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PCS7

The document provides an overview of equipment modules for PCS 7 in the chemical industry, emphasizing the standardization of automation engineering. It outlines the legal information, disclaimer of liability, and security measures related to the use of application examples provided by Siemens. Additionally, it details the structure, preparation, and commissioning of equipment modules, along with their integration into user projects and control functionalities.

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0% found this document useful (0 votes)

15 views162 pages

PCS7

Uploaded by

James Hou

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Available Formats

Download as PDF, TXT or read online on Scribd

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Equipment Modules

for PCS 7 using the

example of the
Chemical Industry
Siemens
SIMATIC PCS 7 V9.0 SP1 Industry
Online
https://support.industry.siemens.com/cs/ww/en/view/53843373 Support
Legal information

Legal information
Use of application examples
Application examples illustrate the solution of automation tasks through an interaction of several
components in the form of text, graphics and/or software modules. The application examples are
a free service by Siemens AG and/or a subsidiary of Siemens AG (“Siemens”). They are non-
binding and make no claim to completeness or functionality regarding configuration and
equipment. The application examples merely offer help with typical tasks; they do not constitute
customer-specific solutions. You yourself are responsible for the proper and safe operation of the
products in accordance with applicable regulations and must also check the function of the
respective application example and customize it for your system.
Siemens grants you the non-exclusive, non-sublicensable and non-transferable right to have the
application examples used by technically trained personnel. Any change to the application
examples is your responsibility. Sharing the application examples with third parties or copying the
application examples or excerpts thereof is permitted only in combination with your own products.
The application examples are not required to undergo the customary tests and quality inspections
of a chargeable product; they may have functional and performance defects as well as errors. It is
your responsibility to use them in such a manner that any malfunctions that may occur do not
result in property damage or injury to persons.

Disclaimer of liability
Siemens shall not assume any liability, for any legal reason whatsoever, including, without
limitation, liability for the usability, availability, completeness and freedom from defects of the
application examples as well as for related information, configuration and performance data and
any damage caused thereby. This shall not apply in cases of mandatory liability, for example
under the German Product Liability Act, or in cases of intent, gross negligence, or culpable loss of
life, bodily injury or damage to health, non-compliance with a guarantee, fraudulent
non-disclosure of a defect, or culpable breach of material contractual obligations. Claims for
damages arising from a breach of material contractual obligations shall however be limited to the
© Siemens AG 2019 All rights reserved

foreseeable damage typical of the type of agreement, unless liability arises from intent or gross
negligence or is based on loss of life, bodily injury or damage to health. The foregoing provisions
do not imply any change in the burden of proof to your detriment. You shall indemnify Siemens
against existing or future claims of third parties in this connection except where Siemens is
mandatorily liable.
By using the application examples you acknowledge that Siemens cannot be held liable for any
damage beyond the liability provisions described.

Other information
Siemens reserves the right to make changes to the application examples at any time without
notice. In case of discrepancies between the suggestions in the application examples and other
Siemens publications such as catalogs, the content of the other documentation shall have
precedence.
The Siemens terms of use (https://support.industry.siemens.com) shall also apply.

Security information
Siemens provides products and solutions with industrial security functions that support the secure
operation of plants, systems, machines and networks.
In order to protect plants, systems, machines and networks against cyber threats, it is necessary
to implement – and continuously maintain – a holistic, state-of-the-art industrial security concept.
Siemens’ products and solutions constitute one element of such a concept.
Customers are responsible for preventing unauthorized access to their plants, systems, machines
and networks. Such systems, machines and components should only be connected to an
enterprise network or the Internet if and to the extent such a connection is necessary and only
when appropriate security measures (e.g. firewalls and/or network segmentation) are in place.
For additional information on industrial security measures that may be implemented, please visit
https://www.siemens.com/industrialsecurity.
Siemens’ products and solutions undergo continuous development to make them more secure.
Siemens strongly recommends that product updates are applied as soon as they are available
and that the latest product versions are used. Use of product versions that are no longer
supported, and failure to apply the latest updates may increase customer’s exposure to cyber
threats.
To stay informed about product updates, subscribe to the Siemens Industrial Security RSS Feed
at: https://www.siemens.com/industrialsecurity.

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Table of contents

Table of contents
Legal information ......................................................................................................... 2
1 Introduction ........................................................................................................ 5
1.1 Overview............................................................................................... 5
1.2 Mode of operation ................................................................................ 6
1.3 Components used ................................................................................ 8
2 Preparation and commissioning ...................................................................... 9
2.1 Preparation ........................................................................................... 9
2.2 Commissioning ................................................................................... 10
3 Integrating the Unit Template in the user project ........................................ 11
3.1 Preparation ......................................................................................... 11
3.2 Copying templates .............................................................................. 11
3.3 Copying Equipment Module ............................................................... 12
3.4 Adapting the OS project ..................................................................... 13
4 Control Module ................................................................................................ 14
4.1 Introduction ......................................................................................... 14
4.2 Best Practice Control Module Type Library........................................ 16
4.3 "ModPreCon" 4x4 multivariable controller .......................................... 17
4.3.1 Standard multivariable controller ........................................................ 17
4.3.2 Predictive controller for only one controlled variable ......................... 20
© Siemens AG 2019 All rights reserved

4.4 "PIDCon” controller............................................................................. 23

4.4.1 Standard controller ............................................................................. 23
4.4.2 Ratio controller ................................................................................... 24
4.4.3 Split range controller .......................................................................... 28
5 Equipment Modules......................................................................................... 32
5.1 "Level-Control" in process plants ....................................................... 33
5.1.1 Exact level control .............................................................................. 33
5.1.2 Buffer level control with feedforward disturbance compensation
"Buffer-Control" .................................................................................. 39
5.1.3 Simulation - structure and parameterization ...................................... 48
5.1.4 Comparison of exact level control with buffer control including
feedforward disturbance compensation ............................................. 52
5.2 "Split-Range-Pressure" control........................................................... 55
5.3 "Ratio-Control" .................................................................................... 61
5.4 "Split-Range-Temperature" control .................................................... 71
5.5 pH value control using a standard controller ...................................... 79
5.6 pH value control using predictive controller ....................................... 86
5.7 "Temperature-Flow-Cascade" ............................................................ 96
5.8 Coarse-/Finestream-Control "Stream-Control” ................................. 103
5.9 Gradient limits in actuators "Gradient-Limit" .................................... 110
5.9.1 Control behavior without active method ........................................... 114
5.9.2 Method 1 "External Reset" ............................................................... 116
5.9.3 Method 2 "Tracking the output value if the deviation is too
large". ............................................................................................... 119
5.9.4 Method 3 "Blocking the integrator" ................................................... 121
5.9.5 Method 4 "Block integrator with gradient calculation". ..................... 123
5.9.6 Methods comparison ........................................................................ 125
5.10 Instance-specific adaptations ........................................................... 127
6 Additional information .................................................................................. 129
6.1 General Information.......................................................................... 129
6.2 Standardized plant units ................................................................... 130

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Table of contents

6.3 Design and structure ........................................................................ 132

6.3.1 CFC naming convention ................................................................... 132
6.3.2 Plant view ......................................................................................... 133
6.4 Controllers and control response ..................................................... 134
6.4.1 Tracking standard and cascade controllers ..................................... 134
6.4.2 Tracking ratio controllers .................................................................. 135
6.4.3 Tracking split range temperature ..................................................... 136
6.4.4 Faults and maintenance for temperature throughflow cascade ....... 137
6.4.5 Faults and maintenance for ratio controllers .................................... 141
6.4.6 Faults and maintenance of split range temperature ......................... 148
6.5 Block description of "pHTitrBlock" .................................................... 153
6.6 Block description of "SimpHTitr"....................................................... 156
6.7 Block description of "ComStruIn" and "ComStruOut"....................... 158
7 Appendix ........................................................................................................ 160
7.1 Service and support ......................................................................... 160
7.2 Links and literature ........................................................................... 161
7.3 Change documentation .................................................................... 162
© Siemens AG 2019 All rights reserved

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1 Introduction

1 Introduction
1.1 Overview
The standardization of automation engineering for processing plants, such as in
the chemical industry, is a major challenge. Different process steps and
procedures, different equipment and flexibility in the production make the task even
more difficult.
One approach for standardization is structuring the plant according to the physical
model of ISA 106. This specifies the lower four levels, i.e. plant, unit, plant unit and
control module. A plant always consists of units. The plant sections can, in turn,
contain standardized plant sections that are based on equipment modules. An
equipment module comprises both the physical equipment and the user program.

This application example contains standardized equipment modules in the form of

software typicals that are provided in SIMATIC PCS 7 as a multiproject.
Using them offers the following benefits:
• A reduction in the expertise necessary to develop applications
• Less effort needed for configuration
• Re-use of field-proven control strategies
• Harmonized structures
© Siemens AG 2019 All rights reserved

• Flexible structuring and adjustment of partial automation solutions

The equipment modules offer a template that comprises the typical components of
a partial automation solution, incl. open- and closed-loop control, the necessary
logic and visualization.
An equipment module is configured independently of the automation hardware and
is a component of a pre-configured PCS 7 project including the process
visualization system. Due to hardware-independent configuration and the modular
structure, it is possible to integrate and use the equipment modules in PCS 7
projects in any way you like.
Equipment modules are composed of control modules (CMs). Function blocks of
the PCS 7 Advanced Process Library (APL) are used to create a control module.

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1 Introduction

1.2 Mode of operation

The equipment module concept provides pre-engineered and unified components
for creating an automation solution, e.g. metering or temperature control.
The diagram below shows the equipment modules as components of a partial
automation solution as an example.

Inflow of input material Pressure control

Stirred tank
© Siemens AG 2019 All rights reserved

Temperature
control
Outflow of product

Equipment module Partial automation solution

The equipment module concept provides pre-engineered and unified components

for creating an automation solution, e.g. metering or temperature control.
The equipment modules are implemented in the PCS 7 multiproject as follows:
• One project for the automation system (AS) and one project for the operator
station (OS) are contained in the component view.
• A hierarchy folder has been created in the plant hierarchy for each equipment
module.
• The master data library contains all of the control module types in use.
In the AS project, all of the open- and closed-loop control functions are
implemented in the form of Continuous Function Charts (CFCs). Apart from this,
the AS project contains a simulation that approximately simulates a procedure, e.g.
a filling level change within an equipment module.
The OS project contains visualization by means of one process picture per
equipment module and shows:
• Schematic representation of the equipment module
• Approximately simulated process response
• Relevant parameters (KPI: Key Performance Indicator)
• Monitoring of control performance

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1 Introduction

The overview picture and the structure of a process picture of an equipment

module are described below. For a detailed description of the core functionality of
an equipment module, please refer to Chapter 5 "Equipment Modules".

Visualization interface

The visualization interface of the equipment modules consists of an overview

picture and a process picture for each equipment module.

Overview picture
The overview picture contains a schematic representation in the form of a material
flow diagram of the process engineering system that includes all the equipment
modules in the example project.
Using the pushbutton of an equipment module, you switch to the respective process
picture that contains the functionality and the specific information of an equipment
module. The system represents the process pictures in the form of an appropriate
section of the P&ID of a system.

Process picture
The process picture of an equipment module consists of the following parts:
• Schematic representation (P&ID)
• Simulation
• Faceplates for controlling the individual components (units)
• Trend curve representation to visualize control response
In the process picture, operators are provided with an overview of the respective
equipment module and can understand the runtime response on a time basis.

Delimitation
The process behavior is not simulated in detail within the equipment module.

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1 Introduction

Required knowledge
Basic knowledge of the following specialist fields is a prerequisite:
• Configuring using SIMATIC PCS 7 CM technology and the APL
• Knowledge of control technology
• Basic knowledge of process technology

1.3 Components used

This application example has been created with the following hardware and
software components:
Component Note
SIMATIC PCS 7 ES/OS For the PCS 7 V9.0 SP1 example project
IPC547G W7
SIMATIC PCS 7 V9.0 Part of SIMATIC PCS°7 ES/OS IPC547G W7
SP1
Advanced Process Part of SIMATIC PCS°7 V9.0 SP1
Library V9.0 SP1
S7-PLCSIM Not part of SIMATIC PCS 7 V9.0 SP1; appropriate licenses are
required.
© Siemens AG 2019 All rights reserved

CFC V9.0 SP2 Update for the part of SIMATIC PCS°7 V9.0 SP1. Under the
following link you find the required Update:
https://support.industry.siemens.com/cs/ww/en/view/109756832

NOTE In case of different hardware, please take heed of the minimum requirements for
installing the software components. The minimum requirements can be found in
the Readme of the PCS 7 under follow link:
https://support.industry.siemens.com/cs/ww/en/view/109750097.

This application example consists of the following components:

Component Note
53843373_EquipmentModules_PROJ_PCS7V90SP1.zip Example project
53843373_EquipmentModules_DOC_PCS7V90SP1_de.pdf This document

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2 Preparation and commissioning

2 Preparation and commissioning

2.1 Preparation
The following instructions describe commissioning of the equipment modules by
simulating the controller using the "S7-PLCSIM" program. If you are using a real
controller, you must configure existing hardware components in the hardware
settings.
1. Copy file "53843373_EquipmentModules_PROJ_PCS7V90SP1.zip" to any
folder on the configuration PC and then open SIMATIC Manager.
2. Click on "File > Retrieve" on the menu bar and select file
"53843373_EquipmentModules_PROJ_PCS7V90SP1.zip". Then click on
"Open" to confirm.
3. Choose the folder where you want to save the project and click on "OK" to
confirm.
The project is retrieved.
4. Confirm the "Retrieve" dialog by clicking on the "OK" button and then click on
"Yes" in the dialog to open the project.
5. Right-click on "EquipmentModules_OS > PCS7901 > WinCC Appl. > OS" and
then click on the "Open object" menu command.
6. Confirm the "Configured server not available" dialog with "OK".
© Siemens AG 2019 All rights reserved

7. In the WinCC Explorer, open the properties of your computer and, in the
opened Properties dialog, click on the "Use local computer name" button.

8. Confirm the "Change computer name" message with "OK".

9. In the WinCC Explorer, click on "File > Exit" and in the subsequent dialog
select "Terminate WinCC Explorer and close project".
10. Then confirm with "OK".
11. Reopen the WinCC Explorer as described in step 5.
12. Open by double-clicking on "Variables library".
13. In the "WinCC Configuration Studio", open "Variables library > SIMATIC S7
Protocol Suite > TCP/IP" and select the menu command "System parameters".
14. In the "Unit" tab, check the "Logical device names" setting. If the "S7 PLCSIM"
program is used, the device name "PLCSIM.TCPIP.12" is selected.
A restart is required after a device name change.

Note If the OS cannot establish a connection with the AS (grayed out module icons),
select the logical device name "CP_H1_1" and restart the OS runtime.

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2 Preparation and commissioning

2.2 Commissioning
You can commission the equipment modules after starting the simulation.
You can find a detailed description in Chapter 5.

Starting the simulation (S7 PLCSIM)

To start the simulation, proceed according to the following instructions:
1. Select "Extras > Simulate Modules" from the menu.
The "S7 PLCSIM" dialog window opens.
2. In the "Open project" dialog, select "Open project from file".
3. Select file "EquipmentModules.plc" from path <project
path>\Function\EM\EquipmentModules.plc>.
4. In the menu, change "PLCSIM(MPI)" to "PLCSIM(TCP/IP)".
5. In the menu, select "Execute > key switch position > RUN-P".

Activate OS (WinCC runtime)

To activate the OS, proceed according to the following instructions:
1. Right-click on the OS and select the menu "Open object".
2. To activate the OS (WinCC Runtime), select the menu command "File >
Activate" in WinCC Explorer.
3. In the "System Login" dialog, enter user name "Equipment" as the "Login" and
© Siemens AG 2019 All rights reserved

"Modules" as the password and then click on "OK" to confirm.

4. In the picture area, select an equipment module; in this example, it is
"temperature flow cascade".

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3 Integrating the Equipment Module in the user project

3 Integrating the Equipment Module in the

user project
3.1 Preparation
1. Copy the file "53843373_EquipmentModules_PROJ_PCS7V90SP1.zip" to the
configuration PC and then open the SIMATIC Manager.
2. Click on "File > Retrieve" in the menu bar and select the file
"53843373_EquipmentModules_PROJ_PCS7V90SP1.zip". Then confirm by
clicking on "Open".
3. Select the folder in which the project will be saved and confirm with the "OK"
button.
The project will be extracted.
4. In the "Retrieve" dialog, click on the "OK" button and then click on "Yes" in the
dialog to open the project.
5. Switch to the "Plant view".
6. At the same time, open the project in which the Equipment Modules is to be
integrated.

3.2 Copying templates

Note If you have already worked with CMTs in your existing project, then check that
they are identical before skipping to the following steps, since this can lead to
errors in your existing project or in the Unit Template you want to integrate.

1. Switch to the plant view.

2. Copy the "BPCM" and "pH" folder containing the CMTs from the master data
library into the target project.

3. Copy the Enumerations from the master data library into the target project.

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3 Integrating the Equipment Module in the user project

3.3 Copying Equipment Module

1. Copy the hierarchy folder with the desired Equipment Module from the AS
project of the Equipment Module to the plant view of the target project.

2. Copy the corresponding process screens from the OS project of the Equipment
© Siemens AG 2019 All rights reserved

Module to the plant view of the target project as well. If you wish, you can also
copy the pictures "Help" and "Overview".

