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Session T3J

Bringing Industrial Automation Environment into


Classroom: A Didactic Three-Tank and Heat
Exchanger Module
Davi Felipe Schultz
Universidade Federal de Juiz de Fora, Faculdade de Engenharia Eltrica, PET - Programa de Educao Tutorial. - Bairro
Martelos - CEP 36036-330 Juiz de Fora Minas Gerais davifsbr@yahoo.com.br

Wagner Moreira Lupinacci


Universidade Federal de Juiz de Fora, Faculdade de Engenharia Eltrica, PET - Programa de Educao Tutorial. - Bairro
Martelos - CEP 36036-330 Juiz de Fora Minas Gerais lupinaccieng@yahoo.com

Francisco Jos Gomes, D. Sc.


Universidade Federal de Juiz de Fora, Faculdade de Engenharia Eltrica, PET - Programa de Educao Tutorial. - Bairro
Martelos - CEP 36036-330 Juiz de Fora Minas Gerais chicogomes@terra.com.br

Abstract - The present work is concerned with a more


realistic industrial process control and automation course
for engineering. It comprises a heat exchanger coupled to a
three tank system, with several possibilities of control and
interaction among the loops. The planned goal is to bring
to the classroom problems and difficulties usually found
only in practical industry, as well as techniques and
solution to those problem, generally not accessible to
engineering students. The plant is designed in such a way
that allows several combinations in the loops topology, as
well in the control solutions. The process variables include
temperature, level and flow, monitored by industrial
sensors; the actuators are motors-driven pumps coupled to
stand-alone inverters while the controllers are industrial
PLCs and PID, the last with auto-tune capability. Dealing
with industrial parameters, what motivates the students,
but keeping the necessary security and didactic focus, it
has revealed itself a powerful tool for apprenticeship of
industrial process control and automation.

Index Terms - Control, Heat Exchanger, PID, Programmable


Logic Controller.
INTRODUCTION
The present work is about the project, construction and study
of applications of a didactic plant with industrial
characteristics: a system of triple tanks connected to a heat
exchanger, based on components and equipment found in
"soil-of-plant". The purpose, with this, is to bring for the
educational scope problems, difficulties and solutions
normally found in the project, operation and maintenance of
industrial systems, situations that the students of electric

engineering, in the majority of the cases, does not get in touch


with in the academic environment. This situation, normally
found in the diverse Engineering courses, it is generally a
result of the lack available resources, compels the pupils work
only with small projects, said of didactic purpose, that are
important and contribute for the development of the necessary
abilities the students, however leaves gaps in the formation of
the students, therefore they do not reflect the reality industrial
which the same ones will go to coexist after their graduation.
In this didactic plant operations of differentiated meshes of
control can be demonstrated, however using the same
components, instrumentation, equipment and "softwares" used
routinely in the configuration and operation of industrial
processes.
In many kinds of situations, practical and theoreticians,
can be carried through in the developed plant: practical
studies and theoretical such as esteem of models using
techniques of rocking of mass and energy or parametric,
allowing to comparison between computational simulations
and practical comments, differentiated topologies of meshes of
open control or reload such as SISO, MIMO and "feedforward", use of classic and modern algorithms of control, also
based in computational intelligence, based industrial
automation in PLCs, study and application of power invertors,
among others.
It is important to say, as final comment, that all the
project, specification and implementation of the plant was
carried through by the proper students, in extremely
productive work where high learning for all involved was
possible.
THE INDUSTRIAL PLANT
The control engineering brings some questions for the
formation of its professionals that has been object of constant

