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4/13/2012 Copyright © 2012 Honeywell International Inc. 1 HPS Automation College written permission required to distribute

Honeywell Confidential and Proprietary

Topic: PID Control Module

Contents

Configure a PID Control Module ............................................................................................................ 3

Calculate Performance Statistics of the Configuration Performed (C200 & C300) ............................. 37

2 Copyright © 2012 Honeywell International Inc. 4/13/2012 HPS Automation College written permission required to distribute


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PID Control Module Configure a PID Control Module



Configure a PID Control Module Practice

Objective

• Configure a Control Module

• Use the naming conventions for the Control Module and function blocks within the control module.

• Configure a Control Module with a single PID loop

Prerequisites

• Experion PKS Server or Client machine loaded with Experion PKS Engineering Tools

• Debutanizer_123 graphic loaded on the Server (This will be required at a later time to check the control strategy.)

• Control Builder running with the Project and Monitoring tree windows open

• SIM-C200E/C200E, or SIM-C300/C300 Controller and IOMs configured

• Excel Data Exchange open and loaded with the simulation spread sheet




Introduction

The Heavy Feed Flow FC01 is built in this lab. This PID loop requires bumpless Auto – Manual transfer with alarms, groups, and historization enabled.

The PID loop will be built, loaded and activated. The remaining Control Modules, of a similar type, are imported into the project.

To create a control strategy, a Control Module 11_FC01 must be built and function blocks inserted and connected. Once the Control Modules are built or imported, you can test them with the simulation.

In this lab, you will build a control module for a simple PID loop 11_FC01 for the heavy feed to the debutanizer tower T-100.




Create a Control Module (CM)

Step Action

1 Open Control Builder through Configuration Studio. • Open one or two Project/Monitor tree windows as desired.

Project Tree

window

Library Tree

window

Monitoring Tree

window




Step Action

2 Select File > New > Control Module.

3 Double-click the blank chart background.




Step Action

4 On the Main properties tab enter the following: • Name: 11_FC01 • Item Name: 11_FC01_item • Parent Asset: Analyser_C11 • Description: Heavy Feed To Debutanizer (Maximum 120 characters) • Click the OK Button • Save and close 11_FC01

ATTENTION

Control Builder numbers all new CMs sequentially. You can use any 16-character unique name for the CM in Project.




Step Action

5 For this Lab, use the specified CM names, because this allows you to test the CMs with the pre-configured Excel spreadsheet, used for simulation.

• CM 11_FC01 is added to the Unassigned node in Project window

ATTENTION

Your Project window may differ. Verify that 11_FC01 is in the Unassigned node.




Step Action

6 Configure the Parameters for 11_FC01. • If the Main property page is not open, right click 11_FC01 • Select Module Properties

7 Enter the following parameter details in the Main tab.

• Engr Units: m3/hr (Maximum 16 characters allowed)

• Accept the defaults for any remaining parameters on the Main tab

ATTENTION

The name of every CM must be unique server wide.




Step Action

8 Click the Server Displays tab. Enter the following Display details:

Point Detail Display: sysDtlPIDA Click the OK button.

ATTENTION

The Group detail display for 11_FC01 in Station will be directly picked from the type of Point detail display specified.

You can directly add a CM, to a Trend and Group by entering trend/group numbers and the pen/position in Trends and Groups windows, here or after building the control strategy in the CM.




Step Action

9 Assign the CM to the controller CEESCEFB61 (For SIM C200E) or SIM_CEEC300 (For SIM C300)

• With the CM 11_FC01 selected, click the (Assign) button on the toolbar, to open the Execution Environment Assignment dialog.

• Select 11_FC01 in the CMs/SCMs tab in Available Modules list box • Select CEESCEFB61 or SIM_CEEC300 in the Assign To list box • Click the Assign button • 11_FC01 is added to Assigned Modules list box • Click the Close button

• 11_FC01 is now assigned to CEESCEFB61 or SIM_CEEC300, as indicated below

For SIM-C200E For SIM C300




Add Function Blocks to a CM

After creating a CM, you must design the control strategy by adding relevant Input/Output blocks and control blocks such as PIDs, device control or logic blocks.

The IOMs configured in the Configure C200E Hardware and Series A IOM/Configure C300 Hardware and Series C IOM lab are used here.