Note When copying the process screens, make sure that you copy the pictures to the
hierarchy level of the target project, which is configured as an OS area.

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3 Integrating the Equipment Module in the user project

3.4 Adapting the OS project

In order to facilitate the changing of colors in the process screen from a central
point, a central color palette was created in the OS project. To display these colors
in the process screen of your own project, you must import the relevant color
palette.
1. Select the "OS" in WinCC Explorer and choose "Object properties..." in the
shortcut menu.
2. Choose the "User Interface and Design" tab and click the "Edit" button.
3. Import the palette into your own project by means of the "Overwrite" option.
The color palette is located in the project folder of the Unit Template at the
path: "<Project path>\EquipmentModules\EM_OS\wincproj\OS\GraCS\
UnitTemplate.xml>". All existing colors will be replaced.
© Siemens AG 2019 All rights reserved

Note Please note that all colors are always used when exporting/importing color
palettes. It is not possible to export partial color tables.

If you have created your own color tables in your project, you can also export them
and use an editor to merge the tables in the XML file. Otherwise you can create a
new color table in your project and configure the colors individually. Make sure, too,
that the color index does not change, otherwise you will have to adjust the color
settings of the objects in the process screen. Of course it is up to you to change the
colors according to your requirements.

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4 Control Module

4 Control Module
4.1 Introduction
A control module is used to control individual pieces of equipment, like motors, valves,
and controllers, for example. The necessary blocks for carrying out this job, e.g.
controlling a valve, are combined in a control module (CM). If a control module is used
several times in the project, e.g. with different characteristics, you create a control
module type (CMT) from it in PCS 7 and store it in the master data library. You can
use this CMT in a flexible way anywhere in the project as an instance with different
characteristics (variants).
Using the technology allows to test automation projects using the program logic
even if you do not have the real hardware.

Note The application example "Control Module (CM) Technology - Efficient

Engineering with SIMATIC PCS 7" gives you a general overview of how to
create, extend, and instantiate a CMT. The application example is available at
the following link:
https://support.industry.siemens.com/cs/ww/en/view/109475748

Master data library

This chapter gives you detailed information about the structure and mode of operation
of the CMTs on which the equipment modules are based. All of the CMTs are stored in
© Siemens AG 2019 All rights reserved

the "EquipmentModules_Lib" master data library of the PCS 7 projects.

The CMTs are sub-divided as follows:

• Multivariable controller in the "ModPreCon" folder
• Analog measured value display in the "MonAn" folder
• Digital measured value display in the "MonDi" folder
• Motor in the "Mot" folder
• Analog value input in the "OpAn" folder
• Digital value input in the "OpDi" folder
• Controller in the "PIDCon" folder
• Valve in the "Vlv" folder

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4 Control Module

CMTs are of compact structure, i.e. all the relevant blocks are at defined locations.
For example, channel blocks are always in chart partition B of a CFC.

Note Folder "pH" contains the source files of the pH simulation and the conversion
block from pH value to concentration difference. The functions and structure of
the block are described in Section 6.5.

Selecting a variant
A variant and the options that are necessary for solving an automation task are
determined in the instance.
1. To do this, the system displays the technological I/Os in the CFC,
2. the available variants are displayed via the shortcut menu and
3. the functionality that is necessary for the automation task is determined by
selecting the options.
© Siemens AG 2019 All rights reserved

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4 Control Module

4.2 Best Practice Control Module Type Library

The Best Practice Control Modules (BPCM) in the form of a Type Library are
available for SIMATIC PCS 7 as a master data library and contain typical, pre-
projected and tested CMT. The BPCM are created with CM technology and enable
more efficient engineering through standardized program components.
The following benefits are achieved by using the BPCM Type Library:
• Extensive library for different applications and industries
• Reduction of the project planning effort
• Reduced maintenance
• Standardized structures
The BPCM Type Library offers typical components as a template for building
automation solutions. The CMT of the BPCM Type Library contain all necessary
function and channel blocks and can be adapted to the project-specific conditions
by instantiation.
The BPCM's are based on the SIMATIC PCS 7 Advanced Process Library (APL)
and Industry Library (IL), are hardware-independent, pre-configured and modular.
The library "109475748_BPCM_LIB_PCS7_V90SP1.zip" provides the following
CMT groups:
• MonAn: Analog measured value display
•
© Siemens AG 2019 All rights reserved

MonDi: Digital measured value display (binary signal)

• OpAn: Setting a analog value by the operator
• OpDi: Setting a binary value by the operator
• PIDConL Controller for standard and cascade control loops
• Mot: Motor control with simple speed control
• MotSpdC: Motor control with variable speed control
• Vlv: Valve actuation with two defined positions
• VlvAn: Valve control with analog control valve

Note The BPCM library uses the name of the central technology block of the APL.

Note A detailed description of each CMT with function description, supported variants
and control elements you can find in the application example "Control Module
(CM) Technology - Efficient Engineering with SIMATIC PCS 7" under the link:
https://support.industry.siemens.com/cs/ww/en/view/109475748

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4 Control Module

4.3 "ModPreCon" 4x4 multivariable controller

The multivariable controller CMTs contains controller blocks, a control performance
monitoring system, interface blocks (slave/actuator) and the link to sequential
function charts.
The CMTs are pre-configured for different areas of application. Using options, you
select or deselect blocks, e.g. the channel blocks, that are needed for the
application.
The following CMTs are available:
• "ModPreCon" for multivariable control using up to four controlled variables
• "ModPreCon4Valve" for one controlled variable with several disturbance
variables

4.3.1 Standard multivariable controller

CMT "ModPreCon" is used for multivariable controllers. Unlike the "PIDCon",

multivariable controllers master up to four manipulated and controlled variables that
are interacting with each other.
The instance receives the process variables with standardization from the "MonAn"
process tags via "from_Indicate_x". The number of controlled variables is
determined by activating options "Ctrl_PV_3” and "Ctrl_PV_4”. It is not possible to
deselect "Ctrl_PV_1" and "Ctrl_PV_2" and they correspond to the smallest
© Siemens AG 2019 All rights reserved

configuration. Each "Ctrl_PV_x" option contains the monitoring of control

performance, interface blocks for the process variable ("MonAn") and controller
process tag as well as the setpoint tolerance limits and manipulated variable
tracking.
Due to the complex control tasks (affected by up to four manipulated variables) and
the required computing power, the multivariable controller is used by preference for
slow control loops.
Examples of multivariable controllers include:
• Control of drying processes (product quality)
• Control of distillation columns (rectification)

Structure
Chart partion A

Sheet 1 Sheet 4

Sheet 2 Sheet 5

Sheet 3 Sheet 6

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4 Control Module

Blocks for static operating point optimization of controlled variables of the MPC
controller are located on sheet 2:
• SP1OptHiLim ("Add04"): Adaptation of the upper tolerance limit for SP1
• SP1OptLoLim ("Add04"): Adaptation of the lower tolerance limit for SP1
• SP2OptHiLim ("Add04"): Adaptation of the upper tolerance limit for SP2
• SP2OptLoLim ("Add04"): Adaptation of the lower tolerance limit for SP2
• SP3OptHiLim ("Add04"): Adaptation of the upper tolerance limit for SP3
• SP3OptLoLim ("Add04"): Adaptation of the lower tolerance limit for SP3
• SP4OptHiLim ("Add04"): Adaptation of the upper tolerance limit for SP4
• SP4OptLoLim ("Add04"): Adaptation of the lower tolerance limit for SP4

Note In the case of operating point optimization, you do not specify an exact setpoint
(e.g. SP1) for a controlled variable; rather, a tolerance range is specified. The
© Siemens AG 2019 All rights reserved

associated command value (CV1) may be within this tolerance. Due to this
tolerance definition, the controller works more flexibly and more economically,
since it does not have to control continuously to a fixed value.

The following blocks are located on sheet 3:

• MV1_TrkOn ("Or04"): Forced manipulated variable (MV1) for the MPC
controller in the case of a hardware fault (CV_Bad) or if cascade switching is
interrupted between the MV1 PID controller and the slave controller
• MV2_TrkOn ("Or04"): Forced manipulated variable (MV2) for the MPC
controller in the case of a hardware fault (CV_Bad) or if cascade switching is
interrupted between the MV2 PID controller and the MV2 slave controller
• MV3_TrkOn ("Or04"): Forced manipulated variable (MV3) for the MPC
controller in the case of a hardware fault (CV_Bad) or if cascade switching is
interrupted between the MV3 PID controller and the MV3 slave controller
• MV4_TrkOn ("Or04"): Forced manipulated variable (MV3) for the MPC
controller in the case of a hardware fault (CV_Bad) or if cascade switching is
interrupted between the MV4 PID controller and the MV4 slave controller

The blocks below for monitoring and display of the control performance and the
control deviation are located on sheet 4:
• Suppr_CPM_Calc_1 ("Or04"): Suppression of CPI calculation and message if
message suppression was caused at an "MPC_CPM_x" (CPI_SuRoot = 1) or a
warning is active due to low control performance (CPI_WL_Act = 1).
• Suppr_CPM_Calc_2 ("Or04"): Suppression of CPI calculation and message if
message suppression was caused at an "MPC_CPM_x" (CPI_SuRoot = 1) or a
warning is active due to low control performance (CPI_WL_Act = 1).

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• Suppr_CPM_Calc_3 ("Or04"): Suppression of CPI calculation and message if

message suppression was caused at an "MPC_CPM_x" (CPI_SuRoot = 1) or a
warning is active due to low control performance (CPI_WL_Act = 1).
• Suppr_CPM_Calc_4 ("Or04"): Suppression of CPI calculation and message if
message suppression was caused at an "MPC_CPM_x" (CPI_SuRoot = 1) or a
warning is active due to low control performance (CPI_WL_Act = 1).
• MPC_CPM_1 ("ConPerMon"): Block for permanent monitoring of control
performance (SP1Out, MV1 and CV1Out)
• MPC_CPM_2 ("ConPerMon"): Block for permanent monitoring of control
performance (SP2Out, MV2 and CV2Out)
• MPC_CPM_3 ("ConPerMon"): Block for permanent monitoring of control
performance (SP3Out, MV3 and CV3Out)
• MPC_CPM_4 ("ConPerMon"): Block for permanent monitoring of control
performance (SP4Out, MV4 and CV4Out)
• QI_1 ("MonAnL"): Display and limit monitoring of the average value of control
deviation for the TimeWindow specified in "MPC_CPM_1"
• QI_2 ("MonAnL"): Display and limit monitoring of the average value of control
deviation for the TimeWindow specified in "MPC_CPM_2"
• QI_3 ("MonAnL"): Display and limit monitoring of the average value of control
deviation for the TimeWindow specified in "MPC_CPM_3"
• QI_4 ("MonAnL"): Display and limit monitoring of the average value of control
deviation for the TimeWindow specified in "MPC_CPM_4"
© Siemens AG 2019 All rights reserved

The following blocks are located on sheet 5:

• from_Indicate_1 ("ComStruOut"): Reception of signals (measured value, unit,
scaling and messages) of the first process value to be controlled
• from_Indicate_2 ("ComStruOut"): Reception of signals (measured value, unit,
scaling and messages) of the second process value to be controlled
• from_Indicate_3 ("ComStruOut"): Reception of signals (measured value, unit,
scaling and messages) of the third process value to be controlled
• from_Indicate_4 ("ComStruOut"): Reception of signals (measured value, unit,
scaling and messages) of the fourth process value to be controlled
• SPLim_1 ("StruScIn"): Upper and lower setpoint limit of the first process value
• SPLim_2 ("StruScIn"): Upper and lower setpoint limit of the second process
value
• SPLim_3 ("StruScIn"): Upper and lower setpoint limit of the third process value
• SPLim_4 ("StruScIn"): Upper and lower setpoint limit of the fourth process
value
• CSF ("Or04"): Formation of an OR output signal of the hardware faults of the
channel blocks of the process values for tracking the respective controller
• OosAct ("Or04"): Formation of an OR output signal of the "OosAct" message of
the channel blocks (field device is being maintained) of the controlled variables
for the MPC

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The link blocks below, which are used for rapid engineering, are located on sheet 6:
• from_CTRL_1 ("ComStruOu"): Reception of control commands of the lower
level PID controller for the MPC controller parameters ("MV1ManHiLim",
"MV1ManLoLim", and "MV1Trk") and the "MV1_TrkOn" block.
• to_CTRL_1 ("ComStruIn"): Output of the manipulated variable as a setpoint to
the lower-level PID controller.
• from_CTRL_2 ("ComStruOu"): Reception of control commands of the lower
level PID controller for the MPC controller parameters ("MV2ManHiLim",
"MV2ManLoLim", and "MV2Trk") and the "MV2_TrkOn" block.
• to_CTRL_2 ("ComStruIn"): Output of the manipulated variable as a setpoint to
the lower-level PID controller.
• from_CTRL_3 ("ComStruOu"): Reception of control commands of the lower
level PID controller for the MPC controller parameters ("MV3ManHiLim",
"MV3ManLoLim", and "MV3Trk") and the "MV3_TrkOn" block.
• to_CTRL_3 ("ComStruIn"): Output of the manipulated variable as a setpoint to
the lower-level PID controller.
• from_CTRL_4 ("ComStruOu"): Reception of control commands of the lower
level PID controller for the MPC controller parameters ("MV4ManHiLim",
"MV4ManLoLim", and "MV4Trk") and the "MV1_TrkOn" block.
• to_CTRL_4 ("ComStruIn"): Output of the manipulated variable as a setpoint to
the lower-level PID controller.
© Siemens AG 2019 All rights reserved

Note The process value is made available to the MPC by linking the MonAn control
module ("to_Indicate" block) with the "from_Indicate_x" block.

4.3.2 Predictive controller for only one controlled variable

The "ModPreCon4Valve" CMT is used for fixed value controllers where the
controlled variable is affected by one or more measurable disturbance variables,
e.g. pH value control.
The MPC gets the units and standardization automatically from the connected
interface blocks, from the controlled and manipulated variables, and from at least
one disturbance variable.

Note The number of disturbance variables is determined by activating option

'"Opt_DVx" and interconnecting the respective process value. The disturbance
variables are interconnected with the following MPC inputs:
• 1st disturbance variable at the DV1 input of the MPC (activated as standard)
• 2nd disturbance variable at the MV2Trk input of the MPC (optional)
• 3rd disturbance variable at the MV3Trk input of the MPC (optional)
• 4th disturbance variable at the MV4Trk input of the MPC (optional)

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Structure
Chart partion „A“

Sheet 1 Sheet 4

Sheet 2 Sheet 5

Sheet 3 Sheet 6
© Siemens AG 2019 All rights reserved

Chart partition A
The following blocks are located on sheet 1:
• MPC ("ModPreCon"): Multivariable controller
• AutoExcitation ("AutoExci"): Process excitation signals for the predictive MPC
(during commissioning of the controller only)
Blocks for static operating point optimization of the controlled variable of the MPC
controller are located on sheet 2:
• SP1OptHiLim ("Add04"): Adaptation of the upper tolerance limit for SP1
• SP1OptLoLim ("Add04"): Adaptation of the lower tolerance limit for SP1

Note In the case of operating point optimization, you do not specify an exact setpoint
(e.g. SP1) for a controlled variable; rather, a tolerance range is specified. The
associated command value (CV1) may be within this tolerance. Due to this
tolerance definition, the controller works more flexibly and more economically,
since it does not control continuously to a fixed value.

The blocks below for monitoring and display of the control performance and the
control deviation are located on sheet 4:
• MPC_CPM ("ConPerMon"): Block for permanent monitoring of control
performance (SP1Out, MV1 and CV1Out)
• QI ("MonAnL"): Display and limit monitoring of the average value of control
deviation for the TimeWindow specified in "MPC_CPM"

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The following blocks are located on sheet 5:

• from_CV ("ComStruOut"): Receiving of signals (measured value, unit, scaling
and messages) of the controlled variable
• CV_Lim ("StruScIn"): Upper and lower setpoint limit of the controlled variable
• from_DV1 ("ComStruOut"): Receiving of signals (measured value, CSF-signal
and unit) of the first disturbance variable
• from_DV2 ("ComStruOut"): Receiving of signals (measured value, CSF-signal
and unit) of the second disturbance variable
• from_DV3 ("ComStruOut"): Reception of signals (measured value, CSF-signal
and unit) of the third disturbance variable
• from_DV4 ("ComStruOut"): Reception of signals (measured value, CSF-signal
and unit) of the fourth disturbance variable
• CSF ("Or04"): Formation of an OR output signal of the hardware faults of the
controlled variable channel blocks and the control valve for tracking the
manipulated variable
• OosAct ("Or04"): Formation of an OR output signal of the "OosAct" message of
the channel blocks (field device is being maintained) of the controlled variables
and the control valve for the MPC

Note The process values of the controlled variable and the disturbance variables are
made available to the MPC by linking the MonAn control modules ("to_Indicate"
© Siemens AG 2019 All rights reserved

block) with the "from_CV", "from_DVx" block.

The link blocks below, used for rapid engineering, are located on sheet 6.
• to_Actor ("ComStruIn"): Transfer of the manipulated variable (MV1), and the
locking status (OosAct) to the actuator.
• from_Actor ("ComStruOu"): Reception of signals and standardization and unit
of the actuator for the MPC (CSF, OosAct, ScaleOut, Unit).
• MV1_Scale ("StruScIn"): Upper and lower manipulated variable limit for limiting
the manipulated variable in the controller in manual and automatic modes.

