SIM(P)ATIC PLC+ Challenge

2016.
Projektni zadatak

Sadraj:
1. Projektni zadatak............................................................................................. 3
 1.1. Vaganje...................................................................................................... 3
1.2. Tank sa toplom vodom............................................................................... 3
1.3. Posuda za meanje slada...........................................................................4
1.4. Neprevrelo pivo......................................................................................... 4
1.5. Dodatni uslovi:........................................................................................... 4
2. UPUTSTVA........................................................................................................ 5
3. P&ID................................................................................................................. 6
4. MODEL SISTEMA............................................................................................... 7
4.1. Posuda za meanje slada...........................................................................7
4.2. Mea vode................................................................................................ 8
4.3. Kontrolni ventili.......................................................................................... 8
5. EVALUACIJA...................................................................................................... 9

SIM(P)ATIC PLC+ Challenge Coratia, Serbia, Slovenia

1. PROJEKTNI ZADATAK
Zadatak je da se implementira PLC program za upravljanje pojednostavljene pivare. Pivara se sastoji od:

Silosa,
Transportne trake,
Posude sa toplom vodom,
Posude za meanje slada,
Posude sa neprevrelim pivom.

1.1. Vaganje
Korak 1 Startovati transport slada (motor M1)
Korak 2 Otvoriti ventil V1 (silos sa jemenim sladom)
Korak 3 Transportovati slad do merne jedinice
Korak 4 Odmeriti teinu od X kg slada
Korak 5 Zatvoriti ventil V1 (silos sa jemenim sladom)
Korak 6 Zaustaviti transporter slada
Napomena: Nakon punjenja posude za meanje slada, neophodno je ponovno zapoeti operaciju jedinice. Pretpostavlja se da
sje silos uvek pun slada. Promenljiva X je veliina iz SCADA-e.

1.2. Posuda sa toplom vodom

Korak 7 Napuniti posudu sa X litara vode (ventil V7)
Korak 8 Zagrejati vodu do temperature od T3=80C (greja se ukljuuje sa S1)
Napomena: Pretpostavlja se da uvek ima vode u posudi sa toplom vodom.

1.3. Posuda za meanje slada

Korak 9 Startovati meae M2 i M3

SIM(P)ATIC PLC+ Challenge Coratia, Serbia, Slovenia 3

Korak 10 Napuniti posudu toplom vodom korienjem ventila V2 do visine H 20 (ventili V5 i V6 zatvoreni, pumpa P1 OFF).
Smea vode temperature T1 mora biti 45. Neophodno je dizajnirati kontroler za temperaturu T 1. Protok Qh
predstavlja poremeaj u kontrolnoj petlji. Kontrolni sistem treba da osigura to bolju regulaciju u prisustvu
poremeaja.
Korak 11 Prvo se posuda puni do 20%, dodaje se X kg slada (pre dodavanja slada ispisati operatoru poruku da doda slad u
posudu; traiti potvrdu
Korak 12 Kada je posuda puna (h2H20), zatvoriti ventil V2, saekati 1 minut.
Korak 13 Otvoriti ventil V5, pumpa P1 ON. Korienjem proporcionalnog ventila V3 zagrejati smeu slad-voda po datom
temperaturnom profilu (ideti poglavlje 3).
Dizajniratei kontroler za temperaturu T2. Temperatura tople vode u primarnom krugu zagrevaa je promenljiva poremeaja.
Zatvorena petlja kontrolnog sistema bi trebalo da minimizuje odstupanje temperature T2 od temperaturnog profila. Traeni
temperaturni profil je poznat unapred.The disturbance action is not known in advance.

Korak 14 Posle konane vrednosti temperature, referenca se dri 1 minut, zatim se iskljuuje pumpa P1 OFF, zatvaraju se
ventili V5 i V3, eka se 1 minut. After the final value of the temperature reference is kept for 1 minute, switch pump
P1 OFF, close valves V5 and V3, wait for 1 minute.

1.4. Posuda za neprevrelo pivo

Korak 15 Upumpati smeu (wort) u posudu: otvoriti ventil V6, ukljuiti pumpu P1 ON, pupmati dok se posuda za meanje
slada i vode ne isprazni, iskljuiti pumpu P1 OFF i zatvoriti ventil V6.
Korak 16 Kuvati slad dok temperatura ne dostigne T4=100C . Za vreme procesa ispisati posruku operateru da doda hmelj i
traiti potvrdu.
Korak 17 Isprazniti posudu korienjem ventila V8 i pumpe P2 (visina h3).
Korak 18 Iskljuiti pumpu P2 OFF i zatvoriti ventil V8.
Korak 19 Sistem je spreman za novu seriju.

