[email protected] www.imepi.com.mx
IMEPI SA de CV

Content
National Polytechnic Institute..................................................................................................1
ESIQIE.....................................................................................................................................1
IMEPI SA de CV collaborators for him development of these practices........................3
National Polytechnic Institute.......................................................................................4
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”....................4
Understanding the System................................................................................................4
1.1 Goals...............................................................................................................8
1.1.1 Generals......................................................................................................8
1.1.2 Specific........................................................................................................8
1.2 Understanding the system.............................................................................10
1.2.1 Closed Control Loop or Closed Flow Control Circuit..............................10
1.2.2 Closed Control Loop or Closed Level Control Circuit...................................13
1.2.3 Closed Control Loop or Closed Pressure Control Circuit.........................15
1.2.4 Closed Control Loop or Closed Circuit Temperature Control..................17
1.4 Control of 3 process variables......................................................................27
1.4.1 Flow-Level-Pressure.................................................................................27
1.5 Questionnaire................................................................................................28
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..................38
National Polytechnic Institute.....................................................................................41
3.2 Theoretical framework:................................................................................42
3.2.1 What is a transmitter?...............................................................................42
National Polytechnic Institute.....................................................................................43
National Polytechnic Institute.....................................................................................44
National Polytechnic Institute.....................................................................................46
National Polytechnic Institute.....................................................................................48
3.2.2 Digital electronic transmitters...................................................................49
National Polytechnic Institute.....................................................................................50
National Polytechnic Institute.....................................................................................52
3.2.3 Differential pressure transmitter...............................................................53
National Polytechnic Institute.....................................................................................54

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3.2.3.1 Yokogawa brand differential pressure transmitter....................................55
INDUSTRIAL PROJECTS
National Polytechnic Institute.....................................................................................56
Galileo Galilei 3865-1C Zapopan Jalisco Mexico
Tel/Fax 3631-5011
3.2.3.2 Tube installation........................................................................................57
[email protected] www.imepi.com.mx
IMEPI 3.2.3.3
SA de CVInstallation of the transmitter for closed tank...........................................57
National Polytechnic Institute.....................................................................................58
3.2.3.4 Wiring.......................................................................................................59
National Polytechnic Institute.....................................................................................60
3.3 Equipment used............................................................................................61
3.4.1 Construction of the calibration curve for the LIT-2 level differential
pressure transmitter..................................................................................................61
National Polytechnic Institute.....................................................................................62
National Polytechnic Institute.....................................................................................64
3.4.2 HART communication protocol for smart transmitters............................65
National Polytechnic Institute.....................................................................................66
National Polytechnic Institute.....................................................................................68
National Polytechnic Institute.....................................................................................70
3.16 3 PACTware software for configuring intelligent transmitters with HART
protocol....................................................................................................................71
National Polytechnic Institute.....................................................................................72
3.5 Material:........................................................................................................73
3.6 Development.................................................................................................73
National Polytechnic Institute.....................................................................................74
National Polytechnic Institute.....................................................................................76
National Polytechnic Institute.....................................................................................78
National Polytechnic Institute.....................................................................................80
National Polytechnic Institute.....................................................................................82
National Polytechnic Institute.....................................................................................83
National Polytechnic Institute.....................................................................................85
National Polytechnic Institute.....................................................................................87
1 .7 Questionnaire................................................................................................88
National Polytechnic Institute.....................................................................................89
National Polytechnic Institute.....................................................................................91
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..................66
National Polytechnic Institute.....................................................................................69
4.1 Aim...............................................................................................................70
4.2 Theoretical framework..................................................................................70
4.2.1 Flow Indicator Controller FIC-1 Brand ABB. (receiver).........................70

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National Polytechnic Institute.....................................................................................71
INDUSTRIAL PROJECTS
National Polytechnic Institute.....................................................................................73
Galileo Galilei 3865-1C Zapopan Jalisco Mexico
Tel/Fax
National Polytechnic 3631-5011
Institute.....................................................................................75
[email protected] www.imepi.com.mx
National
IMEPI Polytechnic Institute.....................................................................................77
SA de CV
National Polytechnic Institute.....................................................................................79
4.2.2 Key functions and entry to the ABB Flow controller display...................80
National Polytechnic Institute.....................................................................................81
4.2.3 ABB Controller Configuration Menu Map...............................................82
4.3 Material Used.....................................................................................................82
National Polytechnic Institute.....................................................................................83
4.4 Development......................................................................................................84
4.4.1 Configuration of levels 5 and 6 of the ABB controller.............................84
National Polytechnic Institute.....................................................................................85
National Polytechnic Institute.....................................................................................87
National Polytechnic Institute.....................................................................................88
4.4.2 Identification of receiver errors (FIC-1 Flow Indicator Controller, ABB
brand).......................................................................................................................89
National Polytechnic Institute.....................................................................................90
National Polytechnic Institute.....................................................................................92
National Polytechnic Institute.....................................................................................94
National Polytechnic Institute.....................................................................................96
4.5 questionnaire......................................................................................................97
National Polytechnic Institute.....................................................................................98
National Polytechnic Institute...................................................................................100
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..................84
Orifice Plate....................................................................................................................84
National Polytechnic Institute.....................................................................................87
5.2 Theoretical framework..................................................................................88
National Polytechnic Institute.....................................................................................89
National Polytechnic Institute.....................................................................................91
National Polytechnic Institute.....................................................................................93
National Polytechnic Institute.....................................................................................95
National Polytechnic Institute.....................................................................................97
National Polytechnic Institute.....................................................................................99
National Polytechnic Institute...................................................................................101
National Polytechnic Institute...................................................................................103
National Polytechnic Institute...................................................................................105

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 MEXICAN ENGINEERING SPECIALIZED IN
National Polytechnic Institute...................................................................................106
INDUSTRIAL PROJECTS
5.2.1 How anGalileo
OrificeGalilei
Plate3865-1C
Works...................................................................107
Zapopan Jalisco Mexico
Tel/Fax
National Polytechnic 3631-5011
Institute...................................................................................108
[email protected] www.imepi.com.mx
IMEPI 5.2.2
SA de CVInstallation of an intelligent differential pressure transmitter to measure
flow with an orifice plate.......................................................................................109
National Polytechnic Institute...................................................................................110
5.3. Material and equipment used..........................................................................111
National Polytechnic Institute...................................................................................112
5.4 Development....................................................................................................113
National Polytechnic Institute...................................................................................114
National Polytechnic Institute...................................................................................116
National Polytechnic Institute...................................................................................118
National Polytechnic Institute...................................................................................120
National Polytechnic Institute...................................................................................121
National Polytechnic Institute...................................................................................123
National Polytechnic Institute...................................................................................125
National Polytechnic Institute...................................................................................127
National Polytechnic Institute...................................................................................129
National Polytechnic Institute...................................................................................131
National Polytechnic Institute...................................................................................133
5.5 Calculations.....................................................................................................134
National Polytechnic Institute...................................................................................135
5.6. Questionnaire..............................................................................................136
National Polytechnic Institute...................................................................................137
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”................112
National Polytechnic Institute...................................................................................116
6.2 Theoretical framework................................................................................117
National Polytechnic Institute...................................................................................120
National Polytechnic Institute...................................................................................124
National Polytechnic Institute...................................................................................126
National Polytechnic Institute...................................................................................128
6.3 Material used...................................................................................................129
National Polytechnic Institute...................................................................................130
6.4. Development...............................................................................................131
National Polytechnic Institute...................................................................................131
National Polytechnic Institute...................................................................................133
6.4 Questionnaire...................................................................................................134

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National Polytechnic Institute...................................................................................135
INDUSTRIAL PROJECTS
"CONTROL MODULEGalileo
MULTI-LOOK OF Zapopan
Galilei 3865-1C PROCESSES
JaliscoINDUSTRIAL”................124
Mexico
Tel/Fax 3631-5011
Proportional Band.........................................................................................................124
[email protected] www.imepi.com.mx
National
IMEPI Polytechnic Institute...................................................................................127
SA de CV
7.1 Aim.............................................................................................................128
7.2 Theoretical framework................................................................................128
7.2.1 Proportional control................................................................................128
National Polytechnic Institute...................................................................................129
National Polytechnic Institute...................................................................................131
National Polytechnic Institute...................................................................................133
National Polytechnic Institute...................................................................................135
National Polytechnic Institute...................................................................................137
7.2.2 Summary of the characteristics of proportional control..........................138
National Polytechnic Institute...................................................................................139
7.2.3 Operation of a proportional band controller...........................................140
7.3 Used material..............................................................................................140
National Polytechnic Institute...................................................................................141
7.4. Development...................................................................................................142
National Polytechnic Institute...................................................................................143
7.4.1. Table and data to build the graph............................................................144
National Polytechnic Institute...................................................................................145
7.5 Questionnaire...................................................................................................146
National Polytechnic Institute...................................................................................147
National Polytechnic Institute...................................................................................144
8.2.1 Types of final control elements...............................................................145
8.2.2 Pneumatic actuator..................................................................................145
National Polytechnic Institute...................................................................................146
National Polytechnic Institute...................................................................................148
National Polytechnic Institute...................................................................................150
8.2.3 Valve body..............................................................................................151
National Polytechnic Institute...................................................................................152
National Polytechnic Institute...................................................................................154
National Polytechnic Institute...................................................................................156
National Polytechnic Institute...................................................................................158
8.2.4 Characteristic of a valve..........................................................................159
National Polytechnic Institute...................................................................................159

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National Polytechnic Institute...................................................................................161
INDUSTRIAL PROJECTS
National Polytechnic Institute...................................................................................163
Galileo Galilei 3865-1C Zapopan Jalisco Mexico
8.2.5 Tel/Fax
Calculation 3631-5011
of valve flow coefficient......................................................164
[email protected] www.imepi.com.mx
National
IMEPI Polytechnic Institute...................................................................................165
SA de CV
National Polytechnic Institute...................................................................................167
National Polytechnic Institute...................................................................................169
National Polytechnic Institute...................................................................................171
National Polytechnic Institute...................................................................................173
National Polytechnic Institute...................................................................................175
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”................154
Cascade Control............................................................................................................154
9.1 Aim.............................................................................................................158
9.2 Theoretical framework................................................................................158
9.2.1 Cascade control.......................................................................................158
9.2.2 Cascade control of the Multiloop Control Module.................................159
9.3 Used material..............................................................................................160
9.4 Development....................................................................................................160
9.5 Questionnaire...................................................................................................168
2.1

Operation manual

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Galileo Galilei 3865-1C Zapopan Jalisco Mexico
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IMEPI SA de CV

2.1 Goals

2.1.1 General

The participant will understand and apply the knowledge obtained throughout this manual, to be able to
correctly use the “Multi-loop control module for industrial processes”.

2.1.2 Specific

-The various instruments for controlling processes for industrial use will be identified.
-The process of starting and stopping the equipment will be understood.

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Operation manual
INDUSTRIAL PROJECTS
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Tel/Fax 3631-5011
[email protected] www.imepi.com.mx
IMEPI SA de CV

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Galileo Galilei 3865-1C Zapopan Jalisco Mexico
Tel/Fax 3631-5011
[email protected] www.imepi.com.mx
IMEPI SA de CV

2.2 Initial Considerations and Recommendations.

1. Connect the different energies required by the Multiloop Control Module for Industrial Processes.
2. Open manual air supply valve and verify that instrument air pressure is not less than 90 PSIG.
3. Open the manual water supply valve and verify that the water levels in tanks T1 and T2 are
approximately 50% water.
4. Check that the main power switch inside the laboratory is on.
5. Check that the main power switch inside the G1 cabinet is on.
6. Verify that the manual valves to drain the equipment are closed.
7. The emergency stop button PE must be deactivated.
8. Power the control panel or cabinet with the power button.
9. Power up the personal computer (operating station).
10. Open program (Aurora HMI SCADA/ESIQIE/RunTime)
11. Verify the communication of the operation station with the control equipment (PLC's).
12. Verify that the instruments are energized.
13. Verify that selector 1 of the board is “F” to control from the operating station with the support of the
Aurora HMI SCADA software.
14. Verify that selector 2 of the board is in the “PLC” position, when the system control is carried out
with the programmable logic controller and with the operation station with the Aurora HMI SCADA
software.
15. Verify that selector 2 on the board is in the “C” position, when system control is carried out with the
digital electronic controllers.
16. Verify that the Flow, Level, Pressure and Temperature instruments have the real values of the
process variables.
17. Once the control board or cabinet is energized, keep it closed and never open it, if the teacher
responsible for the subject and/or the group is not there, since currents of up to 75 amperes are
handled inside it, so , it is a mandatory requirement that the teacher in charge of the practice
permanently supervises any activity inside the control panel or control cabinet G1. Apply the above
for any cabinet integrated into the Ind Process Multiloop Control Module.
18. The Multiloop Control Module for Industrial Processes operates with industrial energy and
equipment, so it is convenient for students to concentrate on carrying out the practices and avoid
playing in the work area.
19. The use of safety equipment, cotton gowns or camisoles, safety glasses, helmet and safety boots is
recommended.
20. At the end of any practice, depressurize the equipment and electrically de-energize the Industrial
Process Multiloop Control Module, as well as close Water, Air and Drain supplies.

jii Operation manual

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IMEPI SA de CV

2.3 Flow Control from the Operation Station (Aurora HMI SCADA).
1. With selector 1 activate the “Transfer to T1” (Tank 1) function.
2. Check on the operation screen and physically that valve 1 (V-1) is open.
3. Check on the operation screen and physically that valve 2 (V-2) is closed.
4. Verify that the valves are not in manual mode.
5. At the operating station, in the FIRC-1 HMI controller and pump B1 box:
a. Modify the SP of the FIRC-1 HMI flow controller to 65 LPM.
b. Activate the FIRC-1 HMI flow controller to automatic mode.
c. Start pump B1 with the virtual button panel.
6. Check the established values in the trend graph.
7. Check controller tuning.
8. Check that the values displayed on the operation station or Aurora HMI SCADA screen, the
electronic controllers and the field instruments are the same.
9. To continue with variable level, leave the flow control active.

2.3.1 Exit Flow control.

1. Turn off pump B1, with the virtual keypad.

2. Modify SP of FIRC-1 HMI to 0 LPM.
3. Change the FIRC-1 HMI controller to manual mode.
4. Modify output to 0% control valve opening.

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Operation manual
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Tel/Fax 3631-5011
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IMEPI SA de CV

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IMEPI SA de CV

2.4 Level Control (HMI).

1. Having in flow operation.

2. Using selector 2 of the Aurora HMI SCADA screen, change selector 2 from “OUT” position to
“LIRC-2 HMI ” level control position
3. On the LIRC-2 HMI level controller:
a. Modify the SP to 50%.
b. Activate automatic mode.
4. With virtual selector 1, Activated in “Flow to T1”,
5. Activate “Transfer T1 to T2” and deactivate “Flow to T1”,
6. Activate “Transfer to T2” and deactivate “Flow T1 to T2”, to be able to control Tank 2 level.
7. Verify that the valves are open: V-2, V-5.
8. Verify that the valve is closed: V-1.
9. Start pump B2, with the virtual button panel on the operation screen.
10. Check the established values in the trend graph.
11. Check LIRC-2 HMI level controller tuning.
12. Verify that the values displayed on the Aurora HMI SCADA operation screen, digital electronic
controllers and field instruments are the same.
13. To continue with pressure with interaction with flow and level, leave the system operating

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Operation manual
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Tel/Fax 3631-5011
[email protected] www.imepi.com.mx
IMEPI SA de CV

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IMEPI SA de CV

14. .1 Exit Level control.

1. Turn off pump B2/acknowledge low flow alarm.

2. Turn off pump B1.
3. In LIRC-2 HMI :
a. Modify SP to 0% level.
b. Change LIRC-2 HMI level controller to manual mode.
c. Modify the output to 0% control valve opening.
4. In FIRC-1 HMI :
a. Modify SP to 0.
b. Switch to manual mode.
c. Modify the output to 0.
5. Both HMI selectors set to Out.

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IMEPI SA de CV

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Galileo Galilei 3865-1C Zapopan Jalisco Mexico
Tel/Fax 3631-5011
[email protected] www.imepi.com.mx
IMEPI SA de CV

2.5 Pressure Control with variable Flow and Level, from the operating station (with Aurora
HMI SCADA software).

1. Confirm air pressures for both instruments and tank pressurization.

2. Verify that HMI selector 2 is in LIRC-2 and selector 1 in Flow to T2
3. Check that the low pressure valve on the wet leg is closed and the high pressure valve is open.
4. In PIRC-2 HMI :
a. Modify the SP to 5 PSIG.
b. Activate the controller to Automatic Mode.
5. Check the established values in the trend graph.
6. Check tuning of the PIRC-2 HMI pressure controller.
7. Check that the values displayed by the HMI screen, controllers and instruments correspond.

2.5.1 Exit Pressure control (HMI).

1. In PIRC HMI .
a) Modify SP to 0.
b) Switch to manual mode.
c) Set the output to 0.
2. Verify that the inlet (PV-2A) and outlet (PV-2B) valves are closed and open respectively.

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2.5.2 Exit Level and Flow control (HMI).

1. Turn off pump B2 / acknowledge low flow alarm / turn off pump B1.
2. Put FIRC HMI and LIRC HMI in manual mode.
3. Modify the output to 0 of both.
4. Modify the SP to 0 for both.
5. In both HMI selectors leave it on outside.

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IMEPI SA de CV

2.6 Pressure control from the operation station (with Aurora HMI SCADA software).

1. Check pressures at 90 PSI for the instruments.

2. Check pressures at 30 PSI for tank pressurization.
3. Confirm that all valves are closed, including manual valves.
4. Check that the low pressure leg valve is closed and that the high pressure valve is open.
5. HMI selector 1 and 2 in Out.
6. In PIRC-2 HMI.
a. Modify the SP to 5 PSI.
b. Activate controller in Automatic Mode.
7. Check the established values in the trend graph.
8. Check tuning.
9. Check that the values displayed by the Aurora HMI SCADA operation screen, controllers and
instruments correspond.

2.6.1 Exit Pressure control.

1. In PIRC HMI .
2. Modify SP to 0.
a. Switch to manual mode.
b. Set the output to 0.
3. Verify that the inlet (PV-2A) and outlet (PV-2B) valves are closed and open respectively.

Operation manual

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2.7 Temperature Control from the operation station (with Aurora HMI SCADA software).

1. Verify that FIRC HMI , PIRC HMI , LIRC HMI are in manual mode.
2. Close low leg pressure valve.
3. Confirm that valve 6 (V-6) is closed.
4. Set selector 2 HMI to “TIRC-2”.
a. Selector 1 HMI Out.
b. Check that valves V3, V4 and HV-6 are open, V2 and V5 are closed.
5. Check that the level of tank T2 is approximately 50%.
6. In TIRC2 HMI .
to. Change the SP at 30 °C.
7. Start pump B2.
8. Activate the TIRC2 HMI temperature controller in automatic mode.
9. Check the established values in the trend graph.
10. Check tuning.
11. Check that the values displayed by the HMI screen, controllers and instruments correspond.

2.7.1 Exit temperature control.

1. Turn off pump 2 / acknowledge alarm.

2. Set HMI selector 2 to off.
3. In PIRC-2.
a. Switch to manual mode.
b. Set the output to 0.

2.8 To control the operation from the Control Board Controllers.

Confirm the following conditions:

HMI Selector 1 "Out"
HMI pumps (B1 and B2) "Manual"
HMI Selector 2 "Out"
PIRC HMI "Manual"
LIRC HMI "Manual"
TIRC HMI "Manual"
FIRC HMI "Manual"

Dashboard selector 2 Control “C”

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2.8.1 Flow Control from the FIC-1 Controller on the Control Board.

1. Open the valves from HMI.

2. On selector 1 HMI select transfer to T1.
3. Verify that V2 is closed.
4. In the electronic controller FIC-1.
a. Modify the SP.
b. Put the control in automatic mode.
5. Start bomb B1 from the board.
6. Verify flow trends in HMI.
7. Check that the values displayed by the HMI screen, controllers and instruments correspond.

Operation manual

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2.8.2 Level Control from the LIC-2 Controller on the Control Board

1. In the LIC-2 electronic controller.

a. Change the SP to 50%.
b. Put in automatic mode.
2. In selector 1 on the dashboard, choose level “L”.
3. In HMI operation, modify selector 1 HMI .
4. Activate flow to T1, activate transfer T1 and T2, deactivate flow to T1, activate transfer to T2,
deactivate flow T1 and T2.
5. Verify the correct closure of V-2.
6. Check level trends in HMI.
7. Check that the values displayed by the HMI screen, controllers and instruments correspond.

Operation manual

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IMEPI SA de CV

2.8.3 Pressure Control from the PIC-2 Controller of the Control Board.

1. Confirm pressures for control valves are 25 PSI

2. In PIC-2
to. Modify the SP
3. Check that the LIT-2 wet leg valve is closed.
4. Check that valves are not open to avoid pressure leaks.
5. Put in automatic mode.
6. Check that the values displayed by the HMI screen, controllers and instruments correspond.

Operation manual

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Tel/Fax 3631-5011
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IMEPI SA de CV

2.9 Turn off the Equipment.

1. Get out of pressure.

2. PIRC-2.
a. Modify the SP to 0.
b. Put in manual mode.
3. Set the output to 0.
4. Turn off pump 2 / acknowledge alarm.
5. Turn off pump B1.

2.9.1 Exit level.

1. Modify the SP to 0.
2. Put in manual mode.
3. Set the output to 0.

2.9.2 Exit flow.

1. Modify the SP to 0.
2. Put in manual mode.
3. Set the output to 0.
4. Check that all valves are closed.
5. Set both dash selectors to off.
6. Set both HMI selectors to off.
7. Verify that all outputs of both the controllers and the HMI are at 0 and in manual mode.
8. Turn off the air supply.
9. Exit HMI RunTime/close program/turn off the device.
10. Press emergency stop.

2.10 Maintenance.

1. With low level alarm at T1.

2. Check that HV-1 is open.
3. Press button N TQE-1 to open valve 7.
4. The valve will close when marking high level on T1.

Operation manual

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IMEPI SA de CV

2.11 Notes.

b BOMB
B.A. START BUTTON
B.P. STOP BUTTON
LIME HEATING
COOLING
ENF FLOW INDICATOR CONTROLLER
FIC FIRC CONTROLLER INDICATOR FLOW RECORDER
FIT FLOW INDICATOR TRANSMITTER
FV LAH FLOW CONTROL VALVE
LAL LIC HIGH LEVEL ALARM
LIRC LOW LEVEL ALARM
LEVEL INDICATOR CONTROLLER
CONTROLLER INDICATOR LEVEL RECORDER
L.V. LEVEL CONTROL VALVE
LIT LEVEL INDICATOR TRANSMITTER
PAH HIGH PRESSURE ALARM
PE EMERGENCY STOP
PIC PRESSURE INDICATOR CONTROLLER
PIRC CONTROLLER INDICATOR PRESSURE RECORDER
PIT PRESSURE INDICATOR TRANSMITTER
PV PRESSURE CONTROL VALVE
REC AL ACKNOWLEDGE ALARM
T.Y. SOLENOID VALVE
SP SETPOINT
TIC TEMPERATURE INDICATOR CONTROLLER
TIRC CONTROLLER INDICATOR TEMPERATURE RECORDER
TIT TEMPERATURE INDICATOR TRANSMITTER
V ON-OFF VALVE,
H.V. MANUAL VALVE

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IMEPI SA de CV

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IMEPI SA de CV

2.12 Recirculation in T1.

1. Activate transfer to T1 in selector 1 HMI .

2. Verify that V-1 is open, V-2 closed.
3. Check that the bottom HV-3 of tank T1 is open.
4. Check that T1 does not have a low level alarm.
5. Start pump B1.

2.13 Transfer from T1 to T2.

1. Select transfer to T2 in selector 1 HMI .

2. Verify that V-1 is closed, V-2 and HV-3 open.
3. Check that there is no high level alarm in T2 or low level alarm in T1.
4. Start pump B1.

2.14 Transfer from T2 to T1.

1. In selector 2 activate LIRC-2 HMI.

2. Check that valve V-5 is open.

3. Verify that LV-2 has an opening greater than 30%.
4. Check that there is no high level alarm in T1 or low level alarm in T2.
5. Start pump B2.