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4.4 "PIDCon” controller

The controller CMTs contain controller blocks, additional monitoring and interlock
functions, interface blocks (master/actuator), and a link to sequential function
charts.
The CMTs are pre-configured for different areas of application.
The following controller CMTs are available:
• "PIDCon” for standard PID controllers
• "PIDConRatio" for ratio controllers
• "PIDConSplitRange” for controllers with one manipulated variable and two
actuators

4.4.1 Standard controller

The "PIDCon” CMT is used for fixed-value and cascade controllers and is a
component from the Best Practice Control Modules (BPCM). The detailed
description of the you can find in the application example "Control Module (CM)
Technology - Efficient Engineering with SIMATIC PCS 7" under the link:
https://support.industry.siemens.com/cs/ww/en/view/109475748
© Siemens AG 2019 All rights reserved

Examples of standard controllers include:

• Fill level controller with inflow and outflow
• Temperature control

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4.4.2 Ratio controller

The "PIDConRatio” control module type is used for ratio controllers. Ratio
controllers are composed of a flow controller (for the main component) and a flow
controller for each additional component. The instance of "PIDConRatio” is used
for the component that is to be added in a defined ratio, e.g. the blended
component.

Note In "Plant View”, you activate master/slave operation by selecting

"Opt_IF_Master”. After activation, the "to_Master” and "from_Master” link blocks
are available.

Using variants, the corresponding channel block is selected or deselected based

on measured value transfer.
In addition, it is possible to use options to activate further functions without
configuration at the CMT instance.
Variants and options are listed and described below.

Variant 1: Controller for analog measurement and manipulated variable (4-20 mA)
Variant 1 is activated by selecting functions PV_In and Opt_PV_Scale at the
instance.
© Siemens AG 2019 All rights reserved

Variant 2: Controller for thermocouples

This variant is used for thermocouples that are connected to an analog input
module for temperature measurement.
Variant 2 is activated by selecting function PV_TE_In at the instance.

Note Scaling on the channel block has already been preset for the range 0 to 1.
You must carry out process value scaling at input "NormPV” of display block "C”.

Variant 3: Controller for digital measurement (field bus)

This variant is used if you are using measuring devices with Profibus PA or
Fieldbus Foundation (FF).
Variant 3 is activated by selecting functions PV_Fb_In and Opt_PV_Scale on the
instance.

Variant 4: Controller for software signal

Variant 4 is the default setting without additional functions activated at the instance.
In this variant, the process value is obtained by direct CFC connection from
existing process tags. Using the optional DeltaCalc function, it is possible to apply
difference measurement for the controlled variable.
Optional functions for all variants:
• PV_Scale#: Standardization of the process value including the channel block
• CPM: Monitoring of the control quality
• IF_Master#: Connection to a master controller (cascade)
• PV_DeltaCalc#: Differentiation
• Interlock: Interlocking block

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The figure below lists the available options.

PV_TE_In
PV_Fb_In
PV_DeltaCálc
IF_Master#
PV_Scale#

PV_In
Intlock
CPM
PIDConRatio
(CMT Master Data Library)

Variants Function Channel block Description

PIDConRatio_Std x o o o x Standard display (analog)
PIDConRatio_TE o o o o x Measured value display for thermocouples
PIDConRatio_Fb x o o o x Measured value display fieldbus
PIDConRatio_SW o o o o o Program logic without channel blocks
x = Selecting a variant o = Selectable functions

Examples of ratio controllers include:

• Blending control of liquids or gases with a defined mixing ratio
• Air feed in a defined ratio to fuel gas feed for gas burners

NOTICE When using the Plant Automation Accelerator (PAA) V2.1, the variant
"PV_Scale#" should not be used.
The scaling is set in PAA at the respective signal and adopted by the appropriate
"Scale" input when exporting to SIMATIC PCS 7.
© Siemens AG 2019 All rights reserved

Note In "plant view", you activate master/slave operation by selecting "IF_Master#".

After activation, the "to_Master" and "from_Master" link blocks are available.

Structure
Chart partion „A“ Chart partion „B“

Sheet 1 Sheet 4 Sheet 1

Sheet 2 Sheet 5 Sheet 2

Sheet 3 Sheet 6 Sheet 3

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Chart partition "A"

The following blocks are located on sheet 1:
• PV_Scale: Standardization of the process value for a channel block and
measured value display
• PV_Unit: Standardization of the unit for a channel block and displaying
measured values
• C ("PIDConL"): PID controller
• CPM ("ConPerMon"): Block for permanent monitoring of control quality
The outputs, operating mode, setpoint, actual value and manipulated variable
of the PID controller are interconnected with the CPM block
The following blocks are located on sheet 2:
• AIF_SFC ("ConnPID"): A free block for SFC linking (not a component of the
APL or the standard library)
• Logic blocks for selecting the operating mode and for interlocking
– SP_LiOp ("Or04"): Setpoint source internal/external
– SP_IntLi ("Or04"): Internal setpoint via interconnection
– MV_Forced ("SelA02In"): Forced manipulated variable with selection ("In1"
undefined, "In2" SFC link)
– MV_ForOn ("Or04"): Activates forced manipulated variable "In2"
(MV_Forced) on the PID controller
© Siemens AG 2019 All rights reserved

– ManModOpLi ("Or04"): Formation of an OR output signal from field device

in maintenance (channel blocks PV and MV) and invalid process value
(channel block PV in chart partition "B", Sheet 1.)
– ModLiOp ("Or04"): Operating mode selection between operator and
interconnection or SFC
– ManModLi ("Or04"): Manual mode via interconnection or SFC (controlled
via ModLiOp = 1)
Using the SFC link, data that is relevant to production is transferred to the PID
controlling via the logic blocks. In addition, channel blocks and the interlocking
block (chart partition "A", Sheet 3) affect the output signals of the logic blocks.
Sheet 3 contains the "Intlock" interlocking module, which combines signals for
standardized interlocking with the option of displaying them on the OS.
The link blocks below, used for rapid engineering, are located on sheet 6.
• to_Actor_Slave ("ComStruIn"): Transfer of the manipulated variable (MV),
setpoint value (SP), process value (PV), and the locking status to the actuator
or slave (slave in the case of cascade control)
• from_Actor_Slave ("ComStruOu"): Reception of the actuating signal feedback
(Rbk), the message with invalid process values, and field device maintenance
of channel blocks MV and Rbk, of the out unit and scaling of the actuating
display and travel range (ScaleOut) of the actuator or slave (slave in the case
of cascade control)
• to_Master ("ComStruIn"): The communication block forms a structure
consisting of outputs (setpoint, block is "out of service" message, message for
cascade switching, process value), of the PID controller, of the CSF block
(message of the channel blocks in the case of an invalid process value), and of
channel blocks PV and MV (unit and scaling of the process value).
• from_Master ("ComStruOu"): The communication block receives from the
controller process tag of the main component the signals of the CSF block and
the setpoint of the PID controller that are relevant to interlocking.

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• Ratio ("Ratio"): The block calculates the setpoint of the slave controller from
the setpoint of the master PID controller and the specified ratio.

Chart partition "B"

The channel blocks are located on sheet 1:
• PV ("Pcs7AnIn"): Channel block for signal processing of an analog measured
value, e.g. 0/4 to 20mA
• PV_TE ("Pcs7AnIn"): Channel block for signal processing of a resistance
thermometer
• PV_FB ("FBAnIn"): Channel block for signal processing of a digitized process
value (PA or FF processing unit)

The modules for the difference display are located on sheet 2:

• PV_DeltaCalc ("Sub02"): Formation of a difference value from two process
values, e.g. differential pressure
• FromDeltaIn1: Input 1 for the difference value
• FromDeltaIn2: Input 2 for the difference value
• PV_IN ("Add08"): Merging the "PV_In" signals (analog process value)
• CSF ("Or04"): Grouping of the "Bad" signals (invalid process value) and
reporting to the motor block and the Permit group block
•
© Siemens AG 2019 All rights reserved

OosAct ("Or04"): Grouping of the "OosAct" signals (device being maintained)

and reporting to the motor block

Note If a thermocouple is used, you must carry out scaling at channel block "PV_TE"
measured value display in addition to scaling at block PV_Scale (process value
scaling).

NOTICE The channel block for the thermocouple has already been preset for the
range 0.0 to 1.0.

On sheet 2, the system additionally acquires the messages of the valve process
tag channel block at blocks CSF and OosAct and transfers them to the controller.
In the case of a positive "OosAct" signal, the controller switches to manual mode.

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4.4.3 Split range controller

The "PIDConSplitRange” control module type is used for controllers where one
manipulated variable controls several actuators (with a limited effective range and
possibly the opposite direction of control action), i.e. the manipulated variable is
split to several actuators.

Note In "Plant View”, you activate master/slave operation by selecting

"Opt_IF_Master”. After activation, the "to_Master” and "from_Master” link blocks
are available.

Using variants, the corresponding channel block is selected or deselected based

on measured value transfer.
In addition, it is possible to use options to activate further functions without
configuration at the CMT instance.
Variants and options are listed and described below.

Variant 1: Controller for analog measurement and manipulated variable (4-20 mA)
Variant 1 is activated by selecting functions PV_In and Opt_PV_Scale at the
instance.

Variant 2: Controller for thermocouples

This variant is used for thermocouples that are connected to an analog input
module for temperature measurement.
Variant 2 is activated by selecting function PV_TE_In at the instance.

Note Scaling on the channel block has already been preset for the range 0 to 1.
You must carry out process value scaling at input "NormPV” of display block "C”.

Variant 3: Controller for digital measurement (field bus)

This variant is used if you are using measuring devices with Profibus PA or
Fieldbus Foundation (FF).
Variant 3 is activated by selecting functions PV_Fb_In and Opt_PV_Scale on the
instance.

Variant 4: Controller for software signal

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The figure below lists the available options.

PV_DeltaCalc#

PV_TE_In
PV_Fb_In
IF_Master#
PV_Scale#

PV_In
Intlock
CPM
PIDConSplitRange
(CMT Master Data library)

Variants Function Channel block Description

PIDConSplitRange_Std x o o o x Standard display (analog)
PIDConSplitRange_TE o o o o x Measured value display for thermocouples
PIDConSplitRange_Fb x o o o x Measured value display fieldbus
PIDConSplitRange_SW o o o o o Program logic without channel blocks
x = Selecting a variant o = Selectable functions

Examples of split-range controllers with opposite direction of control action include:

• Temperature controllers with separate actuators for heating and cooling, e.g.
valves for heating steam and cooling water, or electric heating and fan cooling.
• Pressure control with separate valves for gas feed and purge

Moreover, there are split range applications with several actuators with the same
direction of action (that individually would not be strong enough), e.g.
• Oxygen control in bio fermenters via air feed and stirrer speed.
• Oxygen control in wastewater treatment plants via several compressors.
© Siemens AG 2019 All rights reserved

Structure
Chart partition „A“ Chart partition „B“

Sheet 1 Sheet 4 Sheet 1

Sheet 2 Sheet 5 Sheet 2

Sheet 3 Sheet 6 Sheet 3

The control module type is preconfigured for the following setpoint range:
• Manipulated variable 0 to 100 (from the controller)
• Manipulated variable 50 to 100 corresponds to travel range 0 to 100 with
actuator 1
• Manipulated variable 50 corresponds to the neutral position, i.e. both actuators
are closed
• Travel range 0 to 50 corresponds to travel range 100 to 0 with actuator 2

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Chart partition "A"

– ManModOpLi ("Or04"): Formation of an OR output signal from field device

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• SplitRange ("SplRange"): block to split the manipulated variable MV from the

PID controller. The segmentation is based on the set parameters.
• to_Actor_Slave2 ("ComStruIn"): Transfer of the manipulated variable (MV),
setpoint value (SP), process value (PV), and the locking status to the actuator
or slave (slave in the case of cascade control)
• from_Actor_Slave2 ("ComStruOu"): Reception of the actuating signal feedback
(Rbk), the message with invalid process values, and field device maintenance
of channel blocks MV and Rbk, of the out unit and scaling of the actuating
display and travel range (ScaleOut) of the actuator or slave (slave in the case
of cascade control)
• SplitRangeCut ("Or04"): Grouping of the disconnect signals from the cascaded
valves to the controller.

Chart partition "B"

The modules for the difference display are located on sheet 2:

Note If a thermocouple is used, you must carry out scaling at channel block "PV_TE"
measured value display in addition to scaling at block PV_Scale (process value
scaling).

NOTICE The channel block for the thermocouple has already been preset for the
range 0.0 to 1.0.

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5 Equipment Modules
In this chapter, you will find all the relevant information for each equipment module
including specific properties. The structure and basic functionality of the control
module types that are used are described in Chapter 4 "Control Module".
The following equipment modules are described below:
• "Level-control"
• Buffer level control with feedforward disturbance compensation "Buffer-Control"
• "Split-Range-Pressure" control
• "Ratio-Control"
• "Split-Range-Temperature" control
• pH value control using the "pH-Control-Std" standard controller
• pH value control using the "pH-Control-MPC" model predictive controller
• Temperature cascade control via slave flow control loop "Temperature-Flow-
Cascade"
• Coarse-/Finestream control using the "Stream-Control”
• Gradient limits in actuators "Gradient-Limit"

Note Below, we will use the designations CM for control module and CMT for control
module type.
© Siemens AG 2019 All rights reserved

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5.1 "Level-Control" in process plants

Introduction
Depending on the tasks that a container (e.g. vessel, tank, reactor) has to fulfill in a
process plant, there are different objectives for a level controller. The two following
control strategies are the most common in process industry:
1. Keeping a level as close as possible to a specified setpoint, e.g. in a reactor or
the sump of a column. This is necessary if the level affects chemical reactions
or separation processes, i.e. it is significant to the process. Fluctuations in the
inflow are compensated via variation of outflow to keep the level constant.
2. Use a container (e.g. a tank) as a buffer to achieve an inflow or outflow that is
as uniform as possible. In this context, the system does not maintain a fixed
level value exactly at the setpoint; the level just has to stay within permissible
limits. This task is called "buffering controller" and characterizes the majority of
industrial applications.

5.1.1 Exact level control

In the case of exact level control, input materials are fed via inlet lines to a tank and
the mixture is removed via an outlet. The controller responds to deviations in the fill
level (caused by differences between the amount flowing in and out) and
compensates for them by either decreasing or increasing inflow or outflow.
For exact control of fill levels, a standard design with the PID tuner makes sense.
© Siemens AG 2019 All rights reserved

In this context, you should be aware that most fill level processes have integrating
behavior (e.g. outflow as a manipulated variable). In many cases, a proportional-
only controller (without integral action) is adequate, which harmonizes more easily
with the integrating process dynamics but shows permanent control errors if there
are disturbances in the inflow. If the valve characteristic curve is non-linear, it is
recommended in practice to use a cascade structure. The master controller
regulates the fill level via specification of setpoints for the slave (out)flow controller,
provided flow measurement at the outflow is available.
In the example below, level control is performed by directly manipulating the outlet
valve, i.e. without slave flow controller.

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Overview
Below, the structure in the P&ID schematic is shown and all of the CMs and the
simulation of the equipment module are described.

P&I Diagram
The P&ID below symbolically represents all of the components, such as field
devices and containers relevant to operation.
FI
Inlet

Inflow

LIC
Level

YC FI
Outlet_Level Outlet

Outflow
© Siemens AG 2019 All rights reserved

CM and variants
The "Level Control" equipment module consists of four connected CMs and one
simulation chart. The fill level of a container is simulated in the "Sim_Level”
simulation chart with the help of a non-linear model. In addition, the response of
the valve is simulated in this chart, which leads to a more realistic description of
dynamic valve behavior. In the "Sim_Level” simulation chart, the inflow is simulated
with the help of a valve module and the valve position provided for disturbance
compensation is added.
The following table provides an overview of the CMs of the equipment module
including the associated CMTs.
CM CMT Selected variants Description
FI_Inlet_Level "MonAn" • PV Display of container inlet
• PV_Scale#
FI_Outlet_Level "MonAn" • PV Display of container discharge
• PV_Scale#
LIC_Level "PIDCon" • CPM Level control of a container
• PV
• PV_Scale#
YC_Outlet_Level "ValAn" • GI Outlet valve for container discharge with
• Intlock safety position to prevent overflow
• IF_Ctrl#
• MV_Scale#
• YC

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In the figure below, the structure with the cross-chart interconnections is shown in
simplified form.

Sim_Level LIC_Level YC_Outlet_Level

PT1
PV V
In
SimPV_In MV

PV_in_percent
to_Actor1 from_Ctrl
OUT
Out Out

mul_p_Hydro
from_Actor1 to_Ctrl
OUT
In Out

ValvelDeadtime
VlvAnL
Out FI_Outlet_Level
Rbk
PV
ScaleInlet SimPV_In
OUT FI_Inlet_Level
PV
SimPV_In

Control "LIC_Level" acquires the fill level of the container ("Sim_Level” simulation
chart) and regulates it using "YC_Outlet_Level” control valve. In addition the two
process tags "FI_Outlet_Level" and "FI_Inlet_Level” serve the purpose of
displaying inflow and discharge in the OS.
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Structure and parameterization

"Sim_Level" simulation
The structure and the parameterization of the "Sim_Level" simulation used is
explained in Section 5.1.3.