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debate and studies for specialists for a long time. These
necessities derive, in part, of the characteristics associates to
the control engineering, these characteristics place the focus in
the laboratorial question. Accordance with the wiser positions
in the education of control engineering, [1], the professional of
the area must present some characteristics and knowledge that
fit a basic conceptual on the control theory (control
technology), a capacity to integrate the operational petitions of
a plant with the requirements of its project, the knowledge and
the practical to integrate diversified tools of software and
numerical calculation in the implementation of control
strategies. These necessities and abilities must guarantee that
the control engineers have the capacity to implement the
results of calculations and projects in a real plant transforming
theoretical formularizations into systems and concrete
physical procedures.
The capacity of implementation, necessary to the
control engineer causes a basic prerequisite: the control
engineer is familiar with the contemporaries industrial
equipment of control (sensory and actuators, controllers,
computational hardware and tools of software).
The question between theory-practical assumes
explained contours in the control engineering raising questions
whose solution passes, necessarily, for the laboratorial
conception. It is known that the control courses bring to the
students more interesting and motivation, when based in
applied lines of direction, making possible the student to live
deeply, in the practical, the problems and conditions of
implementation of the theoretical base. A control laboratory
constitutes, in the reality, a tool for multiple applications, such
as development and application, research, training and
education. The central question, therefore, is to use, of
convenient form, this educational tool, adopting the vision that
the processes of real life can extremely be beneficial for
learning of the basic topics in education in the area of control
engineering and the control equipment, with the technology of
the industrial environment, is indispensable in the practical
part of the courses.
The industrial processes, currently, constitute
technological systems integrated by diverse interconnected
sub-processes. The purpose in the assembly was to construct
an equipment with the following characteristics:

The pattern plant pilot must have the appearance of an


industrial plant

The pattern plant must incorporate the most possible


number of elements of industrial control, especially the
variable associates to the industrial processes temperature, outflow, level and pressure.

The adopted configuration must be such that makes


possible the physical separation of the plant in distinct
technological sub-processes, each one incorporating its
characteristics and individualities, as well as advanced
problems of control.

It is desirable that the structure and the properties of the


pattern plant make possible posterior improvements,
incorporating other technological sub-processes,
configurations you add and new procedures of control.

The cost of the equipment, as well as its operation and


maintenance must be adjusted to the budgetary reality of
the Brazilian university.

The final conception begot a system with different


elements of sensors and actuators, and then a great number of
different experiments can be realized, such as control of level,
control of temperature, control of outflow and control of heat
exchange. The used equipment guarantees a great variety of
techniques and conceptions of control that can be used, such
as "feedforward control, mono and multi- variable control,
slave and regulated control, classic and modern algorithms of
control can be projected, implemented and tested in the
practical.
I . Conception
The didactic plant with industrial characteristics was
conceived in two distinct modules, constituting independent
subsystem, however complementary: a system of triple tanks
connected to a heat exchanger, as seen in figure 1. From that
one it is possible to operate the two subsystems in the stanch
or linked form. This conception allows the students to work
with the basic variable used in the applicable structures of
industrial processes control: level of reservoirs, outflow and
temperature of fluids. The system of pressurization, that
allows the development of algorithms and topologies of
control connected to the pressure of the system, even planned
in advance, will be object of future expansion.

Figure 1
Full sight of the plant, with exchanger of heat (left) and triple
tanks (right).
The interaction between these variables, which
incorporate practically all the existing basic complexities in
industrial processes, allows the students a consolidated sight
of the structures, existing interactions and difficulties in the
control of real processes, as well as the respective solutions
that can be done.
II . Tanks System
The module of the heat Exchanger is divided in two "circuits".
The "primary circuit", all mounted in copper tubing, is formed

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by an aluminum tank with capacity of 75 liters, shown in
figure 2, where the water, warmed through two three-phase
resistances of 5,6 KW, circulates stimulated for a centrifugal
three-phase bomb machine cv, with 2 polar regions, rotor in
bronze and mechanical stamp in Viton, thus making possible
the operation of the system in tempers until the order of 85C,
in short situation, or 70C, in continuous situation. The warm
water outflow through the heat exchanger is monitored by a
measurer of turbine type, with operating temperature of -20 C
up to 120 C, and proportional exit of 4mA 20mA. Five term
resistance PT100, with three terminals and exit of 4mA 20mA,
are used for measurement of the temperatures of the water in
the entrance and the exit of the heat exchanger, as well as in
the main tank.
In the "secondary circuit", destined to the refrigeration of
the system, a tubing of PVC Aquatherm was used and a fiber
stored tank with the capacity for 250 liters.
This "secondary circuit" is complemented by a heat
exchanger for refrigeration (automotive radiator) and a
hydraulic circulation single-phase bomb with power of 1/3
HP, with nominal ampere of 1,7A.
The heat exchanger, basic component of this module, is
the type of hoof-pipe, made of beam of pipes and involved a
cylindrical hoof. The minimum outflow in the exchanger is of
0.614 m/h and the most is 6 m/h. The indicated pressure is
2.11 mca.

