topic: pid control module

9/18/2013 Copyright © 2013 Honeywell International Inc. 1

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Honeywell Confidential and Proprietary

Topic: PID Control Module

Contents

Instructions for PID Control Module.......................................................................................................3

Configure a PID Control Module............................................................................................................5

2 Copyright © 2013 Honeywell International Inc. 9/18/2013



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PID Control Module

Instructions for PID Control Module





Introduction

This portion of the document contains important information required to perform to ‘PID Control Module’ lab.

Procedure

Step Action

1

Read the following IMPORTANT information carefully.

Decide if you will be performing labs for C200E (and Series A I/O modules) OR C300 (and Series C I/O Modules). You can opt for either one but not both.

_______ C200E (and Series A I/O modules)

_______ C300 (and Series C I/O Modules)

2

ATTENTION

You must perform the remaining steps of this lab if you skipped any of the prior lessons of this course, else skip the remaining instructions and proceed to the next lab.

Locate the “GUI_DB_Load” Shortcut on desktop.

1. Double click “GUI_DB_Load” Shortcut to launch the import utility.

2. In Controller drop down select either C200 or C300 Controller (as per the option selected in step#1).

3. In Lesson number drop down select Lesson14.

4. Click the LOAD button.

PID Control Module





Step Action

3

ATTENTION

If you are facing any of the following situation while loading the data base:

1. Import wrong Lesson Database

2. Error prompt appears while loading data base.

Then students should wait for at least one minute before reloading the database.

4 Open Control Builder. Select ONLY the Controller and load it. Activate the CEE using

Warmstart option.

5 Now select and load all IO and Control Modules with the “Automatically change All Control ….. …. ” option selected.

6 Ensure that the Controller, IO, and Control Modules are indicated in green color.

7 Open the Excel spreadsheet if not already open. Open either from:

C:\Users\Student\Documents\Tie_back_NEW.xls

OR by double clicking the shortcut on your desktop.

Proceed to next Lab.

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

PID Control Module





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.

PID Control Module





Create a Control Module (CM)

Step Action

1 Open Control Builder through Configuration Studio.

Open one or two Project/Monitor tree windows as desired.

2 Select File > New > Control Module.

3 Double-click the blank chart background.

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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.

PID Control Module





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.

PID Control Module





Step Action

6 Configure the Parameters for 11_FC01.

• If the Main property page is not open, right click 11_FC01.

• Select Module Properties.

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Step Action

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.

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.

PID Control Module





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

PID Control Module





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

PID Control Module





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 R410 > Configuration > Control Building User’s Guide > Creating a Control Module > Creating and saving a control module > Creating an Instance of a Basic Function Block

PID Control Module





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

PID Control Module





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 (or Document available on Desktop) 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 (or Document available on Desktop) 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.

PID Control Module





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.

PID Control Module





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.

PID Control Module





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.

PID Control Module





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.

PID Control Module





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.

g

PID Control Module





Step Action

17 Click the Alarms tab of PID and enter the following:

Type: OP High

Trip Point: 95

Priority: LOW

PID Control Module





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.

PID Control Module





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

PID Control Module





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 (or Document available on Desktop) 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 (or Document available on Desktop) 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.

PID Control Module





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.

PID Control Module





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.

PID Control Module





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.

PID Control Module





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.

PID Control Module





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.

PID Control Module





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.

PID Control Module





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.

PID Control Module





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

PID Control Module





Step Action

CEE/ CEESCE Symbols

1 2 3 4 5 6

1 Grey - As seen in project tree



4 Blue - Inactive

5 Green - Active

6 Red - Configuration Error

CM Symbols

1 2 3 4 5

1 Grey - As seen in project tree



4 Blue - Inactive

5 Green – Active

PID Control Module





Step Action

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.

PID Control Module





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.

PID Control Module





Step Action

17 To see the CM in the Group display:

• Click button on Station.

• Type 11 and press the Enter key.

PID Control Module





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.

PID Control Module





Step Action

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\C200E(or C300)\L14_PID Control Module

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\C200E\L14_PID Control Module

If you are Using SIMC300/C300, the path for Database is:

C:\ Users\Public\Public Documents\ Honeywell\Experion PKS\Ixport\C300\L14_PID Control Module

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

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

PID Control Module





Step Action

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.)