LIC_Level
The instance has the following parameterization.
Block Connection Value Use
PV_Unit In 1342 Process value unit in %
C NegGain Activation of negative gain, since the
controller is used for the outflow
C Gain 2 Controller gain
C TI 111.96 Controller lag
C PV_AH_Li 95.0 Upper alarm limit for the process value
C PV_AH_En 1 Enable upper alarm limit
C PV_AH_Ac Interconnection to the outlet valve
(LIC_Level\to_Actor_Slave.BoStru3)
IF_SFC SP_Ext Connection for operator setpoint input for
comparison
(Compare\SP_Level.PV_In)
to_Actor_Slave BoStru3 Interconnection to PID controller
(LIC_Level\C.PV_AH_Ac)
to_Actor_Slave Out Interconnection to the valve
(YC_Outlet_Level\from_Ctrl.In)
from_Actor_Slave In Interconnection to the valve
(YC_Outlet_Level\to_Ctrl.Out)

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Block Connection Value Use

PV SimOn Activation of simulation on the channel
block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)
PV SimPV_In Interconnection for the simulated process
value
(Sim_Level\PV_in_percent.Out)

YC_Outlet_Level
The instance has the following parameterization.
Block Connection Value Use
V MV Interconnection to the valve simulation
(Sim_Level\PT1.In)
V SafePos 1 Safety position is open status
V Monitor 1 Display of Checkback signal in the OS
from_Ctrl In Interconnection to the controller
(LIC_Level\to_Actor_Slave.Out)
from_Ctrl BoStru3 Interconnection to the Interlock
(YC_Outlet_Level\Intlock.In1)
to_Ctrl Out Interconnection to the controller
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(LIC_Level\to_Actor_Slave.In)
MV_Out SimOn Activation of simulation on the channel
block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)
Intlock InvIn01 1 Inversion of Input 01
Intlock Logic OR OR input interconnection

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Commissioning and operation

2. In the faceplate, change the operating mode to "Automatic".

3. Switch to controller "LIC_Level" and change the operating mode of the

controller to "Automatic".
4. Enter a setpoint of 50 %.

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5. Switch to "Sim_Level/Sim_Flow_Rate” valve and change the setpoint to 50%

6. Wait for about 3 minutes and enter a new setpoint of 25% for the
"Sim_Level/Sim_Flow_Rate” valve.
7. Close the faceplate and observe the plotter for about two minutes until the new
setpoint has been reached again.
8. Then click on the "Start/Stop" icon on the toolbar of the OnlineTrendControl.
© Siemens AG 2019 All rights reserved

Evaluation

After the inflow reduction, the level drops below the setpoint. The controller
observes the level change and then reduces the setpoint of the discharge valve
until the level once again reaches the setpoint. Control towards the setpoint,
however, causes permanent fluctuations in the manipulated variable for the
discharge valve.

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5.1.2 Buffer level control with feedforward disturbance compensation

"Buffer-Control"

In process plants, tanks are often employed as buffer containers. An exact level
control is not necessary provided the level remains within defined limits. Instead
the controller has to work with as few interventions as possible. This reduces wear
on the valves and at the same time reduces resource consumption (compressed
air, etc.). In some applications, the primary aim is to achieve an outflow of the
container that is as even as possible, such that subsequent apparatuses receive
an inflow which is as even as possible. Common controller design methods (e.g. PI
control with deadband) deliver less-than-satisfactory results, because the
uncontrolled process is not asymptotically stable. Typically, there will be
oscillations at the edge or between high and low limit of the deadband.
In this example, we will show the advantages of buffer control including
feedforward disturbance compensation. Feedforward control reacts faster to
disturbances and largely prevents leaving the dead zone. For this, any measured
variable representative of the tank inflow, for example a flow measurement, a valve
position, or a pump rotational speed, is connected as a feedforward disturbance
compensation signal with its own deadband. The deadband of the buffer controller
is activated or deactivated dynamically.

Mode of operation
In the case of a closed-loop control with deadband, the manipulated variable is not
changed as long as the controlled variable moves within the parameterized limits of
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the deadband. Only if the values leave the deadband, the feedback controller and
consequently the final actuator become active.
If the controller is active, the deadband is dynamically switched off until the
controlled variable is again in the center of the deadband. This prevents a
permanent fluctuation at the edge of the deadband.

Note The actuator activity can be further reduced by means of low-pass filtering of the
disturbance variable. This has no effect on the stability of the control loop
because the low-pass filter is only in the feedforward variable and not in the
feedback path of the closed control loop. In addition, the feedforward control is
provided with its own deadband in order to further reduce actuator activity.

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Controller design
In context of a buffer control task, the required behavior is different from exact level
control. In buffer control, the tank volume is used selectively to compensate for
inflow fluctuations. Two options are available when doing this:
• The fill level is not measured continuously at all; rather, the minimum and
maximum limits are monitored by binary (e.g. capacitive) fill level switches.
Continuous control is not used for this solution; rather, discrete-event control is
used, i.e. a binary signal is used to close the inflow or outflow.
• Controller tuning is purposefully set slower. Within the scope of the
specification, the maximum permissible deviation Δhmax of the fill level from the
setpoint is defined, as well as the maximum hight dmax of inflow step
disturbances to be expected. With regard to permanent control deviation, the
gain of a P controller must be defined as greater than Gain= dmax / Δhmax. You
can also set up a PI controller such that the maximum deviation of fill level after
step disturbance is less than dmax. In the Dechema Seminar entitled "Process
Controls – From the the Basics to Advanced Control" (www.dechema.de), the
formulas below are recommended:
– GainEff = 0.7358 dmax / Δhmax
– Ti = 5.4366/Ki * Δhmax / dmax

Note The physical controller gain is in units MV_Unit/PV_Unit. In case of normalization

(NormPV ≠ NormMV), gain must be converted according to the following
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formula:
Gain = GainEff * (NormPV.High - NormPV.Low) / (NormMV.High - NormMV.Low)

It is possible to determine the integration constant Ki of the controlled process in

the unit PV_Unit/s using the PID tuner. You can find the integration constants at
"Gain" in the "Process parameter" sector.

• In order to avoid permanent control deviations, the proportional-only controller

is enhanced with feedforward disturbance compensation. This alternative is
implemented in the template. In this case, the formulas with respect to
disturbance amplitude mentionend in the above paragraph are not relevant.
The controller can be designed with any standard approach considering
stability and control performance, e.g. with PCS 7 PID-Tuner. During
application of PID-Tuner take care that the disturbance variable stays as even
as possible during data logging for step testing. After tuning, the level controller
is temporarely run without deadband to verify loop dynamics, before activating
deadband in order to smooth outflow variations.

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Overview

P&I Diagram
The P&I diagram below symbolically represents all of the components, such as
field devices and tanks relevant to operation.
Inflow FI
Inlet

DV (FFWD)

LIC
Buffer

YC FI
Outlet_Buffer Outlet

Outflow

CM and variants
The "BufferControl" equipment module consists of three connected control
modules, a CFC chart for the dynamic deadband of the feedforward disturbance
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compensation and a simulation plan. The level of a container is simulated in the

"Sim_Buffer” simulation chart with the help of a non-linear model. In addition, the
dynamic response of the valve is simulated in this chart, which leads to a more
realistic model of valve behavior. In the "Sim_Buffer” simulation chart, the inflow is
simulated with the help of a valve module and valve position is provided as
disturbance variable.
The following table provides an overview of the components of the equipment
module including the associated control modules.
CM CM Selected variants Description
FI_Inlet_Buffer "MonAn" • PV Display of the container inlet
• PV_Scale#
FI_Outlet_Buffer "MonAn" • PV Display of container discharge
• PV_Scale#
LIC_Buffer "Ctrl" • CPM Level control
• PV
• PV_Scale#
YC_Outlet_Buffer "ValAn" • GI Outlet valve for container discharge with
• Intlock safety position to prevent overflow
• IF_Ctrl#
• MV_Scale#
• YC

In the figure below, the structure with the cross-chart interconnections is shown in
simplified form.

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Sim_Buffer Dyn_Deadband YC_Outlet

Flow_Limit Flow_Smoothing
V
OUT In
MV

PT1 Flow_to_MV
from_Ctrl
In Out
Out

ValvelDeadtime
to_Ctrl
Out
Out

PV_in_percent LIC_Buffer VlvAnL

OUT
IF_SFC Rbk
FFwd
mul_p_Hydro
OUT FI_Outlet
PV
PV
ScaleInlet SimPV_In
SimPV_In
OUT
to_Actor1
Out
FI_Inlet
PV
from_Actor1
SimPV_In
In
© Siemens AG 2019 All rights reserved

Control "LIC_Buffer" acquires the fill level of the container and regulates it using
"YC_Outlet_Buffer” control valve. In addition the "Sim_Buffer” transmits the
disturbance variable – the inflow into the container – to the "LIC_Buffer” process tag
which adds the "disturbance variable” to the manipulated variable of the controller. In
addition, the simulation generates from the valve state the inlet and outlet of the
tank, which visualize over the both display monitors "FI_Inlet" and "FI_Outlet".

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Structure and parameterization

Sim_Buffer
The structure and the parameterization of the "Sim_Buffer" simulation used is
explained in Section 5.1.3.

LIC_Buffer
The instance has the following parameterization.
Block Connection Value Use
PV_Scale HiScale 100.0 Scaling of the process value upper limit
PV_Unit In 1342 Process value unit in %
C NegGain 1 Activation of negative gain, since the
controller is used for the outflow
C Gain 0.8 Controller gain
C TI 0.0 Controller lag
C DeadBand 15.0 Deadband
C SP_InHiLim 100.0 Maximum value of the internal setpoint
C PV_AH_Li 95.0 Upper alarm limit for the process value
C PV_AH_En 1 Enable upper alarm limit
C SettliFa 0.0 Transient recovery time factor to return to
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deadband
C Feature.Bit3 1 Dynamic deactivation of deadband upon
0 leaving deadband
C PV_AH_Ac Interconnection to the outlet valve
(LIC_Buffer\to_Actor_Slave.BoStru3)
C PhaseDeadb Interconnection for deadband disabling
and upon feedforward control
(DynDeadband\Deadband_disable.In)
IF_SFC SP_Ext Interconnection for operator setting of
setpoint for comparison
(Compare\SP_Level.PV_In)
IF_SFC FFwd Interconnection for disturbance dynamic
deadband
(DynDeadband\DV_to_MV.In)
to_Actor_Slave BoStru3 Interconnection to PID controller
(LIC_Buffer\C.PV_AH_Ac)
to_Actor_Slave Out Interconnection to the valve
(YC_Outlet_Buffer\from_Ctrl.In)
from_Actor_Slave In Interconnection to the valve
(YC_Outlet_Buffer\to_Ctrl.Out)
PV SimOn Activation of simulation on the channel
block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)
PV SimPV_In Interconnection for the simulated process
value
(Sim_Buffer\PV_in_percent.Out)

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Note Determined by the nature of the process, the level does not have to correspond
exactly to the setpoint but must instead be in a mid-container zone instead. For
this reason it is a P-controller with a relatively small controller gain (<1) and an
activated deadband. In order to avoid an oscillation around the deadband limit,
the dynamic deadband disabling is effected via the feature bit 30 of the
"PIDConL” function block. If the fill level leaves the deadband, this is deactivated
and the fill level is brought to the center of the dead zone by the now active
control. Only then is the control deactivated again and the manipulated variable
is held.

Note Feedforward control is realized via the "PIDConL.FFwd" connection. The value
of "FFwd" is internally added to the manipulated variable "MV" by the controller
and thus directly affects the position of the actuator. The flow measurement of
the container inlet is used as the disturbance variable.

Dyn_Deadband
Due to inflow fluctuations, feedforward control leads to a permanent actuator
activity despite the active controller deadband. This undesirable behavior is
suppressed in the "Dyn_Deadband" CFC. In order to calculate the appropriate
value for feedforward control, a characteristic curve for the effect of the disturbance
variable on level control is stored.
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1 4

7
6
3

1. Filtering of steep signal gradients (first order lag with 3 seconds time-constant)
2. Calculation of the upper limit for the adoption of a new disturbance value
(Addition)
3. Calculation of the lower limit for the adoption of a new disturbance value
(Subtraction)
4. Evaluation as to whether a limit has been exceeded or undercut
5. Deactivation of disturbance variable deadband upon disabling of controller
deadband
6. Switchover between new and old disturbance variable
7. Conversion of disturbance variable to manipulated variable signal with the help
of a polygon function block

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Note In practice you will have to determine the interpolation values of the polygon
function block either experimentally or on the basis of pre-existing
measurements. When the deadband is disabled, the associated outflow valve
positions are recorded for the various values of the disturbance variable which
lead to the desired constant level. The value pairs "disturbance variable
measurement / valve position" yield the different interpolation points "InX / OutX"
of the polygon module.

YC_Outlet_Buffer
The instance has the following parameterization.
Block Connection Value Use
V MV Interconnection to valve simulation
(Sim_Buffer\PT1.In)
V SafePos 1 Safety position is open status
V Monitor 1 Display of readback signal in the OS
from_Ctrl In Interconnection to the controller
(LIC_Buffer\to_Actor_Slave.Out)
from_Ctrl BoStru3 Interconnection to the Interlock
(YC_Outlet_Buffer\Intlock.In1)
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to_Ctrl Out Interconnection to the controller

(LIC_Buffer\to_Actor_Slave.In)
MV_Out SimOn Activation of simulation on the channel
block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)
Intlock InvIn01 1 Inversion of Input 01
Intlock Logic OR OR input interconnection

NOTICE Container overflow

In the case of control with deadband, a safety logic must also be implemented in
order to avoid overflow of the container at all costs. For this purpose, an interlock
is implemented which forces the valve immediately into the safety position (in
this case open) in the event of an overflow risk.

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Commissioning and operation

2. In the faceplate, change the operating mode to "Automatic".

3. Switch to controller "LIC_Buffer" and change the operating mode of the
controller to "Automatic".
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4. Enter a setpoint of 50 %.

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5. Switch to "Sim_Buffer/Sim_Flow_Rate” valve and change the manipulated

variable to 50%

6. Wait for about 3 minutes and then enter a new setpoint of 25% for the
"Sim_Buffer/Sim_Flow_Rate” valve.
7. Close the faceplate and observe the plotter for about two minutes until the
setpoint has been reached again.
8. Then click on the "Start/Stop" icon on the toolbar of the OnlineTrendControl.
© Siemens AG 2019 All rights reserved

Evaluation

1. After the inflow has been reduced, the feedforward compensation reduces the
setpoint of the outflow valve such that the tank level does not leave the
deadband. In this case the controller does not need to intervene.
2. Thanks to the relatively wide deadband, the fill level does not reach the
setpoint exactly again, but instead remains slightly below the setpoint.

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However, for this no further intervention of the controller via the outlet valve is
necessary, so that the valve can be operated in a low-wear manner. Outflow
keeps constant for longer time intervals.

5.1.3 Simulation - structure and parameterization

"Sim_Buffer" and "Sim_Level" simulations are of identical structure and are valid
for the level controls in Sections 5.1.1 and 5.1.2. This means the results obtained
from the diverse control concepts can be compared with each other.
Each simulation consists of three separate sheets: Part 1 contains the simulation of
the level and calculates the flow rate of the outflow.
1

3 4 5

6
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7 8

1. Calculation of the flow for the inlet (valve opened by 100% corresponds to
inflow of 250 l/s)
2. Calculation of the flow for the outlet (valve opened by 100% corresponds to
inflow of 0.48 m^2)
3. Determination of level change (addition of inflow and subtraction of discharge)
4. Formation of an integral value by integrating the change in flow (every second)
5. Delay in level (PT1 response with 3.5-second delay)
6. Calculation of flow rate for discharge according to Torricelli’s Law
7. Creation of measurement noise
8. Conversion of level into percentage

Note According to Torricelli’s Law, the higher the level, the higher the flow speed in
the container outflow, proportional to the square root of the fill level. As a
consequence, for the same valve position the discharge rate will vary depending
on the fill level of the container:

Torricelli’s efflux velocity theorem: v ~ √2 ∙ g ∙ h

q = A ∙v
v: Efflux rate g: Gravitational constant
h: Fill height A: Efflux cross-section
q: Outflow quantity

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On sheet 2 an equal percentage characteristic line for the outlet valve is simulated.
In addition the valve reaction is delayed with respect to the valve position setpoint,
and the valve position is discretized to simulate the behavior of an electro-
pneumatic valve positioner.
The following figure shows a linear and an equal-percentage valve characteristic
line:
© Siemens AG 2019 All rights reserved

Note For further information about the equal-percentage valve characteristic line
please refer to standard VDI-2173.

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1. Delay in valve actuation (first order lag with time constant 2 seconds)
2. Valve actuation in integer numbers (1% steps)
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3. Dead time of valve actuation (delay of 1 second)

4. Approximation of the equal percentage valve characteristic by means of a
polygon function block

Note The tank outlet valve is further adapted to a realistic valve behavior through a
small first order lag, a dead time and a discretization of the valve position to
integer percentages.
This means that the valve position follows the manipulated variable of the master
level controller with a certain sluggishness. The discretization only allows integer
percentage values, i.e. the valve simulation cannot reach the setpoint position
with infinite accuracy. The equal-percentage characteristic leads to a non-
linearity in the actuator.