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[email protected] www.imepi.com.mx
IMEPI SA de CV

2.15 Questionnaire

1. What is the procedure to start operating the system?

2. Name the supplies the system requires to operate properly.

3. What is compressed air used for in the equipment?

4. What is the system air operating pressure value?

5. What precautions should be taken with the control panel during system operation?

6. What needs to be verified before controlling the equipment with Aurora HMI SCADA
software?

7. Explain what we mean when we say “virtual button panel”

8. Identify all elements and supplies involved in the closed Flow control operation. of the
Loop
9. Identify all elements and supplies that are involved in the operation of the Loop
Closed Level control.

10. Identify all pressure control supplies involved in the operation of the
elements and closures. Loop

11. Identify all elements and supplies that are involved in the operation of the closed loop
temperature control.

12. Explain what should be done if the values displayed on the operation screen of Aurora HMI
SCADA, digital electronic controllers and field instruments are different.

13. In case of any failure in the operation of the system, explain what must be done to stop the
operation of the Multiloop Control Module immediately and avoid any damage to the
equipment or operating personnel.

14. Write down the actions that must be taken when the equipment is no longer going to be
used.

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15. Explain the advantages of operating the equipment through the control station, instead of the
control panel.

Operation manual

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 IMEPI SA de CV

"CONTROL MODULE
MULTI-LOOK OF PROCESSES
INDUSTRIAL”

Transmitters

"Ideas are not imposed, they are proposed."

John Paul II.
 MEXICAN ENGINEERING SPECIALIZED IN

-EP mH INDUSTRIAL PROJECTS

IMEPI SA de CV Galileo Galilei 3865-1C Zapopan Jalisco Mexico
Tel/Fax 3631-5011
[email protected] www.imepi.com.mx

Content
National Polytechnic Institute....................................................................................................1
ESIQIE.......................................................................................................................................1
IMEPI SA de CV collaborators for him development of these practices..........................3
National Polytechnic Institute.........................................................................................4
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”......................4
Understanding the System...................................................................................................4
1.1 Goals.................................................................................................................8
1.1.1 Generals.........................................................................................................8
1.1.2 Specific..........................................................................................................8
1.2 Understanding the system...............................................................................10
1.2.1 Closed Control Loop or Closed Flow Control Circuit................................10
1.2.2 Closed Control Loop or Closed Level Control Circuit.....................................13
1.2.3 Closed Control Loop or Closed Pressure Control Circuit...........................15
1.2.4 Closed Control Loop or Closed Circuit Temperature Control....................17
1.4 Control of 3 process variables........................................................................27
1.4.1 Flow-Level-Pressure...................................................................................27
1.5 Questionnaire..................................................................................................28
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”....................38
National Polytechnic Institute.......................................................................................41
3.2 Theoretical framework:...................................................................................42
3.2.1 What is a transmitter?..................................................................................42
National Polytechnic Institute.......................................................................................43
National Polytechnic Institute.......................................................................................44
National Polytechnic Institute.......................................................................................46
National Polytechnic Institute.......................................................................................48
3.2.2 Digital electronic transmitters.....................................................................49
National Polytechnic Institute.......................................................................................50
National Polytechnic Institute.......................................................................................52
3.2.3 Differential pressure transmitter.................................................................53
National Polytechnic Institute.......................................................................................54
3.2.3.1 Yokogawa brand differential pressure transmitter......................................55
National Polytechnic Institute.......................................................................................56
3.2.3.2 Tube installation..........................................................................................57
3.2.3.3 Installation of the transmitter for closed tank.............................................57

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 National Polytechnic Institute.......................................................................................58
3.2.3.4 Wiring.........................................................................................................59
National Polytechnic Institute.......................................................................................60
3.3 Equipment used...............................................................................................61
3.4.1 Construction of the calibration curve for the LIT-2 level differential
pressure transmitter....................................................................................................61
National Polytechnic Institute.......................................................................................62
National Polytechnic Institute.......................................................................................64
3.4.2 HART communication protocol for smart transmitters..............................65
National Polytechnic Institute.......................................................................................66
National Polytechnic Institute.......................................................................................68
National Polytechnic Institute.......................................................................................70
3.16 3 PACTware software for configuring intelligent transmitters with HART
protocol......................................................................................................................71
National Polytechnic Institute.......................................................................................72
3.5 Material:..........................................................................................................73
3.6 Development...................................................................................................73
National Polytechnic Institute.......................................................................................74
National Polytechnic Institute.......................................................................................76
National Polytechnic Institute.......................................................................................78
National Polytechnic Institute.......................................................................................80
National Polytechnic Institute.......................................................................................82
National Polytechnic Institute.......................................................................................83
National Polytechnic Institute.......................................................................................85
National Polytechnic Institute.......................................................................................87
1 .7 Questionnaire..................................................................................................88
National Polytechnic Institute.......................................................................................89
National Polytechnic Institute.......................................................................................91
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”....................66
National Polytechnic Institute.......................................................................................69
4.1 Aim.................................................................................................................70
4.2 Theoretical framework....................................................................................70
4.2.1 Flow Indicator Controller FIC-1 Brand ABB. (receiver)............................70
National Polytechnic Institute.......................................................................................71
National Polytechnic Institute.......................................................................................73
National Polytechnic Institute.......................................................................................75
National Polytechnic Institute.......................................................................................77
National Polytechnic Institute.......................................................................................79
4.2.2 Key functions and entry to the ABB Flow controller display.....................80
National Polytechnic Institute.......................................................................................81
4.2.3 ABB Controller Configuration Menu Map.................................................82

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 4.3 Material Used.......................................................................................................82
National Polytechnic Institute.......................................................................................83
4.4 Development........................................................................................................84
4.4.1 Configuration of levels 5 and 6 of the ABB controller...............................84
National Polytechnic Institute.......................................................................................85
National Polytechnic Institute.......................................................................................87
National Polytechnic Institute.......................................................................................88
4.4.2 Identification of receiver errors (FIC-1 Flow Indicator Controller, ABB brand).
...................................................................................................................................89
National Polytechnic Institute.......................................................................................90
National Polytechnic Institute.......................................................................................92
National Polytechnic Institute.......................................................................................94
National Polytechnic Institute.......................................................................................96
4.5 questionnaire........................................................................................................97
National Polytechnic Institute.......................................................................................98
National Polytechnic Institute.....................................................................................100
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”....................84
Orifice Plate......................................................................................................................84
National Polytechnic Institute.......................................................................................87
5.2 Theoretical framework....................................................................................88
National Polytechnic Institute.......................................................................................89
National Polytechnic Institute.......................................................................................91
National Polytechnic Institute.......................................................................................93
National Polytechnic Institute.......................................................................................95
National Polytechnic Institute.......................................................................................97
National Polytechnic Institute.......................................................................................99
National Polytechnic Institute.....................................................................................101
National Polytechnic Institute.....................................................................................103
National Polytechnic Institute.....................................................................................105
National Polytechnic Institute.....................................................................................106
5.2.1 How an Orifice Plate Works.....................................................................107
National Polytechnic Institute.....................................................................................108
5.2.2 Installation of an intelligent differential pressure transmitter to measure
flow with an orifice plate.........................................................................................109
National Polytechnic Institute.....................................................................................110
5.3. Material and equipment used............................................................................111
National Polytechnic Institute.....................................................................................112
5.4 Development......................................................................................................113
National Polytechnic Institute.....................................................................................114
National Polytechnic Institute.....................................................................................116
National Polytechnic Institute.....................................................................................118

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 National Polytechnic Institute.....................................................................................120
National Polytechnic Institute.....................................................................................121
National Polytechnic Institute.....................................................................................123
National Polytechnic Institute.....................................................................................125
National Polytechnic Institute.....................................................................................127
National Polytechnic Institute.....................................................................................129
National Polytechnic Institute.....................................................................................131
National Polytechnic Institute.....................................................................................133
5.5 Calculations.......................................................................................................134
National Polytechnic Institute.....................................................................................135
5.6. Questionnaire................................................................................................136
National Polytechnic Institute.....................................................................................137
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..................112
National Polytechnic Institute.....................................................................................116
6.2 Theoretical framework..................................................................................117
National Polytechnic Institute.....................................................................................120
National Polytechnic Institute.....................................................................................124
National Polytechnic Institute.....................................................................................126
National Polytechnic Institute.....................................................................................128
6.3 Material used......................................................................................................129
National Polytechnic Institute.....................................................................................130
6.4. Development.................................................................................................131
National Polytechnic Institute.....................................................................................131
National Polytechnic Institute.....................................................................................133
6.4 Questionnaire.....................................................................................................134
National Polytechnic Institute.....................................................................................135
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..................124
Proportional Band...........................................................................................................124
National Polytechnic Institute.....................................................................................127
7.1 Aim...............................................................................................................128
7.2 Theoretical framework..................................................................................128
7.2.1 Proportional control..................................................................................128
National Polytechnic Institute.....................................................................................129
National Polytechnic Institute.....................................................................................131
National Polytechnic Institute.....................................................................................133
National Polytechnic Institute.....................................................................................135
National Polytechnic Institute.....................................................................................137
7.2.2 Summary of the characteristics of proportional control............................138
National Polytechnic Institute.....................................................................................139
7.2.3 Operation of a proportional band controller..............................................140
7.3 Used material................................................................................................140

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 National Polytechnic Institute.....................................................................................141
7.4. Development.....................................................................................................142
National Polytechnic Institute.....................................................................................143
7.4.1. Table and data to build the graph..............................................................144
National Polytechnic Institute.....................................................................................145
7.5 Questionnaire.....................................................................................................146
National Polytechnic Institute.....................................................................................147
National Polytechnic Institute.....................................................................................144
8.2.1 Types of final control elements.................................................................145
8.2.2 Pneumatic actuator....................................................................................145
National Polytechnic Institute.....................................................................................146
National Polytechnic Institute.....................................................................................148
National Polytechnic Institute.....................................................................................150
8.2.3 Valve body................................................................................................151
National Polytechnic Institute.....................................................................................152
National Polytechnic Institute.....................................................................................154
National Polytechnic Institute.....................................................................................156
National Polytechnic Institute.....................................................................................158
8.2.4 Characteristic of a valve............................................................................159
National Polytechnic Institute.....................................................................................159
National Polytechnic Institute.....................................................................................161
National Polytechnic Institute.....................................................................................163
8.2.5 Calculation of valve flow coefficient........................................................164
National Polytechnic Institute.....................................................................................165
National Polytechnic Institute.....................................................................................167
National Polytechnic Institute.....................................................................................169
National Polytechnic Institute.....................................................................................171
National Polytechnic Institute.....................................................................................173
National Polytechnic Institute.....................................................................................175
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..................154
Cascade Control..............................................................................................................154
9.1 Aim...............................................................................................................158
9.2 Theoretical framework..................................................................................158
9.2.1 Cascade control.........................................................................................158
9.2.2 Cascade control of the Multiloop Control Module...................................159
9.3 Used material................................................................................................160
9.4 Development......................................................................................................160
9.5 Questionnaire.....................................................................................................168
3.1

4
0
 Transmitters

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3.1 Aim.

The objective of this practice is to determine the type of error of the transmitters and adjust them
if necessary. At the same time, remotely configure smart transmitters.

3.2 Theoretical framework:

3.2.1 What is a transmitter?

Transmitters are devices designed to send signals proportional to the process variables they are
measuring. These instruments are generally part of an open control loop or a closed control loop,
the latter is shown in the following figure 3.1.

Change in Process

VARIABLE VARIABLE
Element
End of PROCESS Element
MANIPULATE Control CONTROLLED
D Primary
3-15 PSIG

Converter Transmitter
Process Controller
4-20mA 4-20mA
Control Modes

Adjustment point or Set Point

Figure 3.1. Closed Control Circuit or Closed Control Loop

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Transmitters

National Polytechnic Institute

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There are different types of transmitters, some of them are: pneumatic transmitters, conventional
electronic transmitters, intelligent electronic transmitters and wireless electronic transmitters. The
most common signals sent by these transmission instruments are:

ELECTRICAL RANGES PNEUMATIC RANGE

4 to 20 mA 3 to 15 lb/in 2
1 to 5V 6 to 30 lb/in 2
1 to 10V 20 to 100KPa

Currently, the most common way to transmit signals in industrial instrumentation is the 4-20 mA
direct current signal. This means that the 4-20 mA current signal is used to transmit measurement
signals from primary elements or to send control output signals to final elements.

That is, a value of 4 mA represents 0% measurement of the primary element (Flow, Level,
Pressure, Temperature, etc.) and a value of 20 mA represents 100% measurement of the primary
element.

For example, if we are performing a measurement from 0% to 100% level, the level transmitter
sends a signal from 4 mA to 20 mA and can be represented with Figure 3.2.

Figure 3.2. Graph of the output signal in mA versus % level.

Transmitters

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Mexico Polytechnic Institute
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IMEPI SA de CV [email protected] www.imepi.com.mx

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Providing 4-20mA signals to process measured variables.

A signal directly proportional to the output of a 4 to 20 mA instrument proportionally represents a
value of the process variable within a scale of 0 to 100%. Which is expressed directly with the
equation of a line, as shown in figure 3.2.
y = mx + b
Where:
y = Instrument output (4-20mA).
x = Instrument Input (Process Variable from 0 to 100%).
m = Slope of the line (at 45° the slope is 1).
b = Origin point with respect to the instrument output (4 mA).

Once the appropriate values for m and b are determined, the values of “x” or “y” can be
determined. This will be very useful to us when we seek to determine the value of the 4-20 mA
signal output of any transmitter, or the position of the stem of a control valve, or any other
correspondence between a 4-20 mA signal and some variable of process.
For the linear equation shown, we can determine the value of the slope (m) by dividing the output
value of the instrument which is obtained by subtracting the maximum and minimum limit (20
mA–4mA) and the difference of the range of the process variable (100 % - 0%).
m= (20-4) / (100-0)= 16 mA / 100%.
Substituting into the equation of a line we have:
y = mx + b
y = (16/100) x + b.
For example, if we have a level in the tank of 50% as shown in figure 3.3, we can calculate the
current value at the output of the level transmitter with the equation of the straight line. With
which:
y = mx + b
y = (16mA / 100%) 50% + 4mA = 8 mA + 4 mA
y = 12 mA

So, 50% level is equivalent to 12 mA transmitter output with range of 4-20 mA.

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Figure 3.3. Graph of the output signal in mA versus % level.

Another example, if a control valve has a linear characteristic and has an opening of 75%, as
shown in Figure 3.4a and 3.4b, we can calculate using the equation of the line what output current
the process variable controller will give. With which:

Controller

Figure 3.4a. Valve opening at 75%.

y = mx + b
y = (16mA / 100%) 75% + 4mA.
y = 16 mA

Transmitters

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Therefore, 75% opening of the control valve is equivalent to 16 mA over a range of 4 20mA.

Figure 3.4b. signal graph output in mA with respect to % Valve opening

control.

The reason for standardizing the ranges of the output signals of the transmitters is to be able to
interconnect instruments of different brands and standardize the receivers. This allows receivers to
receive signals from any variable, regardless of the range of those variables since all transmitters
have standard outputs.

The measuring element is the part sensitive to changes in the variable and is directly connected to
the process, therefore, these elements can be: bourdons if the transmitter is pressure, thermal
systems filled with gas, liquid or steam if the transmitter It will be used to measure the flow
(pressure drop of orifice plates, vents, etc.), or level of liquids.

3.2.2 Digital electronic transmitters.

Around 1983, the Honeywell firm introduced the first so-called “smart” digital transmitter to the
market. This term indicates that the sensor has additional functions incorporated that are added to
those of the exclusive measurement of the variable. Logically, these functions are provided by a
microprocessor, but this is not essential for the instrument to be called "intelligent."

There are two basic models of intelligent transmitters: The capacitive one (figure 3.5 a) is based
on the variation in capacity that occurs in a capacitor formed by two fixed plates and a

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internal sensitive diaphragm and attached to them, when a pressure or differential pressure is
applied through two external diaphragms. The transmission of process pressure is carried out
through a fluid (oil) that fills the interior of the condenser.
The displacement of the sensitive diaphragm is only 0.1 mm at most. A circuit formed by an
oscillator and demodulator transforms the capacity variation into an analog signal. This in turn is
converted to digital, and then passes to an "intelligent" microprocessor that transforms it to the
analog transmission signal of 4-20 mA dc.

The semiconductor one (fig. 3.5 b) takes advantage of the electrical properties of semiconductors
when subjected to stress. The diffused semiconductor model is made from a thin film of silicon
and uses doping techniques to generate a stress-sensitive zone. It behaves as a dynamic
Wheatstone bridge circuit applicable to the measurement of pressure, differential pressure and
level, formed by a diffused silicon chip within which are the resistances RA, RB, Re and Ro of a
Wheatstone bridge.

The unbalance of the bridge caused by changes in the variable, gives rise to an output signal of 4-
20 mA dc Its operation is as follows: When there is no pressure, the voltages El and E2 are equal,
and when the process pressure is applied, RB and Re decrease their resistance and RA and Ro
increase it, giving rise to different voltage drops and a difference between Him and Ez. This
difference applies to a high gain amplifier that controls a variable current regulator. A continuous
current range of 3 to 19 mA dc with 1 mA of the bridge produces a 4 to 20 mA dc output signal
This current flows through the feedback resistor Rfb, raising El to a voltage equivalent to E2 and
rebalancing the bridge. As the voltage drop produced across Rfb is proportional to R2b, this
resistance sets the measurement range (span) of the transducer. The zero of the instrument is
varied by inserting fixed resistors on the left arm of the bridge (coarse zero) and a potentiometer
on the right arm (fine zero).

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a) Capacitive

Figure 3.5. Smart transmitter.

3.2.3 Differential pressure transmitter.

Figure 3.6 illustrates a differential pressure transmitter, which transmits a signal proportional to
the difference in pressures applied to the low and high pressure intakes; The differential pressure
can be caused by a primary flow measurement element (orifice plate, Venturi, nozzle, etc.) or it
can be caused by the liquid level, connecting the high intake to the bottom of the container and the
low intake to the atmosphere if it is an open tank, or to the top of the tank if it is a pressure or
vacuum vessel.

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Figure 3.6. Differential pressure transmitter.

In this part, the differential pressure transmitter for level and flow of the multiloop control module
will be implemented.

It is logical that for each differential pressure a certain force is necessary to achieve balance, since
the force is a function of the pressure in the feedback bellows, it follows that the outlet pressure is
proportional to the differential pressure.

3.2.3.1 Yokogawa brand differential pressure transmitter.

It is an electronic transmitter that is applied to measure differential pressure in a closed tank, it has
two process connections which are “H” high pressure and “L” low pressure. Since there are
changes in the differential pressure inside the tank, it is because the level also changed. These
changes are reflected on the LCD display. This transmitter has the following characteristics:

a) The units indicated on the display can be height (m), percentage (%) or volume (liters).
b) It has a plate indicating its characteristics which are:
■ Power: 24 VDC.
■ Range: 2 to 40” H2O.
■ Output: 4-20 mA.
■ Communication: Hart
■ Rating: NEMA 4X
■ The transmitter head rotates 90°, the process connections "H" and "L" are ¼” NPT
female threads.
c) The transmitter has no moving parts and requires no maintenance.
d) The transmitter is configurable by the Hart Protocol, where the following can be
configured:
■ Measuring range.
■ Engineering units
■ Tag (name).
■ Calibration and date.
■ Display.

Transmitters

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3.2.3.2 Tube installation.

The differential pressure transmitter has a fitting to install it on a 2,000” pipe, the fitting is
screwed to the transmitter and has a “U” type clamp to hold the fitting with the transmitter to the
2,000” pipe as shown in figure 3.7. .

50mm(2-inch) pipe

Figure 3.7 Mounting the differential pressure transmitter.

3.2.3.3 Installation of the transmitter for closed tank.

Figure 3.8 shows a differential pressure transmitter installed in a closed tank, where the high “H”
intake is the one that is connected to the bottom of the tank (0% level) using a ½” or ½” tubing.
¾”, which can be made of bronze or stainless steel and the low “L” connection connects to the top
of the tank (100% level) .

The transmitter has an equalizing valve (manifold) that when opened allows the pressure from
both intakes (“H” and “L”) to pass through, this is done for when the transmitter has to be taken
out of service for maintenance.

Near the high intake “H” it is important that it has a vent. This vent is filled with water and a plug
is placed, with this we can make a pressure compensation for when we put the transmitter into
service and avoid air bubbles in the take “L”.

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Figure 3.8. Installation of the differential pressure transmitter in a closed tank.

3.2.3.4 Wiring.

Figure 3.9 shows the wiring of the differential pressure transmitter, which is a two-wire
instrument, this means that the signal travels from 4 to 20 through the two wires where the
transmitter is powered (24 VDC). mA.

Figure 3.9. Yokogawa differential pressure transmitter wiring.

Most differential pressure transmitters can be calibrated from their minimum range up to 12 or 15
times that range, that is, from 0 – 20 in H 2 O in the most common transmitter. These transmitters
cover ranges from 0 – 1 in H 2 O to 0 – 100 Kg /cm 2 and are capable of withstanding pressures up
to 700 Kg /cm 2 in special designs.

Overpressure protections on the transmitter body prevent the diaphragms from rupturing due to
high pressure.

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3.3 Equipment used.

To carry out the differential pressure practice, a differential pressure transmitter will be used, a
differential pressure transmitter with an adjustable range of 0 – 40 in H 2 O will be used, which
sends a 4-20 mA signal to the LIC-2 level indicator controller, mounted on the control board.

3.4 Practice development.

3.4.1 Construction of the calibration curve for the LIT-2 level differential pressure
transmitter.

The practice will consist of the construction of the calibration curve of the LIT-2 level differential
pressure transmitter, the output of the transmitter with a 4-20 mA signal is sent to the LIC-2 level
indicator controller, considering that the instruments are well calibrated. The steps to follow are:

a) Fill measuring tank T2, align tank T1 towards tank T2 and start pump B1. Take every
10 cm, the water level reading in tank T2 and the equivalent reading displayed on the
dash-mounted level indicator controller LIC-2 and construct the filling curve with
those data.

T2 tank filling data table

Water height or LIC-2 reading (On LIRC-2 reading (On Multimeter Reading
level in T2 control board) Operation Station
screen)

% or cm % or cm % or cm 4-20mA

0
10
20
30
40
50
60
70
80
90
100
Transmitters

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b) Unload measuring tank T2, align tank T2 towards tank T1 and start pump B2. Take every
10 cm, the reading of the water level in tank T2 and the equivalent reading shown on the
level indicator controller LIC-2, mounted on the dashboard, in the same graph as the
previous section, construct the discharge curve with those data.

T2 tank discharge data table

Water height or LIC-2 reading (On LIRC-2 reading (On Multimeter Reading
level in T2 control board) Operation Station
screen)

% or cm % or cm % or cm
4-20mA
100
90
80
70
60
50
40
30
20
10
0

c) On the same graph constructed with the filling curve and the discharge curve, with a red
pencil (preferably), draw the IDEAL CURVE of the level transmitter, considering that 0%
level corresponds to 4 mA and 100% level corresponds at 20 mA.
d) By comparing both curves, determine what type of error the transmitter has and where the
adjustments are located to correct the error(s).
e) Write your conclusions.

Transmitters

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3.4.2 HART communication protocol for smart transmitters.

The HART (High way-Addressable-Remote-Transducer) protocol uses the Bell 202 FSK
(Frequency Shift Keying) standard to superimpose digital communication signals to the closed
circuit or closed loop current 4-20 mA, as shown in Figure 3.10.

Figure 3.10. HART digital communication superimposed on the 4-20mA analog signal

Binary information is represented by a signal of two different frequencies. A logic zero is

represented by a frequency of 2200 Hz, while a logic one is represented by a frequency of 1200
Hz. These tones are superimposed on the DC signal, and since the AC signal has a zero average
value, the DC signal is not affected as shown in Figure 3.11.

The HART protocol allows digital communication in both directions so that it is possible to send
additional information to the transmitted process variable to or from an intelligent field instrument.
The process variable is carried by the analog signal while through digital communication
additional measurements, process parameters, instrument configuration, calibration and diagnostic
information are accessed that, through the HART protocol, travel on the same cable and
simultaneously to the signal. analog as shown in figure 3.11. This represents a great advantage
when implementing this digital communication technology, compared to other digital
technologies, since it is compatible with existing systems. + 0.5 mA - 0.5 mA Analog Signal
Frequency FSK 1200 Hz 2200 Hz Logic "1" "0"

Be
Anaógkca

- 0.5mA

FSK Frequency 12007 220X7

Logic *1" ‘0"

Figure 3.11. FSK coding of the HART protocol on the 4-20mA analog signal.

