4c - Flow Control Loop (Paddlewheel)
4c - Flow Control Loop (Paddlewheel)
SENSOR
Procedure Overview
In this procedure, you will control the rate of flow measured by a
paddlewheel sensor using a PID controller.
1. Perform a lockout/tagout.
2. Perform the following substeps to set up the T5552, as shown in figure 5-1.
NOTE
The appearance of the electrical outlet will differ based on the electrical
power supplied at your location.
ELECTRICAL
PID CONTROLLER FLOW TRANSMITTER
FT1
4-20mA
FLOW SENSORS
FT2
4-20mA TEST
FLOWPVALVE
FV1
4-20mA
PL1 PL2 PL3 PL4
ALM1
ALM2
PROCESS METER
UDI1700
MAX
MIN
OUTLET
SS1 SS2 SS3 SS4 ALM3
ALM4
ALM5
ALM 1234 MAN F
LEVEL SENSORS
0
DI 1234 SET SETUP
PV LT1 LT2
OUT 1234
-sp 0.0
OUTPUT RELAY 1
SP CURRENT INPUT
mA NO COM NC
ENTER
CR2
4-20mA
DISCRETE
AUX. POWER 9 10 11 12 13 14 15 16
DI 1 ALARM
AL1 CR3
DISCRETE
DC POWER SUPPLY PLC ANALOG I/O
DI 2 4-20mA
24 VDC 24 VDC 24VDC 24VDC 24VDC
AL2 OPEN COLLECTOR
SOLENOID VALVES
1 2 3 4 5 6 7 8
SV1 SV2 SV3
GND
9 10 11 12 13 14 15 16
HV 100D
HV 100A
(HV2) AIR SUPPLY
CONNECTION
MANUAL DRAIN
VALVES
(HV 300 (HV3) &
HV 100C (HV4)) PRESSURE
OPEN REGULATOR
SET TO 20 psi
PADDLEWHEEL HV 100B
FLOW SENSOR (HV1) MANUAL FLOW
HAND VALVES CONTROL VALVE
OPEN (FV 100 (HFV))
CLOSED
PID CONTROLLER FLOW TRANSMITTER FLOW SENSORS FLOW VALVE DISCRETE I/O
FT1 FT2 FV1 PL1 PL2 PL3 PL4
-sp 0.0 SP
Setup Run
Hold
ENTER
CR2
4-20mA
DISCRETE
DI1 ALARM AUX. POWER
AL1 CR3
DISCRETE
DC POWER SUPPLY
DI2
24VDC 24VDC 24VDC
AL2 24 VDC
OPEN COLLECTOR
SOLENOID VALVES
SV1 SV2 SV3
GND
DC POWER
SUPPLY
CIRC. PUMP
SS1 P1
+
- ANALOG OUTPUT
FLOW TRANSMITTER CONTROLLER I/P
OUTPUT OUTPUT CONVERTER
AI1 AO1
+ - + - + FV1 -
+
+ -
FLOW TRANSMITTER CONTROLLER
AUX. POWER INPUT
-
+ -
I/P IY PI PC
CONVERTER 100 100D 100
FLOW FIT
100
T5552 P&ID
FCV
AIR
FE 100
100
LET LSH LSH
200-B 200-A 200-B
DUAL-COMPARTMENT
PROCESS TANK
PROPORTIONAL
PADDLEWHEEL
VALVE
FLOW SENSOR
OVERFLOW
wiring are highlighted.
LET
S S 200-A
HV SV HV SV
300 100-B 100-C 100-C
FI INTERFACE
100 TO
T5553,
T5554,
OR
T5555
HV SV
100-A 100-A HV
100D
S
PI FV PI
HV 100-A 100 100-B
400
WATER
PUMP
DRAIN
HV
100-B
RESERVOIR
TANK
S05-4
Figure 5-4 shows the P&ID for the T5552. The active components and
SKILL 5 OPERATE A FLOW CONTROL LOOP USING A PADDLEWHEEL SENSOR
6. Place the GF Signet 9900 transmitter in the Menu mode and set the parameters
as indicated in the table in figure 5-5.