Note Both the tank simulation and the actuator have a non-linear behavior. Therefore
a non-linear characteristic curve must be inserted with the aid of a polygon
function block between the disturbance variable measurement and the
feedforward control.
The interpolation points of this characteristic curve can be determined
experimentally. To do this, for different inflow rates the actuator must be adjusted
until the container level stays constant at the desired value (container mid-
height). The registered value pairs "Inflow measured/Valve position” can then be
used for the polygon block.

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On Sheet 3 of the CFC the inflow with disturbance and measurement noise is
simulated.
1 2 5 6

1. Technological valve operating module for inflow modification in the OS

2. Delay in inflow (first order lag with time constant 2 seconds)
3. Generation of measurement noise (white noise)
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4. Generation of inflow disturbance (colored noise)

5. Determination of inflow quantity with disturbance and measurement noise
(addition)
6. Limitation of inflow to 0 to 100%

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5.1.4 Comparison of exact level control with buffer control including

feedforward disturbance compensation

The two concepts presented for level control are compared against each other in
this chapter. In order to be able to compare the two simulations both must have the
same setpoints and disturbance values. A comparison mode has been
implemented to enable these requirements to be fulfilled. This mode allows to
simultaneously modify inflows and setpoints for both simulations.
To start the comparison, proceed according to the following instructions:
1. Open the plant overview picture "Level Control" or "Buffer Control".
2. Click on the "Compare” button. The corresponding window opens.
© Siemens AG 2019 All rights reserved

3. Click on the SFC icon "Compare_Level_Buffer".

The corresponding window opens.
4. Start the sequence by clicking the "Start” button, and confirm the window that
now opens by "OK”.

5. Wait for about 10 seconds until the SFC has run.

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Note Now all the valves and controllers are pre-configured in such a manner that
manipulated variable and setpoint can be defined via the two analog input
windows in the "Compare” window.

6. Switch to analog input window "SP_Level” and enter a setpoint of 50 %.

7. Switch to analog input window "MV_InletValve” and enter a setpoint of 50 %.

8. Wait for about 3 minutes and enter a new inflow of 75% in the "MV_InletValve”
analog window.
9. Wait 2 more minutes and enter a new inflow of 25% in the "MV_InletValve”
analog window.
10. Wait 3 more minutes and enter a new inflow of 50% in the "MV_InletValve”
analog window.
11. Close the faceplate and observe the plotter for about two minutes until the
setpoint has been reached.
12. Then click on the "Start/Stop" icon on the toolbar of the OnlineTrendControl.

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Evaluation

1 2 3

Inlet PV-Level PV-Buffer MV-Level MV-Buffer

1. After the inflow increase, the level rises above the setpoint for both control
concepts.
The PI controller for the exact level control detects the change in level and
consequently increases the manipulated variable of the outlet valve until the
filling level has reached the desired setpoint again. Control towards the
setpoint, however, produces permanent fluctuations of the manipulated
variable for the outlet valve.
In the case of the buffer level control with feedforward disturbance
compensation, the changed inflow is detected as a change in the disturbance
variable and the manipulated variable is then moved accordingly. The
immediate reaction to the inflow change provides a faster intervention and the
level rises less compared to PI control.
Thanks to the relatively wide deadband, the level does not leave the setpoint
area and the controller has to re-adjust less frequently, which eases the wear
of the actuation mechanism.
2. With the inflow change from 75% to 25% of the maximum inflow, both fill levels
sink and the fill level of the buffer leaves the deadband. This activates the P
controller and the deadband is temporarily deactivated. As soon as the level
approaches the setpoint again, the deadband is activated and the manipulated
variable remains constant.
In a manner analogous to the inflow change described in point 1, the PI
controller reacts to the exact filling level with a change of the outflow valve until
the fill level has reached the setpoint.
3. The third inflow change occurs before the PI controller has reached the fill level
setpoint, the latter thus reacts by overshooting the fill level more than with the
inflow change under point 1.
In contrast to this, the buffer level controller is again within the setpoint range
and therefore reacts only to a change of the inflow with a change of the
manipulated variable via the feedforward control.

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5.2 "Split-Range-Pressure" control

Pressure control in pipelines is similar to flow control and typically allows fast
control loops. For pressure control in tanks, time-constants depend on the ratio of
tank volume to maximal inflow and outflow. The tank pressure is increased by
feeding an inert gas (e.g. nitrogen) via a supply line. Opening the purge valve
allows the gas mixture to escape and the container pressure is reduced. The
controller responds to pressure changes and compensates them by opening the
supply line or the outlet valve.
In the following example, control of the container pressure is solved by pressure
supply and purge valve.
© Siemens AG 2019 All rights reserved

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Overview

P&I Diagram
The P&ID below symbolically represents all of the components, such as field
devices and tanks relevant to operation.

Venting
YC
Out

PIC YC
Split In

Inerting
© Siemens AG 2019 All rights reserved

CM and variants
The "Split-range pressure" equipment module consists of three connected CMs
and one simulation chart. In the simulation chart, a container pressure and the
effects due to feeding and venting inert gas are simulated.
The following table provides an overview of the CMs of the equipment module
including the associated CMTs.
CM CMT Selected variants Description
PIC_Split "PIDConSplitRa • PV Pressure control with one manipulated
nge" • PV_Scale# variable and two actuators

YC_In "ValAn" • IF_Ctrl# Control valve for supplying inert substances

• MV_Scale#
• RbkReturn
• YC
YC_Out "ValAn" • IF_Ctrl# Control valve for ventilation
• MV_Scale#
• RbkReturn
• YC

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In the figure below, the structure with the cross-chart interconnections is shown in
simplified form.

Sim_PresLevel PIC_Split YC_In

PV V
In
SimPV_In MV
In1

Out to_Actor1 from_Ctrl

In1 Out In

PresLevel to_Actor2 to_Ctrl

OUT Out Out

from_Actor1
In YC_Out
V
from_Actor2
MV
In

from_Ctrl
In

to_Ctrl
Out

"PIC_Split" acquires the container pressure ("Sim_PresLevel" simulation chart) and

regulates it with the help of the two control valves "YC_In" and "YC_Out".

Structure and parameterization

"Sim_PresLevel" simulation
The pressure change in the container due to inerting or venting is simulated in the
"Sim_PresLevel" CFC.
The figure below shows the sequence of the simulation.

1 2 3 4

1. Calculation of the pressure change starting from the proportionality factor

(valve opened by 100% corresponds to a change in pressure of 0.1 bar)
2. Reduction in the pressure by 0.01 bar, e.g. due to container pressure loss
3. Time lag of the change in pressure
4. Time integral of pressure changes (every second)

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PIC_Split
The instance has the following parameterization.
Block Connection Value Use
PV_Scale HiScale 10.0 Scaling of the process value upper limit
PV_Unit In 1137 Process value unit in bar
Reversal of the response characteristic for
the valve (valve 1 opens in the case of a
negative control difference instead of a
C NegGain.Value 1 positive one)
C Gain.Value 8.0 Controller gain
C TI.Value 75.0 Controller lag
C SP_InHiLim 10.0 Maximum value of the internal setpoint
ManLoLim Lower limit for the manipulated variable in
C (hidden) -100.0 manual mode
InScale.High 100.0
Split range InScale.Low -100.0 Marginal range for the input signal
Split range NeutPos 0.0 Neutral position
Interconnection to the valve
to_Actor1 Out (YC_In\from_Ctrl.In)
Interconnection to the valve
to_Actor2 Out (YC_Out\from_Ctrl.In)
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Interconnection to the valve

from_Actor1 In (YC_In\to_Ctrl.Out)
Interconnection to the valve
from_Actor2 In (YC_Out\to_Ctrl.Out)
Activation of simulation on the channel block
(Equipment_Modules\\
PV SimOn Activate_Simulation\Sim_Act.Out)
Interconnection for the simulated process
value
PV SimPV_In (Sim_PresLevel\PresLevel.Out)

Note The program "PID Tuner" is available for commissioning the "PIC_Split"
controller. At the beginning, data recording for the "PID-Tuner" is done in an
operating range where only positive values of the manipulated variables are
exptected. After this, a comparable experiment is made in an operating range
where only negative manipulated variables occur.
If both part transfer functions for venting and inerting show significantly different
values for process gain, this must be compensated by a different gradient of both
branches of the split range characteristic curve.
Further information and configuration guidelines can be found in the Online Help
for the "SplitrangeControl" process tag type.

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YC_In and YC_Out

The instances have the following parameterization.
Block Connection Value Use
V Interconnection for the simulation
(YC_In) (Sim_PresLevel\In.In1)
(YC_Out) MV (Sim_PresLevel\Out.In1)
from_Ctrl Interconnection to the controller
(YC_In) (PIC_Split\to_Actror1.Out)
(YC_Out) In (PIC_Split\to_Actor2.Out)
to_Ctrl Interconnection to the controller
(YC_In) (PIC_Split\from_Actror1.In)
(YC_Out) Out (PIC_Split\from_Actror2.In)
Activation of simulation on the
MV_Out channel block
(YC_In) (Equipment_Modules\\
(YC_Out) SimOn Activate_Simulation\Sim_Act.Out)

Commissioning and operation

and activating the OS in chapter 2 "Preparation and commissioning".

Proceed as follows:
1. Click on the symbol display of valve "YC_Out".
The system opens the corresponding faceplate.

2. In the faceplate, change the operating mode to "Automatic".

3. Switch to valve "YC_In" and change the operating mode to "Automatic”.
4. Switch to controller "PIC_Split" and change the operating mode of the controller to
"Automatic".

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5. Enter "1 bar” as setpoint.

The new setpoint will have been reached after about two minutes. To compensate
the pressure loss of the container, the valve is opened to about 10% for venting.
6. Specify "3 bar” as new setpoint for the controller.
7. Close the faceplate and observe the plotter for about two minutes until the new
setpoint has been reached.

Evaluation

1
2

1. After the setpoint step, the manipulated variable is set to -100 and by this, the
pressure feed valve is opened.
2. The process value slightly exceeds the setpoint; the pressure feed valve is
closed evenly.
3. After reaching the setpoint, the pressure feed valve has been opened by about
10%; this means that the pressure loss of the container has been
compensated.

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5.3 "Ratio-Control"
In case of ratio control, different gases or other input materials are fed in fixed
mixing ratios into a tank via inlet lines.
The ratio control scheme consists of one controller for the main input material
(master controller) and one controller for each additional input material (slave
controller).
The example below describes feed control with two input materials, and later on is
expanded with another input material.
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Overview
Below, the structure in the P&ID is shown and all of the CMs and the simulation of
the equipment module are described.

P&I Diagram
The P&ID below symbolically represents all of the components, such as field
devices and containers relevant to operation.
FIC MV YC Legende
MainComp SP MainComp MV = Manipulated variable
SP = Active setPoint

1st Inflow
FFIC YC
Comp_1 Comp_1

2nd Inflow FI
CompFlow

Outflow

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CM and variants
The "ratio control" equipment module consists of four connected CMs and one
simulation chart. On the simulation chart, the system calculates the total of all the
inflows (input materials) and displays them.
The following table provides an overview of the CMs of the equipment module
including the associated CMTs.
CM CMT Selected variants Description
FIC_MainComp "Ctrl" • PV Flow control of the main input material
• PV_Scale#
FFIC_Comp_1 "PIDConR • IF_Master# Flow control of the additional input material
atio" • PV
• PV_Scale#
YC_MainComp "ValAn" • IF_Ctrl# Control valve for the main input material
• MV_Scale#
• RbkReturn
• YC
YC_Comp_1 "ValAn" • IF_Ctrl# Control valve for the additional input
• MV_Scale# material
• RbkReturn
• YC
© Siemens AG 2019 All rights reserved

FI_CompFlow "MonAn" • PV Display of the calculated overall inflow

• PV_Scale#

In the figure below, the structure with the cross-chart interconnections is shown in
simplified form.

Sim_CompFlow FIC_MainComp
YC_MainComp
Scale_MainComp PV V
In1 SimPV_In MV

Scale_Comp_1 to_Actor_Slave
from_Ctrl
In1 Out
In

Lag_MainComp from_Actor_Slave
to_Ctrl
Out In
Out

Lag_Comp_1
Out
FFIC_Comp_1
SumOfFlow YC_Comp_1
PV
Out V
SimPV_In
MV
to_Actor_Slave
Out from_Ctrl
In
FI_CompFlow from_Master
In to_Ctrl
I
Out
PV from_Actor_Slave
In

Control "FIC_MainComp" acquires the flow of the main input material and regulates
it using control valve "YC_MainComp". In addition, "FIC_MainComp" transfers its
own setpoint to process tag "FFIC_Comp_1". This means that "FIC_MainComp" is
the master controller for "FFIC_Comp_1".

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Control "FFIC_Comp_1" acquires the flow of the additional input material and
regulates it using control valve "YC_Comp_1". "FFIC_Comp_1" receives the
setpoint from control "FIC_MainComp"; this means that "FFIC_Comp_1" is the
slave controller.

Structure and parameterization

"Sim_CompFlow" simulation
The flow of the main input material and the additional input material are simulated
in the "Sim_CompFlow" CFC and the overall flow rate is calculated too. Apart from
this, the system displays the flow rate based on process tag type "MonAn".
The figure below shows the sequence of the simulation.
1 2 5

3 4
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1. Calculation of the flow for the main input material (valve opened by 100%
corresponds to inflow of 2000 l/h)
2. Delay in change of flow (PT1 response with 5-second delay)
3. Calculation of the flow for the main input material (valve opened by 100%
corresponds to inflow of 500 l/h)
4. Delay in change of flow (PT1 response with 2-second delay)
5. Determination of the complete flow quantity (addition)
Inputs "In1" of highlighted blocks 1 and 3 get their manipulated variables from valve
blocks "I" of process tags "YC_MainComp" and "YC_Comp_1". The "Out" outputs
of highlighted blocks 2 and 4 are interconnected with the channel blocks of the
controls.

FIC_MainComp
The instance has the following parameterization.
Block Connection Value Use
PV_Scale HiScale 2000.0 Scaling of the process value upper limit
PV_Unit In 1353 Unit of the process value l/h (liters per
hour)
C Gain.Value 0.05 Controller gain
C TI.Value 2.2 Controller lag
C SP_InHiLim 2000.0 Maximum value of the internal setpoint
to_Actor_Slave Out Interconnection to the valve and slave
controller
(YC_MainComp\from_Ctrl.In)
(FFIC_Comp_1\from_Master.In)

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Block Connection Value Use

from_Actor_Slave In Interconnection to the valve
(YC_MainComp\to_Ctrl.Out)
PV SimOn Activation of simulation on the channel
block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)
PV SimPV_In Interconnection for the simulated process
value
(Sim_CompFlow\Lag_MainComp.Out)

Note In the current configuration, the master controller can carry out control regardless
of the status of the slave controller. If you do not want this behavior, you can, for
example, interconnect the "CascaCut" output of the slave controller to the
"Interlock" input or block (can be selected optionally).
If you want to use other signals of the slave controller such as "LockAct" (locking
active) or "OosAct" (out of service) for locking, you can add another
"ComStruOut" communication block to the slave controller and interconnect
block outputs BoStru1 thru BoStru3 to the locking block.

Note The setpoint is transferred to the controller process tag(s) of the additional input
© Siemens AG 2019 All rights reserved

material(s). Using the setpoint instead of the manipulated variable means that
the controller structure does not correspond to a typical cascade controller.
The "PID Tuner" program is available for commissioning the controller. If there is
a considerably difference in closed loop response time after the optimization, you
can try adapting and compensating the parameters of both control loops
manually. The highest priority however is the stability of the transient response of
both individual control loops. In this context, there can be a temporary deviation
from the specified ratio in the case of setpoint steps. If such temporary deviations
in one direction must not occur at all due to safety reasons, additional logic has
to be implemented. E.g. burner control with flow controllers for fuel gas and air in
a fixed ratio: in this case you have to make sure that there is always a little bit
more air than required, because a deficiency of air can be dangerous even in
short time intervalls.

FFIC_Comp_1
The instance has the following parameterization.
Block Connection Value Use
PV_Scale HiScale 500.0 Scaling of the process value upper limit
PV_Unit In 1353 Unit of the process value l/h (liters per
hour)
C Gain.Value 0.25 Controller gain
C TI.Value 4.1 Controller lag
C SP_InHiLim 500.0 Maximum value of the internal setpoint
to_Actor_Slave Out Interconnection to the valve
(YC_Comp_1\from_Ctrl.In)
from_Actor_Slave In Interconnection to the valve
(YC_Comp_1\to_Ctrl.Out)
from_Master In Interconnection to the master controller
(FIC_MainComp\to_Actor_Slave.Out)

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Block Connection Value Use

Ratio RatHiLim 1 Upper limit (ratio)
Ratio RatLoLim 0 Lower limit (ratio)
Ratio RatLiOp 0 Ratio specification by user
PV SimOn Activation of simulation on the channel
block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)
PV SimPV_In Interconnection for the simulated process
value
(Sim_CompFlow\Lag_Comp_1.Out)

YC_MainComp and YC_Comp_1

The instances have the following parameterization.
Block Connection Value Use
V MV Interconnection for the simulation
(YC_MainComp) (Sim_CompFlow\In.In1)
(YC_Comp_1) (Sim_CompFlowl\Out.In1)
from_Ctrl In Interconnection to the controller
(YC_MainComp) (FIC_MainComp\to_Actor_Slave.Out)
(YC_Comp_1) (FFIC_Comp_1\to_Actor_Slave.Out)
to_Ctrl Out Interconnection to the controller
© Siemens AG 2019 All rights reserved

(YC_MainComp) (FIC_MainComp\to_Actor_Slave.In)
(YC_Comp_1) (FFIC_Comp_1\to_Actor_Slave.In)
MV_Out SimOn Activation of simulation on the channel
(YC_MainComp) block
(YC_Comp_1) (Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)

FI_CompFlow
The instance has the following parameterization.
Block Connection Value Use
Scaling of the process value upper
PV_Scale HiScale 3000.0 limit
Unit of the process value l/h (liters
PV_Unit In 1353 per hour)
Interconnection for the simulation:
I PV (Sim_CompFlow/SumOfFlow.Out)

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Commissioning and operation

2. Enter the new ratio of "0.25".

The ratio corresponds to the factor of the flow setpoint at which the additional
input material has to flow to the main input material.
3. Switch to valve "YC_Comp_1" and change the operating mode to "Automatic".
4. Switch to slave controller "FFIC_Comp_1" and change the operating mode to
"Automatic" and the setpoint specification to "External".