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HART is primarily a master/slave protocol which means that the field device (slave) speaks only
when asked by a master. In a HART network two masters (primary and secondary) can
communicate with one slave device. The secondary teachers

Transmitters

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They can communicate with field devices without distorting communication with the primary
master. A primary master can typically be a DCS (Distributed Control System), a PLC, or a PC-
based central monitoring or control system, while a secondary master can be a portable
communicator. A typical configuration with two masters is shown in Figure 3.12.

Figure 3.12. Configuration with two masters to access field information.

Within the HART protocol there are several modes for communicating information from/to
intelligent field instruments and the central controller or monitoring equipment. Simultaneous
master/slave digital communication with the 4-20 mA analog signal shown in Figure 3.13 is the
most common. This mode allows the slave to respond to the master's commands-requests 2 times
per second, while the analog signal, which is continuous, can continue carrying the control
variable.

Figure 3.13. HART master-slave communication.

Another optional communication mode is the “Burst” mode shown in Figure 3.14, which allows a
single slave device to continuously broadcast a standard response HART message.

Figure 3.14. HART communication “Burst” mode. (Optional).

The HART protocol also has the ability to connect multiple field devices over the same pair of
wires in a multidrop network configuration as shown in the figure.

Transmitters

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3.15 . In the multipoint configuration, communication is limited to master/slave digital

communication. The current through each slave device is set to the minimum value to power the
device and has no meaning relative to the process.

Figure 3.15. Connection of HART devices in a multipoint network.

From an installation perspective, the same cable used to transmit the 4-20mA analog signal is used
for HART communication signals. The allowed cable lengths will depend on the type of cable
used and the number of connected devices.

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3.16 3 PACTware software for configuring intelligent transmitters with HART protocol.

PACTware (Process Automation Configuration Tool) is a control software for field devices,
independent of the manufacturer and the fieldbus, and allows you to control any field device with a
single software. For this, the FDT standard is used between the PACTware framework program
and the different software modules for managing the devices. Figure 3.16 shows the
communication architecture using the PACTware software.

Figure 3.16. PACTware architecture.

The software modules for device management are DTM or device management applications
(Device Type Manager). This structure makes it possible to apply modern and simple operating
concepts, since the interface for device control is optimized for the device.

Transmitters

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3.5 Material:

+ Differential pressure indicator transmitter of the LIT-2 Industrial Process Multiloop

Control Module.
+ 24 VDC source.
+ Resistance (250 ohm to 750 ohm).
+ USB HART Modem.

3.6 Development.

In this practice the configuration of the engineering range of the instrument will be carried out.
Listed below is the FIT-1 transmitter range configuration procedure to change the range and units
from the software called PACTware to said instrument:

a) Connect the computer with the USB HART MODEM as shown in figure 3.17 and go to
the properties of My Computer and verify which port it is set to.

Figure 3.17. HART MODEM connected to PC USB port.

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b) Attach the leads of the source to the terminals of the transmitter with a series resistor as
shown in Figure 3.18.

Feeding
Figure 3.18. Power supply with 24 V dc of the FIT-1 transmitter.

c) Connect the USB HART MODEM terminals in parallel with the resistor as shown in figure
3.19.

Figure 3.19. Connecting the Hart Modem tips to the FIT-1 transmitter.

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d) After this procedure, verify that the transmitter is turned on, open the PACTware program
from the computer.

Figure 3.20. PACTware software.

e) In the left panel you will find “host pc”, right click and then choose “add device”.

Figure 3.21. Add Hart communication device.

Transmitters

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f) Choose the “HART Communication” option and click “OK”.

Figure 3.22. Hart communication device selection.

g) Choose the “COM” Communication port where the instrument is connected to the PC.

Figure 3.23. Communication port selection.

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h) Right click on “COMx” and choose the “ADD DEVICE” option) select the DTM of the
instrument (FIT-1) > ok.

Figure 3.24. Add DTM device of the instrument to configure.

i) Select the DTM of the instrument (FIT-1) and click “OK”.

Figure 3.25. DTM device of the instrument to be configured EJA (FIT-1).

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j) Right click on the instrument and choose the “Connect” option.

Figure 3.26. Connect to the instrument to configure EJA (FIT-1).

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k) Again right click on the instrument and choose the “Load from device” option.

Important note: The instrument information is downloaded (load from device), before
anything else, to make a backup of the configuration of the instrument to which it was
connected, in this case it is the EJA (FIT-1). This backup is done to take the real
configuration data of the instrument to be configured. If the configuration is downloaded,
there are no problems with configuration data errors. It is recommended that when
downloading the data (load from device) the file is saved so that in case of any erroneous
data that is given to the configuration, the backup file can be opened and downloaded to
the instrument to be returned to its original configuration.

Figure 3.27. Lower the EJA instrument configuration (FIT-1).

Transmitters

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l) Review the URV (Upper Range Value) and LRV (Lower Range Value) levels and modify
them if necessary.

Figure 3.28. Modification of the engineering, upper and lower ranks of the EJA (FIT- 1).

m) Choose the “User Preset” option in the “Display” tab. Adjust to the desired values that
you want to measure.

Figure 3.29. User set, customizable range of the EJA (FIT-1).

Transmitters

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IMEPI SA de CV [email protected] www.imepi.com.mx

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Galileo Galilei 3865-1C Zapopan Jalisco
Mexico
Tel/Fax 3631-5011
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1 .7 Questionnaire.
2 .- What is a transmitter?

3 .- How many types of digital (smart) transmitter models are there and what are they?

4 .- What are the ranges of the electrical and pneumatic signals of the transmitters?

5 .- What is the difference between an analog signal and a digital signal?

6 .- Under what communication protocol is the configuration of the digital (intelligent)

differential pressure transmitter carried out?

7 .- What is the basic operating principle of electronic transmitters?

8 .- Do you list the different ways to configure an electronic transmitter?

9 .- Can intelligent instruments be configured remotely with the HART protocol?

10 .- Do you list the advantages of using intelligent instruments in production processes?

11 .- Can smart instruments be installed in classified process areas or better known as process
areas with risk of explosion?

12 .- Is it possible to display at the same time, in the ABB commander C250 controller, the
values of the level variable from 0 to 100% and the volume in liters?

13 .- Is it possible to display at the same time, on the operating station with the Aurora HMI
SCADA software, the values of the level variable from 0 to 100% and the volume in liters?

14 .- Is it possible to save operating data of the level variable in the ABB commander C250
controller?

15 .- Is it possible to save data of the level variable in the operation station with the Aurora HMI
SCADA software and if so, how is it done?

16 .- Is it possible to display trend graphs of the level variable on the operating station with the
Aurora HMI SCADA software?

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Transmitters
Mexico
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 Transmitters

National Polytechnic Institute

9
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 IMEPI SA de CV
"CONTROL MODULE
MULTI-LOOK OF PROCESSES
INDUSTRIAL”

Receivers

"If you dare to teach, do not stop learning."

John Cotton Dana
 MEXICAN ENGINEERING SPECIALIZED IN

-EP mH INDUSTRIAL PROJECTS

IMEPI SA de CV Galileo Galilei 3865-1C Zapopan Jalisco Mexico
Tels/Fax 3631-5011
[email protected] www.imepi.com.mx

Content
National Polytechnic Institute....................................................................................................1
ESIQIE.......................................................................................................................................1
IMEPI SA de CV collaborators for him development of these practices..........................3
National Polytechnic Institute.........................................................................................4
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”......................4
Understanding the System...................................................................................................4
1.1 Goals.................................................................................................................8
1.1.1 Generals.........................................................................................................8
1.1.2 Specific..........................................................................................................8
1.2 Understanding the system...............................................................................10
1.2.1 Closed Control Loop or Closed Flow Control Circuit................................10
1.2.2 Closed Control Loop or Closed Level Control Circuit.....................................13
1.2.3 Closed Control Loop or Closed Pressure Control Circuit...........................15
1.2.4 Closed Control Loop or Closed Circuit Temperature Control....................17
1.4 Control of 3 process variables........................................................................27
1.4.1 Flow-Level-Pressure...................................................................................27
1.5 Questionnaire..................................................................................................28
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”....................38
National Polytechnic Institute.......................................................................................41
3.2 Theoretical framework:...................................................................................42
3.2.1 What is a transmitter?..................................................................................42
National Polytechnic Institute.......................................................................................43
National Polytechnic Institute.......................................................................................44
National Polytechnic Institute.......................................................................................46
National Polytechnic Institute.......................................................................................48
3.2.2 Digital electronic transmitters.....................................................................49
National Polytechnic Institute.......................................................................................50
National Polytechnic Institute.......................................................................................52
3.2.3 Differential pressure transmitter.................................................................53
National Polytechnic Institute.......................................................................................54
3.2.3.1 Yokogawa brand differential pressure transmitter......................................55
National Polytechnic Institute.......................................................................................56
3.2.3.2 Tube installation..........................................................................................57
3.2.3.3 Installation of the transmitter for closed tank.............................................57

6
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 National Polytechnic Institute.......................................................................................58
3.2.3.4 Wiring.........................................................................................................59
National Polytechnic Institute.......................................................................................60
3.3 Equipment used...............................................................................................61
3.4.1 Construction of the calibration curve for the LIT-2 level differential
pressure transmitter....................................................................................................61
National Polytechnic Institute.......................................................................................62
National Polytechnic Institute.......................................................................................64
3.4.2 HART communication protocol for smart transmitters..............................65
National Polytechnic Institute.......................................................................................66
National Polytechnic Institute.......................................................................................68
National Polytechnic Institute.......................................................................................70
3.16 3 PACTware software for configuring intelligent transmitters with HART
protocol......................................................................................................................71
National Polytechnic Institute.......................................................................................72
3.5 Material:..........................................................................................................73
3.6 Development...................................................................................................73
National Polytechnic Institute.......................................................................................74
National Polytechnic Institute.......................................................................................76
National Polytechnic Institute.......................................................................................78
National Polytechnic Institute.......................................................................................80
National Polytechnic Institute.......................................................................................82
National Polytechnic Institute.......................................................................................83
National Polytechnic Institute.......................................................................................85
National Polytechnic Institute.......................................................................................87
1 .7 Questionnaire..................................................................................................88
National Polytechnic Institute.......................................................................................89
National Polytechnic Institute.......................................................................................91
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”....................66
National Polytechnic Institute.......................................................................................69
4.1 Aim.................................................................................................................70
4.2 Theoretical framework....................................................................................70
4.2.1 Flow Indicator Controller FIC-1 Brand ABB. (receiver)............................70
National Polytechnic Institute.......................................................................................71
National Polytechnic Institute.......................................................................................73
National Polytechnic Institute.......................................................................................75
National Polytechnic Institute.......................................................................................77
National Polytechnic Institute.......................................................................................79
4.2.2 Key functions and entry to the ABB Flow controller display.....................80
National Polytechnic Institute.......................................................................................81
4.2.3 ABB Controller Configuration Menu Map.................................................82

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 4.3 Material Used.......................................................................................................82
National Polytechnic Institute.......................................................................................83
4.4 Development........................................................................................................84
4.4.1 Configuration of levels 5 and 6 of the ABB controller...............................84
National Polytechnic Institute.......................................................................................85
National Polytechnic Institute.......................................................................................87
National Polytechnic Institute.......................................................................................88
4.4.2 Identification of receiver errors (FIC-1 Flow Indicator Controller, ABB brand).
...................................................................................................................................89
National Polytechnic Institute.......................................................................................90
National Polytechnic Institute.......................................................................................92
National Polytechnic Institute.......................................................................................94
National Polytechnic Institute.......................................................................................96
4.5 questionnaire........................................................................................................97
National Polytechnic Institute.......................................................................................98
National Polytechnic Institute.....................................................................................100
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”....................84
Orifice Plate......................................................................................................................84
National Polytechnic Institute.......................................................................................87
5.2 Theoretical framework....................................................................................88
National Polytechnic Institute.......................................................................................89
National Polytechnic Institute.......................................................................................91
National Polytechnic Institute.......................................................................................93
National Polytechnic Institute.......................................................................................95
National Polytechnic Institute.......................................................................................97
National Polytechnic Institute.......................................................................................99
National Polytechnic Institute.....................................................................................101
National Polytechnic Institute.....................................................................................103
National Polytechnic Institute.....................................................................................105
National Polytechnic Institute.....................................................................................106
5.2.1 How an Orifice Plate Works.....................................................................107
National Polytechnic Institute.....................................................................................108
5.2.2 Installation of an intelligent differential pressure transmitter to measure
flow with an orifice plate.........................................................................................109
National Polytechnic Institute.....................................................................................110
5.3. Material and equipment used............................................................................111
National Polytechnic Institute.....................................................................................112
5.4 Development......................................................................................................113
National Polytechnic Institute.....................................................................................114
National Polytechnic Institute.....................................................................................116
National Polytechnic Institute.....................................................................................118

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 National Polytechnic Institute.....................................................................................120
National Polytechnic Institute.....................................................................................121
National Polytechnic Institute.....................................................................................123
National Polytechnic Institute.....................................................................................125
National Polytechnic Institute.....................................................................................127
National Polytechnic Institute.....................................................................................129
National Polytechnic Institute.....................................................................................131
National Polytechnic Institute.....................................................................................133
5.5 Calculations.......................................................................................................134
National Polytechnic Institute.....................................................................................135
5.6. Questionnaire................................................................................................136
National Polytechnic Institute.....................................................................................137
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..................112
National Polytechnic Institute.....................................................................................116
6.2 Theoretical framework..................................................................................117
National Polytechnic Institute.....................................................................................120
National Polytechnic Institute.....................................................................................124
National Polytechnic Institute.....................................................................................126
National Polytechnic Institute.....................................................................................128
6.3 Material used......................................................................................................129
National Polytechnic Institute.....................................................................................130
6.4. Development.................................................................................................131
National Polytechnic Institute.....................................................................................131
National Polytechnic Institute.....................................................................................133
6.4 Questionnaire.....................................................................................................134
National Polytechnic Institute.....................................................................................135
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..................124
Proportional Band...........................................................................................................124
National Polytechnic Institute.....................................................................................127
7.1 Aim...............................................................................................................128
7.2 Theoretical framework..................................................................................128
7.2.1 Proportional control..................................................................................128
National Polytechnic Institute.....................................................................................129
National Polytechnic Institute.....................................................................................131
National Polytechnic Institute.....................................................................................133
National Polytechnic Institute.....................................................................................135
National Polytechnic Institute.....................................................................................137
7.2.2 Summary of the characteristics of proportional control............................138
National Polytechnic Institute.....................................................................................139
7.2.3 Operation of a proportional band controller..............................................140
7.3 Used material................................................................................................140

6
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 National Polytechnic Institute.....................................................................................141
7.4. Development.....................................................................................................142
National Polytechnic Institute.....................................................................................143
7.4.1. Table and data to build the graph..............................................................144
National Polytechnic Institute.....................................................................................145
7.5 Questionnaire.....................................................................................................146
National Polytechnic Institute.....................................................................................147
National Polytechnic Institute.....................................................................................144
8.2.1 Types of final control elements.................................................................145
8.2.2 Pneumatic actuator....................................................................................145
National Polytechnic Institute.....................................................................................146
National Polytechnic Institute.....................................................................................148
National Polytechnic Institute.....................................................................................150
8.2.3 Valve body................................................................................................151
National Polytechnic Institute.....................................................................................152
National Polytechnic Institute.....................................................................................154
National Polytechnic Institute.....................................................................................156
National Polytechnic Institute.....................................................................................158
8.2.4 Characteristic of a valve............................................................................159
National Polytechnic Institute.....................................................................................159
National Polytechnic Institute.....................................................................................161
National Polytechnic Institute.....................................................................................163
8.2.5 Calculation of valve flow coefficient........................................................164
National Polytechnic Institute.....................................................................................165
National Polytechnic Institute.....................................................................................167
National Polytechnic Institute.....................................................................................169
National Polytechnic Institute.....................................................................................171
National Polytechnic Institute.....................................................................................173
National Polytechnic Institute.....................................................................................175
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..................154
Cascade Control..............................................................................................................154
9.1 Aim...............................................................................................................158
9.2 Theoretical framework..................................................................................158
9.2.1 Cascade control.........................................................................................158
9.2.2 Cascade control of the Multiloop Control Module...................................159
9.3 Used material................................................................................................160
9.4 Development......................................................................................................160
9.5 Questionnaire.....................................................................................................168
4.1

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 Receivers

National Polytechnic Institute

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4.1 Aim.

Teach the student to configure and identify the errors of a receiver (Indicator Controller), which
can be indicators or one or two pointers, or trend graphs.

4.2 Theoretical framework.

Receivers are devices designed to receive a pneumatic or electrical signal from transmitters; This
feature allows them to indicate or register any variable, and they can be exchanged with each
other. Normally the scale of the receiver is graduated in the same units as that of the transmitter;
Therefore, if the scale (or graph) is changed, the signal from another transmitter can be read.
There are also percentage scales, in which case it is necessary to use a factor to determine the
value of the measured variable.
The signals that these receivers can receive are the same as those sent by the transmitters, that is:

ELECTRICAL RANGES PNEUMATIC RANGE

4 to 20 mA 3 to 15 lb/in 2
1 to 5V 6 to 30 lb/in 2
1 to 10V 20 to 100KPa

4.2.1 Flow Indicator Controller FIC-1 Brand ABB. (receiver)

The digital electronic indicator controller to measure and control the variable flow FIC-1, is
installed in front of the control board G1, it has two functions:

1) The first function is as a receiver, receiving the 4-20 mA signal sent by the FIT-1 flow
indicator transmitter and digitally indicating the volumetric flow value on the front
display of the FIC-1 controller;
2) The second function is to control the process variable based on the desired set point of the
process variable. For this, the FIC-1 controller sends a 4-20 mA signal to the final control
elements.

The FIC-1 flow indicator control performs its automatic control function in the following two
stages:

The first stage is to compare the value of the process variable (PV) and the set point or desired
adjustment point (SP); if there is a difference between the two, an error (e) is produced.
e = SP – PV

Receivers

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The second stage is to process the error with the different error correction modes, called Control
Modes, namely:
- Proportional (P),
- Proportional + Integral (P+I),
- Proportional + Integral + Derivative (P+I+D).

Once the Control Modes process the error, they generate an output signal (S) of 4-20 mA, which
is sent to the final control elements to correct deviations or errors in the process.

The precision and responsiveness of these signals is the basic limitation on the controller's ability
to correctly control the measurement. If the transmitter does not send an accurate signal, or if
there is a delay in measuring the signal, the controller's ability to manipulate the process will be
diminished. At the same time, the controller must receive a precise reference signal (Set – Point,
also known as Adjustment Point).

The COMMANDER C250 Process Indicator Controller, figure 4.1, is a highly versatile, single-
loop controller in 1/4 DIN format that was designed to be exceptionally easy to install and
operate.

Figure 4.1. Dimensions and hardware of the commander C250 controller from the ABB brand.

Universal input and an integral transmitter power supply ensure that the COMMANDER C250
has the capabilities to measure a wide variety of process signals such as temperature, pressure,
flow and level.

Optimized performance through analog, logic and relay control outputs, all equipped as standard,
with the option to add additional I/O capabilities such as additional relays, remote set point,
analog relay and digital input, to suit your application.

Receivers

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Mexico
Tel/Fax 3631-5011
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Configuration of the COMMANDER C250 controller is accomplished by flipping the safety

micro switch and entering a simple code from the front panel keys or through PC configuration
software. No passwords, no entry links and no complications.

With NEMA4X/IP66 front panel and superior RF immunity as standard devices, the
COMMANDER C250 has been designed to reliably control in today's harshest industrial
environments.

It has the following features:

• Size: 1/4 DIN

• 1 PID with generation of Ramps/Plateaus
• 1 Universal Input (mA, mV, V, RTD, Thermocouple)
• 1 Remote set point and retransmission
• 1 digital input with 2 output relays
• NEMA 4X (IP66) Rating
• RS485/Modbus communication output for SCADA, PLC, and open systems.

DISPLAY.

The display has fluorescent digits for easy reading, each parameter is easily configurable.

Access to the configuration is done by pressing its keys, through which the parameters are set
according to the needs of each application. And also for set point changes and manual operation
of control valves.

MOUNTING.

This instrument is intended and designed for industrial control applications. It must be installed in
a panel (control panel) with its wiring terminals included in said panel. It can also be mounted
anywhere in the plant or factory. The front of said controller is NEMA 3 and IP55 rated, although
it can be changed to NEMA 4X and IP66 rated for more severe applications. It withstands a
temperature of 55 °C and is resistant to vibrations and shocks. It should not be installed in areas
where there are chemical substances or compounds that represent an explosion risk.

Receivers

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Mexico
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WIRING AND CONNECTIONS.

The wiring and connections of the C250 are made on the back where the power inputs, current
input signal, current output signal and other additional inputs and outputs are located, which can
be analog, digital or communication (Modbus) as shown. shown in figures 4.2 and 4.3.
I- Line J

Auxiliary Input
(Remote Set
Point) Analog Input
(see below)
Entran
ce

relay
Exit 2

Analog*
----------------------- relay
RS485 Output
Relay 1
0/P3
From 85 V minimum to - 265
Analog _ V maximum, r 24 cc
O/P2~ 15COW - *
Read the warnings
.ible type
on page 52
T and
external
disconnector)

Figure 4.2. ABB Commander C250 Controller Wiring.

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National Polytechnic Institute

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3-wire
RTD

3rd
thread

2-wire
transmitter

2-wire RTD Milliampers * Milliampers

and resistance
Using the internal power supply to the associated transmitter Use the 1009
shunt resistor provided with the instrument Attach the arc suppression
component provided with the instrument
Figure 4.3. Commander C250 Controller Universal Analog Input Wiring
ABB.

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National Polytechnic Institute

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Below we present an image of the ABB brand Commander C250 controller (figure 4.4).

Figure 4.4. Front view of the ABB brand C250 Commander controller.

4.2.2 Key functions and entry to the ABB Flow controller display.

We will enter each of the display parameters through a procedure to familiarize ourselves with our
controller. First we will mention the function of each of its front panel keys.

Each of the keys is described below according to the configuration order to follow:

Up / Forward

Down / Back

Automatic/Manual

Parameter advancement

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National Polytechnic Institute

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4.2.3 ABB Controller Configuration Menu Map.

The parameters to navigate the display configuration are divided into several levels that we
present in figure 4.5.

Figure 4.5. ABB Controller Configuration Menu Map.

4.3 Material Used.

■ Commander C250 controller from the ABB brand of the Industrial Process Multiloop
Control Module identified as FIC-1.
■ ABB Commander C250 controller manual.
■ Differential Pressure Indicator Transmitter to measure flow of the Industrial Process
Multiloop Control Module identified as FIT-1.

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Receivers
Mexico
Tel/Fax 3631-5011
IMEPI SA de CV National Polytechnic Institute
[email protected] www.imepi.com.mx

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Mexico
Tel/Fax 3631-5011
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4.4 Development.

Before starting the procedure for identifying errors in a receiver, the receiver must be configured,
that is, the FIC-1 controller, which will allow changes to the ranges, units, and type of analog
input signal of said controller. . The range of the Flow Indicator Transmitter must correspond to
the range of the receiver, which in this case is the Flow Indicator Controller FIC-1, if the value
indicated on the Flow Indicator Transmitter FIT-1 is different from the value indicated on the FIC-
1 receiver, then an adjustment must be made by entering the receiver configuration, which in this
case is the Flow Indicator Controller.

4.4.1 Configuration of levels 5 and 6 of the ABB controller.

Figure 4.6. Map of levels 5 and 6 of the ABB Controller.

The controller configuration will be done in levels as shown in the following procedure (figure
4.6).

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A. Previous procedure for configuration of levels 5 and 6:

1. The controller is energized.

2. The switch is changed to configuration mode as shown in figure 4.7.

Figure 4.7. Location of Switch Configuration Mode or Normal Mode of the ABB Controller

3. The following display will .

appear
with the arrows the following configuration levels can be accessed
4.
LEU.6

B. Commander C250 Controller Analog Input Configuration

ABB brand.

Once the switch was changed to “configure mode” as shown in figure 4.7 and appears

Figure 4.8. Commander C250 controller analog input configuration map

To configure the analog input based on figure 4.8, perform the following procedure:

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1. “A”.- Hardware Configuration

Frequency Rly 1 Rly 2* Rly 3* Logic O/P An. O/P 1 An. O/P 2* Control Type

60Hzb
Alm 1 aim 2 None None O/P 1 PV Analog Prop.

2. “b”.- Input type and range configuration 2= 4 to 20 mA.

