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Integrated Process Controllers
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  1. Emerging Control Technology Integrated Process Controllers • What Are They? • Where Are They Used? • How Are They Configured? • Application Examples • Validation Considerations

  2. 623 405 134 722 PUSHBUTTONS, SWITCHES, LIGHTS, INDICATORS CONTROLLERS Honeywell ? F1 F2 F3 ANNUNCIATORS ESC F4 3 4 1 5 2 RECORDERS LOGIC, TIMERS Integrated Process Controllers What are they? Process Controllers With Integrated Logic and OI Designed For Conventional Panel Replacement

  3. Integrated Process Controllers What do they provide? Low Installed Cost • Low Equipment Cost • Minimizes purchase cost • Integrated Process and Logic Control • Shortens design time • Pre-formatted Color Displays • Reduces HMI Development Time • Graphic PC Configuration • Reduces Configuration Time • Automatic Tuning and Fuzzy Logic • Cuts Startup Time

  4. Integrated Process Controllers What do they provide? Reduced Operational Cost • Tighter Process Control • Better accuracy & repeatability • Autotune Minimizes Process Deviations • More time “on-spec” • Less energy usage & product scrap • Recipe Handling • Fast, accurate product changeover • Integrated Control and OI Integration • OI replacement without software reload • Reduced process downtime

  5. Integrated Process Controllers What do they provide? Reduced Life-Cycle Engineering Costs • Configuration Changes via Common Engineering Tool • Single configuration tool for Controller & OI • Reduced configuration errors • Reduced troubleshooting/startup time • Common text and configuration file simplifies validation

  6. Configuration Software Honeywell ? ALARM F1 F2 F3 ESC Controller F4 2 1 3 4 5 Operator Interface Integrated Process Controllers What are the elements?

  7. Vertical Honeywell Horizontal Exceptional Functionality • Modular design • PID Control • Profiles • Logic • Timers • Math ? F1 F2 F3 ESC F4 1 2 3 4 5 Operator Interface Integrated Process Controllers Versatile Operation • Loops • Setpoint Programs • Recipes • Bar Graphs • Trends • Alarm Groups

  8. Universal AI Card+ TC, RTD, mV, V, mA, etc. • Isolated I/O+ Isolation minimizes ground loops, noise, etc.! • Accurate Analog I/O+15 Bit A/D Conversion provides 0.05% calibration! • Accutune/Fuzzy Logic+ Auto Calculates P,I & D +Eliminates Overshoot Controller Analog I/O Designed For Process Applications Embedded Accutune/Fuzzy Logic Cuts Startup Time Embedded Accutune/Fuzzy Logic Reduces Off-Spec Product

  9. Trending/Data Storage+ Integral Feature • Graphic Templates+ Most Common Types+ Saves Development TIME! • Configuration + Stored in controller 2500.0 07:55 0.0 RUN Operator Interface Pre-formatted Displays Emulate Traditional Instruments Common Configuration Tool for Controller and OI Configuration Storage In Controller Reduces OI Downtime

  10. Function Block+ Intuitive (looks like P&ID)+ Integrates Loop & Logic on SAME Page!+ Function Blocks Engineered for Continuous & Batch Applications • Self Documenting+ Graphical Printout Can Serve as Pseudo P&ID Configuration Tools Common Configuration Tool for Controller and OI Complete Configuration with Text Stored in Controller

  11. Configuration Tools • PID Auto -Tune • Overshoot Suppression • Position Proportional PID • Carbon Potential PID • Setpoint Profile/Schedule Block • Bumpless Transfer Block • Hand/Auto Bias Block • Predefined Mass Flow Block • Predefined Dewpoint & RH Blocks • Advanced Floating Point Math(e.g. log, exp, yx etc.) • Predefined averaging blocks Broad Selection Of Process Oriented Function Blocks

