HNG DN CHUNG CHO TH NGHIM IU KHIN QU TRNH Ni dung chnh ca vic th nghim iu khin qu trnh l tm hiu nguyn l hot

ng ca h thng iu khin, hiu c vai tr cc thit b trong h thng nh cm bin, c cu chp hnh, b iu khin. Trn c s bit hiu chnh cc thang o ca cm bin, c cu chp hnh tng ng vi di hot ng ca h thng. Cc bc tin hnh trong qu trnh thc nghim tng ng vi qu trnh lm vic trong thc t sn xut nh: kho st c tnh thc nghim ca i tng iu khin t la chn cc phng php iu khin v hiu chnh cc tham s b iu khin. chun b th nghim sinh vin cn c ti liu th nghim v chun b ti nh trc khi n trng th nghim. Sinh vin cn nm r l thuyt v cc bc thc hin th nghim vic th nghim t hiu qu v hon thnh trong thi gian nh trc. V thi gian dnh cho th nghim cn hn ch nn trong th nghim ch hng dn cch lm mt s bi th nghim iu khin qu trnh c trng v cn thit.

Phn I. L thuyt 1.1. Ci khi nim c bn v iu khin qu trnh H thng iu khin vi mch vng n c bn c th hin hnh 1.1

Hnh 1.1 S khi mch vng iu khin

Trong :

Thit b o (Measurement Sensor/Transmitter) B iu khin (Controller) C cu chp hnh (Final Control Element) Gi tr t Sai lch iu khin Tn hiu iu khin Set Point (SP), Set Value (SV) Controller Error (CE) Controller output signal, Control Signal, Controller Output (CO) Bin iu khin Bin c iu khin Tn hiu o Control Variable, Manipulated Variable (MV) Controlled Variable (CV), Process Value (PV) Measured Variable, Measurement Signal

Bi ton iu khin cn c thc hin l bin c iu khin n nh vi gi tr t trc vi cc nhiu qu trnh tc ng khc nhau ln h thng. 1.2 M hnh bn th nghim iu khin p sut M hnh th nghim iu khin p sut 38-714 ca hng Feedback c thit k sinh vin lm quen v thc hnh vic o lng v iu khin mt qu trnh thc t. Di y l m hnh bn th nghim v s kt ni cc thit b hnh 1.2

Hnh 1.2. M hnh bn th nghim iu khin p sut

Cc thit b trn c kt ni th hin s di y:

Hnh 1.3. S kt ni cc thit b bn th nghim iu khin p sut Cc thit b c trong m hnh: Thit b lc kh u vo (Filter). Hai nm iu chnh p sut R1, R2. Thit b bin i tn hiu dng in/ p sut ( I/ P Converter). Van iu khin kh nn ( Pneumatic Control Valve). Cm bin p sut ( Pressure Sensor). Mt b chuyn i o chun ( Transmitter). Mt bnh kh nn cui qu trnh (Tank). Mt lu lng k thu tinh ( Flowmeter). Su van ng m bng tay k hiu t V1 V6 (Manual valve). Su p k k hiu t G1- G6. Nguyn l hot hot ca m hnh th nghim nh sau: Kh c cp t mt my kh nn vo qu trnh qua mt thit b lc kh (Filter). Thit b lc kh c tc dng lm sch ngun kh trc khi a vo qu trnh trnh lm bi bn van v cc thit b o, gy sai s ln cho qu trnh. Kh sau khi c lc s c cp cho hai nhnh ca qu trnh. Kh vo nhnh s 1 cp cho thit b chp hnh ca h thng. p sut hot ng c ch th trn p k G1 v c iu chnh bi nm iu chnh R1. Kh vo nhnh 1 dng iu chnh ng m van iu khin, p sut kh c a vo iu khin van thng qua mt

thit b bin i tn hiu dng in/ kh nn (I/P Converter). ng m van s quyt nh lu lng kh i vo qu trnh qua nhnh 2, ng thi quyt nh p sut o c cm bin p sut (ti ng h G5) Kh cp cho qu trnh qua nhnh 2 c iu chnh bi nm iu chnh R2 v p sut hot ng c ch th trn p k G3. Vi mt m van c iu khin, lu lng kh i vo qu trnh c hin th trn mt lu lng k thu tinh (Flowmeter). Dng kh sau khi i qua van iu khin s c thi trc tip ra ngoi kh quyn hoc qua mt bnh kh nn (tank) thay i s tr qu trnh. 1.3. Cc thnh phn c bn trong m hnh th nghim iu khin p sut Trong m hnh th nghim iu khin p sut c cu chp hnh gm thit b bin i tn hiu dng/ p sut (I/P Converter) v c cu truyn ng kh nn, cn phn t iu khin chnh l Van iu khin. Thit b bin i tn hiu dng/ p sut (I/P Converter): y l c cu chp hnh trong h thng, c nhim v bin i tn hiu in t b iu khin thnh tn hiu kh nn vn hnh Van iu khin. Tn hiu u vo l 4-20mA, tn hiu u ra l 3 15psi (0,2-1 bar).