3. “C”.- Temperature units 0= no temperature units.

4. d”.- position of the decimal

point
Displ
ay
2 XX. XX
5. Press the key until you leave level 5.

C. Engineering rank.

LEU.6

1. Enter level 6 with switch in configuration mode.

2. Press key once and it appears to change to

worth
(EnGH; Engineering range high at 20mA).

3. Press key once and it appears

to change to
worth
(EnGL; Engineering range under 4mA).

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4. Press key CL , press to change to

once and it appears
worth
(SP-H; SET POINT High Limit).

I Cl I
5. Press value key once and it appears , press to change to

(SP-L; SET POINT Low Limit).

6. Change the switch to normal position as shown in figure 4.9.

Figure 4.9. Switch Configuration Mode or Normal Mode of the ABB Controller.

4.4.2 Identification of receiver errors (FIC-1 Flow Indicator Controller, ABB brand).

Procedure:

1 .- Align the manual and modulating control valves Flow circuit of the Industrial Process
Multiloop Control Module shown in figure 4.10 as follows:
■ Open the bottom manual valve of tank T1 identified as HV-3.
■ Make sure manual valve HV-5 is open.
■ In the control cabinet of the Industrial Process Multiloop Control Module, place the selector
in position “C” (Controllers), so that the system obeys the command of the FIC-1
Controller.

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Galileo Galilei 3865-1C Zapopan Jalisco
Mexico
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx

■ From the operation station using the Aurora HMI SCADA software, press the “FLOW TO
T1” button on “SELECTOR 1” of the operation screen as shown in figure 4.11.

Representation in Aurora HMI SCADA

Figure 4.11. Flow

Figure 4.10. Alignment of valves HV-3, FV-1, V-1 and HV-5. button to T1
selected.

2 .- Open the flow modulating valve FV-1 to 100%, pressing the manual key 9 to put the FIC-1
controller in MANUAL mode and with the arrows A and T
increase the
value up to 100.0% at the output, as shown in figure 4.12.

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Receivers

National Polytechnic Institute

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 Figure 4.12. FIC-1 controller, in MANUAL mode and with 100.00% output.

3 .- Start Pump B1 from the control board of the Multiloop Process Control Module by pressing the
BA-1 button.

4 .- Write down the values indicated by the Flow Indicator Transmitter FIC-1 and the Flow
Indicator Controller FIC-1 as shown in figure 4-13.

Record values of
the Indication of Annotate
the Flow variable. values of
the
Indication
of the
variable

Figure 4.13. Record the indication in Flow Indicator Controller FIC-1 and record the indication in
Flow Indicator Transmitter FIC-1.

5.- Change the valve opening percentage and repeat this step 5 until you obtain all the values in the
following table:
FV-1 opening % Reading in FIT-1 Reading in FIC-1 Reading in FIRC-1
Aurora HMI SCADA

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100%
75%
50%
25%

Receivers

National Polytechnic Institute

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Mexico
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6 .- Build the CURVES of the readings obtained from FIT-1, FIC-1 and FIRC-1 with respect to
the valve opening.

7 .- Comparing the FIT-1 curve with respect to FIC-1, determine what type of error the receiver
has (FIC-1) and, if present, make the necessary adjustments.

8 .- Write conclusions.

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Galileo Galilei 3865-1C
Receivers Zapopan Jalisco
Mexico
Tel/Fax 3631-5011
IMEPI SA de CV National Polytechnic Institute
[email protected] www.imepi.com.mx

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4.5 questionnaire.

1. Briefly explain what a receiver is.

2. What type of receiver is used in this practice?

3. What needs to be done to adjust the receiver?

4. What do the controller configuration levels indicate?

5. What operating conditions does the Normal/Configure switch cause in the automatic
controller?

6. What is the operating voltage value of the ABB brand Commander C250 controller?

7. At what level is the Commander C250 controller engineering range set?

8. What are the advantages of using the operating station with Aurora HMI SCADA
software as a receiver, compared to the Commander C250 controller?

9. Is it possible to continuously graph process variable data, with the Aurora HMI SCADA
software installed on the operating station?

10. What is the function of the Aurora HMI SCADA software, installed on the operation
station and what does HMI SCADA mean?

11. Is it possible to indicate and/or record at the same time with the Aurora HMI SCADA
software, the values indicated in the ABB controllers and the values indicated on the
operation screen coming from the Allen Bradley PLC?

12. If the previous question is affirmative, how can it be demonstrated?

13. Write the advantages of using the operation station to manipulate and supervise the
operation of the flow control loop in the Industrial Process Multiloop Control Module?

14. In the flow control loop, which instruments have HART communication and what
advantages does it represent?

15. In the flow control loop, what is the electrical classification of all the instruments
involved?

Receivers

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Galileo Galilei 3865-1C Zapopan Jalisco
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Mexico Polytechnic Institute
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IMEPI SA de CV [email protected] www.imepi.com.mx

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IMEPI
IMEPI SA de CV
Galileo Galilei 3865-1C Zapopan Jalisco Mexico
Tels/Fax 3631-5011
[email protected] www.imepi.com.mx

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 Receivers

National Polytechnic Institute

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 IMEPI SA de CV
"CONTROL MODULE
MULTI-LOOK OF PROCESSES
INDUSTRIAL”

Orifice Plate

"The only symbol of superiority I know is kindness."

L.V. Beethoven.
 MEXICAN ENGINEERING SPECIALIZED IN

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Mexico
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Content
National Polytechnic Institute....................................................................................................1
ESIQIE.......................................................................................................................................1
IMEPI SA de CV collaborators for him development of these practices..........................3
National Polytechnic Institute.........................................................................................4
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”......................4
Understanding the System...................................................................................................4
1.1 Goals.................................................................................................................8
1.1.1 Generals.........................................................................................................8
1.1.2 Specific..........................................................................................................8
1.2 Understanding the system...............................................................................10
1.2.1 Closed Control Loop or Closed Flow Control Circuit................................10
1.2.2 Closed Control Loop or Closed Level Control Circuit.....................................13
1.2.3 Closed Control Loop or Closed Pressure Control Circuit...........................15
1.2.4 Closed Control Loop or Closed Circuit Temperature Control....................17
1.4 Control of 3 process variables........................................................................27
1.4.1 Flow-Level-Pressure...................................................................................27
1.5 Questionnaire..................................................................................................28
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”....................38
National Polytechnic Institute.......................................................................................41
3.2 Theoretical framework:...................................................................................42
3.2.1 What is a transmitter?..................................................................................42
National Polytechnic Institute.......................................................................................43
National Polytechnic Institute.......................................................................................44
National Polytechnic Institute.......................................................................................46
National Polytechnic Institute.......................................................................................48
3.2.2 Digital electronic transmitters.....................................................................49
National Polytechnic Institute.......................................................................................50
National Polytechnic Institute.......................................................................................52
3.2.3 Differential pressure transmitter.................................................................53
National Polytechnic Institute.......................................................................................54
3.2.3.1 Yokogawa brand differential pressure transmitter......................................55
National Polytechnic Institute.......................................................................................56

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3.2.3.2 Tube installation..........................................................................................57
Mexico
3.2.3.3 Installation of the3631-5011
Tel/Fax transmitter for closed tank.............................................57
IMEPI SA de Polytechnic
National CV [email protected] www.imepi.com.mx
Institute.......................................................................................58
3.2.3.4 Wiring.........................................................................................................59
National Polytechnic Institute.......................................................................................60
3.3 Equipment used...............................................................................................61
3.4.1 Construction of the calibration curve for the LIT-2 level differential
pressure transmitter....................................................................................................61
National Polytechnic Institute.......................................................................................62
National Polytechnic Institute.......................................................................................64
3.4.2 HART communication protocol for smart transmitters..............................65
National Polytechnic Institute.......................................................................................66
National Polytechnic Institute.......................................................................................68
National Polytechnic Institute.......................................................................................70
3.16 3 PACTware software for configuring intelligent transmitters with HART
protocol......................................................................................................................71
National Polytechnic Institute.......................................................................................72
3.5 Material:..........................................................................................................73
3.6 Development...................................................................................................73
National Polytechnic Institute.......................................................................................74
National Polytechnic Institute.......................................................................................76
National Polytechnic Institute.......................................................................................78
National Polytechnic Institute.......................................................................................80
National Polytechnic Institute.......................................................................................82
National Polytechnic Institute.......................................................................................83
National Polytechnic Institute.......................................................................................85
National Polytechnic Institute.......................................................................................87
1 .7 Questionnaire..................................................................................................88
National Polytechnic Institute.......................................................................................89
National Polytechnic Institute.......................................................................................91
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”....................66
National Polytechnic Institute.......................................................................................69
4.1 Aim.................................................................................................................70
4.2 Theoretical framework....................................................................................70
4.2.1 Flow Indicator Controller FIC-1 Brand ABB. (receiver)............................70
National Polytechnic Institute.......................................................................................71
National Polytechnic Institute.......................................................................................73
National Polytechnic Institute.......................................................................................75
National Polytechnic Institute.......................................................................................77

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National Polytechnic Institute.......................................................................................79
Mexico
4.2.2 Key functions
Tel/Faxand entry to the ABB Flow controller display.....................80
3631-5011
IMEPI [email protected]
SA de Polytechnic
National CV www.imepi.com.mx
Institute.......................................................................................81
4.2.3 ABB Controller Configuration Menu Map.................................................82
4.3 Material Used.......................................................................................................82
National Polytechnic Institute.......................................................................................83
4.4 Development........................................................................................................84
4.4.1 Configuration of levels 5 and 6 of the ABB controller...............................84
National Polytechnic Institute.......................................................................................85
National Polytechnic Institute.......................................................................................87
National Polytechnic Institute.......................................................................................88
4.4.2 Identification of receiver errors (FIC-1 Flow Indicator Controller, ABB brand).
...................................................................................................................................89
National Polytechnic Institute.......................................................................................90
National Polytechnic Institute.......................................................................................92
National Polytechnic Institute.......................................................................................94
National Polytechnic Institute.......................................................................................96
4.5 questionnaire........................................................................................................97
National Polytechnic Institute.......................................................................................98
National Polytechnic Institute.....................................................................................100
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”....................84
Orifice Plate......................................................................................................................84
National Polytechnic Institute.......................................................................................87
5.2 Theoretical framework....................................................................................88
National Polytechnic Institute.......................................................................................89
National Polytechnic Institute.......................................................................................91
National Polytechnic Institute.......................................................................................93
National Polytechnic Institute.......................................................................................95
National Polytechnic Institute.......................................................................................97
National Polytechnic Institute.......................................................................................99
National Polytechnic Institute.....................................................................................101
National Polytechnic Institute.....................................................................................103
National Polytechnic Institute.....................................................................................105
National Polytechnic Institute.....................................................................................106
5.2.1 How an Orifice Plate Works.....................................................................107
National Polytechnic Institute.....................................................................................108
5.2.2 Installation of an intelligent differential pressure transmitter to measure
flow with an orifice plate.........................................................................................109
National Polytechnic Institute.....................................................................................110

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5.3. Material and Galileo Galilei 3865-1C Zapopan Jalisco
equipment used............................................................................111
Mexico
National Polytechnic Institute.....................................................................................112
Tel/Fax 3631-5011
IMEPI 5.4 [email protected] www.imepi.com.mx
SA Development......................................................................................................113
de CV
National Polytechnic Institute.....................................................................................114
National Polytechnic Institute.....................................................................................116
National Polytechnic Institute.....................................................................................118
National Polytechnic Institute.....................................................................................120
National Polytechnic Institute.....................................................................................121
National Polytechnic Institute.....................................................................................123
National Polytechnic Institute.....................................................................................125
National Polytechnic Institute.....................................................................................127
National Polytechnic Institute.....................................................................................129
National Polytechnic Institute.....................................................................................131
National Polytechnic Institute.....................................................................................133
5.5 Calculations.......................................................................................................134
National Polytechnic Institute.....................................................................................135
5.6. Questionnaire................................................................................................136
National Polytechnic Institute.....................................................................................137
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..................112
National Polytechnic Institute.....................................................................................116
6.2 Theoretical framework..................................................................................117
National Polytechnic Institute.....................................................................................120
National Polytechnic Institute.....................................................................................124
National Polytechnic Institute.....................................................................................126
National Polytechnic Institute.....................................................................................128
6.3 Material used......................................................................................................129
National Polytechnic Institute.....................................................................................130
6.4. Development.................................................................................................131
National Polytechnic Institute.....................................................................................131
National Polytechnic Institute.....................................................................................133
6.4 Questionnaire.....................................................................................................134
National Polytechnic Institute.....................................................................................135
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..................124
Proportional Band...........................................................................................................124
National Polytechnic Institute.....................................................................................127
7.1 Aim...............................................................................................................128
7.2 Theoretical framework..................................................................................128
7.2.1 Proportional control..................................................................................128

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National Polytechnic Institute.....................................................................................129
Mexico
National Polytechnic Institute.....................................................................................131
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx
National Polytechnic Institute.....................................................................................133
National Polytechnic Institute.....................................................................................135
National Polytechnic Institute.....................................................................................137
7.2.2 Summary of the characteristics of proportional control............................138
National Polytechnic Institute.....................................................................................139
7.2.3 Operation of a proportional band controller..............................................140
7.3 Used material................................................................................................140
National Polytechnic Institute.....................................................................................141
7.4. Development.....................................................................................................142
National Polytechnic Institute.....................................................................................143
7.4.1. Table and data to build the graph..............................................................144
National Polytechnic Institute.....................................................................................145
7.5 Questionnaire.....................................................................................................146
National Polytechnic Institute.....................................................................................147
National Polytechnic Institute.....................................................................................144
8.2.1 Types of final control elements.................................................................145
8.2.2 Pneumatic actuator....................................................................................145
National Polytechnic Institute.....................................................................................146
National Polytechnic Institute.....................................................................................148
National Polytechnic Institute.....................................................................................150
8.2.3 Valve body................................................................................................151
National Polytechnic Institute.....................................................................................152
National Polytechnic Institute.....................................................................................154
National Polytechnic Institute.....................................................................................156
National Polytechnic Institute.....................................................................................158
8.2.4 Characteristic of a valve............................................................................159
National Polytechnic Institute.....................................................................................159
National Polytechnic Institute.....................................................................................161
National Polytechnic Institute.....................................................................................163
8.2.5 Calculation of valve flow coefficient........................................................164
National Polytechnic Institute.....................................................................................165
National Polytechnic Institute.....................................................................................167
National Polytechnic Institute.....................................................................................169
National Polytechnic Institute.....................................................................................171
National Polytechnic Institute.....................................................................................173
National Polytechnic Institute.....................................................................................175

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"CONTROL MODULE Galileo Galilei 3865-1C Zapopan Jalisco
MULTI-LOOK OF PROCESSES INDUSTRIAL”..................154
Mexico
Cascade Control..............................................................................................................154
Tel/Fax 3631-5011
IMEPI 9.1 [email protected] www.imepi.com.mx
SA de Aim...............................................................................................................158
CV
9.2 Theoretical framework..................................................................................158
9.2.1 Cascade control.........................................................................................158
9.2.2 Cascade control of the Multiloop Control Module...................................159
9.3 Used material................................................................................................160
9.4 Development......................................................................................................160
9.5 Questionnaire.....................................................................................................168
5.1

Orifice Plate

National Polytechnic Institute

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5.1 Aim.

Obtain the calibration curve of an orifice plate with intelligent differential pressure
transmitter and receiver (FIC-1 Flow Indicator Controller) with linear scale in percentage, as well
as the error produced by faulty installation.

5.2 Theoretical framework.

As is known, in the industry there are multiple and varied flow meters to control industrial
processes; Generally you want to know the quantity that enters and leaves the process. Because
most materials are transported as fluids, the speed at which they pass through a pipe or channel
should be measured whenever possible. Methods for measuring flow currents are classified as
follows:

1. Direct weighing meters.

2. Dynamic or fixed area meters (orifice, venturi, etc.).
3. Variable area meters (rotameters).
4. Current meters (cup and propeller meters).
5. Positive displacement meters (disc, piston, rotary).
6. Open Channel Meters (Weirs, V-Notch, Cipolletti, Parshall).
7. Electrical meters (magnetic, turbines).

The most common method to determine the flow of a fluid through a pipe is by restricting the
passage of the fluid by decreasing the area through which it flows. Flow measurement by this
method is achieved with a primary measurement element, which produces the pressure differential,
and a secondary measurement element that measures said differential.

The primary measuring element is a restriction in the flow line that causes the fluid to contract, and
as the flow rate is constant, its velocity increases and the static pressure decreases, at the same time,
the differential represents an index of flow velocity ; To obtain the flow, the velocity index is
multiplied by the area.

Simplifying, the pressure loss caused by the restriction is proportional to the square of the flow
velocity; According to Bernoulli, the fluid contracts, the flow is constant, the velocity increases and
the static pressure decreases. Some of these constant area and flow velocity elements are illustrated
in Figure 5.1.

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Orifice Plate
Mexico
Tel/Fax 3631-5011
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[email protected] www.imepi.com.mx

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Figure 5.1. Orifice Plate

The secondary measuring element is a device known as a differential pressure transmitter, which
essentially consists of two opposing chambers that receive the pressures before and after the
primary element and subtract them to obtain the differential. Which can be converted into a
movement to manipulate a pen in the case of a flow recorder, or into a movement to obtain a
pressure or direct current output in the case of using a differential pressure transmitter (see the
practice of transmitters). ).

Currently the orifice plate is the most used measuring element in the industry; Its design and
construction are very simple. However, it has several disadvantages compared to the Venturi and
nozzle; its permanent friction losses are comparatively much greater; The amount of flow it
delivers is 37.5% less than a Venturi or nozzle. Its advantages are basically economic, since it is
the lowest cost and easiest to acquire element.

The orifice plate consists of a perforated plate that is installed in the pipe, the orifice it has is a
cylindrical or prismatic opening through which the fluid flows. The orifice is normalized, the
characteristic of this edge is that the jet it generates does not touch the wall of the orifice again at
its exit. Flow rate can be determined by differential pressure readings. Two outlets connected to
the front and back of the plate capture this differential pressure.

The orifice plate has different shapes depending on the type of fluid to be measured; Figure 5.2
shows the different orifice plates, there are concentric, eccentric, segmented and round-edged
ones.

Orifice Plate

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Figure 5.2. Types of Orifice Plate.

The concentric plate is used for clean fluids.

The eccentric orifice plate is used for liquids or gases with occluded or gases that entrain liquids,
where pressure changes imply condensation. When fluids contain a high percentage of dissolved
gases.

The segmented orifice plate is used where the fluid has particles in suspension, which implies
turbulence that will clean (so that particles do not agglomerate) the high pressure side, avoiding
errors in the measurement.

In order to avoid entrainment of solids or gases that the fluid may carry, the plate incorporates a
purge hole, as mentioned above. Among the various hole profiles used, as shown in Figure 5.3, the
following can be highlighted: sharp-edged, quarter-circle and conical entry.

Figure 5.3 Types of Orifice Plate.

Figure 5.4 illustrates a concentric hole used for flow measurement. If the cut of the orifice is
sharp, the fluid should not suffer any loss in the velocity it acquires when passing through the
orifice. In this same figure the distribution of pressures is observed; It is also noted that the
permanent pressure loss is 60% of the maximum differential pressure created by the flow on the
plate.

Orifice Plate

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Figure 5.4 (a)

Figure 5.4 pressure distribution in an orifice plate.

The use of the plate has been around for a long time in the industry for the commercial
measurement of fluids, so that a set of standards and qualities have been established that an
orifice plate must meet to perform a good measurement. Which are:

1. Be made of a resistant material, capable of avoiding deformations when subjected to

ordinary pressure stress, or to the impact of a fluid without corrosion.
2. As for the thickness of the hole, it is related to its diameter: for pipes up to 4” in diameter,
plates with a thickness of 1/16” are used; For pipes with a diameter between 4 and 16” plates
with a thickness of 1/8” are used and finally for pipes larger than 16” they are used with a
thickness of ¼”.
3. The face of the plate corresponding to the high pressure should be mounted perpendicular to
the axis of the pipe and its edge turned square and mirror polished for best results. In the
rounded edge plate, the flat face faces the discharge.
4. The edge of the hole should not be thicker than 1/8”, and for plates with a hole less than ½”
the thickness of the edge should not exceed 1/16”. If to achieve this it is necessary to bevel
the edge, it will be done on the pressure bean side and at an angle of no less than 45 degrees.

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Galileo Galilei Orifice
3865-1C Zapopan Jalisco
Plate
Mexico
Tel/Fax 3631-5011
IMEPI SA de CV National Polytechnic Institute
[email protected] www.imepi.com.mx

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5. The minimum required distance of straight pipe section before and after the orifice plate is
regulated by ASME and depends on the configuration of the pipe where the plate is
mounted.

Figure 5.5 indicates different methods for taking pressure in an orifice. Intake holes in the pipe,
which do not appear in the figure, are used with some frequency; The most used method, and at
the same time the simplest in practice, is to drill the holes for the tap connections in the flanges
that support the hole. Intake holes in the contracted vein are found less frequently.

The pressure differential taps on an orifice plate can be made in five different ways:

Figure 5.5. Types of pressure taps.

1. Corner shot. The pressure measurement is done on the faces of the plate. It is used when
the pipe is less than 1 ½” NPT.

2. Flange socket. Measurements are made one inch before and one inch after the face of the
plate. Flange sockets are widely used, since the flanges are available ready to install and
in threaded, weldable or high pressure form.

3. Radio socket. The shot before the plate is made 1 diameter away, the shot after the plate
1/2 diameter (one radius).

Orifice Plate

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Galileo Galilei 3865-1C Zapopan Jalisco
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Mexico Polytechnic Institute
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IMEPI SA de CV [email protected] www.imepi.com.mx

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Mexico
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4. Intake of vena contracta. It should be used if you want to take advantage of the maximum
pressure differential. The measurement is made one pipe diameter before and the distance
after the plate is determined by the diameter ratio (figure 5.6).

5. Pipe socket. The measurement is made 8 pipe diameters before the plate and 2.5 pipe
diameters after the plate.

6. There must be a sufficient length of straight pipe of uniform diameter upstream of the
orifice to obtain a normal flow pattern from the orifice.

Pipe diameters from orifice plate.

Figure 5.6. Outlet pressure connection location for vena contracta intake.

The presence of flanges, elbows, valves and other accessories located near the orifice make it
necessary, in practice, to calibrate the device in its true situation.

It is very important that there is sufficient length of straight pipe before and after the orifice, so
that the type of flow is normal and not distorted by valves, accessories or other devices. If this
does not happen, the velocity distribution will be abnormal and the spill coefficient will be
affected in an unpredictable way. Data are available for the minimum length of straight pipe that
must exist upstream and downstream of the orifice to ensure a normal velocity distribution; the
standard is from the American Society of Mechanical Engineering (ASME) of July 1945.

If the required length of straight pipe is not available upstream of the orifice, straightening vanes
could be installed, thereby making the minimum upstream length between vanes

Orifice Plate

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Mexico Polytechnic Institute
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and the hole will be reduced. Another more advisable way is to introduce a bundle of small tubes
into the pipe that completely fill the cross section; The maximum diameter of the tube must be
one quarter of the diameter of the pipe, and the length, at least ten times its diameter.

Straightening vanes destroy cross currents and thus help establish normal velocity distribution.

Figure 5.7 shows a standard of the necessary distances, published by ASME. More complicated
arrangements of fittings or the presence of partially closed valves upstream of the orifice require
a long length of straight pipe to establish the normal velocity distribution.

The coefficient of an orifice is more empirical than that of the venturi tube; Therefore, rigorous
and detailed standards for orifice meters are available in the literature, which must be followed
exactly if the meter is to be used without prior calibration.
For an approximate or preliminary design, the following equation is used satisfactorily:

Where:

U 0 = Velocity through the hole (m/sec).

β= Relationship between the diameter of the hole and the inner diameter of the tube .
P a and P b = Pressures of the points before and after the hole.
C 0 = Hole coefficient.

% c= gravity CONVERSION FACTOR , NEWTON 's law , 9.8067 (mkg/kg sec 2 ).

ρ= Density (kg/m 3 ).
m= Mass flow rate, (kg/sec).
D 0 = Pipe diameter.

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Due to the high friction losses to the eddies that are generated in the re-expansion of the jet, once
the vena contracta is passed, the pressure recovery in an orifice gauge becomes very different.
The power loss that arises is a of the disadvantages of the orifice meter. The fraction of the
differential pressure between the diameter of the orifice and the diameter of the tube, as seen in
Figure 5.8.