Note While master controller "FIC_MainComp" is not working in automatic mode, it

does not return a setpoint (proportionally) to the slave controller either.

5. Switch to valve "YC_MainComp" and change the operating mode to

"Automatic".
6. Switch to master controller "FIC_MainComp" and change the operating mode to
"Automatic".
7. Enter the setpoint "1000 l/h" in the master controller.

Note The system displays the current actual value of the ratio in the "Ratio" block,
which results from the setpoint directed to the slave controller.

Both controller setpoints will have been reached after about 1 minute.

8. Enter a new setpoint of "1500 l/h" in master controller "FIC_MainComp".

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9. Wait for about 90 seconds and then click on the "Start/Stop" icon on the toolbar
of the OnlineTrendControl.
10. On the toolbar of the OnlineTrendControl, click on the "Ruler" icon and move
the ruler to the lowest value with the greatest deviation, as show in the
evaluation below.

Evaluation
The "OnlineTrendControl" that is embedded in the process picture is set to the
maximum value ranges. If the ratio changes, the value range of the additional input
material adapts automatically.
© Siemens AG 2019 All rights reserved

Due to the different response times of the controllers, the ratio is temporarily 29%
(0.29). Compared to the ratio setpoint of 25% (0.25), a deviation of 4% results
temporarely before the correct ratio is reached in the steady state.

In this case, it is not possible to improve the controller design for slave controller
"FFIC_Comp_1" by means of PID controller optimization, since the aim of the
controller design is optimum tracking of the additional input material.

Note For further information and configuration guidelines, refer to the Online Help for
the "RatioControl" process tag type. You can find the process tag type in "PCS 7
– Advanced Process Library”.

The response curves from the OnlineTrendControl lead to the considerations below
for the controller design to match the transient responses of the master and slave
loops as closely as possible to one another:
• The relatively large deviation at the start of step response indicates that the
gain of the slave controller is too high, i.e. the slave controller process value
rises faster than the actual value of the master controller.

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• The relatively slow speed with which the final value of the setpoint step-change
is reached, indicates an integration time of the master controller that is too
high, i.e. the master controller enters the steady state slower than the slave
controller.
A change in the gain of slave controller "FFIC_Comp_1" from 0.25 to 0.1 with a
simultaneous change in the integral-action time of master controller
"FIC_MainComp" from 2.2 to 2 generates the result below with the same setpoint
steps.
© Siemens AG 2019 All rights reserved

Due to the different response times of the controllers, the ratio after optimization is
temporarily 25.6% (0.256). Compared to the set ratio of 25% (0.25), a deviation of
0.6% results briefly.

Adding another input material

Using the "Ratio Control" equipment module, you can set up a large number of
ratio controllers. The number of additional input materials is limited by the interlock
block or the number of interlock inputs that it has.

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Note If the number of locking signals of the slave controller has to be acquired in the
master controller, the options below are available for adapting the Ctrl type
(CMT):
1. Group the signals of the communication blocks (from_Actor_Slave) using OR
blocks. As a result, one valve and seven additional input materials are
interconnected by means of one interlock block.
Disadvantage:
Inaccurate error display, i.e. the system does not differentiate between errors
in the cascade controller, an "out of service” signal of the controller block,
and a "Bad” status of the controller channel blocks.
2. Duplicate the existing interlock block and group the two (Out) outputs of the
interlock blocks using an OR block. For interconnection (Out output) of the
OR block, use the (Out output) interconnections of the existing interlock
block.
You can call up the faceplate of the first interlock block from the controller's
faceplate. The faceplate of the second interlock block is opened by means of
its block display symbol in the process picture.
3. Replace the existing locking block with 8 input signals (Intlk08) with a locking
block with 16 input signals (Intlk16). Apply all the interconnections of the
previous locking block.

Requirements
If different additional input materials are measured in different measurement units,
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the conversion factor in the ratio block also includes conversion of the units.

Note In the case of different physical units, you must specify the other measurement
unit for the additional input material. The ratio factor in the ratio function block
now has to include the conversion from the flow unit of the master controller to
the flow unit of the slave controller.
Additionally, when displaying the trend curves in a common diagram, it is
advisable to label clearly.

If different travel ranges are needed in the case of the partial control loops of a
ratio controller, you must delete the corresponding interconnections and
parameterize them for the respective partial control loop.

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Description
To add another additional input material to the equipment module, proceed as
follows:
1. Copy CMs "FFIC_Comp_1" and "YC_Comp_1" at the same time. Paste the
copied CMs back into the same hierarchy folder. Rename the process tags
appropriately (below, the CMs will be referred to as "FFIC_Comp_2" and
"YC_Comp_2").

Note When you copy the process tags at the same time (highlight the process tags
and then click on Edit > Copy on the menu bar), the connections between the
highlighted process tags are retained.

2. Open process tag "FFIC_Comp_2" and make the following interconnections:

Block Connection Use
from_Master In Interconnection to the master controller
(FIC_MainComp\to_Actor_Slave.Out)

3. The simulation model is designed for two additional input materials. Make the
interconnections below in CFC "FFIC_Comp_2" to connect the second
additional input material to the simulation.
© Siemens AG 2019 All rights reserved

Block Connection Use

PV SimOn Activation of simulation on the channel block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)
PV SimPV_In Interconnection for the simulated process value
(Sim_CompFlow\Lag_Comp_1.Out)

4. Open process tag "YC_Comp_2" and make the following interconnections in

chart partition "A" sheet 1:
Block Connection Use
V MV Interconnection for the simulation
(Sim_Level\Scale.In1)
MV_Out Activation of simulation on the channel block
(Equipment_Modules\\
SimOn Activate_Simulation\Sim_Act.Out)

Note When additional input materials are added to the "Ratio-Control” equipment
module, you must compile and load the blocks and charts and compile the OS.

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5.4 "Split-Range-Temperature" control

Temperature control in tanks, heat exchangers, columns or reactors typically
involves large heat capacities and results in slow control loops. To achieve a
specified temperature inside a tank, the system feeds either hot steam or cooling
water via supply lines with control valves into the service medium side of a heat
exchanger or reactor jacket. The reactor jacket can contain the service medium in
the sense of a heat exchanger. On the other hand there are external heat
exchangers for reactors, where the reactor content is pumped through pipes to the
heat exchanger and back. Due to separation by means of heat-permeable walls, all
of these procedures are indirect heat transfers.
The usual assumption for temperature control of tanks is a complete mixture of
tank content (e.g. via stirrer), such that it is sufficient to measure temperature at
one single point and assume that this temperature is representative for the whole
tank. Continuous turnover via pump provides homogenous temperature distribution
in cooling jackets as well.
On the other hand, in heat exchangers that are not directly linked to a tank or
reactor, typically only the outlet temperature of the product medium is measured
and controlled. Inside the heat exchanger there are significant temperature
gradients.

Note The "Split-Range-Temperature" equipment module can be used for tanks or

reactors in which temperature control is provided via the reactor jacket or an
external heat exchanger.
© Siemens AG 2019 All rights reserved

In the following example, reactor temperature control is carried out using an

external heat exchanger.

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Overview
Below, the structure in the P&ID is shown and all of the CMs and the simulation of
the equipment module are described.

P&I Diagram
The P&ID below symbolically represents all of the components, such as field
devices and tanks relevant to operation.
TIC
Temp

TIC YC
Split Heat

Inflow
heating
medium
YC
Cool

Inflow
cooling
medium

Outflow
© Siemens AG 2019 All rights reserved

NS
PumpMixture

CM and variants
The "Split-range temperature" equipment module consists of four interconnected
CMs, one CM for pump control, and one simulation chart. The simulation chart
simulates the internal temperature of a container (input material mixture), the
temperature of a heat exchanger, and the effect of changes in temperature
(heating steam and cooling water).
The following table provides an overview of the CMs of the equipment module
including the associated CMTs.
CM CMT Selected variants Description
TIC_Temp Ctrl • PV Master controller for temperature control
• PV_Scale#
TIC_Split PIDConS • IF_Master# Slave controller for split-range control with
plitRange • PV one manipulated variable and two actuators
• PV_Scale#
YC_Heat ValAn • IF_Ctrl# Control valve for the first manipulated
• MV_Scale# variable
• RbkReturn
• YC
YC_Cool ValAn • IF_Ctrl# Control valve for the second manipulated
• MV_Scale# variable
• RbkReturn
• YC

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CM CMT Selected variants Description

NS_PumpMixture Mot • 1Fbk# A pump (e.g. a flow pump) for continuous
pumped circulation of the contents of the
container

Note The "NS_PumpMixture” CM is interconnected in the SFC (Sequential Function

Chart) It is not necessary to interconnect with other process tags in the "Split-
Range Temperature” equipment module.
To ensure that the system does not generate an error message due to a missing
feedback signal, the "Start" output signal is interconnected with the "FbkRun"
input signal of motor block "U".

In the figure below, the structure with the cross-chart interconnections is shown in
simplified form.

Sim_TempLevel TIC_Temp TIC_Split

Cool to_Actor_Slave to_Master

In1 Out Out

Heat from_Master
from_Actor_Slave
© Siemens AG 2019 All rights reserved

In1 In
In

HeatExchanger Splitrange
PV
OPEN1_11 SimPV_In Out1
OPEN1_1 Out2
Out1Act
TempLevel Out2Act
Out YC_Heat
PV from_Ctrl
HeatExchanger SimPV_In In
V
to_Actor1 to_Ctrl
Out Out

to_Actor2
Out YC_Cool

from_Actor1 from_Ctrl

In In

from_Actor2 to_Ctrl
In Out

Controller "TIC_Temp" uses the simulated internal container temperature from

simulation chart "Sim_TempLevel" and generates the setpoint specification for the
split range control. The desired temperature progression is thus configured in
process tag "TIC_Temp".
Controller "TIC_Split" receives the setpoint specification from the master controller
and regulates the simulated temperature of a heat exchanger that transfers heat to
the inside of the container.

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Structure and parameterization

"Sim_TempLevel” simulation
In CFC "Sim_TempLevel", the system simulates a temperature change due to hot
steam or cooling water onto the heat exchanger and simulates the internal
temperature of the container.
The figure below shows the sequence of the simulation.
1
2

1. Reduction of the manipulated variable for simulation. This makes it possible to

represent the valve openings of the heating and cooling valves with more
emphasis in the trend display.
2. Calculation of the temperature of a heat exchanger. The change in
© Siemens AG 2019 All rights reserved

temperature depends on the openings of both valves (a bipolar signal is

distributed to the heating steam and cooling water valve) and it is processed
after passing through a time-delay block.
3. Internal container temperature that changes depending on the inflow from the
heat exchanger. The temperature in the inside of the container is 40% lower
than in the heat exchanger (a factor of 0.6) and it is calculated after passing
through two delay elements. The output signal (internal container temperature)
has small signal noise.

Note Simulation behavior does not correspond to a real process and it is only used to
demonstrate the functionality and mode of operation of the "Split range
temperature" equipment module. Block "SIMU_AI" has integrating behavior
whereby heating and cooling act with the same intensity. With real heat
exchangers, both heat losses into the surroundings and different behavior when
heating (e.g. steam) and cooling (e.g. flowing water) are to be expected.

TIC_Temp
The instance has the following parameterization.
Block Connection Value Use
PV_Scale HiScale 100.0 Scaling of the process value upper limit
PV_Unit In 1001 Unit of the process value in degrees
Celsius
C Gain 1.5 Controller gain
C TI 7.054 Controller lag
C TD 1.855 Controller differential time
C SP_InHiLim 100.0 Maximum value of the internal setpoint
to_Actor_Slave Out Interconnection to the slave controller
(TIC_Split\from_Ctrl.In)

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Block Connection Value Use

from_Actor_Slave In Interconnection to the slave controller
(TIC_Split\to_Ctrl.Out)
PV SimOn Activation of simulation on the channel
block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)
PV SimPV_In Interconnection for the simulated process
value
(Sim_TempLevel\TempLevel.Out)

TIC_Split
The instance has the following parameterization.
Block Connection Value Use
PV_Unit In 1001 Unit of the process value in degrees Celsius
C Gain 3.5 Controller gain
C DeadBand 0.2 Width of deadband
C SP_InHiLim 100.0 Maximum value of the internal setpoint
C ManLoLim -100.0 Lower limit for the manipulated variable in
(hidden) manual mode
Split range InScale.High 100.0 Marginal range for the input signal
InScale.Low -100.0
© Siemens AG 2019 All rights reserved

Split range NeutPos 0.0 Neutral position

Split range Out1 Interconnection for the simulation
(Sim_TempLevel\Cool.In1)
Split range Out2 Interconnection for the simulation
(Sim_TempLevel\Heat.In1)
Split range Out1Act Interconnection for the simulation
(Sim_TempLevel\HeatExchanger.OPEN1_11)
Split range Out2Act Interconnection for the simulation
(Sim_TempLevel\HeatExchanger.OPEN1_1)
to_Actor1 Out Interconnection to the valve
(YC_Heat\from_Ctrl.In)
to_Actor2 Out Interconnection to the valve
(YC_Cool\from_Ctrl.In)
from_Actor1 In Interconnection to the valve
(YC_Heat\to_Ctrl.Out)
from_Actor2 In Interconnection to the valve
(YC_Cool\to_Ctrl.Out)
PV SimOn Activation of simulation on the channel block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)
PV SimPV_In Interconnection for the simulated process
value
(Sim_TempLevel\HeatExchanger.V)

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Note The "PID Tuner" program is available for commissioning the "TIC_Split"
controller.
At the beginning, experiments for data recording by "PID-Tuner" are conducted
in an operating range where only positive values of manipulated variables are
expected. After this, a comparable experiment is made in an operating range
where only negative manipulated variables occur. If both part transfer functions
for heating and cooling show significantly different values for processgain, this
must be compensated by a different gradient in both branches of the split range
characteristic curve. After the slave controller including the split range has been
completely commissioned and tested, the master controller "TIC_Temp" is
optimized using the "PID Tuner" program.
For further information and configuration guidelines, refer to the Online Help for
the "CascadeControl" process tag type of the PCS 7 Advanced Process Library.

YC_Heat
The instance has the following parameterization.
Block Connection Value Use
from_Ctrl In Interconnection to the controller
(TIC_Split\to_Actror1.Out)
to_Ctrl Out Interconnection to the controller
(TIC_Split\from_Actror1.In)
© Siemens AG 2019 All rights reserved

YC SimOn Activation of simulation on the

channel block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)

YC_Cool
The instance has the following parameterization.
Block Connection Value Use
from_Ctrl In Interconnection to the controller
(TIC_Split\to_Actror2.Out)
to_Ctrl Out Interconnection to the controller
(TIC_Split\from_Actror2.In)
YC SimOn Activation of simulation on the
channel block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)

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Commissioning and operation

2. In the faceplate, change the operating mode to "Automatic".

3. Switch to "YC_Cool" valve and change the operating mode to "Automatic".
4. Switch to "TIC_Split" slave controller, change its operating mode to "Automatic"
and the setpoint specification to "External".
5. Switch to "TIC_Temp" master controller and change the operating mode of the
controller to "Automatic".
6. In master controller "TIC_Temp", enter a setpoint of "30" °C for the operating
range.
7. Wait for about one minute and enter a new setpoint of "40” °C.
8. Observe the plotter for about one minute until the new setpoint has been
reached.
9. Then click on the "Start/Stop" icon on the toolbar of the OnlineTrendControl.

Note The motor can be started with the "Start" command on the faceplate.
In process mode, the motor is controlled via an SFC, e.g. at start up of the plant.

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Evaluation

TIC_Temp TIC_Split

After setpoint change SP1, the master controller calculates a manipulated variable
MV1 and forwards it in the cascade to the slave controller. This manipulated
variable is represented as setpoint SP2 for the slave controller in the curve chart.
The slave controller calculates manipulated variable MV2 from setpoint curve SP2.
MV2 acts on the heating and cooling valves and yields temperature curve PV2 of
the heat exchanger.
Temperature PV1 in the container follows the temperature of heat exchanger PV2
with a delay.
© Siemens AG 2019 All rights reserved

Legend The noise of process variable PV1 leads to noise of manipulated variable MV1
and consequently of setpoint SP2. The oscillation of manipulated variable MV2
1 in real world applications has to be avoided (e.g. by definition of deadbands)
especially around the neutral point of the split-range characteristic, because this
means alternating of heating and cooling. In the simulation, the oscilation is
actually centered around the neutral point because heat losses into the
surroundings are neglected.