Step Action

1 Double-click 11_FC01 in the Project window to open the chart view, and then maximize the view.

2 Add Function Blocks to the CM • From the Library tab, expand the IOCHANNEL (For Series A I/O) or

Series_C_IO AI-HL (For Series C I/O) • Select AICHANNEL

For Series A I/O

For Series C I/O




Step Action

3 Drag AICHANNEL into the 11_FC01 Project chart view.

4 Drag the following Function Blocks from their respective block Libraries and add to the CM. Block Family Block

DATAACQ DATAACQ REGCTL PID IOCHANNEL (For Series A I/O) or SERIES_C_IO AO (For Series C I/O) AOCHANNEL

ATTENTION

Add the blocks in the order specified above. For more information on adding function blocks to a CM, refer to the Knowledge Builder along the path Experion R400 > Configuration > Control Building User’s Guide > Creating a Control Module > Creating an Instance of a Basic Function Block




Step Action

5 After adding all the blocks, arrange them as shown below.

For SIM-C200E

For SIM-C300

6 Configure AIChannel parameters: • Double-click the AICHANNEL block to open the AI parameter configuration

form. • Enter the Channel Name as FI.

For Series A I/O

For Series C I/O

TIP (Only for Series C IO Channels)

Channel PV Range parameters can be configured in Series C AI Channel block

Therefore, PV ranges for Analog Inputs must be configured for both the Series C AI Channel block and the DACA block

7 For C300s ONLY: Change the ranges of the FI block as follows: PV Extended High Range 600.9 PV High Range 600 PV Low Range 0 PV Extended Low Range -6.9




Step Action

8 Assign the AI Channel to an AI Module. For C200E:

Step Action

1 Refer to Appendix 1 – C200E I/O list assignments at the end of Appendix for the following information on 11_FC01.FI: Module Name: Channel Number:

2 In the properties of the AI channel (FI block), use the pull-down list to select the module name.

3 Select the channel number.

4 Click the ‘Assign Channel Block’ button.

5 Click the OK button to close FI properties.

For C300:

Step Action

1 Refer to Appendix 1 – C300 I/O list assignments at the end of Appendix for the following information on 11_FC01.FI: Module Name: Channel Number:

2 Click the OK button to close FI properties.

3 Right-click the AI channel (FI block) and select Function Block Assign.

4 In the ‘Function Block Assignment Dialog’, select the appropriate channel (use the Module Name (IOM Name), and the Channel Number from above), and click the Assign button.




Step Action

9 Configure a Data Acquisition Block. Double-click the Data Acquisition Block, to open the configuration form, and enter the following:

Name: DACA Description: Heavy Feed to Debutanizer Engr Units: m3/hr PVEU Range Hi: 600 PVEU Range Lo: 0 PV Extended Hi Limit: 600.9 PV Extended Lo Limit: -6.9 Clamping Option: ENABLE

Accept the defaults for any remaining parameters on this tab.

ATTENTION

You must name this block DACA so that the Honeywell supplied Analog Point Details display functions properly when called from Station




Step Action

10 Select the Show Parameter Names checkbox located at the lower left corner. Note that the parameter names now appear in place of the parameter descriptions.

ATTENTION

This displays the parameter names instead of parameter descriptions.

11 Uncheck the Show Parameter Names checkbox.




Step Action

12 To Configure Alarms, select the Alarms tab. Enter the following: PV High: 500 Priority: HIGH PV Low: 0 Priority: Low Accept the defaults for all remaining parameters.

13 Click OK.




Step Action

14 To Configure a PID Block: Double click PIDA. Enter the following:

Name: PIDA Description: Heavy Feed to Debutanizer Engineering Units: m3/hr

PVEU Range Hi: 600 PVEU Range Low: 0 Select the Enable Secondary Initialization Option checkbox.

Normal Mode: AUTO Normal Mode Attribute: OPERATOR Accept the defaults for all remaining parameters on this tab.

ATTENTION

This block must be named PIDA for the Honeywell supplied standard PID Point Detail Display to function properly.




Step Action

15 Click the Algorithm tab in the PID configuration form and enter the following Control Equation type: EQB Integral Time (T1): 0.2 Linear Gain Options: LIN Overall Gain: 0.40

ATTENTION

The Algorithm form allows you to configure PID control equation types, associated PID equation parameters and gain options for the PID block.

16 Click the SetPoint Tab and enter the following: High Limit: 600 Low Limit: 0 Ensure Enable PV Tracking is selected.




Step Action

17 Click the Alarms tab of PID and enter the following: Type: OP High Trip Point: 95 Priority: LOW




Step Action

18 To add or remove Block Pins in a Functional Block : Click on the Block Pins tab. In the ‘Selected Parameters’ portion of the window, for the PV parameter, change the location to ‘Left’ by: Click on the “TOP” value on the PV parameter Location column. Select LEFT from the drop down combo box.