1.5. Dodatni uslovi:

1. Pratiti i zapisati vreme svakog koraka. Monitor and record time for every single step.
2. Pre startovanja pumpi otvoriti ventile koji blokiraju cev, pumpa se ne moe ukljuiti ako ventil nije otvoren.

SIM(P)ATIC PLC+ Challenge Coratia, Serbia, Slovenia 4

2. UPUTSTVA
1. Za reavanje projektnog zadatka koristiti dati softver: Tia Portal V13 SP1 Step 7 Proffesional za PLC programiranje i
WinCC Advanced za vizualizaciju, PLC Sim za simulaciju
2. Koristiti dati templejt projekat.
3. U poglavlju 3 moete nai P&ID.
4. Temperaturni profil za PID2 je neopadajua funkcija. Vreme odabiranja profila je 30 sekundi.
5. U poglavlju pet moete nai sve formule koje se koriste za modeliranje sistema. Model je implementiran sa vremenom
odabiranja od 1 sekunde.
6. Parametri evaluacije su definisani u poglavlju 6.
7. DB101 u templejtu sadri sve ulaze/izlaze vezane za proces.

SIM(P)ATIC PLC+ Challenge Coratia, Serbia, Slovenia 5

3. P&ID

SIM(P)ATIC PLC+ Challenge Coratia, Serbia, Slovenia 6

4. THE SYSTEM MODEL
4.1. Mash tun
dh2
A V2ON / OFF Qh Qt V6ON / OFF QP1
dt

A=1 cross-section of mash tun [m2]

=1000 water density [kg/m3]

h2 water height (H20=1) [m]

V2ON/OFF 0 - V2 closed, 1 - V2 open
Qh mass flow of cold water (approximately 5, but can vary between 4 and 6 in
an unknown way) [kg/s]
Qt mass flow of hot water [kg/s]
V6ON/OFF 0 - V6 closed, 1 - V6 open
QP1=10 mass flow through pump P1 (0 or const.) [kg/s]
----------------

with V5ON/OFF=1 and QP10:

A h2 dT2 2Qvv hizm Aizm

Tvv T2
QP1 dt 2cQP1Qvv hizm AizmQP1 Qvv hizm Aizm

T2 water temperature mash tun [K]

Qvv mass flow hot water primary loop of heat exchanger [kg/s]
hizm=4000 heat transfer coefficient of the exchanger contact surface [W/(m 2K)]
Aizm=3 the effective contact area for heat exchange in the heat exchanger [m 2]
c=4186 specific water heat capacity [J/(kgK)]
Tvv hot water temperature heater inlet temperature (approximately 363, but
can change between 358 and 368 in an unknown way) [K]
--------------
with V5ON/OFF=1 and QP1= 0:

SIM(P)ATIC PLC+ Challenge Coratia, Serbia, Slovenia

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dT2
0
dt

-------------

with V5ON/OFF=0 and h20:

dT2
A h2 Qh Qt V2ON /OFF T1 T2
dt

T1 water temperature after mixing hot and cold water [K]

-------------
with h2=0
T2=NaN
When changing h2, T2 is initialized as T2:=T1

4.2. Water mixer

Qh Qt
T1 Th Tt
Qh Qt Qh Qt

Th cold water temperature (approximately 283, but can vary between 280 and
286 in an unknown way) [K]
Tt hot water temperature (approximately 353, but can vary between 350 and
356 in an unknown way) [K]
PID1 controller consists only of integral part.

4.3. Control valves

V3:

xv 3 Q
vv
100% Qvv ,max

xv3 valve V3 openness; control variable of the controller (spans from 0 to 100)
[%]
Qvv,max=10 maximum flow of hot water through V3 (constant) [kg/s]

SIM(P)ATIC PLC+ Challenge Coratia, Serbia, Slovenia

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V4:

xv 4 Qt

100% Qt ,max

xv4 valve V4 openness; control variable of the controller (spans from 0 to 100)
[%]
Qt,max=10 maximum flow of hot water through V4 (const.) [kg/s]

5. EVALUATION
1. Tracking of the temperature profile for mash tun
Two minutes after the temperature regulation has started, with
temperature reference on 45C, the reference temperature profile is
applied which needs to be followed by the controller; temperature
following is over after two minutes of the profile being set to maximal
value of 75C
The temperature references are known in advance, the performance is
assessed as sum of squared regulation errors
2. Control of the water temperature T1 after mixing hot and cold water
The regulator needs to act such that the settling time after the disturbance
action is approximately 10 seconds
3. Visual impression - example - Valves must be shown that it is clear when
they are open or closed, for each component manual or automatic mode
can be selected. Manual mode means control via SCADA and automatic
mode means control by the PLC program.
4. Functionality

According to each parameter teams will be ranked from first to last, and
thereafter will be total ranked.

SIM(P)ATIC PLC+ Challenge Coratia, Serbia, Slovenia

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