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5.5 pH value control using a standard controller

The pH of the product is set in pH value control "pH-Control-Std". For this, a
neutralizer is added to the product in continuous operation to reach the desired pH
value.
Due to the highly non-linear titration curve, this means that the gain of the
controlled system may fluctuate severely, depending on the operating point. Only
for applications in which the pH value is to be kept constant in a very tight range
and the disturbances are limited, a simple PID controller with fixed
parameterization is sufficient for pH value control. The special feature of the
equipment module presented here is the fact that the pH setpoint and the pH
process value are converted to concentration differences to achieve linearization of
the controlled system characteristic. Unlike the pH value, the difference in
concentration between OH- and H30+ ions depends in a linear manner on the
controller manipulated variable, i.e. on the feed of neutralizing agents. Conversion
is carried out on the basis of an inverse titration curve that describes the chemical
reaction of the considered process at least approximately. Details on the titration
curve can be found in section 6.5.
In difficult applications with long dead times (due to the measurement dead time of
the pH probe, the time needed for mixing, and the response time of the
neutralization reaction) and the need for dynamic feedforward control based on the
inflow pH value, we recommend using a predictive controller to compensate the
influences.
© Siemens AG 2019 All rights reserved

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Overview
Below, the structure in the P&ID is shown and all of the CMs and the simulation of
the equipment module are described.

P&I Diagram
The P&ID below symbolically represents all of the components, such as field
devices and containers to operation.

Neutralizing agent

YC
NeutSubst

QIC
pH_Control_Std

QI
© Siemens AG 2019 All rights reserved

pH_Tank

CM and variants
The "pH-Control-h" equipment module consists of three interconnected CMs and
one simulation chart. In the simulation chart, the system carries out pH setpoint
specification (OpAnL block) and calculates the pH setpoint based on the difference
in concentration from the input substance and the neutralizing agent.
The controller gets the converted pH values (setpoint and actual values) as
differences in concentration to control.
The following table provides an overview of the CMs of the equipment module
including the associated CMTs.
CM CMT Selected Description
variants
QI_pH_Tank MonAn • PV Display of the product pH value-
• PV_Scale#
QIC_pH_Control_Std PIDCon • PV_Scale# Standard PID controller without channel
blocks for controlling the difference in
concentration
YC_NeutrSubst VlvAn • IF_Ctrl# Control valve for the neutralizing agent
• MV_Scale#
• RbkReturn
• YC

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In the figure below, the structure with the cross-chart interconnections is shown in
simplified form.
Sim_pH QI_pH_Tank QIC_pH_Control_Std YC_NeutrSubst

pH_Std PV V
pHTitrConvert
Neutr_MV SimPV_In MV
CV
SP
pH_Std from_Ctrl
I
pH In
PV_Out to_Actor_Slave
Out
pH_SP to_Ctrl
SP_Out Out
from_Actor_Slave
In

Structure and parameterization

"Sim_pH” simulation
In CFC "pH_Std" the system calculates the pH value. On sheet 2, there is an
OpAnL block to specify the pH setpoint.
The following figure shows parameterization of the simulation block.
© Siemens AG 2019 All rights reserved

In the block inputs, fictional parameters are entered for buffer parameter "Alfa" and
the "Ampl_pH" amplitude range that is to be crossed. In addition, fixed values are
specified for the pH value and flow amount of input material. No deadtime is set for
the pH simulation value (simulation process).

Note You can find additional information in Section 6.6 "Block description of
"SimpHTitr"".

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QI_pH_Tank
The pH value of the product in the tank is acquired and displayed in the instance.
The instance has the following parameterization.
Block Connection Value Use
PV_Scale HiScale 15.0 Scaling of the pH process value upper limit
PV_Unit In 1422 Unit of the process value as a pH value
PV SimOn Activation of simulation on the channel block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)
PV SimPV_In Interconnection for the simulated process value
(Sim_pH\pH_Std.pH)
PV SimPV_Out Interconnection to the controller
(QIC_pH_Control_Std\pHTitrConvert.CV)

QIC_pH_Control_Std
In the instance, the system converts the pH value provided by display
"QI_pH_Tank" to a concentration difference using block "pHTitrBlock". The
concentration difference is used for control. The instance has the following
parameterization.
Block Connection Value Use
© Siemens AG 2019 All rights reserved

PV_Scale HiScale 10000.0 Scaling of the concentration difference

LoScale -10000.0 process value limits
PV_Unit In 1399 Unit of the process value in mol/L
(concentration difference)
C Gain 40.0 Controller gain
C TI 8.0 Controller lag
C SP_InHiLim 10000.0 Maximum value of the internal setpoint
C SP_InLoLim -10000.0 Minimum value of the internal setpoint
pHTitrBlock Newly inserted as "pHTitrConvert" to
convert pH values to concentration
differences
pHTitrConvert CV Interconnection to pH measured value
display
(QI_pH_Tank\PV_In.PV_Out)
pHTitrConvert SP Interconnection to the OpAnL setpoint
specification in the simulation chart
(Sim_pH\pH_SP.SP_Out)
pHTitrConvert Alfa 35000 Buffer parameter
pHTitrConvert Ampl_pH 5.0 The amplitude range that is to be
covered
pHTitrConvert CV_Out Interconnection to the controller block
(C.PV)
pHTitrConvert SP_Out Interconnection to the SFC block
(IF_SFC.SP_Ext)
to_Actor_Slave Out Interconnection to the valve
(YC_NeutrSubst\from_Ctrl.In)
from_Actor_Slave In Interconnection to the valve
(YC_NeutrSubst\to_Ctrl.Out)

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Note You must carry out parameterization of the titration curve for a concrete chemical
process before setting the PID controller using the PID tuner. If large variations
in the inflow amount of the input materials are to be expected, it is recommend to
compensate the disturbance by means of linear manipulated variable conversion
using the "pHTitrBlock" block. You can find additional information about
converting the pH value into a concentration difference in the block description in
Section 6.5.

Note The "PID Tuner" program is available for commissioning controller

"QIC_pH_Control_Std". The system first records data for the "PID-Tuner" in an
operating range in which only positive manipulated variables occur. After this, a
comparable experiment is made in an operating range in which only negative
manipulated variables occur. Optimization of the pH value-control was carried
out based on the concentration difference using different manipulated variables
(MV) with a constant (input material) inflow amount.

Note The following messages of the measurement "QI_pH_Tank" are not displayed in
the controller:
• for hardware fault (CSF)
• device being maintained (OosLi)
If they are needed, interconnect them additionally with blocks "CSF" and
"OosAct" in chart partition "B" sheet 3.
© Siemens AG 2019 All rights reserved

Alternatively, you can activate the "to_Indicate" option in the display process tag
and add an appropriate "from_Indicate" link block to the Ctrl CMT and
interconnect it appropriately. As an example, you can use the "ModPreCon" CMT
as a guide.

YC_NeutrSubst
The instance has the following parameterization.
Block Connection Value Use
V MV Interconnection for the simulation
(Sim_pH\pH_Std.Neutr_MV)
from_Ctrl In Interconnection to the controller
(QIC_pH_Control_Std\to_Actor_Slave.Out)
to_Ctrl Out Interconnection to the controller
(QIC_pH_Control_Std\from_Actor_Slave.In)
MV_Out SimOn Activation of simulation on the channel block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)

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Commissioning and operation

2. In the faceplate, change the operating mode to "Automatic".

3. Switch to controller "QIC_pH_Control_Std" and change the operating mode of
the controller to "Automatic" and the setpoint specification to "External".

Note The controller uses the preset pH value of the OpAnL symbol display as the
setpoint. In this symbol display, 7 pH is set as the setpoint (neutral zone) on the
basis of which the amount of neutralizing agent is fed (regulated).

4. Wait for about 2 minutes until the process value reaches its specified operating
range.
5. Switch to operator control block "pH_SP" and specify a new setpoint of 6.5 pH.
6. Close the faceplate and observe the plotter for about one minute until the new
setpoint has been reached.

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Evaluation

1
© Siemens AG 2019 All rights reserved

The controller is optimized without overshooting to reach the setpoint. After

changing the setpoint, the controller regulates the addition of neutralizer with a
slight delay.

Note The controller is set for an operating point of ± 0.5 pH around the neutral zone 7
pH. Under some circumstances, different operating points may make it
necessary to optimize the controller again.

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5.6 pH value control using predictive controller

pH value control using a "pH-Control-MPC" model predictive controller is used for
the same tasks with the special features due to the highly non-linear titration
characteristic curve. In addition to pH value control using standard controller, the
MPC allows targeted compensation of dead times of the controlled system (due to
the measurement dead time for mixing, and the reaction time of the neutralization
reaction) as well as model-based compensation of measurable disturbances due to
fluctuations of the pH value in the inflow.
In the following example of pH value control by addition of a neutralizing agent, we
will consider the pH value and feed flow of the input material besides the pH value
in the tank.
The example is designed for continuous operation and it is possible to modifiy the
pH value and the inflow of the input material.
© Siemens AG 2019 All rights reserved

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Overview
Below, the structure in the P&ID is shown and all of the CMs and the simulation of
the equipment module are described.

P&I Diagram
The P&ID below symbolically represents all of the components, such as units and
containers, etc. relevant to operation.

Neutralizing agent
CV
QIC MV YC
DV
pH_Control_MPC Neutralizer

QI FI
© Siemens AG 2019 All rights reserved

pH_Feed Feed

QI
pH_Product

Inflow

Outlet

CM and variants
The "pH-Control-MPC" equipment module consists of five interconnected CMs and
one simulation chart. In the simulation chart, the pH value of the product is
determined from the pH value and the inflow amount of the input material and of
the neutralizer (manipulated variable of the valve).
Operators can adapt in the OS the pH value for the input material and the pH
setpoint as well as the inflow amount. For this, OpAnL blocks have been inserted in
the simulation chart and the controller process tag.
For regulation, the controller uses the converted pH values (setpoint and actual
values of the product and actual value of the input material) as concentration
differences. In addition, the inflow amount of the input material affects the inflow
amount of the neutralizer, since the maximum manipulated variable changes
proportionally to the factor from the actual inflow amount and the maximum inflow
amount of the input material.

Note Additional information about calculating the manipulated variable or scaling in the
block description can be found in Section 6.5.

You specify the values below in the OpAnL blocks and can adjust them in the
Operator Station:

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• pH setpoint (product)
• pH value of the input material
• inflow amount of the input material
To simplify the project, an additional display process tag was not implemented for
each value specification.
The following table provides an overview of the CMs of the equipment module
including the associated CMTs.
CM CMT Selected Description
variants
QIC_pH_Control_MPC ModPreCon4Val Multivariable controller for regulating
ve the pH value of the product
QI_pH_Product MonAn • PV Display of the pH value of the product
• PV_Scale#
• To_Indicate
QI_pH_Feed MonAn • PV Display of the pH value of the input
• PV_Scale# material
• To_Indicate
FI_Feed MonAn • PV Throughflow display of the input
• PV_Scale# material

YC_Neutralizer VlvAn • IF_Ctrl# Control valve for the neutralizing agent

• MV_Scale#
© Siemens AG 2019 All rights reserved

• RbkReturn
• YC

In the figure below, the structure with the cross-chart interconnections is shown in
simplified form.

Sim_pH_MPC QI_pH_Product QIC_pH_Control_MPC YC_Neutralizer

to_Actor
pH_MPC PV from_Ctrl
Out
Neutr_MV SimPV_In In
from_Actor
To_Indicate to_Ctrl
pH_MPC In
Out Out
pH
from_CV
QI_pH_Feed In V
MV
PV
from_DV1
SimPV_In
pH_Feed In
SP_Out To_Indicate
Out
pHConverting
FI_Feed Feed_PV_Out
Flow_Feed Feed_PV_Out
PV
SP_Out
SimPV_In

PV
PV_Out IF_SFC
ScaleOut SP1

pH_SP
SP_Out

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Multivariable controller "QIC_pH_Control_MPC" acquires the pH value of the input

material, the pH value of the draining product, and the pH setpoint specification as
concentration differences. Depending on the pH difference (setpoint and actual
value of the product), the system feeds the necessary amount of neutralizer to the
tank via control valve "YC_Neutralizer".

Structure and parameterization

Simulation "Sim_pH_MPC"
In CFC "Sim_pH_MPC" the system calculates the pH value. On sheet 2, there is
an OpAnL block to specify the pH setpoint, the pH value, and the inflow amount of
the input material.
The following figure shows parameterization of the simulation block.
© Siemens AG 2019 All rights reserved

In the block inputs, fictional parameters are entered for buffer parameter "Alfa" and
the "Ampl_pH" amplitude range that is to be crossed. In addition, the manipulated
variable of control valve "YC_Neutralizer" and the inflow amount of the input material
(OpAnL block on sheet 2) are used for the calculation.
A deadtime of 10 seconds, a neutralizer inflow delay of 10 seconds, and a gain
factor of 3 are set for the pH simulation value (simulation process).

Note You can find additional information in the block description in Section 6.5.

QI_pH_Product
The pH value of the product is acquired and displayed in the instance. The instance
has the following parameterization.
Block Connection Value Use
PV_Scale HiScale 15.0 Scaling of the pH process value upper limit
PV_Unit In 1422 Unit of the process value as a pH value
to_Indicate Out Interconnection to the multivariable controller
(QIC_pH_Control_MPC\from_CV.In)
PV SimOn Activation of simulation on the channel block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)
PV SimPV_In Interconnection for the simulated process
value
(Sim_pH_MPC\pH_MPC.pH)

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QI_pH_Feed
The pH value of the input material is acquired and displayed in the instance.
The instance has the following parameterization.
Block Connection Value Use
PV_Scale HiScale 15.0 Scaling of the pH process value upper limit
PV_Unit In 1422 Unit of the process value as a pH value
to_Indicate Out Interconnection to the multivariable controller
(QIC_pH_Control_MPC\from_DV1.In)
PV SimOn Activation of simulation on the channel block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)
PV SimPV_In Interconnection for the simulated process value
(Sim_pH_MPC\pH_Feed.SP_Out)

FI_Feed
The amount of the input material is acquired and displayed in the instance.
The instance has the following parameterization.
Block Connection Value Use
PV_Scale HiScale 5000.0 Scaling of the amount
PV_Unit In 1038 Process value unit in L (liters)
© Siemens AG 2019 All rights reserved

PV SimOn Activation of simulation on the channel block

(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)
PV SimPV_In Interconnection for the simulated process value
(Sim_pH_MPC\Flow_Feed.SP_Out)
PV PV_Out Interconnection to the multivariable controller
(QIC_pH_Control_MPC\pHConverting.Feed_PV
_Out)
PV Scale_Out Interconnection to the multivariable controller
(QIC_pH_Control_MPC\pHConverting.Feed_Sc
ale)

QIC_pH_Control_MPC
In the multivariable controller, the system converts the pH value provided by
display "QI_pH_Product" to a concentration difference using block "pHTitrBlock".
The concentration difference is used for control. In the same way, the system
converts the setpoint specification as well as the pH value of the input material
disturbance variable to a concentration difference.
The instance has the following changes and parameterization.
Block Connection Value Use
MPC CV1 Existing interconnection deleted. New
interconnection to the conversion block
(pHConverting.CV_Out)
MPC DV1 Existing interconnection deleted. New
interconnection to the conversion block
(pHConverting.DV_Out)
MPC SP1 Existing interconnection deleted. New
interconnection to the conversion block
(pHConverting.SP_Out)
MPC SP1HiLim 500 Upper setpoint limit for the concentration

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Block Connection Value Use

difference
MPC SP1LoLim -500 Lower setpoint limit for the concentration
difference
MPC MV1HiLim Existing interconnection deleted. New
interconnection to the conversion block
(pHConverting.MVHiLim)
MPC CV1_Unit 1399 Existing interconnection deleted. Unit of
measurement for the controlled variable in
mol/L (process value)
MPC DB_No 50 Data block with controller data
MPC MV1 Existing interconnection deleted. New
interconnection to the conversion block
(pHConverting.MV)
pHTitrBlock Newly inserted as "pHConverting" to convert
pH values
pHConverting CV New interconnection to the link block
(from_CV.ReStru1)
pHConverting DV New interconnection to the link block
(from_DV1.ReStru1)
pHConverting SP New interconnection to the IF_SFC block
(IF_SFC.SP1Out)
pHConverting MV New interconnection from controller block
© Siemens AG 2019 All rights reserved

(MPC.MV1)
pHConverting Feed_PV_Out New interconnection from throughflow display
of the input material
(FI_Feed\PV_In.PV_Out)
pHConverting Feed_Scale New interconnection from throughflow display
of the input material
(FI_Feed\PV_In.ScaleOut)
TitrConverting CV_Out Interconnection to the controller block
(MPC.CV1)
TitrConverting DV_Out Interconnection to the controller block
(MPC.DV1)
TitrConverting SP_Out Interconnection to the controller block
(MPC.SP1)
TitrConverting MVHiLim Interconnection to the controller block
(MPC.MV1HiLim)
TitrConverting MV_Valve Interconnection to the communication block
(to_Valve.ReStru1)
IF_SFC SP1 Interconnection of OpAnL block for setpoint
specification
(Sim_pH_MPC\pH_SP.SP_Out)
to_Actor Out Interconnection to the valve
(YC_Neutralizer\from_Ctrl.In)
from_Actor In Interconnection to the valve
(YC_Neutralizer\from_Ctrl.Out)

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Note The multivariable controller was optimized using the MPC configurator for an
operating range from 7.5 to 6.5 pH and stored in DB 50. The relevant influencing
variables were an inflow amount of the input material of 3000 L/s with pH 4 and a
neutralizing agent with a pH of 12.
For trend recording, the manipulated variable was excited using the "AutoExci"
block and the disturbance variable was changed (±10%).