Step Action

19 As a result of the previous change in pin location, the PV pin shifted to the left side of the PID block faceplate, as indicated below.

Click OK.

20 Configure the AO Block. Double-click the AOChannelA Block and enter the following:

Channel Name: FV




Step Action

21 Assign the AO block to an AO channel. For C200E:

Step Action

1 Refer to Appendix 1 – C200E I/O list assignments at the end of Appendix for the following information on 11_FC01.FV: Module Name: Channel Number:

2 In the properties of the AO channel (FV block), use the pull-down list to select the module name.

3 Select the channel number.

4 Click the ‘Assign Channel Block’ button.

5 Click the OK button to close FV properties.

For C300:

Step Action

1 Refer to Appendix 1 – C300 I/O list assignments at the end of Appendix for the following information on 11_FC01.FV: Module Name: Channel Number:

2 Click the OK button to close FV properties.

3 Right-click the AO channel (FV block) and select Function Block Assign.

4 In the ‘Function Block Assignment Dialog’, select the appropriate channel (use the Module Name (IOM Name), and the Channel Number from above), and click the Assign button.




Connect Function Blocks

After adding the Function Blocks, wire them together to form a Control Strategy. You can wire Blocks together anytime you choose, before or after configuring block parameters.

Step Action

1 From the Main Menu, Select Chart > Insert > Wire, OR Click the button in the toolbar. • The cursor changes to a PLUS (+) sign inside the Project chart window • Click the PV pin displayed in the AICHANNEL (FI) block and then click the P1 pin

in the DATAACQ (DACA) block • These function blocks are now connected




Step Action

2 Repeat the above steps to connect PV pin of DATAACQ (DACA) to the PV of PIDA.

3 Connect the PIDA OP pin to the OP pin of AO. • Your CM should be similar to the one shown below.

4 Select File > Save.




Step Action

5 Configure History Collection, Trends and Groups. Double-click in the white space of the chart view of 11_FC01 to open its configuration form. Select the Server History tab.

In the History Configuration section, in the Parameter column, row 1, click the (Point Selection) button to open the Point Selection form. Select the row having Point name 11_FC01 and Block Name PIDA, as shown in the screen capture. Select OP for the Parameter. Click OK to close the Point selection form.

6 11_FC01.PIDA.OP appears in the History Configuration table. • Click to select the FAST (Fast History) and STD (Standard History) options • 11_FC01.PIDA.OP will now be historized




Step Action

7 Repeat the above steps to configure History Collection for 11_FC01.PIDA.PV in row 2 of the Parameter column.

8 Add Point Parameters to Trends. Click the Server Displays tab in the configuration form. In the Trends section, in row 1, specify Trend # 1 as the Trend number. In row 1, Pen column, click to select 1 from the drop-down menu. In row 1, Enter 11_FC01.PIDA.PV as the Trend Parameter. • You can also select the parameter with the help of Point selection list, as shown in

an earlier step. In the Groups section, row 1, specify Group # 11, Position # 1 and Group Parameter 11_FC01.PIDA.PV. Click OK.




Step Action

9 Click File > Save.

10 Close the 11_FC01 Project chart window. • This CM is located under CEESCEFB61 or SIM_CEEC300, which means it is

assigned to that execution environment

• The symbol “ “indicates that the CM has not yet been downloaded to the controller

• The color gray of the connection icon indicates the CM is in Project mode.

ATTENTION

The screen capture might look different if you are using SIM-C300




Step Action

11 Download this CM. • Select 11_FC01

• Click the on the toolbar • Click Continue on the Load window showing the warning • Select the Automatically change… checkbox.

This ensures that the post load state is automatically set as ACTIVE

12 Click OK. • A Load dialog box appears and closes on a successful download

• In Project, notice that there is no “ “ symbol in front of 11_FC01




Step Action

13 Click the Monitoring tab to verify that 11_FC01 is active (green).

• If the CM is active (green) skip the next step • If the CM is inactive (blue) perform the next step

ATTENTION

The screen capture might look different if you are using SIM-C300




Step Action

14 Activate the CM (right-click 11_FC01 and select “Activate”) or select 11_FC01 and click

the (Toggle State) button from the toolbar, to open the following.