Cnh bo: p sut u vo I/P Converter khng c vt qu 30 psi. Cc thit b c th hng nu vt qu p sut ny.

Hnh 1.4. Thit b chp hnh trong h thng iu khin p sut

Van iu khin kh nn (Pneumatic Control Valve) : Thit b chp hnh quan trng v ph bin nht trong cc h thng iu khin qu trnh, cho php iu chnh lu lng lu cht qua cc ng ng dn. Cu to van bao gm thn van ni vi mt c ch chp hnh (cng vi cc ph kin lin quan) c kh nng thay i m van theo tn hiu iu khin C ch chp hnh van (actuator valve): mt c ch truyn ng kh nn nh v thnh phn ng m van. Trong m hnh th nghim iu khin p sut van iu khin l van kiu in kh vi ng m van c th thay i c bng cch thay i tn hiu iu khin a vo Converter. Khi tn hiu vo thay i t 4 20mA th thng qua Converter s c mt p sut kh nn tng ng ng m van.C th nh sau: + 4mA ti u vo Converter = 3 psi t u ra Converter (ch th trn p k G2) -> Van iu khin kh nn m. + 20mA ti u vo Converter =15 psi t u ra Conveter (ch th trn p k G2) Van iu khin kh nn ng. ->

Hnh 1.5. Cu trc tiu biu ca mt van kh nn

Kiu tc ng ca van: Van iu khin trong th nghim iu khin p sut l van m an ton v khi khng c tn hiu iu khin th van m hon ton. Chiu tc ng ca van l chiu tc ng thun ngha l khi tn hiu iu khin tng th m van gim. b) Thit b o Thit b o c ngha c bit quan trng trong iu khin bi mi thng tin qu trnh c b iu khin ghi nhn v s dng a ra tc ng u da trn cc s liu t thit b o a v. Thit b o c chc nng cung cp tn hiu ra t l vi i lng o. Thit b o gm hai thnh phn c bn: Mt cm bin p sut thc hin chc nng t o p sut phn hi v t h thng v bin i thnh mt tn hiu in vi dng in chun 4-20mA.

Cnh bo: p sut ti a m cm bin c th chu c l 30psi. Cm bin c th h hng nu p sut vt qu 30 psi.

. Hnh 1.6. Cc thnh phn c bn ca thit b o Mt b chuyn i o chun (Transmitter) l mt b chuyn i o m u ra l mt tn hiu chun (v d 1-10V, 0-20mA, 4-20mA, RS-485, tn hiu bus trng,...). Transmitter trong h thng iu khin p sut s dng chun 4-20mA a tn hiu phn hi v b iu khin.

b) Thit b iu khin

Hnh 1.7. Cu trc c bn ca thit b iu khin Thit b iu khin (control equipment) hay b iu khin (controller) l mt thit b t ng thc hin chc nng iu khin, l thnh phn quan trng trong h thng iu khin qu trnh. Trn c s cc tn hiu o v mt cu trc iu khin/ sch lc iu khin c la chn, b iu khin thc hin thut ton iu khin v a ra cc tn hiu iu khin can thip li qu trnh k thut thng qua cc thit b chp hnh. Tu theo dng tn hiu vo ra v phng php th hin lut iu khin, mt thit b iu khin c th c xp loi l thit b iu khin tng t (analog controller), thit b iu khin logic (logic controller) hoc thit b iu khin s. Cc thit b iu chnh c, kh nn hoc in t c xp vo loi tng t.

Hnh 1.8. PLC c dng iu khin m hnh B iu khin c s dng cho cc th nghim l khi PID trong PLC CompactLogix ca Rockwell Automation. Tn hiu vo tng t t cm bin p sut qua mt b chuyn i o chun (Transmitter) s c a vo PLC qua ng vo tng t v c bin i thnh tn hiu logic CPU s dng. Di tn hiu vo PLC l 4-20mA. B x l trung tm CPU ca PLC s

tnh ton v thc thi cc php tnh iu khin da trn thut ton PID c lp trnh sn a ra tn hiu iu khin. Sau PLC s a tn hiu ra qua ng ra tng t. Tn hiu t ng ra tng t c di 4-20mA dng iu khin thit b chp hnh (c th l iu khin m van trong h thng iu khin p sut). d) Cc thit b khc Ngoi thit b chp hnh, thit b iu khin, thit b o, m hnh iu khin p sut cn c mt s thit b khc gm: * Van ng m bng tay (Manual valve) Van tay l mt thit b kh n gin v d vn hnh. Mt van tay c m hon ton khi nm xoay ca n song song vi trc van hoc ng hon ton khi nm v tr vung gc. Chiu tc ng nh sau: m van-xoay nguc chiu kim ng h, kha van-xoay theo chiu kim ng h. m ca van c iu chnh gia hai v tr gii hn thay i lu lng qua van.