CALIBRATION (CAL) PARAMETERS
PARAMETER SETTING
HOLD OUTPUTS NO
KF 3160.000
TF 1.0000
RATE CAL NA
VOLUME CAL NA
LAST CAL Today’s Date and Initials (MM-DD-YYYY
II)
INPUT PARAMETERS
PARAMETER SETTING
NAME FLOW
SENSOR FREQ
FLOW UNITS GPM
TOT Unit GALLONS
AVERAGE OFF
SENSITIVITY 100.00 GPM
LOOP PARAMETERS
PARAMETER SETTING
4 mA SETPNT 0.0000
20 mA SETPNT 1.5000
ERROR VALUE 22 mA
ADJUST 4 mA 4.00 mA
ADJUST 20 mA 20.00 mA
TEST LOOP NA
RELAY PARAMETERS
PARAMETER SETTING
R1 NORMAL OPEN
R1 MODE HIGH
R1 SET HIGH 1.5000
R1 HYSTERESIS 0.0
R1 ON DELAY 0.0
R1 TEST RELAY NA
R2 MODE OFF
R2 TEST RELAY NA
R3 MODE OFF
OPTION PARAMETERS
PARAMETER SETTING
CONTRAST 3
BACKLIGHT AUTO
SET BAR MIN 0.0000 GPM
SET BAR MAX 1.5000 GPM
FLOW DECIMAL _ _ _._ _
TOTAL DECIMAL _ _ _._ _
TOTAL LOCK OFF
PASSWORD TYPE STD
MEMO GFSIGNET_COM
REMOTE SETUP NO
8. Place the Honeywell UDC 3500 controller in manual mode using the Man/
Auto key and program it according to the parameters listed in the table in
figure 5-6. Recall that the Setup key is used to scroll through the parameter
groups and the Func Loop 1/2 key is used to select a parameter group. The up
and down keys () are used to change parameter values.
GROUP PROMPT FUNCTION PROMPT VALUE OR SELECTION
ALGORTHM CONT ALG PID A
TUNING GAIN 2.5
RATE MIN 0
RSET MIN 0.5
OUT ALG OUT ALG CURRENT
INPUT 1 IN1 TYPE 1-5 V*
XMITTER1 LINEAR
IN1 HIGH 1.5
IN1 LOW 0
BIAS IN1 0
CONTROL PV SOURCE INPUT 1
PID SETS 1 ONLY
SP HiLIM 1.5
SP LoLIM 0
ACTION DIRECT
OUT RATE ENABLE
PCT/M UP 75
PCT/M DN 75
PBorGAIN GAIN
MINorRPM MIN
OPTIONS DIG INP1 NONE
DIG INP2 NONE
COM ComSTATE DISABLE
ALARMS A1S1TYPE NONE
A1S2TYPE NONE
A2S1TYPE NONE
A2S2TYPE NONE
DISPLAY DECIMAL TWO
PWR FREQ 60 HZ
LANGUAGE ENGLISH
*The flow transmitter provides a 4-20 mA output signal. However, the input termi-
nals of the loop controller have a 250-ohm resistor installed across them, chang-
ing the 4-20 mA signal to a 1-5 V signal.
NOTE
The RATE MIN (derivative) function is set to zero (0) because you are
using PI control.
J. Record the value at which the PV reaches a steady state, the controller
output at steady state, and the error (deviation value) at steady state.
Consider the controller in steady state if the process variable remains
constant for at least 2 minutes.
Steady State PV Value ___________________________________ (gpm)
12. Perform the following substeps to cause a disturbance and observe the
response of the system.
A. Place the controller in manual mode using the Man/Auto key.
B. Use the down arrow key to change the controller output (OUT) to 0.0.
C. Adjust the manual flow control valve, FV 100 (HFV), until the displays
on both the PID controller and the flow transmitter read 1.0 gpm. This sets
the maximum flow rate to 1.0 gpm.