algorithms of digital control, based or not in computational


intelligence, as the algorithms DMC, Auto-adjustable, "deadbeats", misty and other more. Other aspects that must be
salient are the diverse possible techniques of modeling, esteem
of parameters, optimization and correlated procedures, for
which the acquisition and digital treatment of the data
proceeding from the plant are necessary.
The Programmable Logical Controller used has 4
modules being one of processing with capacity of
programming of 12Kbytes Flash, 8I/8O "N" and
communication RS232, one for digital expansion with
24I/24O "N" (24Vcc), one of analogical expansion with 4I/4O,
a specific one for sensor of temperature PT100 with 4
entrances, beyond a HMI.
For an isolated operation, or of a complementary form to
the CLP, a controller PID was incorporated the plant, which
possess two entrances for heat resistors of some models,
system of auto-regulation and two exits 0-12Vdc, which are
connected to one relay of solid state three-phase world-wide
standard, with control signal of 5/32V of 24/480V load and
drive of vac with keyed chain capacity of 50A. This relay
controls the feeding of the electrical resistors heating located
in the tank of the heat exchanger.
The insertion of the CLP and the PID as possible
structures of control was completed with the possibility of
integral digital treatment of the plant, using for this the
digitalization of the signals. For such, the sensors of level and
outflow had been specified to operate with signals of exit of 4
20mA and that, by passing through of a converting plate PCL711, they are acquired by a computer, where it becomes
possible the execution of a variety of control strategies,
esteem, modeling and optimization of the process.
These characteristics adopted for the plant will allow
future developments, of which the first one programmed is the
implementation of an integrated environment of control, based
on field net, already having the option of the installation of a
CAN-Bus net, from the standardization of the signals in the
band of 4 to 20 mA. The control panel is shown in figure 3.

Figure 2
Aluminum tank.
III. Control of the Plant
The project and the implementation of the control of the plant
are based on the control laws , in which are included the
stability criteria and actions of control that will provide
effective results. Besides, they were made such a way that the
students can have a contact with all the diversity of existing
solutions in industrial environments. It's known that, in these
environments, the Programmable Logical Controllers - PLC are extensively used, doing a direct control of the diverse
meshes by a independent way or coupled to PID controllers or
equivalents.
This combination not only allows the direct control, but
also the hierarquization of the structures, with supervisory or
Figure 3
even optimized levels. Additionally, it has that to bring to the
Control
Panel.
student the information and possibilities of work with the
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final result. Here, the system will be disturbed getting excited
it outflow of the hydraulic circuit, through the bomb

Figure 4
Complete view of the plant.

IV. Operational Flexibility


One plant with didactic characteristics as the
implemented one must make possible diversified experiments,
that allow to the students to have a contact with the topologies,
structures and the most varied conceptions, enclosing the
different procedures and necessities of the automation an
control area. To reach this objective, a planning was effected
that involved all the connections between the diverse
components, used sensors and actuators and its
interconnections.
To exemplify this situation, it can be considered the case
of the heat exchanger module and the distinct example of
topologies and procedures that can be used by the students.
In the module of the heat exchanger the warm water in
the tank circulates passing through the bomb, and after that by
the heat exchanger. In which the exchange of energy between
this water, with a superior temperature, occurs with the
proceeding one from the secondary circuit, with the ambient
temperature, and finally reaching the desired temperature. It
had been used, in this module, sensors of temperature PT-100,
making possible to monitor the temperatures of entrance and
exit of the reservoir of storage water, as well as the ones of
entrances and exit of the water of the heat exchanger. The
sensor of temperature of the exit of the primary circuit of the
exchanger sends a signal for controller PID, which controls
the relay of solid state that feeds the heating resistor.
A first configuration is shown in figure 5. In this
configuration, it is desired to control the temperature of exit of
the heat exchanger, by controlling the heating resistor. A
PT100 sensor monitor the temperature of exit of the heat
exchanger sending a signal for a controller PID, who can act
in On-Off way, P, PI, PID or PID with auto tuning, depending
on the choice of the user. For one same adopted topology, the
user will be able to collate the performance of the different
algorithms of control and to verify its influences in the desired

commanded for the frequency inverter. It can, also, monitor


the disturbances introduced in the system through the sensor
of outflow.