M van

Kha van

Hnh 1.9. Hng dn chiu tc ng van tay Trong thit b th nghim iu khin p sut c 6 van ng m bng tay c k hiu t V1 n V6. Trong van V1, V3 iu chnh lng kh i vo v i ra khi bnh kh nn, van V2 iu chnh lng kh a n cc van x, cc van V4, V5, V6 va c tc dng n nh p sut v lu lng kh trong m hnh va kho st nhiu qu trnh nh hng ti h thng. * Mt bnh kh nn cui qu trnh. Bnh kh nn c tc dng lm n nh p sut u ra qu trnh, nhng n cng lm tng tr qu trnh * Mt my nn kh v mt thit b lc cung cp ngun kh sch cho qu trnh. p sut

phi c cung cp y v ng tin cy khi tin hnh th nghim.

Hnh 1.10. My nn kh c s dng cp kh cho qu trnh

Cnh bo: p sut cung cp ti a khng c vt qu 40psi

* Hai nm iu chnh R1, R2 iu chnh p sut vo hai nhnh ca qu trnh. R1 iu chnh p sut a vo Van iu khin kh nn iu khin ng m ca van. R2 iu chnh p sut a vo bnh cha.

Hnh 1.10. Hai nm iu chnh p sut trong m hnh Cch iu chnh nh sau: Gi nm R1 (hoc R2) ko ra pha ngoi iu chnh, quay theo chiu kim ng h tng p sut v ngc chiu kim ng h gim p sut. Sau khi iu chnh xong th y nm tr li. * H thng ng ng dn kh. * Su p k c k hiu t G1 n G6 c b tr nhiu v tr cho ta bit p sut trong ton qu trnh v mt lu lng k cho ta bit lu lng kh a vo qu trnh. * H thng cc van an ton dng bo v qu p sut.

Phn II. Th nghim S gi cn thit lm th nghim: 3 gi. Tt c cc thao tc vn hnh phi di s gim st, ng ca cn b hng dn th nghim Bi th nghim 1: Kim tra hiu chnh thang o cm bin v c cu chp hnh a. Mc ch th nghim: La chn thang o cm bin v c cu chp hnh theo yu cu iu khin p sut b. Hng dn chung: Trc khi tin hnh th nghim sinh vin cn c ti liu hiu r s hot ng v v tr ca cc thit b trn h thng v thc hin theo cc bc sau y: Hiu chnh b ngun dng: Ni thit b theo hnh di: B hin th

Process Interface

Chit p

Span

Zero

Xoay chit p ngun dng t 4-20mA kim tra s b hin th c gi tr tng ng 0-100%. Nu gi tr khng tng ng cn phi hiu chnh 2 nt xoay span v zero.

Kim tra di hot ng c cu chp hnh Ni thit b nh trn hnh v

Khi ng my nn kh cp kh u vo Cn hiu chnh van R1 p sut G1 bng 20 psi t gi tr ngun dng 4mA p sut G2 s hin th 3 psi

t gi tr ngun dng 20mA p sut G2 s hin th 15 psi

Kim tra thang o cm bin Ni thit b nh hnh v

M van V2, V4, V5. V tr m van song song ng ng dn kh. Kha van R2 ng h p sut G5 hin th 0 psi v b hin th hin th 4mA hay 0%. Kha van V2 v m van V1. Xoay van R2 t t v kim tra s thay i p sut G5 v b hin th, t gi tr 0 ln 10psi tng ng 100%.

Bi th nghim 2: Kho st c tnh i tng (Trc khi thc hin bi th nghim ny cn chuyn i a ch IP ca cc my tnh theo a ch tnh t 192.168.1.30 n 192.168.1.50 di s hng dn ca cn b th nghim.) bi th nghim ny, ta nhn dng hm truyn t i tng iu khin t th p ng qu ca i tng ng vi mt gi tr u vo do ta t trc:

do thi dap ung qua do cua qua trinh 2

1.8

1.6

1.4

1.2

0.632 y

K U

0.8

0.6

0.4

0.2

L
0 0 0.5

T
1 1.5 2 2.5 3 3.5 4 t(s)