The equation that governs constant area meters, determined by Torricelli, is:
Q = AC √ 2gh
Where:
Q = Maximum expenditure.
c = Discharge coefficient in the restriction.
A = Area of the restriction.
g = Acceleration of gravity.
h = Pressure drop at minimum flow.
According to this equation, the measurement of flow is a quadratic function of the differential
pressure (h); This fact limits the use of this type of meter, because below 50% of the flow rate the
discharge coefficient of the orifice plate is not constant and the equation turns out to be false.

Figure 5.7 (a)

Orifice Plate

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Figure 5.7(b)

For orifices and nozzles with For orifices and nozzles in

reduction and expansion atmospheric intake
input type onñico
bell mouth or mouth gives hujo

p<X accesses anser KX

es 40.0

0.1 02 0.3 04 0 5 08 0.7 0.8 0 9

dihmeter ratio

Figure 5.7(c)

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Figure 5.7(e)
Figure 5.7. Installation of orifice plates.
(Trans. ASME, July 1945, p. 346).

Figure 5.8. Total pressure loss.

Orifice Plate

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5.2.1 How an Orifice Plate Works.

It is important to understand that in any pipe through which water circulates, the pressure
increases when the velocity decreases and the pressure decreases when the velocity increases.
Let's refer to figure 5.9, where a cross section of the measuring device is shown.

Let's imagine that water circulates through a normal steel pipe without anything stopping it; in this
case the speed from one point of the pipe to another does not change. But the orifice plate (point
C) inserted in the pipe causes the water to collide with the plate and slow down. Due to the
reduction in velocity, the pressure just before the orifice (point B) is slightly higher than the
operating pressure in the upstream drive line (point A).

As the water passes through the hole, to compensate for the decrease in area, the speed increases
and the pressure decreases, reaching its lowest value when the speed is maximum.

Downstream of this point, the flow disperses, slows down and there is an increase in pressure at
point D.

After the plate, the velocity recovers because water circulates throughout the pipe (point E).

Let's call the pressure upstream of the orifice plate as h1, while the pressure downstream as h2.
The difference between the two (h1-h2) is known as the differential pressure, which we will
symbolize by h.

Figure 5.9. Orifice plate causing the speed to increase and the pressure to decrease.

Orifice Plate

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5.2.2 Installation of an intelligent differential pressure transmitter to measure flow

with an orifice plate.

Figure 5.10 shows the installation of the intelligent differential pressure transmitter to measure the
differential pressure generated by an orifice plate whose mechanical installation is with plate
holder flanges. This figure shows two sockets connected to the plate holder flange. These sockets
are : the high intake (H) and the low intake (L), then an arrangement is made with blocking valves,
manifold and tubing, so that in this way the differential pressure generated in the two intakes (H
and L) is by the differential pressure transmitter.

Figure 5.10. Installation of an intelligent differential pressure transmitter on an orifice plate.

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5.3. Material and equipment used.

■ Multiloop Control Module for Industrial Processes.
■ FE-1 orifice plate of the Multiloop Control Module for industrial processes.
■ Intelligent differential pressure transmitter for measuring flow FIT-1.
■ PACTware and HART MODEM software for configuration and calibration of the
intelligent differential pressure transmitter.
■ Operation station of the Multiloop Control Module for Industrial Processes.

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5.4 Development.

Before starting the practical development, it is important to know the configuration procedure via
HART software of the intelligent transmitter, since if during the practical procedure it is necessary
to make adjustments to the Intelligent Differential Pressure Transmitter to measure FIT-1 flow,
you have the knowledge of how to make said configuration and adjustments.

1) Configuration via HART protocol of differential pressure transmitter to measure flow

FIT-1 : In order to work with the orifice plate identified as FE-1 in the Multiloop Control
Module, it is important to know how to change the engineering ranges of the FIT-1
transmitter shown in Figure 5.18, this is done with the PACTware software whose procedure
is as follows:

a) Connect the computer with the USB HART MODEM as shown in figure 5.11 and go to
the properties of My Computer and verify which port it is set to.

USB HART
MODEM

PACTwar
e HART MODEM connected to PC USB port.
Figure 5.11.

b) Attach the leads of the source to the terminals of the transmitter with a series resistor as
shown in Figure 5.12.

Figure 5.12. Power supply with 24 V dc of the FIT-1 transmitter.

c) Connect the USB HART MODEM terminals in parallel with the resistor as shown in
figure 5.13.

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Figure 5.13. Connecting the Hart Modem tips to the FIT-1 transmitter.

d) After this procedure, verify that the transmitter is turned on, open the PACTware
program from the computer.

e) Open the PACTware program.

Figure 5.14. PACTware software.

Orifice Plate

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f) In the left panel you will find “pc host”, right click and then choose “add device”.

Figure 5.15. Add Hart communication device.

g) Choose the “HART Connection” option and click “OK”.

Figure 5.16. Hart communication device selection.

Orifice Plate

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h) Choose the “COM” Communication port where the instrument is connected to the PC.

Figure 5.17. Communication port selection.

i) Right click on “COMx” and choose the “Add Device” option )

select the instrument DTM (FIT-1) > ok.

Figure 5.18. Add DTM device of the instrument to configure.

Orifice Plate

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j) Select the DTM of the instrument (FIT-1) and click “OK”.

Figure 5.19. DTM device of the instrument to be configured EJA (FIT-

1).
k) Right click on the instrument and choose the “Connect” option.

Figure 5.20. Connect to the instrument to configure EJA (FIT-1).

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l) Again right click on the instrument and choose the “Load from Device” option.

Important note: The instrument information is downloaded (loaded from the device),
before anything else, to make a backup of the configuration of the instrument to which it
was connected, in this case it is the EJA (FIT-1). This backup is done to take the real
configuration data of the instrument to be configured. If the configuration is downloaded,
there are no problems with configuration data errors. It is recommended that when
downloading the data (loading from the device) the file is saved so that in case of any
erroneous data that is given to the configuration, the backup file can be opened and
downloaded to the instrument to return it to its original configuration.

Figure 5.21. Lower the EJA instrument configuration (FIT-1).

Orifice Plate

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m) Review the URV (Highest Range Value) and LRV (Lowest Range Value) levels and modify
them if necessary.

Figure 5.22. Modification of the engineering, upper and lower ranks of the EJA (FIT-
1).

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n) Choose the “Input Pressure” option in “Display” and press Enter. With this the instrument
will have been configured to measure differential pressure.

Figure 5.23. Input press to measure differential pressure.

2) Obtaining the calibration curve: Once the range of the differential pressure transmitter
identified as FIT-1 has been modified, the construction of the calibration curve of the
differential pressure transmitter will be carried out, where the reading will be taken from
said differential pressure transmitter identified as FIT-1. To do this you have to do the
following procedure:

a) Align the Multiloop Control Module flow circuit shown in Figure 5.24 as follows:

■ Open the bottom manual valve of tank T1 identified as HV-3.

■ Make sure valve V-1 is closed.

■ In the multiloop control cabinet, set the selector to PLC, so that the system
obeys the PLC command through the operation station (PC).

■ From the operation station using the Aurora HMI SCADA software, press the
“FLOW TO T2” button on “SELECTOR 1” of the operation screen as shown
in figure 5.25.

Orifice Plate

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a) Symbolic representation.
Figure 5.24. Symbolic representation Circuit from T1 to T2 of the Multiloop Control Module for
Industrial Processes.

Figure 5.25. Flow button to T1 pressed.

b) Start pump B1 to transfer water from tank T1 to tank T2.

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c) Open the flow modulating valve FV-1 to 100% by putting the FIRC-1 panel in
MANUAL mode and writing a value of 100.0 at the output, as shown in figure 5.26.

Write FV-1 opening

percentage

Figure 5.26. FIRC-1 panel, in MANUAL mode and with 100.00% output.

The FV-1 valve is opened manually to measure the differential pressure generated
when the valve is 100% open, said differential pressure measurement will be made by
the differential pressure transmitter FIT-1 as illustrated in figure 5.27.

FIT-1 differential
pressure pressure
transmitter .

Figure 5.27. FIT-1 differential pressure transmitter represented on the screen.

d) Using a stopwatch, measure the time tank T2 reaches a certain height.

e) Position the FV-1 valve at the different opening percentages as indicated in the
following table:

Orifice Plate

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Table 5.1 Differential pressure reading values obtained with respect to the opening percentage of
the FV-1 valve.
Open Time Level Actual flow Ideal flow Flow Error (%)
percentage of (min) (cm) (%) (%)
valve FV-1
100%
81%
64%
49%
36%
25%
16%
9%
4%
0%

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5.5 Calculations.

The calculation of each of the level readings is done by applying the following formula:

0.785 D2L I
1,000 T min
Where:
Q = Expense (in l/min).
D = Tank diameter (in cm).
L = Level obtained (in cm).
T = Time (in minutes).

Simplified equation:

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5.6. Questionnaire.

1. Make the graph. Two curves: Receiver reading in % against actual flow in % and ideal
flow in %.
2. What is the pressure – velocity relationship in an orifice plate?
3. What are the types of pressure taps that an orifice plate can have?
4. What considerations must be taken to install an orifice plate?
5. What other element is required, in addition to the orifice plate, to measure flow?
6. What tool is used to calibrate the Differential Pressure Indicator transmitter?
7. What happens to the differential pressure when the modulating valve FV-1 is at 100%?
8. What happens to the differential pressure when the modulating valve FV-1 is at 4%?
9. What is the flow behavior in the trend graph of Aurora HMI SCADA software?
10. Write conclusions.

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 IMEPI SA de CV

"CONTROL MODULE
MULTI-LOOK OF PROCESSES
INDUSTRIAL”

Two Position Control

"Ideas are not imposed, they are proposed." John Paul II.
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Content
National Polytechnic Institute...............................................................................................1
ESIQIE..................................................................................................................................1
IMEPI SA de CV collaborators for him development of these practices.....................3
National Polytechnic Institute....................................................................................4
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”................4
Understanding the System.............................................................................................4
1.1 Goals...........................................................................................................8
1.1.1 Generals...................................................................................................8
1.1.2 Specific....................................................................................................8
1.2 Understanding the system.........................................................................10
1.2.1 Closed Control Loop or Closed Flow Control Circuit..........................10
1.2.2 Closed Control Loop or Closed Level Control Circuit...............................13
1.2.3 Closed Control Loop or Closed Pressure Control Circuit.....................15
1.2.4 Closed Control Loop or Closed Circuit Temperature Control..............17
1.4 Control of 3 process variables...................................................................27
1.4.1 Flow-Level-Pressure..............................................................................27
1.5 Questionnaire............................................................................................28
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..............38
National Polytechnic Institute..................................................................................41
3.2 Theoretical framework:.............................................................................42
3.2.1 What is a transmitter?............................................................................42
National Polytechnic Institute..................................................................................43
National Polytechnic Institute..................................................................................44
National Polytechnic Institute..................................................................................46
National Polytechnic Institute..................................................................................48
3.2.2 Digital electronic transmitters...............................................................49
National Polytechnic Institute..................................................................................50
National Polytechnic Institute..................................................................................52
3.2.3 Differential pressure transmitter............................................................53
National Polytechnic Institute..................................................................................54
3.2.3.1 Yokogawa brand differential pressure transmitter................................55
National Polytechnic Institute..................................................................................56

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3.2.3.2 Tube installation....................................................................................57
Mexico
3.2.3.3 InstallationTels/Fax
of the transmitter
3631-5011 for closed tank........................................57
IMEPI SA de
National CV
Polytechnic [email protected] www.imepi.com.mx
Institute..................................................................................58
3.2.3.4 Wiring....................................................................................................59
National Polytechnic Institute..................................................................................60
3.3 Equipment used.........................................................................................61
3.4.1 Construction of the calibration curve for the LIT-2 level differential
pressure transmitter..............................................................................................61
National Polytechnic Institute..................................................................................62
National Polytechnic Institute..................................................................................64
3.4.2 HART communication protocol for smart transmitters.........................65
National Polytechnic Institute..................................................................................66
National Polytechnic Institute..................................................................................68
National Polytechnic Institute..................................................................................70
3.16 3 PACTware software for configuring intelligent transmitters with HART
protocol................................................................................................................71
National Polytechnic Institute..................................................................................72
3.5 Material:....................................................................................................73
3.6 Development.............................................................................................73
National Polytechnic Institute..................................................................................74
National Polytechnic Institute..................................................................................76
National Polytechnic Institute..................................................................................78
National Polytechnic Institute..................................................................................80
National Polytechnic Institute..................................................................................82
National Polytechnic Institute..................................................................................83
National Polytechnic Institute..................................................................................85
National Polytechnic Institute..................................................................................87
1 .7 Questionnaire............................................................................................88
National Polytechnic Institute..................................................................................89
National Polytechnic Institute..................................................................................91
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..............66
National Polytechnic Institute..................................................................................69
4.1 Aim............................................................................................................70
4.2 Theoretical framework..............................................................................70
4.2.1 Flow Indicator Controller FIC-1 Brand ABB. (receiver)......................70
National Polytechnic Institute..................................................................................71
National Polytechnic Institute..................................................................................73
National Polytechnic Institute..................................................................................75
National Polytechnic Institute..................................................................................77

National Polytechnic
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National Polytechnic Institute..................................................................................79
Mexico
4.2.2 Key functions
Tel/Faxand entry to the ABB Flow controller display...............80
3631-5011
IMEPINational
SA de CV [email protected]
Polytechnic www.imepi.com.mx
Institute..................................................................................81
4.2.3 ABB Controller Configuration Menu Map...........................................82
4.3 Material Used.................................................................................................82
National Polytechnic Institute..................................................................................83
4.4 Development..................................................................................................84
4.4.1 Configuration of levels 5 and 6 of the ABB controller.........................84
National Polytechnic Institute..................................................................................85
National Polytechnic Institute..................................................................................87
National Polytechnic Institute..................................................................................88
4.4.2 Identification of receiver errors (FIC-1 Flow Indicator Controller, ABB
brand)...................................................................................................................89
National Polytechnic Institute..................................................................................90
National Polytechnic Institute..................................................................................92
National Polytechnic Institute..................................................................................94
National Polytechnic Institute..................................................................................96
4.5 questionnaire..................................................................................................97
National Polytechnic Institute..................................................................................98
National Polytechnic Institute................................................................................100
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..............84
Orifice Plate.................................................................................................................84
National Polytechnic Institute..................................................................................87
5.2 Theoretical framework..............................................................................88
National Polytechnic Institute..................................................................................89
National Polytechnic Institute..................................................................................91
National Polytechnic Institute..................................................................................93
National Polytechnic Institute..................................................................................95
National Polytechnic Institute..................................................................................97
National Polytechnic Institute..................................................................................99
National Polytechnic Institute................................................................................101
National Polytechnic Institute................................................................................103
National Polytechnic Institute................................................................................105
National Polytechnic Institute................................................................................106
5.2.1 How an Orifice Plate Works................................................................107
National Polytechnic Institute................................................................................108
5.2.2 Installation of an intelligent differential pressure transmitter to measure
flow with an orifice plate...................................................................................109
National Polytechnic Institute................................................................................110

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5.3. Material and equipment 3865-1C Zapopan Jalisco
used......................................................................111
Mexico
National Polytechnic Institute................................................................................112
Tels/Fax 3631-5011
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5.4 Development................................................................................................113
National Polytechnic Institute................................................................................114
National Polytechnic Institute................................................................................116
National Polytechnic Institute................................................................................118
National Polytechnic Institute................................................................................120
National Polytechnic Institute................................................................................121
National Polytechnic Institute................................................................................123
National Polytechnic Institute................................................................................125
National Polytechnic Institute................................................................................127
National Polytechnic Institute................................................................................129
National Polytechnic Institute................................................................................131
National Polytechnic Institute................................................................................133
5.5 Calculations..................................................................................................134
National Polytechnic Institute................................................................................135
5.6. Questionnaire..........................................................................................136
National Polytechnic Institute................................................................................137
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”............112
National Polytechnic Institute................................................................................116
6.2 Theoretical framework............................................................................117
National Polytechnic Institute................................................................................120
National Polytechnic Institute................................................................................124
National Polytechnic Institute................................................................................126
National Polytechnic Institute................................................................................128
6.3 Material used................................................................................................129
National Polytechnic Institute................................................................................130
6.4. Development...........................................................................................131
National Polytechnic Institute................................................................................131
National Polytechnic Institute................................................................................133
6.4 Questionnaire...............................................................................................134
National Polytechnic Institute................................................................................135
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”............124
Proportional Band......................................................................................................124
National Polytechnic Institute................................................................................127
7.1 Aim..........................................................................................................128
7.2 Theoretical framework............................................................................128
7.2.1 Proportional control.............................................................................128

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Galileo Galilei 3865-1C Zapopan Jalisco
National Polytechnic Institute................................................................................129
Mexico
National Polytechnic Institute................................................................................131
Tel/Fax 3631-5011
IMEPINational
SA de CV [email protected] www.imepi.com.mx
Polytechnic Institute................................................................................133
National Polytechnic Institute................................................................................135
National Polytechnic Institute................................................................................137
7.2.2 Summary of the characteristics of proportional control......................138
National Polytechnic Institute................................................................................139
7.2.3 Operation of a proportional band controller........................................140
7.3 Used material..........................................................................................140
National Polytechnic Institute................................................................................141
7.4. Development...............................................................................................142
National Polytechnic Institute................................................................................143
7.4.1. Table and data to build the graph........................................................144
National Polytechnic Institute................................................................................145
7.5 Questionnaire...............................................................................................146
National Polytechnic Institute................................................................................147
National Polytechnic Institute................................................................................144
8.2.1 Types of final control elements...........................................................145
8.2.2 Pneumatic actuator..............................................................................145
National Polytechnic Institute................................................................................146
National Polytechnic Institute................................................................................148
National Polytechnic Institute................................................................................150
8.2.3 Valve body...........................................................................................151
National Polytechnic Institute................................................................................152
National Polytechnic Institute................................................................................154
National Polytechnic Institute................................................................................156
National Polytechnic Institute................................................................................158
8.2.4 Characteristic of a valve......................................................................159
National Polytechnic Institute................................................................................159
National Polytechnic Institute................................................................................161
National Polytechnic Institute................................................................................163
8.2.5 Calculation of valve flow coefficient..................................................164
National Polytechnic Institute................................................................................165
National Polytechnic Institute................................................................................167
National Polytechnic Institute................................................................................169
National Polytechnic Institute................................................................................171
National Polytechnic Institute................................................................................173
National Polytechnic Institute................................................................................175

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Galileo Galilei OF
"CONTROL MODULE MULTI-LOOK 3865-1C Zapopan INDUSTRIAL”............154
PROCESSES Jalisco
Mexico
Cascade Control.........................................................................................................154
Tels/Fax 3631-5011
IMEPI
9.1SA de CV [email protected] www.imepi.com.mx
Aim..........................................................................................................158
9.2 Theoretical framework............................................................................158
9.2.1 Cascade control...................................................................................158
9.2.2 Cascade control of the Multiloop Control Module..............................159
9.3 Used material..........................................................................................160
9.4 Development................................................................................................160
9.5 Questionnaire...............................................................................................168
6.1

Two Position Control

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Tels/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx

6.1 Aim.

The goal of this lab is to determine the effect of changing faces on the response of a two-position
controller.

6.2 Theoretical framework.

Given its simplicity, this type of control is very popular whether pneumatic, electrical or
mechanical. Its action is essentially cyclical, although under almost ideal conditions, the
magnitude of the variation of the controlled variable can be extremely small. It can be considered
that there is always a small change in the value of the variable called differential, within which the
final control element maintains its extreme positions.

Let us consider an ideal case: a two-position controller is applied to a process without self-
regulation. The driver is supposed to be without delays. This case is similar to controlling a liquid
level in an open tank that receives water from the top of the tank and discharges by means of a
positive displacement pump (figure 6.1).

If the controller has a differential, the level would increase steadily until it reaches the upper limit
of the differential. At this moment the valve that admits water is closed. The level begins to
decrease at a constant speed until reaching the lower limit of the differential.

Figure 6.1. Level control.

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Position Control Jalisco
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As shown in curve “A” in Figure 6.2, the variable oscillates between the limits of the differential.

The process in the example has a reaction speed where the capacity is dominant, the rest of the
delays are considered negligible.

With a process capacitance as shown in the “AA” curve, the cycle period is comparatively small.
If the process capacitance is increased in such a way that the rate of change of level is lower than
its initial value, as shown in curve “BB”, the cycle period is increased, as seen in curve “B”. .

The amplitude of the cycle remains constant since it is numerically equal to the width of the
differential. If we reduce the differential, the period and amplitude of the cycle are also reduced, as
seen in curve “C”.

If the system has considerable dead time, the cycle amplitude will be proportional to the reaction
rate, since the greater the reaction rate of the process, the greater the deviation before the
controlled variable can return to the set point.

Time------------> C Curve
Figure 6.2. Effect of reaction speed without dead time.

The amplitude of the cycle in case of dead time in any variable is inversely proportional to the
reaction speed of the process, and directly proportional to the amplitude of the differential and the
duration of the dead time.

Two Position Control

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When there is a dead time, the process capacitance or the reaction speed of the corresponding
process has a great influence on the cycle amplitude. In Figure 6.3, two controlled systems are
illustrated, with the same dead time but different reaction rates.

When a two-position differential control is used in the process that has a higher reaction speed
(curve “AA”), the cycle amplitude is 1.7 units. If the reaction rate is reduced (“BB” curve), the
cycle amplitude is reduced to one unit.

The practical case differs from the ideal due to increased transmission delay, measurement and
controller delays. In addition, the process itself has a delay, especially since two-position control is
widely used for thermal processes.

Note that in the process that has a slower reaction speed, the variable remains closer to the
differential. The cycle period is increased with a slow reaction rate.

Delays in the controlled system round off the peaks of the controlled variable waveform and may
appear as a sine wave.

Figure 6.3. Effect of reaction speed on dead time.

By varying the process load conditions, the cycle takes on an asymmetrical appearance if a two-
position control is applied to a system that has transmission delays. In a thermal process, for
example, to obtain a greater heat demand, the time that the final control element remains energized
(valve open) must be longer than the time it remains disconnected (valve closed).

IffeN
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Two Position Control
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In Figure 6.4, it is seen that the magnitude of the controlled variable must be lower when the
demand is high in order to provide a greater amount of heat. The variable deviates too far from the
set point when there is a load change because the heat supplied is inadequate for the new demand.

Figure 6.4 Effect of load changes.

Two Position Control

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Conclusions that can be deduced from what was previously described: The cycle period:

1. It increases with a lower reaction speed.

2. Increases with delays in transmission.

3. Increases with downtime.

4. Increases with controller differential.

Cycle width:

1. Increases with higher reaction speed.

2. Increases with transmission delays.

3. Increases with downtime.

4. Increases with controller differential.

The most important thing to obtain a small cycle amplitude is that the transmission delays and
dead time are as small as possible. In processes that have a high response speed, the downtime
should be almost zero.

A slower reaction speed allows for a slight downtime. A large delay in the measurement would
produce a serious dynamic error and the value of the variable would not be true. A process with a
slow response speed allows for fairly accurate two-position control. But if the period were too
long due to a very low response speed, the controller would react too slowly to a change in load or
a change in set point. For a period of 30 minutes, for example, the controlled variable would take 1
or 1.5 hours to stabilize.

In summary, two-position control is satisfactory when:

1 .- Transmission delays and downtime are negligible.

2 .- The response speed of the process is slow.

3 .- Measurement and control delays are small.

4 .- Load changes are not large or frequent.

Two Position Control

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Mexico
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The most commonly used two-position controllers are of the electrical or electronic type (figure
6.5). The final control element is usually an electrical relay, a solenoid valve, or a motor that
operates a valve. The control mechanism is such that the contacts open and close when the
variable passes the set point. These contacts are called high and low and the differential between
them constitutes a small percentage of the full scale, unless the controller is intentionally built
with a differential. A differential of 0% of the scale is impossible to obtain. In most two-position
electric controllers the differential makes up about 1% of full scale.

Figure 6.5. Two position controller.

The differential is used to reduce overuse of the control mechanism and is generally less than 2%
of full scale. If a two-position electrical controller is used to operate a relay or solenoid valve, the
control lag, that is, the time it takes for a contact on the controller to open or close, will be
negligible; This is not the case if the final control element is moved by a two-position motor, since
their stroke takes more than two and less than 120 seconds, depending on the motor (figure 6.6).

Two Position Control

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Mexico
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Figure 6.6. Two-position control features, with motorized valve.