Figure 5
Diagram of blocks of the drive of controller PID.
The same circuit can be used for another different
experiment as, for example, the esteem of parameters for
modeling the exchanger or just control its temperature, in new
topology. In this case that the control element is the hydraulic
bomb, the electrical resistance appears as a disturbance
element, as it can be seen in figure 7. The PT100 that
measures the temperature of the hot water on the exit of the
exchanger is now connected to the CLP, which, through its
analogical exits, controls the inverter of frequency of the B1
bomb. In this configuration, the heating resistor starts to
operate as a disturbance of the system, introducing alterations
in the temperature of entrance of the heat exchanger, being the
outflow monitored by the sensor of outflow.

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Diagram of blocks of the modeling of the heat exchanger.

Figure 7
Diagrama de blocos do controle realizado pelo CLP.
In the triple tanks module, the main objective is to control
the level and/or the temperature of the tank of number 3 being
used, as element of control, the hydraulic bombs, of numbers 4
and 5 (see figure 1), set in motion for the frequency inverter.
This control is realized by the CLP that receives the signals
from the level keys and the analogical signal of the digital
outflow measurer. The disturbances can occur manually,
through the existing manual valves in the module and/or
through the release of the water flow of the heat exchanger for
the tank number 1. Also it is possible to use the tanks to
promote a more efficient temperature control, through the
water exchange between the modules. The system is entirely
endowed with manuals and solenoids valves making possible
alterations of the topology of the circuit and the respective
associated strategies of control.

CONCLUSIONS
Elements of control and softwares are changing very quickly
and the technological equipment gifts will be outdated in a
short period of time. However, since that they represent low
costs for the plant pilot, they can be replaced by more modern
products.
The equipment of the control laboratory is responsible
for the contemporary knowledge transference to the industry.
One gives credit that practical courses involving the plant
pilot, using available equipment and commercially softwares,
can significantly help developing the level of formation of the
engineers. The distinguishing characteristic of the same one is
in the chance that it offers the students of deals with a tool of
bigger transport, and gift in diverse industrial systems. This
option allows the students to learn, of practical and dynamic
form, the operation of some meshes of control, using the same
developed instruments and softwares of configuration for
application in industrial control. Moreover, it presents itself of
extreme utility for studies, analyses and modeling of smaller
systems of control.
ACKNOWLEDGMENT
To the Program of Tutorial Education - PET/SESu/UFJF Electric Engineering, for the support to the development of the
plant, the Foundation Technological Center and the College of
Engineering of the UFJF.

IV. Operational Security

REFERENCES

It's unnecessary to emphasize here the necessary security to


the control laboratories. For this reason it's necessary to
establish a set of security procedures to prevent any risks or
dangers for the users. The biggest detected potential risks had
been the involved three-phase tensions, that feed the electrical
resistance of heating and the hydraulic bombs, the high
temperatures, that can reach 85C, and an increase of the
pressure of the primary, decurrent circuit caused by improper
operation and vapor generation in the tank of heating.
To minimize the decurrent risks of the high tensions it
was adopted, additionally to a careful isolation of all the
connections and linkings, the insertion of all the wiring in
appropriate ducts, preventing exposition of the conductors.
Beyond the use of breakers in all the circuits of feeding of the
bombs and the heating resistors, the module of the heat
exchanger has a relief valve preventing high pressures in the
circuit in the primary circuit that hinders rupture of the tubing
for raised pressures, decurrent of incorrect operation. For
protection against temperatures raised in the primary circuit,
especially for the students who will be operating the plant, a
blanket of thermal isolation was used through all the copper
tubing of the primary circuit, as well as around of the tank of
heating.
Operationally, the protection against overflows was
implemented by some interrupting valves of levels high and
low, for all the tanks of the plant.

[1]

De Vaal, P. L. & Van Niekerk, F. J. Advanced Process Control:


Bringing the Gap between the Academic and Pratical Environments,
Proceedings of the European Symposium on Computer Aided Process
Engineering-3, Supplementary Volume, ESCAPE-3, Graz, Austria,
July 1993, 68-72.

[2]

Couto de Moraes, C. & Castrucci, P. Engenharia de Automao, Rio de


Janeiro, LTC, 2001.

[3]

Jovan, V. & Petrov, J. Process Laboratory A Necessary Resource in


Control Engineering Education, Computers chem.. Engng Vol. 20,
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[4]

Georgini, M. Automao Aplicada, So Paulo, rica, 2000.

[5]

Ogata, K. Engenharia de Controle Moderno, So Paulo, Prentice-Hall,


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http://www.atos.com.br

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http://www.contechind.com.br

[10] http://www.ab.com/manuals/
[11] http://www.weg.com.br

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