Trn c s xc nh 3 tham s: k, T, L nh sau: L: l khong thi gian k t khi t gi tr u vo ti khi c s thay i p ng u ra T: l khong thi gian k t khi c s thay i u ra n khi u ra t 0,632 ln gi tr xc lp. K: h s t l gia gi tr xc lp u ra v gi tr t u vo M hnh i tng iu khin p sut s c xp x v khu qun tnh bc nht c hm truyn t:

G(s) = Cc bc tin hnh:

My nn kh np y v c kt ni vi u vo m hnh. Cc van V1, V3, V4 m. Cc van cn li ng. Chy chng trnh RSLogix5000. M bi th nghim Bi_thi_nghiem_k52.acd.Chng trnh main routine hin ra:

Trn y l ton b phn lp trnh cho PLC. Nhim v cn lm l mi sinh vin cn phi to mt trend ( th) v ng c tnh qu . Cch thc hin:

Kich chut phi vo mc Trend ( gc di ca s nh bn tri mn hnh ), chn new trend

t tn cho trend to ra,ap_suat chng hn:

Sau cn add cc tag cn v th.Vi bi th nghim ny 2 tag cn add l ap_suat v do_mo_van( y c th hiu cc tag chnh l cc bin ta cn o ,khi add tag nh vy chng trnh s v th da trn gi tr ca chnh cc bin trong qu trnh)

Ri click finish.

Tip theo cn ci t thuc tnh cho Trend. Kich chut phi vo trend va to c,chn properties.

t khong thi gian cho trc X axis (trc thi gian) khong 200s-v qu trnh qu ca i tng cng nm trong khong thi gian ny

Tip tc chn gi tr cho trc Yaxis: y cc gi tr t u vo ( m van) v gi tr u ra (p sut) u tnh theo phn trm nn ta t trc Y nhn gi tr t 0-100 bng cch chn custom/min=0 v max=100

Cui cng chn mu cho cc tag.Vo Pens Nn chn mu v en thun tin cho quan st,cn background ta mu trng

Sau khi to trend xong, bt u th nghim,sinh vin theo ch dn ca gio vin vo trend va to ra,bm run quan st qu trnh qu ca i tng. Khi thi gian yu cu,sinh vin bm stop quan st th nhn c,ng thi s dng th tnh ton cc gi tr K,P,L cng nh cc gi tr Kp,Ti,Td ca b iu khin nh phn trn cp:

Ri in vo ch trng di y: B P : Kp= B PI : kp=

0,9T = kL 1.2T = kL

TI=

10 L= 3

B PID : kp=

TI=2L=

TD=

L = 2

Bi th nghim 3: Ci t tham s b iu chnh v th nghim kt qu My nn kh np y v c kt ni vi u vo m hnh. Hon thnh kt ni ba cp t m hnh iu khin p sut (cp chp hnh) n PLC (cp iu khin) n my tnh (cp gim st) nh theo hng dn ca cn b th nghim. Cc van V1, V3, V4 m. Cc van cn li ng. Vn gi chng trnh Bai_thi_nghiem_k52.acd

 ci t cc thng s cho b iu chnh cn lm nh sau: Bm chut vo pidas

Trong Tuning nhp cc thng s kp, TI(kI), TD(kD) tnh ton trong phn nhn dng qu trnh cho b iu khin.

Trong Configuration: PID Equaton: Chn Dependent. Hm truyn b iu khin c dng ph thuc R(s)= kp[1+
1 +TDs] . Nhp cc gi tr kp, TI, TD vo cc kp, kI, kD trong Tuning. TI s

Chn Independent. Hm truyn b iu khin c dng c lp R(s)= kp+ Tuning.

kp kI +kDs. Vi kI= (1/s), kD=60 kp. TD(s). Nhp gi tr kp, kI, kD trong 60TI s

Control Action: chn SP-PV Loop Update Time: thi gian vng lp,ly khong 0.1 (s) CV High Limit: 100 CV Low Limit: 0 Trong Scaling: Chn di tn hiu logic m PLC s dng, di tn hiu ny c ci t trong module vo ra tng t. y chn dng d kiu Percent Range nn cn nhp 0 cho Min v 10000 cho Max.

ng thi cc gi tr engineering unit max=10000 v engineering unit min=0 Nhp cc gi tr tham s kp, Ti, Td ca mi b P, PI, PID vo trong hm PID.

Cng ging nh bi 2,ta vn phi to trend quan st p ng ca i tng ,tuy nhin hon ton c th s dng trend vi cc c tnh to,ch c iu ta khng add tag do_mo_van na m thay vo ta add tag gia_tri_dat:

Delete do_mo_van

V add gia_tri_dat

Ri kick OK Thay i gi tr t (set point) quan st tc ng ca mi b iu khin.