6.3 Material used.

■ Multiloop Control Module for Industrial Processes.

■ Diagram of figure 6.7.
■ ABB commander C250 controller configuration manual.
■ Commander C250 Controller of the Multiloop Control Module identified as LIC-1.

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Two Position Zapopan Jalisco
Control
Mexico
Tel/Fax 3631-5011
IMEPI SA de CV National Polytechnic Institute
[email protected] www.imepi.com.mx

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Mexico
Tel/Fax 3631-5011
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6.4. Development.

1. Based on figure 6.7, from the operating station open valve V-2 to align the flow from T1 to
T2 from the Aurora HMI screen selector of the operating station.

2. Set the control cabinet selector identified as G1 to “L”.

3. Set a set point between 20 and 40% of the level to the LIC-2 (the teacher selects the data).

4. Set a proportional band value of approximately 0 to the LIC-2 controller and in the auto
position. This can be done on the Aurora HMI Controllers screen or from the LIC-2
controller itself.

5. Start pump B1 with the button located in the control cabinet.

6. Start pump B2 with the button located in the control cabinet.

7. Wait until the process becomes repetitive. (open the HV-6 discharge valve to 50%).

8. Write down the minimum and maximum level data (to establish the differential).

9. With a stopwatch, take the time it takes for the level to reach the lower limit of the
differential to the upper limit (three readings).

10. Now take the time when the level moves from the upper limit to the lower limit (to establish
the period time).

11. Repeat steps 8,9 and 10 with the HV-6 discharge valve fully open (100% load).

12. Carry out the entire process again for a set point between 60 and 80 percent.

13. Plot the four graphs (level versus time) and obtain conclusions by change in load in demand
and in position of the set point.

Two Position Control

National Polytechnic Institute

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Valve of

Figure 6.7. Level Circuit.

Table 6.1. Data for the construction of the graphs:

Time going
set point Demand (%) High limit Low limit Time rising
down

Note: Plot the graphs on a single sheet of graph paper, with the fit point on the ordinate and the load on
the abscissa. Attach the sheet to the report.

Two Position Control

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IMEPI SA de CV [email protected] www.imepi.com.mx

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Galileo Galilei 3865-1C Zapopan Jalisco
Mexico
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx

6.4 Questionnaire.

1. How does a two position control work?

2. Where is a two-position control applied?

3. What happens to the period if the process capacitance is increased?

4. What happens to the period and differential when the cycle amplitude of the two-position
control is reduced?

5. How does the reaction speed behave when faced with a time-out?

6. When is a two-position control satisfactory?

7. Briefly describe what elements make up a two-position controller.

8. What about two position control with a proportional band of approximately 0 with the
wastegate restricted to 50% open?

9. What about two position control with a proportional band of approximately 0 with the
wastegate restricted to 100% open?

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Galileo Galilei 3865-1C
Two Position Zapopan Jalisco
Control
Mexico
Tel/Fax 3631-5011
IMEPI SA de CV National Polytechnic Institute
[email protected] www.imepi.com.mx

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 IMEPI SA de CV

"CONTROL MODULE
MULTI-LOOK OF PROCESSES
INDUSTRIAL”

Proportional Band

"Where there is education there is no distinction of classes". Confucius

 MEXICAN ENGINEERING SPECIALIZED IN

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Galileo Galilei 3865-1C Zapopan Jalisco
Mexico
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx

Content
National Polytechnic Institute........................................................................................................1
ESIQIE...........................................................................................................................................1
IMEPI SA de CV collaborators for him development of these practices.............................3
National Polytechnic Institute.............................................................................................4
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”.........................4
Understanding the System......................................................................................................4
1.1 Goals....................................................................................................................8
1.1.1 Generals............................................................................................................8
1.1.2 Specific.............................................................................................................8
1.2 Understanding the system..................................................................................10
1.2.1 Closed Control Loop or Closed Flow Control Circuit...................................10
1.2.2 Closed Control Loop or Closed Level Control Circuit........................................13
1.2.3 Closed Control Loop or Closed Pressure Control Circuit..............................15
1.2.4 Closed Control Loop or Closed Circuit Temperature Control.......................17
1.4 Control of 3 process variables............................................................................27
1.4.1 Flow-Level-Pressure......................................................................................27
1.5 Questionnaire.....................................................................................................28
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”.......................38
National Polytechnic Institute...........................................................................................41
3.2 Theoretical framework:......................................................................................42
3.2.1 What is a transmitter?.....................................................................................42
National Polytechnic Institute...........................................................................................43
National Polytechnic Institute...........................................................................................44
National Polytechnic Institute...........................................................................................46
National Polytechnic Institute...........................................................................................48
3.2.2 Digital electronic transmitters........................................................................49
National Polytechnic Institute...........................................................................................50
National Polytechnic Institute...........................................................................................52
3.2.3 Differential pressure transmitter.....................................................................53
National Polytechnic Institute...........................................................................................54
3.2.3.1 Yokogawa brand differential pressure transmitter.........................................55
National Polytechnic Institute...........................................................................................56

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3.2.3.2 Tube installation.............................................................................................57
Mexico
3.2.3.3 Installation ofTel/Fax
the transmitter
3631-5011 for closed tank.................................................57
IMEPI SAPolytechnic
National de CV [email protected] www.imepi.com.mx
Institute...........................................................................................58
3.2.3.4 Wiring.............................................................................................................59
National Polytechnic Institute...........................................................................................60
3.3 Equipment used..................................................................................................61
3.4.1 Construction of the calibration curve for the LIT-2 level differential pressure
transmitter.....................................................................................................................61
National Polytechnic Institute...........................................................................................62
National Polytechnic Institute...........................................................................................64
3.4.2 HART communication protocol for smart transmitters.................................65
National Polytechnic Institute...........................................................................................66
National Polytechnic Institute...........................................................................................68
National Polytechnic Institute...........................................................................................70
3.16 3 PACTware software for configuring intelligent transmitters with HART
protocol.........................................................................................................................71
National Polytechnic Institute...........................................................................................72
3.5 Material:.............................................................................................................73
3.6 Development......................................................................................................73
National Polytechnic Institute...........................................................................................74
National Polytechnic Institute...........................................................................................76
National Polytechnic Institute...........................................................................................78
National Polytechnic Institute...........................................................................................80
National Polytechnic Institute...........................................................................................82
National Polytechnic Institute...........................................................................................83
National Polytechnic Institute...........................................................................................85
National Polytechnic Institute...........................................................................................87
1 .7 Questionnaire.....................................................................................................88
National Polytechnic Institute...........................................................................................89
National Polytechnic Institute...........................................................................................91
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”.......................66
National Polytechnic Institute...........................................................................................69
4.1 Aim.....................................................................................................................70
4.2 Theoretical framework.......................................................................................70
4.2.1 Flow Indicator Controller FIC-1 Brand ABB. (receiver)...............................70
National Polytechnic Institute...........................................................................................71
National Polytechnic Institute...........................................................................................73
National Polytechnic Institute...........................................................................................75
National Polytechnic Institute...........................................................................................77

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Galileo Galilei 3865-1C Zapopan Jalisco
National Polytechnic Institute...........................................................................................79
Mexico
4.2.2 Key functionsTel/Fax
and entry to the ABB Flow controller display........................80
3631-5011
IMEPI SAPolytechnic
National de CV [email protected] www.imepi.com.mx
Institute...........................................................................................81
4.2.3 ABB Controller Configuration Menu Map....................................................82
4.3 Material Used..........................................................................................................82
National Polytechnic Institute...........................................................................................83
4.4 Development...........................................................................................................84
4.4.1 Configuration of levels 5 and 6 of the ABB controller..................................84
National Polytechnic Institute...........................................................................................85
National Polytechnic Institute...........................................................................................87
National Polytechnic Institute...........................................................................................88
4.4.2 Identification of receiver errors (FIC-1 Flow Indicator Controller, ABB brand).
.......................................................................................................................................89
National Polytechnic Institute...........................................................................................90
National Polytechnic Institute...........................................................................................92
National Polytechnic Institute...........................................................................................94
National Polytechnic Institute...........................................................................................96
4.5 questionnaire...........................................................................................................97
National Polytechnic Institute...........................................................................................98
National Polytechnic Institute.........................................................................................100
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”.......................84
Orifice Plate..........................................................................................................................84
National Polytechnic Institute...........................................................................................87
5.2 Theoretical framework.......................................................................................88
National Polytechnic Institute...........................................................................................89
National Polytechnic Institute...........................................................................................91
National Polytechnic Institute...........................................................................................93
National Polytechnic Institute...........................................................................................95
National Polytechnic Institute...........................................................................................97
National Polytechnic Institute...........................................................................................99
National Polytechnic Institute.........................................................................................101
National Polytechnic Institute.........................................................................................103
National Polytechnic Institute.........................................................................................105
National Polytechnic Institute.........................................................................................106
5.2.1 How an Orifice Plate Works........................................................................107
National Polytechnic Institute.........................................................................................108
5.2.2 Installation of an intelligent differential pressure transmitter to measure flow
with an orifice plate.....................................................................................................109
National Polytechnic Institute.........................................................................................110

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5.3. Material and equipment used...............................................................................111
Mexico
National Polytechnic Institute.........................................................................................112
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx
5.4 Development.........................................................................................................113
National Polytechnic Institute.........................................................................................114
National Polytechnic Institute.........................................................................................116
National Polytechnic Institute.........................................................................................118
National Polytechnic Institute.........................................................................................120
National Polytechnic Institute.........................................................................................121
National Polytechnic Institute.........................................................................................123
National Polytechnic Institute.........................................................................................125
National Polytechnic Institute.........................................................................................127
National Polytechnic Institute.........................................................................................129
National Polytechnic Institute.........................................................................................131
National Polytechnic Institute.........................................................................................133
5.5 Calculations...........................................................................................................134
National Polytechnic Institute.........................................................................................135
5.6. Questionnaire...................................................................................................136
National Polytechnic Institute.........................................................................................137
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”.....................112
National Polytechnic Institute.........................................................................................116
6.2 Theoretical framework.....................................................................................117
National Polytechnic Institute.........................................................................................120
National Polytechnic Institute.........................................................................................124
National Polytechnic Institute.........................................................................................126
National Polytechnic Institute.........................................................................................128
6.3 Material used.........................................................................................................129
National Polytechnic Institute.........................................................................................130
6.4. Development....................................................................................................131
National Polytechnic Institute.........................................................................................131
National Polytechnic Institute.........................................................................................133
6.4 Questionnaire........................................................................................................134
National Polytechnic Institute.........................................................................................135
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”.....................124
Proportional Band...............................................................................................................124
National Polytechnic Institute.........................................................................................127
7.1 Aim...................................................................................................................128
7.2 Theoretical framework.....................................................................................128
7.2.1 Proportional control......................................................................................128

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National Polytechnic Institute.........................................................................................129
Mexico
National Polytechnic Institute.........................................................................................131
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx
National Polytechnic Institute.........................................................................................133
National Polytechnic Institute.........................................................................................135
National Polytechnic Institute.........................................................................................137
7.2.2 Summary of the characteristics of proportional control...............................138
National Polytechnic Institute.........................................................................................139
7.2.3 Operation of a proportional band controller.................................................140
7.3 Used material...................................................................................................140
National Polytechnic Institute.........................................................................................141
7.4. Development........................................................................................................142
National Polytechnic Institute.........................................................................................143
7.4.1. Table and data to build the graph.................................................................144
National Polytechnic Institute.........................................................................................145
7.5 Questionnaire........................................................................................................146
National Polytechnic Institute.........................................................................................147
National Polytechnic Institute.........................................................................................144
8.2.1 Types of final control elements....................................................................145
8.2.2 Pneumatic actuator.......................................................................................145
National Polytechnic Institute.........................................................................................146
National Polytechnic Institute.........................................................................................148
National Polytechnic Institute.........................................................................................150
8.2.3 Valve body...................................................................................................151
National Polytechnic Institute.........................................................................................152
National Polytechnic Institute.........................................................................................154
National Polytechnic Institute.........................................................................................156
National Polytechnic Institute.........................................................................................158
8.2.4 Characteristic of a valve...............................................................................159
National Polytechnic Institute.........................................................................................159
National Polytechnic Institute.........................................................................................161
National Polytechnic Institute.........................................................................................163
8.2.5 Calculation of valve flow coefficient...........................................................164
National Polytechnic Institute.........................................................................................165
National Polytechnic Institute.........................................................................................167
National Polytechnic Institute.........................................................................................169
National Polytechnic Institute.........................................................................................171
National Polytechnic Institute.........................................................................................173
National Polytechnic Institute.........................................................................................175

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Mexico
Cascade Control.................................................................................................................154
Tel/Fax 3631-5011
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9.1 Aim...................................................................................................................158
9.2 Theoretical framework.....................................................................................158
9.2.1 Cascade control............................................................................................158
9.2.2 Cascade control of the Multiloop Control Module......................................159
9.3 Used material...................................................................................................160
9.4 Development.........................................................................................................160
9.5 Questionnaire........................................................................................................168
7.1

Proportional Band

National Polytechnic Institute

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7.1 Aim.

The objective of this practice is to obtain the response curve of a proportional controller and
determine the percentage error of the proportional band dial

7.2 Theoretical framework.

7.2.1 Proportional control.

Proportional or modulating control is one in which the control output is proportional to the
magnitude of the deviation.

The deviation of the variable with respect to the set point within the proportional band is
converted to an output position.

Proportional band. It is the percentage of scale that the variable must travel to change its output
from one extreme position to the other (0 – 100%).

With a narrow proportional band, only a small deviation of the variable is required to change the
output by 100%.

When the proportional band is wide, a large deviation in the controlled variable is required to
change the output 100%.

Figure 7.1 represents the relationship between the controlled variable and the position of the
output for different proportional bands. Note that when the proportional band is more than 100%,
it is impossible to obtain 0 or 100% of the output even when the controlled variable is located at
zero or at 100% of the controller scale.

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Figure 7.1. Proportional band effect.

In an automatic system operated with the proportional mode, the deviation of the variable produces a
change in the position of the output in the appropriate direction to return to the variable is caused by a
change in demand in the process, known as load change, The output will try to correct the deviation
by changing position and reaching an equilibrium point in which the position of the output is different
than the one it had before the load change, but the variable maintains a “sustained deviation.”

This is easy to understand if we start from the fact that for each outlet position there corresponds a
valve opening position and there is a certain expenditure of the manipulated variable.

In a load change, a change in the expenditure of the manipulated variable is necessary to keep the
variable controlled at the set point.

Manual reset is used to vary the position of the output when the controlled variable has a permanent
deviation (Figure 7.2).

Figure 7.2 illustrates how, if the manual reset is set, the proportional band is run across the controller
scale to obtain 38 and 73% valve opening when the variable is at the set point.

Proportional Band

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Figure 7.2. Effect of manual reset

In order to analyze the dynamic action of proportional control, the output response, which results
from different changes in the variable, is plotted. The response is proportional to the value of the
proportional band (figure 7.3)

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Figure 7.3. Control response to sudden and slow changes.

The proportional controller equation can be developed from the above two figures. It can be expressed
as a relationship of the position of the output to the controlled variable.

The position of the output is given, assuming a linear scaling controller, by:

-p
E
Y =- - -- M
b

Where.

Y= Valve position in %/100 (this is the controller output)

B= Proportional band in %/100
M= Constant that depends on the manual reset position.
E= Position of the variable in %/100.
P= Control point position in %/100.

The negative sign is included in the equation in order to represent the opposition caused in automatic
control.

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The control output action must always produce a change in the controlled variable opposite to that
which caused the first corrective action.

When the output is at 50% of its stroke and there is no deviation, M can be 0.5 and:

Y = Í( E — P )+ 0.5
If we assume that B = 0.20 and that the plume is 7% outside the control point.
-Y = 1 (0.07 + 0.50)
0.20
— Y = 0.85

In these conditions the valve will move from 50 to 85%.

The smaller the proportional band, there is greater corrective action and tighter control limits.
Consequently, in proportional control it is advantageous to have processes with large capacitance.

Practically, it is possible to apply proportional control to processes with more than one capacity
where there is an appreciable transmission delay.

Since most thermal processes have at least two capacities and one resistance, we are presented
with a practical problem.

The control response and its stability depend on the value of the proportional band; a very narrow
proportional band produces too much oscillation before stabilizing the variable.

On the other hand, a wide proportional band produces excessive deviation.

Figure 7.4 shows the variation of the sustained deviation, a deviation that depends on the
proportional band, as it becomes smaller if the proportional band is reduced.

Since a wide proportional band is necessary for processes with transmission delay, load changes
will cause a greater sustained deviation.

The reaction speed of the process, together with transmission delays and dead time, determine the
value of the proportional band.

If the response speed of the process increases, it is essential to expand the band; The period of
oscillation decreases but the sustained deviation increases. (The dead time effect means increasing
the period of oscillation.)

Proportional Band

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If we increase the band to reduce the excess oscillation, the large dead time will cause serious
consequences in the automatic control.

Trompe—P

Figure 7.4. Proportional control - sustained deviation

7.2.2 Summary of the characteristics of proportional control.

1. A slow response speed allows a narrow proportional band.

2. Transmission delays and small dead time require a wide proportional band.

3. A large change causes a sustained deviation of the variable.

If you have a high-capacity intermittent process (bump), small transmission delay and dead time, the
appropriate proportional band should be small, 10% or less. Thus, the sustained deflection
accompanying a load change will be negligible since the deflection generally cannot be greater than a
fraction of the band, which diminishes the importance of a load change.

Proportional Band

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PROPORTIONAL CONTROL CAN BE APPLIED WHEN:

1. There are no frequent or large load changes.

2. There are no major transmission delays and downtime.

3. The reaction speed of the process is slow.

7.2.3 Operation of a proportional band controller.

Controllers are devices designed to make corrections in a process by comparing two signals, one
comes from the variable (which can be detected directly or through a transmitter) and another set
manually by the operator, both signals must be compatible.

The controllers used in this practice are of the electronic type, that is, the variable signal and the
set point signal are electrical from 4 to 20 mA.
The controllers can work in DIRECT ACTION OR REVERSE ACTION. It is understood that a
controller is direct acting when increasing the variable with the fixed set point increases the output
signal, while in a reverse acting controller, increasing the variable decreases the output signal.

7.3 Used material.

■ Diagram of figure 7.5.

■ ABB commander C250 controller configuration manual.

■ Commander C250 Controller of the Multiloop Control Module identified as LIC-1.

Proportional Band

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7.4. Development.

The practice will consist of the study of a proportional band controller in static and dynamic
conditions. A schematic of the Multiloop Control Module Level circuit is shown in figure 7.5.

Valve of
Level controller level control.

Transmitter
Modulating flow Level indicator
control valve.

Figure 7.5. Level Circuit.

Flow Indicator Transmitter

a) static condition.

a.1) Based on figure 7.5, fill the water level of tank T2 up to approximately 50%;
In these conditions the output of the LIT-2 transmitter must be close to 12 mA
and the indication on its display must be 50%.

a.2) Adjust the set point of the LIC-2 controller, so that its value is the same as the

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level, that is, 50%; Under these conditions the controller output must be
between 4 and 20 mA E = P therefore, in the proportional band equation:

Note that in this condition “M” corresponds to the position of the outlet when the
process is in equilibrium.

Proportional Band

National Polytechnic Institute

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a.3) Taking several values of the controlled variable, graph them against output
positions for a given proportional band, whose value will be given by the teacher.

b) Dynamic Condition b.1) Based on figure 7.5, open the discharge valve HV-6
of tank T2, start pump B1 to supply water to tank T2 and start pump B2, in the
LIC-2 controller set the setting proportional band at the minimum value and
observe the level oscillations.

b.2) Adjust the proportional band until the oscillations cease with the minimum
possible band. If there is a deviation between variable and set point, write it down.

b.3) Abruptly change the position of the adjustment point and observe if the
variable obeys using the trend graph.

7.4.1. Table and data to build the graph.

STATIC CONDITION.

Proportional band _____________________ M= ___________________(for E=P).

Data to build the graph:

Dial error calculation;

Level Exit

DYNAMIC CONDITION.

Set point: _______

Proportional band: _______
Deviation:

Proportional Band

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National Polytechnic Institute

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Conclusions:

7.5 Questionnaire.

1. What is proportional band?

2. What happens at the outlet of valve LV-2 when the set point is equal to the process
variable?

3. What happens at the output of the LV-2 valve (open percentage) when the proportional
band is minimum?

4. What happens at the output of the LV-2 valve (open percentage) when the proportional
band is maximum?

5. To change the valve output to 100% with a small deviation; What value should the
proportional band have?

6. At what proportional band values was the control most stable?

7. Verify the history of the values obtained in the graph in the trend graph of the Aurora
HMI SCADA software and draw your conclusions.

8. Make the graph of the data obtained.

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 IMEPI SA de CV

“MULTI-LOOP CONTROL MODULE OF INDUSTRIAL PROCESSES”

Control valve.

