CENTUM VP COURSE PROJECT LESSON 6

OBJECTIVE OF THIS LESSON

This project will allow the student to construct feedback and sequence control function blocks to
manipulate a predefined batch application. The project will be built and tested in the “Test Function”, then
anytime during the three parts, you can load the project to the FCS.

This project is made up of three parts, each built on the preceding part. Information in the previous tabs
will come into play, plus you will need to refer to the FCS on-line Function Manual.

Create a New Project.

• Make your FCS an AFV10D and use the “General Purpose” database type.
• Make your HIS address HIS0164.

Create the I/O. NOTE: You will need to create a NODE #1.
• Make IOM #1 an analog input/output module AAI841-H (8 input/8 output)
• Create IOM #2 a 32-point digital input module ADV151.
• Create IOM #3 a 32-point digital output module ADV551.
• Create the function blocks, and sequence controls defined in each part.

Points to Note for the Project:

• On the “Detail Page” for the BSETUs and PIDs make the “Fully-open, Tightly-shut” = “No”.
• Remember to setup the totalization of the BSETUs for MIN.
• In the CALCU tuning panel, for the tank level, make P01 = 0.01 and P02 = 0.5.
• You can, at any point in this lab, make the project “Current” and load it to the FCS and HIS.
• After you have completed part 1 of this exercise create a graphic to control the process. Add to the
graphic as you complete the remaining parts.

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 CENTUM VP COURSE PROJECT LESSON 6

Ingredient 1
Ingredient 2
Ingredient 3

MIXER COOKING
PROFILE
(PG-L13)

LEVEL
TEMP

STEAM

DRAIN

PUMP

Item Instrument Scale BSET Input Output

INGR-1 BSETU-2 0-1000 GPM 500 %Z011101 %Z011109
INGR-2 BSETU-2 0-1000 GPM 500 %Z011102 %Z011110
INGR-3 BSETU-2 0-100 GPM 50 %Z011103 %Z011111

Item Instrument Scale Output

Cooking Profile PG-L13 480 Seconds (Quick return) TEMP.SET
X02=60, X03=120, X04=180, X05=240, X06=300, X07=360, X08=420
Y01=120, Y02=290, Y03=290, Y04=150, Y05=150, Y06=70, Y07=50

Item Instrument Scale Input Output

TEMP PID 50-300 DEGF %Z011107 STEAM.SET
STEAM PID 0-200 LB/H (SQRT) %Z011108 %Z011112
LEVEL PVI 0-100 % CALC.CPV
CALC CALCU 0-100 LEVEL.PV
DRAIN SIO-11 %Z012101 %Z013101
PUMP SIO-11 %Z012102 %Z013102
MIXER SIO-11 %Z012103 %Z013103
COMP RL

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CENTUM VP COURSE PROJECT LESSON 6

PART 1

Create the instruments on the previous page, defining them as described. At the bottom of the page is the
calculation to be put into the CALCU to simulate the level filling or draining in the tank. You will need to
refer to the FCS Function Manual for specific details on these instruments. After they have been created,
test them on a control group before you build the sequence table that will control the process.

Process Steps:
1. When the process starts, add ingredients 1 & 2. When the level in the tank reaches 30%, turn on the
agitator and start the temperature profile.

2. When the profile gets to zone 3 add ingredient 3.

3. When the profile finishes, open the drain and turn on the pump.

4. When the level in the tank drops to 30% turn off the agitator.

5. When the tank is empty, turn off the pump and close the drain valve. Return the table to step #1.

Instruments:
• Make all of the fill and drain valves plus agitators to be SIO-11s
• Use this calculation in the CALCU feeding the reactors PVI for your level simulation.
1 program
2 alias D drain.MV *NOTE: Substitute the names shown in italics with the block names you
3 alias E ingr-1.MV created on the previous page.
4 alias F ingr-2.MV
5 alias G ingr-3.MV
6 H=P01*(E+F+G)
7 FI=RV+H-P02*D
8 IF (FI<0) THEN
9 FI=0
10 ELSE IF (FI>100) THEN
11 FI=100
12 END IF
13 CPV=FI
14 END

Calculation and
PV IN
PVI connection LEVEL CALC
for level simulation
IN CPV
PVI CALCU

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CENTUM VP COURSE PROJECT LESSON 6

MIX-A MIX-B MIX-C

Ingredient
Ingredient
Ingredient

MIXER COOKING
PROFILE
(PG-L13)

LEVEL
TEMP

STEAM

DRAIN

PUMP

Item Instrument Registers to change

MIX-A BDSET-1L INGR-1.BSET (500)
INGR-2.BSET (500)
INGR-3.BSET (50)
Profile: Y01=120, Y02=290, Y03=290, Y04=150, Y05=150, Y06=70,
Y07=50
MIX-B BDSET-1L INGR-1.BSET (500)
INGR-2.BSET (450)
INGR-3.BSET (80)
Profile: Y01=120, Y02=275, Y03=260, Y04=190, Y05=170, Y06=100,
Y07=50
MIX-C BDSET-1L INGR-1.BSET (250)
INGR-2.BSET (600)
INGR-3.BSET (40)
Profile: Y01=120, Y02=250, Y03=290, Y04=265, Y05=165, Y06=90,
Y07=50

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CENTUM VP COURSE PROJECT LESSON 6

PART 2

Part 2 allows the operator to make a pre-selected grade mix of the product. Listed on the previous page
are the instrument types and the specifications to use, use the FCS On-Line Builder manual (or use this
course manual) to look up specifics for what a BDSET-1 does.

What is the “BSET” register in a BSETU used for?

The process steps are the same except that the operator must select the desired mix first, and then start
the process.

New Process Step:

1. When the operator starts the process, he must then select a mix, which is down loaded to the INGR
and to the PROFILE from the BDSET-1.

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CENTUM VP COURSE PROJECT LESSON 6

MIX-A MIX-B MIX-C

Ingredient
Ingredient
Ingredient 3

MIXER COOKING
PROFILE
(PG-L13)

LEVEL
TEMP

STEAM

DRAIN

PUMP

FILL_A FILL_B FILL_C

LI Store LI Store LI Store

MIX-A MIX-B MIX-C

DRAIN_A DRAIN _B DRAIN _C

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CENTUM VP COURSE PROJECT LESSON 6

PART 3

Part 3 adds storage tanks for the different mixes. Make these tanks in a new control drawing. This will
require reading the Reactor’s drain status in a new sequence table in the control drawing.

• Use the PVI and calculation configuration shown on page 3 of the lab for these new tanks.

Add these Process Steps:

1. When a mix is selected, create a new sequence table that will open the appropriate storage tank fill
valve when the reactors drain opens after the batch completes. Close the storage fill valve when the
reactor drain closes.

2. If a storage tank is above 70% full don’t allow the associated mix to start and output an “Operator
Guide Message” stating which storage tank is too full.

Instruments:

1. Make all of the fill and drain valves SIO-11s

• Do not connect these to the I/O, instead put the SIMM=1 on the instrument’s tuning panel.

2. Make 3 storage tank PVIs with CALCUs for the simulation.

• Modify the following calculation to fit each of the CALCUs depending upon the mix. As a starting
point, make P01 and P02 = .5.

1 program
2 alias D fill-x.MV (This is the storage tank’s fill valve!)
3 alias E drain-x.MV (This is the storage tank’s drain valve!)
4 F=P01*D
5 FI=RV+F-P02*E
6 IF (FI<0) THEN
7 FI=0
8 ELSE
9 CPV=FI
10 END IF
11 END

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