  12. Integrated Process Controllers Where Are They Used?

  13. Control loop functions (PID, input and output selections, etc.) Specialized functions - signal selection, calculations Set point programming with event outputs Logic operations, timing, counting Interaction - loop and logic Operator Interface Application Requirements

  14. Loop and Logic Interaction Reactor Jacket Temperature Example: Function Blocks Top Temp AI 1 PID Loops TEMP Control PV Multiple Input Average Mid Temp AI 2 PID Steam Valve AO 1 RSP Bottom Temp AI 3 CR 1 Run DI 3 Force Manual Universal Inputs Setpoint Programmer # 1 Hold DI 4 Reset DI 5 Loop / Logic Interaction AC/DC I/O Plus Ladder Logic DI 1 DI 2 CR 1 DO 1 DO 1 Timer 1

  15. Integrated Process Controllers Typical Pharmaceutical/Biotech Applications: • Reactors • Fluidized Bed Drying • Lyophilization • Wet Granulation • Tablet Coating • Water for Injection • Boiler Control

  16. Integrated Process Controllers How Are They Configured?

  17. What are Function Blocks? “Pre-programmed functions or algorithms for user configuration of control strategies through soft-wire connection” Function Blocks MASS FLOW SWITCH

  18. Flexibility in process control Ease of implementation Ease of understanding Ease of change Simplifies documentation Why Use Function Blocks?

  19. Math - Add, Subtract, Multiply, Divide Advanced Math - Free form Selectors Switch 1 2 Select 1 of 2 inouts by discrete input Function Block Examples A * B * SQRT(C/D) + 5 Multiple Level of Parenthesis Operators: +, -, x, /, SQRT, ABS, yx, ex, log, ln, neg, sin, cos Rotary Switch First-Good High/Low 8 First Good 1 1 > 2 2 2 or 1 < 8 8 Select 1st good input in sequence 8 Select Highest (or Lowest) of 8 inputs Select 1 of 8 by number

  20. Timers/Counters Logic Function Block Examples OS ITIMER MINUTES 0.1 to 9999.9 OV RUN/RESET 1 1 A B 2 AND X OR 2 OR Boolean C 8 8 H Up to 8 inputs, with inverted input selection Up to 8 inputs Exclusive OR Boolean Expression (A + B) * C = 1 Inverter

  21. PID Set Point Programmer Function Block Control Simple Advanced PV % Carbon Dual Output Position Proportioning Auto-tune Ratio, Cascade Tracking OUT RSP Force MAN Output Set Point Run Programmer Hold / Pause Event 1 (10 to 32 Ramp/Soak Steps) Reset Event 16

  22. Simple Control Loop Sensor Selection Input 1 Switch AI 1 PID AO1 AI 2 Input 2 External DI

  23. Expanded Control Loop Input 1 Switch AI 1 PID Input 2 AO1 AI 2 Set Point Run Programmer Hold / Pause Compare Event 1 A > B 1500 (10 to 32 Ramp/Soak Steps) Reset Event 16

  24. Logic Circuit With Function Blocks Stop Start ON Lamp Ladder Logic and Timing Replaced by Function Blocks DI1 CR1 DI2 Start/Stop Circuit CR1 On Timer PUMP 1 20 SEC DO 2 CR1

  25. Table Entry Method Configuration Methods

  26. Graphic Entry Method Configuration Methods

  27. Integrated Process Controllers Application Examples

  28. Loop and Logic Integration Reactor Jacket Temperature Example: AI1 A01 A12 LOW Selector Block PID Block PV AI3 Alarm Block Hi Alm SP=20 Output to solenoid valve DO1 On Timer Alarm Block Lo Alm SP=125 AND Block 10 Min.

  29. Loop and Logic Integration Function Block PC-Configured Representation

  30. Loop and Logic Integration Simplified Temperature Profiler For Lyophilizer

  31. Integrated Process Controllers Validation Considerations

  32. Integrated Process Controllers • Design! • Detail! • Document! • With One Tool!