"Do not exchange health for wealth, nor freedom for power." Benjamin Franklin.
 MEXICAN ENGINEERING SPECIALIZED IN

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Content
National Polytechnic Institute...............................................................................................1
ESIQIE..................................................................................................................................1
IMEPI SA de CV collaborators for him development of these practices.....................3
National Polytechnic Institute....................................................................................4
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”................4
Understanding the System.............................................................................................4
1.1 Goals............................................................................................................8
1.1.1 Generals...................................................................................................8
1.1.2 Specific....................................................................................................8
1.2 Understanding the system.........................................................................10
1.2.1 Closed Control Loop or Closed Flow Control Circuit...........................10
1.2.2 Closed Control Loop or Closed Level Control Circuit...............................13
1.2.3 Closed Control Loop or Closed Pressure Control Circuit.....................15
1.2.4 Closed Control Loop or Closed Circuit Temperature Control..............17
1.4 Control of 3 process variables...................................................................27
1.4.1 Flow-Level-Pressure..............................................................................27
1.5 Questionnaire.............................................................................................28
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..............38
National Polytechnic Institute..................................................................................41
3.2 Theoretical framework:.............................................................................42
3.2.1 What is a transmitter?............................................................................42
National Polytechnic Institute..................................................................................43
National Polytechnic Institute..................................................................................44
National Polytechnic Institute..................................................................................46
National Polytechnic Institute..................................................................................48
3.2.2 Digital electronic transmitters................................................................49
National Polytechnic Institute..................................................................................50
National Polytechnic Institute..................................................................................52
3.2.3 Differential pressure transmitter............................................................53
National Polytechnic Institute..................................................................................54
3.2.3.1 Yokogawa brand differential pressure transmitter................................55
National Polytechnic Institute..................................................................................56

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3.2.3.2 Tube installation....................................................................................57
Mexico
3.2.3.3 Installation of the
Tel/Fax transmitter for closed tank........................................57
3631-5011
IMEPINational
SA de CV [email protected]
Polytechnic www.imepi.com.mx
Institute..................................................................................58
3.2.3.4 Wiring....................................................................................................59
National Polytechnic Institute..................................................................................60
3.3 Equipment used.........................................................................................61
3.4.1 Construction of the calibration curve for the LIT-2 level differential
pressure transmitter..............................................................................................61
National Polytechnic Institute..................................................................................62
National Polytechnic Institute..................................................................................64
3.4.2 HART communication protocol for smart transmitters.........................65
National Polytechnic Institute..................................................................................66
National Polytechnic Institute..................................................................................68
National Polytechnic Institute..................................................................................70
3.16 3 PACTware software for configuring intelligent transmitters with HART
protocol.................................................................................................................71
National Polytechnic Institute..................................................................................72
3.5 Material:....................................................................................................73
3.6 Development.............................................................................................73
National Polytechnic Institute..................................................................................74
National Polytechnic Institute..................................................................................76
National Polytechnic Institute..................................................................................78
National Polytechnic Institute..................................................................................80
National Polytechnic Institute..................................................................................82
National Polytechnic Institute..................................................................................83
National Polytechnic Institute..................................................................................85
National Polytechnic Institute..................................................................................87
1 .7 Questionnaire............................................................................................88
National Polytechnic Institute..................................................................................89
National Polytechnic Institute..................................................................................91
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..............66
National Polytechnic Institute..................................................................................69
4.1 Aim............................................................................................................70
4.2 Theoretical framework..............................................................................70
4.2.1 Flow Indicator Controller FIC-1 Brand ABB. (receiver)......................70
National Polytechnic Institute..................................................................................71
National Polytechnic Institute..................................................................................73
National Polytechnic Institute..................................................................................75
National Polytechnic Institute..................................................................................77

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National Polytechnic Institute..................................................................................79
Mexico
4.2.2 Key functions
Tel/Faxand entry to the ABB Flow controller display...............80
3631-5011
IMEPINational
SA de CV [email protected]
Polytechnic www.imepi.com.mx
Institute..................................................................................81
4.2.3 ABB Controller Configuration Menu Map............................................82
4.3 Material Used.................................................................................................82
National Polytechnic Institute..................................................................................83
4.4 Development..................................................................................................84
4.4.1 Configuration of levels 5 and 6 of the ABB controller.........................84
National Polytechnic Institute..................................................................................85
National Polytechnic Institute..................................................................................87
National Polytechnic Institute..................................................................................88
4.4.2 Identification of receiver errors (FIC-1 Flow Indicator Controller, ABB
brand)....................................................................................................................89
National Polytechnic Institute..................................................................................90
National Polytechnic Institute..................................................................................92
National Polytechnic Institute..................................................................................94
National Polytechnic Institute..................................................................................96
4.5 questionnaire..................................................................................................97
National Polytechnic Institute..................................................................................98
National Polytechnic Institute................................................................................100
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..............84
Orifice Plate.................................................................................................................84
National Polytechnic Institute..................................................................................87
5.2 Theoretical framework..............................................................................88
National Polytechnic Institute..................................................................................89
National Polytechnic Institute..................................................................................91
National Polytechnic Institute..................................................................................93
National Polytechnic Institute..................................................................................95
National Polytechnic Institute..................................................................................97
National Polytechnic Institute..................................................................................99
National Polytechnic Institute................................................................................101
National Polytechnic Institute................................................................................103
National Polytechnic Institute................................................................................105
National Polytechnic Institute................................................................................106
5.2.1 How an Orifice Plate Works................................................................107
National Polytechnic Institute................................................................................108
5.2.2 Installation of an intelligent differential pressure transmitter to measure
flow with an orifice plate....................................................................................109
National Polytechnic Institute................................................................................110

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5.3. Material andGalileo Galilei 3865-1C Zapopan Jalisco
equipment used......................................................................111
Mexico
National Polytechnic Institute................................................................................112
Tel/Fax 3631-5011
IMEPI SA de CV [email protected] www.imepi.com.mx
5.4 Development................................................................................................113
National Polytechnic Institute................................................................................114
National Polytechnic Institute................................................................................116
National Polytechnic Institute................................................................................118
National Polytechnic Institute................................................................................120
National Polytechnic Institute................................................................................121
National Polytechnic Institute................................................................................123
National Polytechnic Institute................................................................................125
National Polytechnic Institute................................................................................127
National Polytechnic Institute................................................................................129
National Polytechnic Institute................................................................................131
National Polytechnic Institute................................................................................133
5.5 Calculations..................................................................................................134
National Polytechnic Institute................................................................................135
5.6. Questionnaire...........................................................................................136
National Polytechnic Institute................................................................................137
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”............112
National Polytechnic Institute................................................................................116
6.2 Theoretical framework............................................................................117
National Polytechnic Institute................................................................................120
National Polytechnic Institute................................................................................124
National Polytechnic Institute................................................................................126
National Polytechnic Institute................................................................................128
6.3 Material used................................................................................................129
National Polytechnic Institute................................................................................130
6.4. Development...........................................................................................131
National Polytechnic Institute................................................................................131
National Polytechnic Institute................................................................................133
6.4 Questionnaire................................................................................................134
National Polytechnic Institute................................................................................135
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”............124
Proportional Band......................................................................................................124
National Polytechnic Institute................................................................................127
7.1 Aim..........................................................................................................128
7.2 Theoretical framework............................................................................128
7.2.1 Proportional control.............................................................................128

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National Polytechnic Institute................................................................................129
Mexico
National Polytechnic Institute................................................................................131
Tel/Fax 3631-5011
IMEPINational
SA de CV [email protected] www.imepi.com.mx
Polytechnic Institute................................................................................133
National Polytechnic Institute................................................................................135
National Polytechnic Institute................................................................................137
7.2.2 Summary of the characteristics of proportional control......................138
National Polytechnic Institute................................................................................139
7.2.3 Operation of a proportional band controller........................................140
7.3 Used material...........................................................................................140
National Polytechnic Institute................................................................................141
7.4. Development...............................................................................................142
National Polytechnic Institute................................................................................143
7.4.1. Table and data to build the graph........................................................144
National Polytechnic Institute................................................................................145
7.5 Questionnaire................................................................................................146
National Polytechnic Institute................................................................................147
National Polytechnic Institute................................................................................144
8.2.1 Types of final control elements...........................................................145
8.2.2 Pneumatic actuator...............................................................................145
National Polytechnic Institute................................................................................146
National Polytechnic Institute................................................................................148
National Polytechnic Institute................................................................................150
8.2.3 Valve body...........................................................................................151
National Polytechnic Institute................................................................................152
National Polytechnic Institute................................................................................154
National Polytechnic Institute................................................................................156
National Polytechnic Institute................................................................................158
8.2.4 Characteristic of a valve......................................................................159
National Polytechnic Institute................................................................................159
National Polytechnic Institute................................................................................161
National Polytechnic Institute................................................................................163
8.2.5 Calculation of valve flow coefficient..................................................164
National Polytechnic Institute................................................................................165
National Polytechnic Institute................................................................................167
National Polytechnic Institute................................................................................169
National Polytechnic Institute................................................................................171
National Polytechnic Institute................................................................................173
National Polytechnic Institute................................................................................175

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"CONTROL MODULEGalileo Galilei 3865-1C Zapopan Jalisco
MULTI-LOOK OF PROCESSES INDUSTRIAL”............154
Mexico
Cascade Control.........................................................................................................154
Tel/Fax 3631-5011
IMEPI SA
9.1de CV [email protected] www.imepi.com.mx
Aim..........................................................................................................158
9.2 Theoretical framework............................................................................158
9.2.1 Cascade control....................................................................................158
9.2.2 Cascade control of the Multiloop Control Module..............................159
9.3 Used material...........................................................................................160
9.4 Development................................................................................................160
9.5 Questionnaire................................................................................................168
8.1.1
The characteristic of a valve, that is, the way in which the value of the flow
changes as the valve plug moves along its stroke, can be indicated by means of a
graph or a table........................................................................................................... 142
In the general case, that is, when the proportional band cannot be narrow and
relatively large load changes occur, there will be different
National Polytechnic Institute...............................................................................................1
ESIQIE..................................................................................................................................1
IMEPI SA de CV collaborators for him development of these practices.....................3
National Polytechnic Institute....................................................................................4
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”................4
Understanding the System.............................................................................................4
1.1 Goals............................................................................................................8
1.1.1 Generals...................................................................................................8
1.1.2 Specific....................................................................................................8
1.2 Understanding the system.........................................................................10
1.2.1 Closed Control Loop or Closed Flow Control Circuit...........................10
1.2.2 Closed Control Loop or Closed Level Control Circuit...............................13
1.2.3 Closed Control Loop or Closed Pressure Control Circuit.....................15
1.2.4 Closed Control Loop or Closed Circuit Temperature Control..............17
1.4 Control of 3 process variables...................................................................27
1.4.1 Flow-Level-Pressure..............................................................................27
1.5 Questionnaire.............................................................................................28
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..............38
National Polytechnic Institute..................................................................................41
3.2 Theoretical framework:.............................................................................42
3.2.1 What is a transmitter?............................................................................42
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National Polytechnic Institute..................................................................................44
National Polytechnic Institute..................................................................................46

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3.2.2 Digital Tel/Fax
electronic transmitters................................................................49
3631-5011
IMEPINational
SA de CV [email protected]
Polytechnic www.imepi.com.mx
Institute..................................................................................50
National Polytechnic Institute..................................................................................52
3.2.3 Differential pressure transmitter............................................................53
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3.2.3.1 Yokogawa brand differential pressure transmitter................................55
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3.2.3.2 Tube installation....................................................................................57
3.2.3.3 Installation of the transmitter for closed tank........................................57
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3.2.3.4 Wiring....................................................................................................59
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3.3 Equipment used.........................................................................................61
3.4.1 Construction of the calibration curve for the LIT-2 level differential
pressure transmitter..............................................................................................61
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National Polytechnic Institute..................................................................................64
3.4.2 HART communication protocol for smart transmitters.........................65
National Polytechnic Institute..................................................................................66
National Polytechnic Institute..................................................................................68
National Polytechnic Institute..................................................................................70
3.16 3 PACTware software for configuring intelligent transmitters with HART
protocol.................................................................................................................71
National Polytechnic Institute..................................................................................72
3.5 Material:....................................................................................................73
3.6 Development.............................................................................................73
National Polytechnic Institute..................................................................................74
National Polytechnic Institute..................................................................................76
National Polytechnic Institute..................................................................................78
National Polytechnic Institute..................................................................................80
National Polytechnic Institute..................................................................................82
National Polytechnic Institute..................................................................................83
National Polytechnic Institute..................................................................................85
National Polytechnic Institute..................................................................................87
1 .7 Questionnaire............................................................................................88
National Polytechnic Institute..................................................................................89
National Polytechnic Institute..................................................................................91
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..............66

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4.1 Aim............................................................................................................70
Tel/Fax 3631-5011
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4.2de CV
[email protected] www.imepi.com.mx
framework..............................................................................70
4.2.1 Flow Indicator Controller FIC-1 Brand ABB. (receiver)......................70
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National Polytechnic Institute..................................................................................73
National Polytechnic Institute..................................................................................75
National Polytechnic Institute..................................................................................77
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4.2.2 Key functions and entry to the ABB Flow controller display...............80
National Polytechnic Institute..................................................................................81
4.2.3 ABB Controller Configuration Menu Map............................................82
4.3 Material Used.................................................................................................82
National Polytechnic Institute..................................................................................83
4.4 Development..................................................................................................84
4.4.1 Configuration of levels 5 and 6 of the ABB controller.........................84
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National Polytechnic Institute..................................................................................87
National Polytechnic Institute..................................................................................88
4.4.2 Identification of receiver errors (FIC-1 Flow Indicator Controller, ABB
brand)....................................................................................................................89
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National Polytechnic Institute..................................................................................92
National Polytechnic Institute..................................................................................94
National Polytechnic Institute..................................................................................96
4.5 questionnaire..................................................................................................97
National Polytechnic Institute..................................................................................98
National Polytechnic Institute................................................................................100
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..............84
Orifice Plate.................................................................................................................84
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5.2 Theoretical framework..............................................................................88
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National Polytechnic Institute..................................................................................91
National Polytechnic Institute..................................................................................93
National Polytechnic Institute..................................................................................95
National Polytechnic Institute..................................................................................97
National Polytechnic Institute..................................................................................99
National Polytechnic Institute................................................................................101

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National Polytechnic Institute................................................................................105
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Polytechnic Institute................................................................................106
5.2.1 How an Orifice Plate Works................................................................107
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5.2.2 Installation of an intelligent differential pressure transmitter to measure
flow with an orifice plate....................................................................................109
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5.3. Material and equipment used......................................................................111
National Polytechnic Institute................................................................................112
5.4 Development................................................................................................113
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National Polytechnic Institute................................................................................116
National Polytechnic Institute................................................................................118
National Polytechnic Institute................................................................................120
National Polytechnic Institute................................................................................121
National Polytechnic Institute................................................................................123
National Polytechnic Institute................................................................................125
National Polytechnic Institute................................................................................127
National Polytechnic Institute................................................................................129
National Polytechnic Institute................................................................................131
National Polytechnic Institute................................................................................133
5.5 Calculations..................................................................................................134
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5.6. Questionnaire...........................................................................................136
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"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”............112
National Polytechnic Institute................................................................................116
6.2 Theoretical framework............................................................................117
National Polytechnic Institute................................................................................120
National Polytechnic Institute................................................................................124
National Polytechnic Institute................................................................................126
National Polytechnic Institute................................................................................128
6.3 Material used................................................................................................129
National Polytechnic Institute................................................................................130
6.4. Development...........................................................................................131
National Polytechnic Institute................................................................................131
National Polytechnic Institute................................................................................133
6.4 Questionnaire................................................................................................134

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SA de CVBand......................................................................................................124
Proportional
National Polytechnic Institute................................................................................127
7.1 Aim..........................................................................................................128
7.2 Theoretical framework............................................................................128
7.2.1 Proportional control.............................................................................128
National Polytechnic Institute................................................................................129
National Polytechnic Institute................................................................................131
National Polytechnic Institute................................................................................133
National Polytechnic Institute................................................................................135
National Polytechnic Institute................................................................................137
7.2.2 Summary of the characteristics of proportional control......................138
National Polytechnic Institute................................................................................139
7.2.3 Operation of a proportional band controller........................................140
7.3 Used material...........................................................................................140
National Polytechnic Institute................................................................................141
7.4. Development...............................................................................................142
National Polytechnic Institute................................................................................143
7.4.1. Table and data to build the graph........................................................144
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7.5 Questionnaire................................................................................................146
National Polytechnic Institute................................................................................147
National Polytechnic Institute................................................................................144
8.2.1 Types of final control elements...........................................................145
8.2.2 Pneumatic actuator...............................................................................145
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National Polytechnic Institute................................................................................148
National Polytechnic Institute................................................................................150
8.2.3 Valve body...........................................................................................151
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National Polytechnic Institute................................................................................154
National Polytechnic Institute................................................................................156
National Polytechnic Institute................................................................................158
8.2.4 Characteristic of a valve......................................................................159
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National Polytechnic Institute................................................................................161
National Polytechnic Institute................................................................................163

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8.2.5 Calculation of valve flow coefficient..................................................164
Mexico
National Polytechnic Institute................................................................................165
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Polytechnic Institute................................................................................167
National Polytechnic Institute................................................................................169
National Polytechnic Institute................................................................................171
National Polytechnic Institute................................................................................173
National Polytechnic Institute................................................................................175
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”............154
Cascade Control.........................................................................................................154
9.1 Aim..........................................................................................................158
9.2 Theoretical framework............................................................................158
9.2.1 Cascade control....................................................................................158
9.2.2 Cascade control of the Multiloop Control Module..............................159
9.3 Used material...........................................................................................160
9.4 Development................................................................................................160
9.5 Questionnaire................................................................................................168
8.2

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8.1 Aim.

Obtain the inherent and installed characteristic curves of a pneumatic control valve.

8.2 Theoretical framework.

8.2.1 Types of final control elements.

The final control element is a mechanism that varies the expenditure of the control agent or the
energy that enters the process in response to the action of the automatic control.

Although it is usually some type of valve, the final control elements can be of another type, such
as shutters, resistors, relays or electrical switches, depending on how the control is carried out.

The control agent can be vapor, gas, a liquid or simply electrical current. Said agent largely
determines the type of final element necessary for a particular application. The elements usually
constitute, in the final element itself, and a motor unit that drives it.

An interesting example of a final control element is the switch of a pyrometer for electric ovens, in
which the current that feeds the oven resistances is managed by said switch without the use of
auxiliary relays. In this case the switch is the final control element. If an auxiliary relay is used,
this would be the final control element.

In summary, the final control element is the mechanism that alters the value of the manipulated
variable in response to an output signal from the automatic controller.

A pneumatic control valve generally consists of:

a. An actuator, which transforms the controller's output signal into the position of a
stem capable of exerting considerable force.
b. A valve body that, actuated by the actuator, is capable of varying the manipulated
variable.

8.2.2 Pneumatic actuator.

Pneumatic actuators directly operate the output signal of a pneumatic controller or can use a
separate source of compressed air converting pressure into motion.

The spring actuator operates directly with the output signal from the controller, giving an output
position proportional to the inlet air pressure, which is typically 3 to 15 psig, or 12 psig of reach.
There are actuators with 4, 6, 9, and 24 psig range, for special applications.

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The diaphragm, usually made of an elastic material, moves under the action of two forces:

1. That produced by air pressure acting on the diaphragm.

2. That exerted by the spring when it is compressed and acting against the air
pressure as seen in figure 8.1.

Figure 8.1.

Calling these two forces F1 and F2, we have that:

F1 = PA.
F2 = Kx.
Where:
A= It is the area of the diaphragm.
K=It is the elastic constant of the spring.
x= It is the movement of the stem.

Generally, the operating range of actuators is 3 to 15 psi. Stem movement is between ¼” and 3”.
Theoretically, the position of the stem is proportional to the pressure applied.
In practice there is a deviation from proportionality due to various factors.

a. Friction between the stem and the fixed parts of the actuator and valve body.
b. The nonlinearity of the spring.
c. The forces exerted on the stem by the fluid manipulated by the valve.

All of those problems can be eliminated by the use of a device called a positioner.
The actuator that has been considered is Direct Action. When the pressure increases, the stem
lowers. There is, on the other hand, the reverse action, in which the stem rises. In the case of

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If these two types were used in conjunction with a body that could be inverted, the combinations
indicated in Figure 11.2 could be obtained. In cases “a” and “d” air will be needed to close; in
cases “b” and “c”, air to open.

a) Air, close b) Air, close c) Air, open d) Air, open

Direct action Reverse action

Figure 8.2

The type of appropriate action is selected taking into account the safety condition that the valve
should take, in the event of a lack of pressurized air. For example, if the process requires that by
increasing the controlled variable the valve will close, this result could be obtained with the valve
in Figure 8.2a and a direct action controller, or with the one in Figure
8.2b and a reverse action controller. However, if there is a lack of pressurized air, the spring would
cause the first valve to remain open and the second closed.

At the point where the actuator stem joins the valve body stem there is an indicator on a small
scale that can be moved vertically in order to obtain correct indications. When the valve is
completely closed, there is a reference point to set the position of the aforementioned scale.

Once the diaphragm and spring have been selected, it is not possible to alter the relationship
between the changes in air pressure and the displacements of the stem, since the driving part does
not have any device for this, that is, it has no amplitude adjustment and acts as according to the
elasticity coefficient of the spring.

On the other hand, if there is a zero adjustment, in other words, it is possible to modify the
position of the stem that corresponds to a given air pressure. This would be obtained by moving
the adjustment nut to give more or less compression to the spring.

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8.2.3 Valve body.

In figure 8.3 you can see the different parts of the valve body. In order to prevent the fluid
circulating through it from escaping, the stem passes through a stuffing box.

As can be seen, there are some parts that do not form a single unit with the body, such as the seat
on which the cap rests, the parts that serve as a guide for the moving part and some metal parts
that are part of the stuffing box; These pieces, together with the moving part, form what is known

TO. valve body

B Replaceable seat
c. Discs
d. Valve guide stem
E Guide piece
F. Valve cap
G Support ring
H. Sopone arms
J Diaphragm
K. Coupling between the
diaphragm and the valve stem
L. Spring retention rod
M. Dock
N. Dock seat
EITHER. Connection (Fisher)

Figure 8.3. Double seat valve.

as interior parts, which are usually made of a different material than the valve body.

The body presented in figure 8.2 is of the type that can be inverted, thereby achieving that when
the stem is lowered, the valve opens instead of closing.
The body that has been considered is a single seat. As normally the inlet pressure is greater than
the outlet pressure, this differential creates a force that tends to lift the plug, causing it to take a
position different from that required. With a double seat body this effect is reduced to a minimum.

In Figure 8.3, it is seen that the inlet pressure tends to move the upper plug upwards and the lower
plug downwards. However, as for mounting reasons the diameter of the upper plug is larger than
that of the lower one, the force caused by the pressure difference is not completely eliminated.
Double seat valves have the disadvantage of not producing a tight seal.

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The flow direction against the closing direction of the plug has the following advantage: in most
applications, as the valve closes, the pressure drop across it also increases the force that tends to
move the plug. plug.
If the flow was in the opposite direction, when the plug was close to the seat, the force would be
large enough to overcome the spring force and slam the plug shut.

Other types of bodies are angular and three-way, figure 8.4 and 8.5. The first has the particularity
of reducing the turbulence produced in the fluid as it passes through the valve, and its use is
recommended in the case of liquids with solids in suspension or liquids that evaporate when
passing through the valve, when subjected to at the lowest outlet pressure. Despite the valve's
tendency to slam shut, already mentioned before, the usual flow direction is that indicated in
Figure 8.4, in order to obtain a greater reduction in turbulence.

Figure 8.5 represents a three-way valve, used as a two-flow mixer or diverter. The relationship
between the values of the two flows would change as the plug took different positions.

The Saunders valve (figure 8.6) is recommended in those applications that handle viscous or
corrosive liquids, or that contain suspended solids. Likewise, when you want the valve to close
hermetically.

In figure 8.6, it can be seen that the stem is not in contact with the circulating liquid, and that the
closure is obtained through a diaphragm. Due to its large surface area, the force caused by the
pressure drop across the valve is much greater than in the case of other types, making it impossible
to precisely fix the position of the diaphragm. For this reason, the Saunders valve is especially
suitable for two-position control. Proportional action can be obtained using a positioner; How this
works will be mentioned later.

Figures 8.4.

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Figure 8.5.

Figure 8.6.

Figure 8.3 shows some details of the stuffing box. The packing is made up of several rings that
surround the stem and are put under pressure by means of a stuffing press. In order to ensure that
the friction produced by the stuffing box is not excessive, it is necessary to lubricate it, which is
done using the lubricator shown in figure 8.3. The metal piece that surrounds the stem and is in
front of the lubricator distributes appropriately.

The rings that form the gasket can be made of graphite-impregnated asbestos, Teflon-impregnated
asbestos, asbestos wrapped in an aluminum-based alloy sheet, or they can be made of Teflon. In
the latter case there is no need to use lubricant.

It had already been mentioned that in some applications the moving part of the valve is subject not
only to the influence of the forces generated by the air pressure and the spring, but also to other
forces, which can have an appreciable value. . In such a case, the position of the plug could not be
precisely fixed. One way to solve this problem is to use a positioner.

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Figure 8.7. Scheme and drawing of positioner.

When a positioner is used, the pressure from the controller is not received by the valve, but by the
positioner (figure 8.7). This simultaneously receives an indication of the valve position, and makes
a comparison of the two received signals.

If there is no correspondence between them, the valve sends the air pressure necessary for the
valve to take the position that must correspond to the pressure that the controller is sending.

For example, assuming that a valve needed air to close, and that the pressure sent by the controller
was 9 lb/in 2 , the valve would take a 50% opening.
If the pressure drop of the fluid through the valve was excessive and would tend to open it, it
would move away from the mentioned position, and would return to it only if the air pressure it
received was greater than 8 lb/in 2 .

As can be seen, the pressure that the positioner sends to the valve is the pressure necessary to
obtain the desired position, regardless of the values that the other forces acting on the moving part
may have, including the force of the spring.

In addition, other useful results can be obtained with the use of the positioner, such as having
greater power and faster response. Likewise, it is possible to use two control valves in such a way
that one operates when the controller pressure varies between 9 and 15 lb/in 2 , even if the valves
had springs with ranges from 3 to 15 lb/in 2 , it would be necessary to use a positioner for each
valve, with ranges of 3 to 9 lb/in 2 and 9 to 15 lb/in 2 respectively.

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8.2.4 Characteristic of a valve.

The characteristic of a valve, that is, the way in which the value of the flow changes as the
valve plug moves along its stroke, can be indicated by means of a graph or a table.

Curve B in figure 8.8 corresponds to a valve with a linear characteristic. Both valve opening and
flow are expressed as percentages of the corresponding maximum values.

If we consider that the pressure drop across the valve has remained constant as the plug moves
from end to end of its stroke, then we will say that the graph represents the inherent characteristic
of the valve.

Curve C represents the inherent characteristic of a quick opening valve. As can be seen, with only
an opening of 30% the flow acquires a value equal to 75% of the maximum.

Figure 8.8. Characteristic of a valve.

Apparently a valve with an inherent linear characteristic should be ideal for use in a control system
with proportional action, if the variations suffered by the flow, which would be the manipulated
variable, are proportional to the displacements of the plug, these proportional to the changes of
controlled air pressure and in turn proportional to the changes of the controlled variable. However,
there are some reasons to prefer, in many cases, a valve with a different characteristic.

The equal percentage characteristic corresponding to a graph similar to A in Figure 8.8. This type
of characteristic, when the plug admits a displacement with a certain value, the increase in position
percentage generates an increase in the same percentage as the flow that existed before the
displacement. For example, if the plug had a displacement of 10% of the

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stroke, the flow would increase 40%, regardless of whether the plug goes, for example, from 30 to
40% open, or from 80 to 90%.
This relationship between opening and flow has the particularity that when represented by means
of a semi-logarithmic graph, it gives rise to a straight line as shown in figure 8.9.

