353X Series

Instrumentation and Process Control

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