D. Place the controller in the automatic mode using the Man/Auto key.
E. Press the Lower Display key to display the controller output (OUT).
F. Record the value at which the PV reaches a steady state, the controller
output at steady state, and the error (deviation value) at steady state.
Consider the controller in steady state if the process variable remains
constant for at least 2 minutes.
Steady State PV Value ___________________________________ (gpm)
13. Perform the following substeps to observe the system response to changing
the SP to a higher value.
A. Leave the controller in the manual mode and change the setpoint to 1.2 gpm.
Placing the controller in manual mode and changing the setpoint provides
a more accurate step change than leaving the controller in automatic mode.
B. Place the controller in automatic mode using the Man/Auto key.
C. Press the Lower Display key to display the controller output (OUT).
D. Record the value at which the PV reaches a steady state, the controller
output at steady state, and the error (deviation value) at steady state.
Steady State PV Value ___________________________________ (gpm)
15. Perform the following substeps to control the flow using only proportional
control.
This allows you to see the effects of no integral control on the system’s
performance.
A. Turn off SS1 to stop the circulation pump.
B. After the controller output goes to 0.0, place the controller in manual
mode using the Man/Auto key.
C. Enter the SETUP menu.
D. Scroll to the ALGORITHM function group and adjust the CONT ALG
parameter setting to PD+MR.
E. Scroll to the TUNING function group and adjust the MAN RSET
parameter to 0.
F. Exit the SETUP menu.
G. Adjust the controller’s setpoint to 0.8 gpm.
H. Turn on selector switch SS1 to start the circulation pump.
I. Place the controller in automatic mode using the Man/Auto key.
J. Press the Lower Display key to display the controller output (OUT).
K. Record the value at which the PV reaches a steady state, the controller
output (OUT) at steady state, and the offset (deviation value) at steady
state. Consider the controller in steady state if the process variable remains
constant for at least 2 minutes.
Steady State PV Value ___________________________________ (gpm)
E. Record the value at which the PV reaches a steady state, the controller
output at steady state, and the offset (deviation value) at steady state.
Steady State PV Value ___________________________________ (gpm)
M. Press the Lower Display key to display the controller output (OUT).
N. Record the value at which the PV reaches a steady state, the controller
output at steady state, and the offset (deviation value) at steady state.
Steady State PV Value ___________________________________ (gpm)
Controller Output (OUT) ___________________________________(%)
Offset (DEV) __________________________________________ (gpm)
The steady state PV value should be approximately 0.89 ± 0.04 gpm. This
value may be slightly less than the steady state value observed in step 17E.
The steady state controller output (OUT) value should be approximately
17-21%. This value may be slightly more than the steady state value
observed in step 17E.
As you can see, increasing the proportional gain this much worsens the
transient response and does not significantly reduce the offset.
O. Turn off SS1 to stop the circulation pump.
P. After the controller output goes to 0.0, place the controller in manual
mode using the Man/Auto key.
Q. Enter the SETUP menu and select the TUNING option.
R. Use the Func Loop 1/2 key to select the GAIN option and then adjust the
GAIN setting to 15.0.
S. Exit the SETUP menu.
T. Turn on selector switch SS1 to start the circulation pump.
U. Place the controller in automatic mode using the Man/Auto key.
V. Press the Lower Display key to display the controller output (OUT).
W. Observe the behavior of the PV, controller output, and offset (deviation)
for at least 2 minutes, and record your observations.
PV _______________________________________________________
Controller Output (OUT) ______________________________________
Offset (DEV) _______________________________________________
You should find that the PV continuously oscillates between 0.80 gpm and
0.84 gpm and the controller output oscillates ±4% or more about a value
that is close to the steady state output observed in step 17E. Note that the
midpoint of the PV oscillation is closer to the SP than the earlier steady
state results in this step, but even with this much larger gain the midpoint
of the oscillation is still above the SP value. The continuous oscillation in
the controller output would significantly reduce the life of the valve. The
continuous oscillation in the PV would be unacceptable from a process
control standpoint.