1 5 10 50 100

Rujo
Figure 8.9. Characteristic

According to the above, even if the inherent characteristic of the valve was linear. The effective
feature, which is the important one in applications, might not be. The way to obtain an effective
linear, or approximately linear, characteristic is to use a valve with an inherent characteristic such
as the one represented in graph A of Figure 8.8, which could deform, potentially giving, in a
certain application, a characteristic curve. effective similar to curve B.

The linear characteristic that has been considered is an inherent characteristic, that is, it is obtained
when the pressure drop across the valve is the same for the different values of the opening. In
some applications this condition is met, as in the case presented in Figure 8.10, in which it is
assumed that the liquid contained in the tank, whose level remains constant, receives heat through
the injection of steam.

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If the inlet pressure of this valve were fixed, the pressure drop across the valve would be constant,
regardless of the opening. However, in many applications this condition is not met. The case is
very common in which the pressure drop increases as the valve closes, as occurs when the valve is
connected to other resistors in series. Under these conditions, the curve that represents the
relationship between valve opening and flow undergoes deformation.

Assuming, for example, that in a certain case the pressure difference across the valve and other
resistances, necessary to produce the flow, remains constant at 80 psi, that 50% of said difference
constitutes the pressure drop across the valve. valve, if it remains completely open, and that under
these conditions the flow is 100 l/min. If the valve had an inherent linear characteristic, the line
shown in Figure 8.11 would give the linear relationship between opening and flow, as long as the
pressure drop across the valve remained constant, that is, equal to 40 psi. In this case, with 50%
opening 50 l/min would be obtained.

Figure 8.11. Installed feature.

However, by reducing the valve's opening, the flow would have to decrease and the pressure drop
across the pipe and other resistances would also decrease, making the pressure drop across the
valve more than 40 psi and 50 % opening, that is, greater than 50 l/min. In the graphic
representation, point B would be obtained, which would be to the right of A.

As the same would occur for other valve openings, the set of all the points obtained in this way,
that is, curve B, should give the relationship that would actually exist between the valve opening
and the flow. Said curve would represent the effective characteristic of the valve, in the specific
application considered.

Even if for all applications there would always be a valve that would have an effective linear
characteristic, this characteristic would not always be the most appropriate, since it would be
determined by the peculiarities of the process to be controlled and by the values that were desired
to be obtained for the controlled variable.

Differential Pressure with Manometer

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When the process required a narrow proportional band (10% or less), the valve characteristic
would have little importance, since whatever it was, a small change in the variable would
correspond to a relatively large change in the flow.

The type of characteristic would also not be important in those cases where, even if the
proportional band was wide, the load changes were very small and there was also no need to
modify the position of the set point; In this case the valve would always operate with the same
approximate opening, leaving it a little.

In the general case, that is, when the proportional band cannot be narrow and relatively
large load changes occur, there will be different possibilities, determined by the nature of
the process.

In some processes, good control could be obtained with a valve with a linear effective
characteristic, if a certain proportional bandwidth is used, regardless of the value of the load and
the set point; This would mean that a certain change in the variable would always cause the same
change in flow.

On the other hand, there are processes for which it would be advisable for the relationship between
the change in flow and the change in variable to decrease when the load (and therefore the flow)
was small. This could be obtained with a valve that had an effective characteristic of the type of
graph A (figure 8.8), without the need for the proportional band to increase in amplitude as the
load and flow decrease. In general, multiple capacitance processes are of this type.

Finally, there could be cases in which the demand did not suffer significant changes, but there
were frequent changes in the set point. Under such conditions it could happen that good control
was obtained with a constant relationship between flow change and variable change, or that said
relationship, as frequently happens, would have to decrease as the set point decreases. In the first
case it would be advisable to use an effective characteristic of type B, and in the second of type A
(figure 8.8).

As can be deduced from what has been said above, the inherent characteristic that is used in most
applications is the one that has the same percentage, if we take into account, as already seen, that
an inherent characteristic tends to give an effective characteristic in another way. and, furthermore,
that in many processes it is convenient to have an effective type B characteristic (figure 8.8).

8.2.5 Calculation of valve flow coefficient.

The valve is the element that operates the flow of the control agent; Therefore, it must be sized
based on the maximum flow that is intended to pass through the pipe.

There is a universal standard (established by the ISA) that defines the flow coefficient C v for
sizing a control valve; This is C v is the number of gallons per minute of water at 60°F passing
through the control valve with a pressure drop of 1 psi.

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So for example, if in a certain valve C v = 6 at 100% opening, this means that when fully open it
would allow 6 gpm of water to pass with a 1 psi drop through it, and 12 gpm with a 4 psi drop.

8.3 Development of the practice.

The practice will consist of the construction of the calibration curve of the differential pressure
manometer. The reading will be taken from a differential pressure gauge identified as PDI-1. The
steps to follow are:

a) Align the Multiloop Control Module flow circuit shown in Figure 8.3 as follows:

■ Open the bottom manual valve of tank T1 identified as HV-3.

■ Make sure valve HV-5 is open.

■ In the multiloop control cabinet, set the selector to PLC, so that the system
obeys the PLC command through the operation station (PC).

■ From the operation station using the Aurora HMI SCADA software, press the
“FLOW TO T1” button on “SELECTOR 1” of the operation screen as shown
in figure 8.4.

Differential Pressure with Manometer

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Figure 8.3. Flow Circuit.

Figure 8.4. Flow button to T1 pressed.

b) Open the flow modulating valve FV-1 to 100% by putting the FIRC-1 panel in
MANUAL mode and writing a value of 100 at the output, as shown in figure 8.5.

Write FV-1 opening

percentage

Figure 8.5. FIRC-1 panel, in MANUAL mode and with 100.00% output.
The FV-1 valve is opened manually to measure the differential pressure generated
when the valve is 100% open, said differential pressure measurement will be made by
the differential pressure manometer that is bypassed with the modulating valve FV-1
as illustrated in Figure 8.6.

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PDI-1 differential
pressure gauge

Differential Pressure with Manometer

National Polytechnic Institute

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Figure 8.6. PDI-1 differential pressure manometer represented on the screen.

c) Position the FV-1 valve at the different opening percentages as indicated in the following
table:

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Table 8.1 Differential pressure reading values obtained with respect to the opening
percentage of the FV-1 valve.

FV-1 valve opening Differential pressure

percentage in PDI-1
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%

8.4 Questionnaire.

1. How does a differential pressure sensor work?

2. What elements of the flow circuit must be aligned to perform water recirculation in tank
T1 and from where is said alignment carried out?
3. What happens to the differential pressure indicated by the PDI-1 manometer when the
valve is open at 100% and when it is open at 10%?
4. What happens when a flow restriction is made with the HV-5 valve?
5. Create a curve of differential pressure values with respect to the percentage of opening of
the FV-1 valve according to the data obtained from table 8.1.
6. Write the conclusions.

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Differential Pressure with Manometer

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National Polytechnic Institute

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 IMEPI SA de CV

"CONTROL MODULE
MULTI-LOOK OF PROCESSES
INDUSTRIAL”

Cascade Control

For the defects of others, the wise man corrects his own. Publilius Syrus.
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Content
National Polytechnic Institute....................................................................................................1
ESIQIE.......................................................................................................................................1
IMEPI SA de CV collaborators for him development of these practices..........................3
National Polytechnic Institute.........................................................................................4
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”......................4
Understanding the System...................................................................................................4
1.1 Goals.................................................................................................................8
1.1.1 Generals.........................................................................................................8
1.1.2 Specific..........................................................................................................8
1.2 Understanding the system...............................................................................10
1.2.1 Closed Control Loop or Closed Flow Control Circuit................................10
1.2.2 Closed Control Loop or Closed Level Control Circuit.....................................13
1.2.3 Closed Control Loop or Closed Pressure Control Circuit...........................15
1.2.4 Closed Control Loop or Closed Circuit Temperature Control....................17
1.4 Control of 3 process variables........................................................................27
1.4.1 Flow-Level-Pressure...................................................................................27
1.5 Questionnaire..................................................................................................28
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”....................38
National Polytechnic Institute.......................................................................................41
3.2 Theoretical framework:...................................................................................42
3.2.1 What is a transmitter?..................................................................................42
National Polytechnic Institute.......................................................................................43
National Polytechnic Institute.......................................................................................44
National Polytechnic Institute.......................................................................................46
National Polytechnic Institute.......................................................................................48
3.2.2 Digital electronic transmitters.....................................................................49
National Polytechnic Institute.......................................................................................50
National Polytechnic Institute.......................................................................................52
3.2.3 Differential pressure transmitter.................................................................53
National Polytechnic Institute.......................................................................................54
3.2.3.1 Yokogawa brand differential pressure transmitter......................................55
National Polytechnic Institute.......................................................................................56
3.2.3.2 Tube installation..........................................................................................57
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of the transmitter for closed tank.............................................57
National Polytechnic Institute.......................................................................................58
3.2.3.4 Wiring.........................................................................................................59
National Polytechnic Institute.......................................................................................60
3.3 Equipment used...............................................................................................61
3.4.1 Construction of the calibration curve for the LIT-2 level differential
pressure transmitter....................................................................................................61
National Polytechnic Institute.......................................................................................62
National Polytechnic Institute.......................................................................................64
3.4.2 HART communication protocol for smart transmitters..............................65
National Polytechnic Institute.......................................................................................66
National Polytechnic Institute.......................................................................................68
National Polytechnic Institute.......................................................................................70
3.16 3 PACTware software for configuring intelligent transmitters with HART
protocol......................................................................................................................71
National Polytechnic Institute.......................................................................................72
3.5 Material:..........................................................................................................73
3.6 Development...................................................................................................73
National Polytechnic Institute.......................................................................................74
National Polytechnic Institute.......................................................................................76
National Polytechnic Institute.......................................................................................78
National Polytechnic Institute.......................................................................................80
National Polytechnic Institute.......................................................................................82
National Polytechnic Institute.......................................................................................83
National Polytechnic Institute.......................................................................................85
National Polytechnic Institute.......................................................................................87
1 .7 Questionnaire..................................................................................................88
National Polytechnic Institute.......................................................................................89
National Polytechnic Institute.......................................................................................91
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”....................66
National Polytechnic Institute.......................................................................................69
4.1 Aim.................................................................................................................70
4.2 Theoretical framework....................................................................................70
4.2.1 Flow Indicator Controller FIC-1 Brand ABB. (receiver)............................70
National Polytechnic Institute.......................................................................................71
National Polytechnic Institute.......................................................................................73
National Polytechnic Institute.......................................................................................75
National Polytechnic Institute.......................................................................................77
National Polytechnic Institute.......................................................................................79
4.2.2 Key functions and entry to the ABB Flow controller display.....................80
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Institute.......................................................................................81
4.2.3 ABB Controller Configuration Menu Map.................................................82
4.3 Material Used.......................................................................................................82
National Polytechnic Institute.......................................................................................83
4.4 Development........................................................................................................84
4.4.1 Configuration of levels 5 and 6 of the ABB controller...............................84
National Polytechnic Institute.......................................................................................85
National Polytechnic Institute.......................................................................................87
National Polytechnic Institute.......................................................................................88
4.4.2 Identification of receiver errors (FIC-1 Flow Indicator Controller, ABB brand).
...................................................................................................................................89
National Polytechnic Institute.......................................................................................90
National Polytechnic Institute.......................................................................................92
National Polytechnic Institute.......................................................................................94
National Polytechnic Institute.......................................................................................96
4.5 questionnaire........................................................................................................97
National Polytechnic Institute.......................................................................................98
National Polytechnic Institute.....................................................................................100
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”....................84
Orifice Plate......................................................................................................................84
National Polytechnic Institute.......................................................................................87
5.2 Theoretical framework....................................................................................88
National Polytechnic Institute.......................................................................................89
National Polytechnic Institute.......................................................................................91
National Polytechnic Institute.......................................................................................93
National Polytechnic Institute.......................................................................................95
National Polytechnic Institute.......................................................................................97
National Polytechnic Institute.......................................................................................99
National Polytechnic Institute.....................................................................................101
National Polytechnic Institute.....................................................................................103
National Polytechnic Institute.....................................................................................105
National Polytechnic Institute.....................................................................................106
5.2.1 How an Orifice Plate Works.....................................................................107
National Polytechnic Institute.....................................................................................108
5.2.2 Installation of an intelligent differential pressure transmitter to measure
flow with an orifice plate.........................................................................................109
National Polytechnic Institute.....................................................................................110
5.3. Material and equipment used............................................................................111
National Polytechnic Institute.....................................................................................112
5.4 Development......................................................................................................113
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Institute.....................................................................................114
National Polytechnic Institute.....................................................................................116
National Polytechnic Institute.....................................................................................118
National Polytechnic Institute.....................................................................................120
National Polytechnic Institute.....................................................................................121
National Polytechnic Institute.....................................................................................123
National Polytechnic Institute.....................................................................................125
National Polytechnic Institute.....................................................................................127
National Polytechnic Institute.....................................................................................129
National Polytechnic Institute.....................................................................................131
National Polytechnic Institute.....................................................................................133
5.5 Calculations.......................................................................................................134
National Polytechnic Institute.....................................................................................135
5.6. Questionnaire................................................................................................136
National Polytechnic Institute.....................................................................................137
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..................112
National Polytechnic Institute.....................................................................................116
6.2 Theoretical framework..................................................................................117
National Polytechnic Institute.....................................................................................120
National Polytechnic Institute.....................................................................................124
National Polytechnic Institute.....................................................................................126
National Polytechnic Institute.....................................................................................128
6.3 Material used......................................................................................................129
National Polytechnic Institute.....................................................................................130
6.4. Development.................................................................................................131
National Polytechnic Institute.....................................................................................131
National Polytechnic Institute.....................................................................................133
6.4 Questionnaire.....................................................................................................134
National Polytechnic Institute.....................................................................................135
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..................124
Proportional Band...........................................................................................................124
National Polytechnic Institute.....................................................................................127
7.1 Aim...............................................................................................................128
7.2 Theoretical framework..................................................................................128
7.2.1 Proportional control..................................................................................128
National Polytechnic Institute.....................................................................................129
National Polytechnic Institute.....................................................................................131
National Polytechnic Institute.....................................................................................133
National Polytechnic Institute.....................................................................................135
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Institute.....................................................................................137
7.2.2 Summary of the characteristics of proportional control............................138
National Polytechnic Institute.....................................................................................139
7.2.3 Operation of a proportional band controller..............................................140
7.3 Used material................................................................................................140
National Polytechnic Institute.....................................................................................141
7.4. Development.....................................................................................................142
National Polytechnic Institute.....................................................................................143
7.4.1. Table and data to build the graph..............................................................144
National Polytechnic Institute.....................................................................................145
7.5 Questionnaire.....................................................................................................146
National Polytechnic Institute.....................................................................................147
National Polytechnic Institute.....................................................................................144
8.2.1 Types of final control elements.................................................................145
8.2.2 Pneumatic actuator....................................................................................145
National Polytechnic Institute.....................................................................................146
National Polytechnic Institute.....................................................................................148
National Polytechnic Institute.....................................................................................150
8.2.3 Valve body................................................................................................151
National Polytechnic Institute.....................................................................................152
National Polytechnic Institute.....................................................................................154
National Polytechnic Institute.....................................................................................156
National Polytechnic Institute.....................................................................................158
8.2.4 Characteristic of a valve............................................................................159
National Polytechnic Institute.....................................................................................159
National Polytechnic Institute.....................................................................................161
National Polytechnic Institute.....................................................................................163
8.2.5 Calculation of valve flow coefficient........................................................164
National Polytechnic Institute.....................................................................................165
National Polytechnic Institute.....................................................................................167
National Polytechnic Institute.....................................................................................169
National Polytechnic Institute.....................................................................................171
National Polytechnic Institute.....................................................................................173
National Polytechnic Institute.....................................................................................175
"CONTROL MODULE MULTI-LOOK OF PROCESSES INDUSTRIAL”..................154
Cascade Control..............................................................................................................154
9.1 Aim...............................................................................................................158
9.2 Theoretical framework..................................................................................158
9.2.1 Cascade control.........................................................................................158
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control of the Multiloop www.imepi.com.mx
Control Module...................................159
9.3 Used material................................................................................................160
9.4 Development......................................................................................................160
9.5 Questionnaire.....................................................................................................168
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9.1 Aim.

The student will understand and analyze the behavior of a cascade control, supported by two
conventional controllers.

9.2 Theoretical framework.

9.2.1 Cascade control.

Cascade control is an alternative structure to feedforward control to reject partially measurable

disturbances. The basic idea is to feed back intermediate variables between the point where the
disturbance enters and the exit.

This structure has two loops:

- A primary loop with a primary controller C1.

- A secondary loop with a secondary controller C2.

Secondary control is designed to attenuate the effect of the disturbance before it significantly
affects the output. Let's look at an example to motivate the idea.

Cascade control is mainly used for:

- Eliminate the effect of disturbances on the manipulated variable.

•Improve the dynamic characteristics of control loops in processes that are sequenced or
composed of sub-processes.
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9.2.2 Cascade control of the Multiloop Control Module.

Figure 9.1 shows the cascade control of the Multiloop Control Module, which is made up of a master
controller C1 identified as LIC-2 and a slave control C2 identified as FIC-1.

The LIC-1 controller receives the signal from the level transmitter LIT-2, the slave control FIC-1
receives the output signal from the master control and takes it as a remote set point, it also receives
the signal from the flow variable through the FIT-1 differential pressure transmitter. The slave
controller sends its output signal to the modulating control valve.

Figure 9.1. Cascade control of the multi-loop control module.

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9.3 Used material.

■ Diagram of figure 9.1.

■ ABB brand COMMANDER C250 controller configuration manual.

■ COMMANDER C250 Multi-Loop Control Module controllers identified as LIC-2 and

FIC-1.

9.4 Development.

To carry out this practice, the ABB COMMANDER C250 controllers are first wired and
configured so that they remain in a cascade arrangement, since they are originally independent
controllers, one is a FIC-1 flow controller and the other is an LIC-level controller. 2.

The cascade control arrangement must be made in such a way that the LIC-2 must be the master
controller and the FIC-1 is the slave controller.

1 .- Realization of cascade control with COMMANDER C250 controllers.

To carry out the cascade control, figure 9.1 is taken as a base, where it is observed that two
controllers (master and slave) are configured as cascade control, the output signal of the master
controller is sent as a set point to the slave controller so that it can control it. time send its output
signal to a flow modulating control valve. Figure 9.2 illustrates the cascade control arrangement
with two ABB COMMANDER C250 controllers.
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Figure 9.2. Cascade control with ABB brand COMMANDER C250 controllers.

FIC-1 (SLAVE)

2 .- Configuration to enable the remote Set Point of the COMMANDER C250 controller
identified in the cabinet as FIC-1 so that it operates in the cascade control as a slave.

L
c) The following display will EL.5
appear
L»F

d) Press the key

RbLd
an The display will 2400
d) appear
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a) The FIC-1 controller is energized.

b) The switch is changed to configuration mode (configure).

Switch in “configure” position

Configure

Figure 9.3. FIC-1 Controller Configuration Mode Switch Location.

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F Press again C.
) T.
EFOH
g) [rm] will appear
.

h) Press the key and the letter “F” on the display will light up, if the button is
pressed again.
key The letter “G” will light up and if you press the key will light up
letter “H” onagain
the display as shown in figure 9.4.

Figure 9.4. Access to configuration level “H ” for remote setpoint selection.

H

Y Being on the display 0

move the value from “0” to “1” with the such
o so that the display looks like this
keys

Note: Table 1 shows that the number “1” corresponds to a Remote Set Point
configuration. To see more details of this configuration, review page 35 of the
COMMANDER C250 controller manual.

Table 1. Set Point type configuration.

j) Place the switch in normal operating position. k)

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Figure 9.5. FIC-1 Controller Normal Mode Switch Location.

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3 .- Remote set point selection from the display.

To change the “Local Set Point” to “Remote Set Point” you must access level 3 of the
COMMANDER C250 controller display identified as FIC-1.

to Access to level 3: Press the key 41 for several seconds, with the keys [ALT
) LÉU.3
select the display \5EtP .

b) Press the key and you see that the display

appears
n5Pn
c) Press the CT key again to display display 155.8 .

d) With the EE keys

select the type of remote setpoint r 5P5

rSPS - remote set point rSP.n - local set point

an Return to the operating level (Level 1) by pressing the CT key 8 times until
d)
the GPPer display appears.

f) Press the CT key to leave the display in normal operation.

4 .- Wiring of cascade control with COMMANDER C250 controllers.

On the back of the FIC-1 and LIC-2 controllers, the terminal connections are numbered as shown
in figure 9.6. What you have to do is disconnect the cables from terminals 5 and 6 corresponding
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to the output. of the LV-2 valve and connect said terminals to the “Auxiliary Input” input,
terminals 25 and 26 of the FIC-2 controller, that is, the output signal of the LIC-2 controller will
be sent to the auxiliary input signal (control signal). remote set point) of the FIC-1 controller, as
shown in figure 9.7.
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LIC-2 Master FIC-1 Slave

Figure 9.6. Controller wiring for cascade control configuration.

Figure 9.7. Wiring the LIC-2 and FIC-1 controllers to operate in cascade.
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5 .- Tuning of the LIC-2 master and FIC-1 slave controllers.

To tune the controllers it is necessary to enter level 2 (Level 2), as the procedure to adjust the
tuning is the same for the two controllers FIC-1 and LIC-2, only one procedure will be explained,
which is the following:

a) With the display in normal operation, press the □ key several times until I LEin
. 8PEr .

_____ _____ LELe

b) With the ALT keys select the EüE display
HH5
c) Press key 41 and the hysteresis value display t in which you can change a
J!
will appear with the arrows Era .
Da
.x . . /020 , in which you can change the
Proportional band value with rare arrows.
Iakr
an Press key 41 and the integral value display will 20 , in which you can change the
d) appear with the arrows rare .

c56t
f) Press the P key and display 50 will appear, in which you can change the reset value with the
arrow keys.

Was
g) Press the 4- key and the display y i 10 will appear, in which you can change the
derivative value with arrows rare .

LELe I I EU. >

h) Press key 41 and the ELE display will appear and change to EKZ with the arrows A.

LEU. Yo
Y Being in SPEr 4 to return to normal operating mode.
o press the key

9.5 Questionnaire.

1. What is a waterfall control?

2. What is cascade control used for?

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Galileo Galilei 3865-1C Zapopan Jalisco
Mexico
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3. What elements of the Multiloop Control Module are required to perform a cascade
control?

4. Which modulating valve is left out of service when cascade control is enabled?

5. What has to be done to the ABB brand COMMANDER C250 controllers identified as
LIC-2 and FIC-1 so that they can work in cascade control?

6. Which controller is the master control and which controller is the slave control and
why?

7. What type of set point does the slave controller receive?

8. What advantages are observed when working with cascade control?

9. What is the behavior of waterfall control in the Aurora HMI SCADA software
graphics?

10. Change the tuning values from the controllers operation screen from Aurora HMI
SCADA and explain how it is done.
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IMEPI
IMEPI SA de CV
Galileo Galilei 3865-1C Zapopan Jalisco Mexico
Tels/Fax 3631-5011
[email protected] www.imepi.com.mx

Bibliography.

Instrumentation and control laboratory.

Rodolfo Díaz Murillo. National Polytechnic Institute.
Mexico DF. 2008.

Microprocessors and digital devices: Programmable Logic Controllers.

Industrial Training.
Corporation. Herndon, Virginia. USA 1993.

Instrumentation Basics: Tuning.

Industrial Training Corporation. Herndon.
Virginia. USES. 1992.

Flow Measurement. D.W. Spitzer.

Instrument Society of America.
USA, 1991.

Fundamentals of Industrial Control.

CL Albert, D.A. Coggan.
Instrument Society of America.
USA 1991.

Industrial instrumentation.
Antonio Creus Sole. Alfaomega, 7th edition. Mexico.
DF. 2006.

User Guide IM/C250_5.

Commander C250 User Manual BRAND ABB, 2005.

“IM 1C21B1-01E”, Yokogawa brand differential pressure transmitter User

Manual.

17
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 MEXICAN ENGINEERING SPECIALIZED IN

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Galileo Galilei 3865-1C Zapopan Jalisco
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Tels/Fax 3631-5011
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Important Recommendations:

- Do not modify parameters in the PLC ladder program

- Do not get involved in the configuration of the controllers (Dip
Switch) by activating them (G2 cabinet interior)
- Do not open G2 cabinet when it is energized.

17