Click Yes. • Notice that the 11_FC01 changes to green indicating it is now active

Monitoring tree status information is indicated by different symbols and colors, as shown below: CPM/SCE Symbols

1 Grey - As seen in project tree. 1 Grey – Project tree 2 Grey - Loaded not monitored 3 Red - Communication failure 4 Yellow - Not used 5 Green - Active 6 Red - Failed 7 Yellow - Not Loaded 8 Blue – Loaded

1 2 3 4 5 6 7 8




Step Action

CEE/ CEESCE Symbols

1 2 3 4 5 6

1 Grey - As seen in project tree 2 Grey - Loaded not monitored 3 Red - Communication failure 4 Blue - Inactive 5 Green - Active

6 Red - Configuration Error

CM Symbols

1 2 3 4 5

1 Grey - As seen in project tree 2 Grey - Loaded not monitored 3 Red - Communication failure 4 Blue - Inactive 5 Green – Active

15 Open Station, access and refresh the Debutanizer_123 graphic. • Change the 11_FC01 controller to AUTO mode • Click the SP value and enter 400 in the 11_FC01 faceplate.

ATTENTION

Open the Tie_Back_New Excel spreadsheet to observe the values for PV and OP.

If the PV value for the point is not updating then restart the Tie_Back_New Excel spreadsheet. This spreadsheet is used for simulation purposes.




Step Action

16 To watch the trend in Station:

Click the button in Station. Enter 1 in command line. Change the trend interval, if necessary. Zoom the line trend to get a closer display.

17 To see the CM in the Group display:

• Click button on Station. • Type 11 and press the Enter key.




Step Action

18 From the Group Display, change the MD to MAN. Change the OP to 30. • The PV will change because the OP changed. The SP follows the PV because PV

tracking is enabled • This tests your CM 11_FC01

19 In Control Builder, import (with CEE assignment) 11_FC02, 11_FC28 and 11_PC15 from the following location: C:\ Users\Public\Public Documents\Honeywell\Experion PKS\ Ixport\Student_DB\Series_A (or _C).

ATTENTION

If needed, follow the steps in the Import/Export Lab for importing the above CMs.

If you are Using SIMC200E/C200E the path for Database is C:\ Users\Public\Public Documents\ Honeywell\Experion PKS\Ixport\Student_DB\Series_A

If you are Using SIMC300/C300, the path for Database is C:\ Users\Public\Public Documents\ Honeywell\Experion PKS\Ixport\Student_DB\Series_C

20 From Project, download (with activation) the CMs imported in the previous step.




Step Action

21 Verify that the three CMs are active (green) in the Monitoring tab.

22 Open Station and access the Debutanizer_123 graphic.

ATTENTION

Verify that the imported CMs have values. (If necessary, place the imported loops in AUTO mode and provide suitable SP values to see a PV response.)

PID Control Module Calculate Performance Statistics of the Configuration Performed (C200 & C300)



Calculate Performance Statistics of the Configuration Performed (C200 & C300) Practice

Objective

• To calculate the Processing Units and Memory units for given blocks for C200E, and C300.

Prerequisites

• Knowledge of Memory Units and Process Units in C200E, and C300.

Introduction

• This exercise will allow you to determine about Memory Units and Process Units used in C200E, and C300.

PID Control Module Calculate Performance Statistics of the Configuration Performed (C200 & C300)



Procedure

Control Module Calculation

Step Action

1 Calculate MU and PU for C200E, and C300.

2 If CM is build using 1AI, 1DACA, 1PID, and 1AO, 6 Logic FBs, total Memory Units consume is______?

3 If CM is build using 1AI, 1DACA FB, Total Memory Units Consume is ______?

4 Calculate Processing Units (PU) for a typical Regulatory control CM with Execution Period of .5 Sec _____?

5 Calculate Processing Units (PU) for a typical Analog Data Acquisition CM with Execution Period of .5 Sec _____?

6 Calculate Processing Units (PU) for 20 Analog Data Acquisition CM with Execution Period of .1 Sec _____?

7 Calculate Processing Units (PU) for 40 Regulatory control CM with Execution Period of .5 Sec _____?

8 Where do you verify the Memory Units (MU) consumption in C300? _______

9 Calculate Processing Units (PU) for a typical Device control CM with Execution Period of .1 Sec _____?

10 Calculate Processing Units (PU) for 50 Device control CM with Execution Period of .1 Sec _____?

11 Calculate Processing Units (PU) for 4 SCM with Execution Period of .1 Sec _____?

12 Calculate Memory Units (MU) for 40 Regulatory control CM _____?

13 Calculate Memory Units (MU) for 5 Auxiliary Function CM _____?

14 Calculate Memory Units (MU) for 10 Analog Data Acquisition CM _____?

15 Calculate Memory Units (MU) for 100 Device control CM _____?

16 Calculate Memory Units (MU) for 10 Logic control CM _____?