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workshop - Control Station Software For Process Control...

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Hands-on Workshop Series Using Control Station Copyright 2000 by Douglas J. Cooper All Rights Reserved Hands-on Workshop Series using Control Station version 2.5 Doug Cooper Control Station Software For Process Control Training, Tuning & Analysis
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Hands-on Workshop Series Using Control Station Copyright 2000 by Douglas J. Cooper All Rights Reserved 1 Table Of Contents Page Workshop 1: Exploring Dynamics of the Gravity Drained Tanks 1 Workshop 2: P-Only Control of Tank Level 4 Workshop 3: The Hazard of Tuning PI Controllers by Trial and Error 7 Workshop 4: PI Control of Heat Exchanger Temperature 9 Workshop 5: PID Control of Heat Exchanger Temperature 13 Workshop 6: Modeling Process Dynamics For Linear Simulation 15 Workshop 7: Cascade Control of the Jacketed Reactor 19 Workshop 8: Feed Forward Control of the Jacketed Reactor 22 Workshop 9: Advanced Feed Forward Control of the Heat Exchanger 25 Workshop 10: Multivariable Decouplers and Distillation Control 28 Workshop 11: Dead Time Compensation Using the Smith Predictor 34
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Hands-on Workshop Series Using Control Station Copyright 2000 by Douglas J. Cooper All Rights Reserved 2 Workshop 1: Exploring Dynamics of the Gravity Drained Tanks Objective: To generate open loop step test data and learn how to describe the observed dynamic process behavior with a first order plus dead time (FOPDT) model. Also, to learn about the nonlinear nature of processes. Reference: °Practical Process Control± Chapters 1-3 1) We always begin a controller design by analyzing the dynamic behavior of the process, or how the measured process variable responds to changes in the controller output signal. Here we analyze the dynamic behavior of the gravity drained tanks process. Click the Case Studies button on the main Control Station screen. From the pop-up list of processes, click "Gravity Drained Tanks" to start the simulation. Study the graphic and observe how a change in the controller output signal will cause the valve position to change, which changes the flow rate of liquid into the top tank, which ultimately changes the level in the lower tank. Liquid level in the lower tank is our measured process variable. 2) The formal approach for analyzing the behavior of a process is to fit a dynamic model to process data. Good data starts with the process at steady state. The controller output signal is then moved far enough and fast enough so that it forces a clear response in the measured process variable. For a step test, the controller output signal is stepped from one value to another and the response of the measured process variable signal is recorded from initial steady state to final steady state. At the upper right of the draining tanks graphic on your screen, locate the white number box below the Controller Output label. The number displayed should be 70, corresponding to a 70% output signal from the controller.
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