YC_Neutralizer
The instance has the following parameterization.
Block Connection Value Use
V MV Interconnection for the simulation
(Sim_pH_MPC\pH_MPC.Neutr_MV)
from_Ctrl In Interconnection to the controller
(QIC_pH_Control_MPC\to_Actor.Out)
to_Ctrl Out Interconnection to the controller
(QIC_pH_Control_MPC\from_Actor.In)
MV_Out SimOn Activation of simulation on the channel block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)
© Siemens AG 2019 All rights reserved

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Commissioning and operation

2. In the faceplate, change the operating mode to "Automatic".

3. Switch to controller "QIC_pH_Control_MPC" and change the controller's
operating mode to "Automatic".

4. Wait for about 1 minute until the process value reaches its specified operating
range.

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5. Switch to operator control block "pH_Feed" and specify a new setpoint of 4.5
pH.
© Siemens AG 2019 All rights reserved

6. Close the faceplate and observe the plotter for about one minute until the new
setpoint has been reached.

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Evaluation

1
2

1. The controller is optimized to reach the setpoint exactly and consequently,

slowly. The controller detects the change in the disturbance variable and it
modifies the manipulated variable before the process responds to influencing
of the disturbance variable (set deadtime in the simulation block). The
disturbance variable acts on the actual value without delay (time delay
elements).
2. In the example, the pH value of the input material was increased by 0.5 pH;
however, it had an effect of about 1 pH on the product.
Despite detecting the disturbance variable in good time, the controller needs about
90 seconds for compensation and regulation. This time is also needed for control
with bigger changes in the pH value of the input material.

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5.7 "Temperature-Flow-Cascade"
Temperature control via flow controller for a service medium (e.g. heating steam,
cooling water, or fuel) in cascade structure is used for applications in which
fluctuations within the auxiliary control loop (of the flow controller) have to be
compensated quickly, or the slave controller can compensate other unpleasant
properties of the actuator (e.g. a non-linear valve characteristic curve) which are
therefore invisible for the master controller. Temperature flow cascades are used
for heat exchangers, reactors or burners, for example.
In the heat exchanger, the system continuously pumps the contents of the
container through the heat exchanger via piping. This heats up or cools the product
material to a defined temperature by means of thermal transfer from the service
medium.
The same control concept is used with a burner, i.e. the amount of fuel flow
regulates the temperature.

Note The "temperature flow cascade" equipment module can be used for any process
applications where temperature control is carried out via flow.

In the following example, we will consider temperature control on a heat exchanger

that is heated by means of a heating medium. It is also possible to use heat
© Siemens AG 2019 All rights reserved

exchangers to cool a material flow. In this case, the flow of cooling medium is
manipulated instead of heating medium. The usual generic term for a heating or
cooling medium is "service medium”. The controller structure of heat exchangers
does not depend on whether they are used for heating or cooling. The only change
is the sign of the master controller's controlled system.

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Overview
Below, the structure in the P&ID is shown and all of the CMs and the simulation of
the equipment module are described.

P&I Diagram
The P&ID below symbolically represents all of the components, such as units and
containers, etc. relevant to operation.
TIC
Temperature

FIC YC
ServMedium ServMedium

Inflow
Service medium
Outflow
Service medium
Inflow
Product

CM and variants
The "temperature flow cascade" equipment module consists of three
© Siemens AG 2019 All rights reserved

interconnected CMs and one simulation chart. The simulation chart simulates the
effect of the heat exchanger on the input material temperature.
The following table provides an overview of the CMs of the equipment module
including the associated CMTs.
CM CMT Selected variants Description
TIC_Temperature PIDCon • PV Master controller for temperature control
• PV_Scale#
FFIC_ServMedium PIDCon • IF_Ctrl# Slave controller for the flow control
• PV
• PV_Scale#
YC_ServMedium VlvAn • IF_Ctrl# Control valve for the heating medium
• MV_Scale#
• RbkReturn
• YC

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In the figure below, the structure with the cross-chart interconnections is shown in
simplified form.
TIC_Temperature

PV
SimPV_In

to_Actor_Slave
Out

from_Actor_Slave
In

Sim_Temperature FIC_ServMedium
YC_ServMedium
to_Master
Lag_Heat_Slave
Out V
In
MV
from_Master
Noise_Master
In from_Ctrl
Out
In
PV
Gain_Slave
SimPV_In to_Ctrl
Out
Out
to_Actor_Slave
Out

from_Actor_Slave
In

Controller "TIC_Temperature" uses the temperature of a material to be regulated

from the "Sim_Temperature" simulation chart and generates the setpoint
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specification for the slave controller. This means that the desired temperature
curve is configured in process tag "TIC_Temperature". Slave controller
"FIC_ServMedium" regulates the flow rate of the heating medium by means of
control valve "YC_ServMedium" based on the setpoint specification of the master
controller.

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Structure and parameterization

"Sim_Temperature" simulation
In CFC "Sim_Temperature", the system simulates a temperature change of a
material by a heat exchanger. The figure below shows the sequence of the
simulation.
1

2 4

5
3
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1. If a valve is 100% open, with a 3-second delay, a flow of 5 t/h (factor 0.05) is
sent to the slave controller as the flow rate actual value.
2. With a 10-second delay (as a simulation for heating up of the thermal capacity
of the heat exchanger), ten times the value of the heating steam flow rate is
sent to the reference junction as the actual value of the hot air temperature.
3. Alternating input material temperature that changes every 90 seconds between
20 °C and 21 °C to simulate a disturbance.
4. Input material temperature for the master controller that changes in
dependence on the heat exchanger. The output signal can be given slight
signal noise.
5. Material temperature before being heated by the heat exchanger.

Note Simulation behavior does not correspond to a real process and it is only used to
demonstrate the functionality and mode of operation of the "temperature flow
cascade" equipment module.

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TIC_Temperature
The instance has the following parameterization.
Block Connection Value Use
PV_Scale HiScale 200.0 Scaling of the process value upper limit
PV_Unit In 1001 Unit of the process value in degrees
Celsius
C TI 7.3 Controller lag
C SP_InHiLim 200.0 Maximum value of the internal setpoint
to_Actor_Slave Out Interconnection to the slave controller
(FIC_ServMedium\from_Ctrl.In)
from_Actor_Slave In Interconnection to the slave controller
(FIC_ServMedium\to_Ctrl.Out)
PV SimOn Activation of simulation on the channel
block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)
PV SimPV_In Interconnection for the simulated process
value
(Sim_Temperature\Noise_Master.Out)

FIC_ServMedium
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The instance has the following parameterization.

Block Connection Value Use
PV_Scale HiScale 10.0 Scaling of the process value upper limit
PV_Unit In 1328 Unit of the process value in t/h (tons per
hour)
C Gain.Value 2.8 Controller gain
C TI 1.7 Controller lag
C SP_InHiLim 10.0 Maximum value of the internal setpoint
to_Actor_Slave Out Interconnection to the control valve
(YC_ServMedium\from_Ctrl.In)
from_Actor_Slave In Interconnection to the control valve
(YC_ServMedium\to_Ctrl.Out)
to_Master Out Interconnection to the master controller
(TIC_Temperature\from_Actor_Slave.In)
from_Slave In Interconnection to the master controller
(TIC_Temperature\to_Actor_Slave.Out)
PV SimOn Activation of simulation on the channel
block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)
PV SimPV_In Interconnection for the simulated process
value
(Sim_Temperature\Gain_Slave.Out)

Note The "PID Tuner" program is available for commissioning the controller. Please
remind that you optimize the slave controller (service medium flow) first, and
then the master temperature controller.

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YC_ServMedium
The instance has the following parameterization.
Block Connection Value Use
V MV Interconnection for the simulation
(Sim_Temperature\Lag_Slave.In)
from_Ctrl In Interconnection to the controller
(FIC_ServMedium\to_Actor_Slave.Out)
to_Ctrl Out Interconnection to the controller
(FIC_ServMedium\from_Actor_Slave.In)
MV_Out SimOn Activation of simulation on the channel block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)

Commissioning and operation

2. In the faceplate, change the operating mode to "Automatic".

3. Switch to slave controller "FIC_ServMedium”, change its operating mode to
"Automatic" and the setpoint specification to "External".
4. Switch to master controller "TIC_Temperature" and change the operating
mode of the controller to "Automatic".
5. Enter a new setpoint of 21°C in master controller "TIC_Temperature".
6. Wait for about 2 minutes and then click on the "Start/Stop" icon on the toolbar
of the OnlineTrendControl.

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Evaluation

TIC_Temp TIC_Serv

1. The temperature of the product medium changes every 90 seconds. The

master controller responds to this change and regulates towards the
temperature setpoint of 21°C.
2. On detecting a temperature change, the master controller transfers a new
setpoint to the slave controller. The slave controller responds directly to this
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change with a new setpoint (brown trend display) and tracks the process value
(gray trend display) to the setpoint (orange trend display).
The slave controller (flow of the heating medium in t/h) is configured for exact
control without overshooting.

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5.8 Coarse-/Finestream-Control "Stream-Control”

In some process operating modes (start-up, production operation, load changes,
etc.), it is necessary to control large flow rates very precisely. In these situations,
two valves are used, since the control ratio of continuous valves for flow rates in
pipelines is limited. Typically, the maximum flow rate cannot be more than 50 times
greater than the minimum controllable flow rate.
A large valve in a pipeline of great diameter controls the larger percentage of the
material flow. However, the large valve cannot dose very precisely and also reacts
relatively slowly. A thinner pipe with a smaller valve acts in parallel; it can dose
more exactly and can control faster. Downstream of the valves, the two pipes are
joined again to maintain the desired overall flow.
The task of a coarse/fine flow control scheme is to control the two valves in such a
way that the requirements regarding the control range, precision, and dynamics of
the total flow are met.
Typical fields of application are:
• Quality control in chemical processes, such as pH control with flow control of
the neutralizing agent.
• Temperature controls on distillation towers or reactors with flow control of the
heating/cooling medium.
• Provision of auxiliary energy (heating steam, compressed air) for process
plants, e.g. with a large and a small steam generator or a large and a small
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compressor.
The fine flow controller uses the overall flow as controlled variable. The coarse flow
controller uses as its controlled variable the position of the control valve for the fine
flow, with a setpoint of 50% and a relatively broad deadband. The aim of the
coarse flow controller is to roughly adjust the main mass flow so that the fine flow
controller remains in the middle of its working range and can perform the fine
regulation.

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Overview
Below, the structure in the P&ID is shown and all of the CMs and the simulation of
the equipment module are described.

P&I Diagram
The P&ID below symbolically represents all of the components, such as field
devices and pipes. relevant to operation.

YC
FineStream

Fine inflow
FIC
TotalStream

FIC
CoarseStream

YC
CoarseStream

Coarse inflow
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CM and variants
The "Stream Control" equipment module consists of four connected CMs and one
simulation chart. On the simulation chart, the system forms the total from the two
inflows (fine and coarse inflow).
The following table provides an overview of the CMs of the equipment module,
including the associated CMTs.
CM CMT Selected variants Description
FIC_TotalStream PIDCon • PV_Scale# Throughflow control of fine stream
YC_FineStream VlvAn • IF_Ctrl# Control valve for the fine stream
• MV_Scale#
• RbkReturn
• YC
FIC_CoarseStream PIDCon • PV_Scale# Throughflow control of coarse stream with
acquisition of the manipulated value from the
fine stream valve
YC_CoarseStream VlvAn • IF_Ctrl# Control valve for the coarse stream
• MV_Scale#
• RbkReturn
• YC

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In the figure below, the structure with the cross-chart interconnections is shown in
simplified form.

Sim_Stream FIC_TotalStream YC_FineStream

PV V
Scale_FineStream
SimPV_In MV
In1

Scale_CoarseStre to_Actor_Slave from_Ctrl

In1 Out In

SumOfFlow from_Actor_Slave to_Ctrl

Out In Out

FIC_CoarseStream YC_CoarseStream

C V

PV MV

to_Actor_Slave from_Ctrl
Out In

from_Actor_Slave to_Ctrl
In Out
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Control "FIC_TotalStream" acquires the flow of the total stream and regulates the
fine stream with control valve "YC_FineStream".
The "FIC_CoarseStream" controller acquires the manipulated value of the
"YC_FineStream" control valve and regulates the coarse flow with the
"YC_CoarseStream" control valve. The setpoint for the "FIC_CoarseStream"
controller is 50%. With it the "FIC_CoarseStream" controller works to keep the
"YC_FineStream" control valve in the optimum working range of 50%.

Structure and parameterization

"Sim_Stream" simulation
The flow of both the fine stream and the coarse stream are simulated in the
"Sim_Stream" CFC and the overall flow rate is calculated as well. Apart from this,
the system displays the total flow rate based on process tag type "MonAn".
1 2 6

3 4

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1. Calculation of the flow for the fine stream (valve 100% open corresponds to
inflow of 200 l/h)
2. Delay in change of flow (PT1 response with 8-second delay)
3. Calculation of the flow for the coarse stream (valve 100% open corresponds to
inflow of 2000 l/h)
4. Delay in change of flow (PT1 response with 24-second delay)
5. Determination of the complete flow quantity (addition)
6. Creation of measurement noise

FIC_TotalStream
The instance has the following parameterization.
Block Connection Value Use
PV_Scale HiScale 2200.0 Scaling of the process value upper limit
PV_Unit In 1353 Unit of the process value l/h (liters per
hour)
C Gain.Value 5 Controller gain
C TI.Value 5 Controller lag
C SP_InHiLim 2200.0 Maximum value of the internal setpoint
to_Actor_Slave Out Interconnection to the valve
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(YC_FineStream\from_Ctrl.In)
from_Actor_Slave In Interconnection to the valve
(YC_FineStream\to_Ctrl.Out)
PV SimOn Activation of simulation on the channel
block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)
PV SimPV_In Interconnection for the simulated process
value
(Sim_Stream\SumOfStream.Out)

Note Procedure for controller tuning:

1. Take coarse stream controller in manual mode, go to typical operating point
2. Optimized fine stream controller by PID-Tuner and take it to automatic mode.
3. Adjust deadband of fine stream controller with respect to measurement
noise, such that the movements of the manipulated variable are sufficiently
smooth.
4. Optimize coarse flow controller by PID-Tuner in manual mode, with a small
step of manual value. The controlled process has negative gain: if the coarse
flow controller opens its valve, the fine stream controller will compensate this
by closing its valve. Process gain can be estimated from the ratio of maximal
flows of both valves. Typical is a factor of about 10 between coarse flow and
fine flow.
5. Specify the deadband of coarse flow controller with respect to the precision,
that can be achieved realistically by the coarse flow controller, such that the
coarse flow valve does not move at all in steady state operation.

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FIC_CoarseStream
The instance has the following parameterization.
Block Connection Value Use
PV_Scale HiScale 100.0 Scaling of the process value upper limit
PV_Unit In 1342 Process value unit %
C NegGain 1 Negative gain of PID controller
C Gain.Value 5 Controller gain
C TI.Value 24 Controller lag
C DeadBand 10.0 Deadband
C PV_In Interconnection for the simulated process
value
(Sim_FineStream\V.MV)
to_Actor_Slave Out Interconnection to the valve
(YC_CoarseStream\from_Ctrl.In)
from_Actor_Slave In Interconnection to the valve
(YC_CoarseStream\to_Ctrl.Out)

YC_FineStream
The instance has the following parameterization.
Block Connection Value Use
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V MV Interconnection for the simulation

(Sim_Stream\Scale_FineStream.In1)
Interconnection to the controller
(YC_CoarseStream\C.PV)
from_Ctrl In Interconnection to the controller
(FIC_TotalStream\to_Actor_Slave.Out)
to_Ctrl Out Interconnection to the controller
(FIC_Totalstream\to_Actor_Slave.In)
MV_Out SimOn Activation of simulation on the channel block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)

YC_CoarseStream
The instance has the following parameterization.
Block Connection Value Use
V MV Interconnection for the simulation
(Sim_Stream\Scale_CoarseStream.In1)
from_Ctrl In Interconnection to the controller
(FIC_CoarseStream\to_Actor_Slave.Out)
to_Ctrl Out Interconnection to the controller
(FIC_Coarsestream\to_Actor_Slave.In)
MV_Out SimOn Activation of simulation on the channel block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)

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Commissioning and operation

2. In the faceplate, change the operating mode to "Automatic".

3. Switch to controller "FIC_TotalStream" and change the controller's operating

mode to "Automatic".
4. Enter a setpoint of "800 l/h".

5. Switch to "YC_CoarseStream" valve and change the operating mode to

"Automatic".
6. Switch to "FIC_CoarseStream" valve and change the operating mode to
"Automatic" and the setpoint to "External".

Hinweis The controller uses the preset setpoint "50"% as external setpoint to keep the
valve "YC_FineStream" in the middle of the working range.

7. Then wait about 1 minute until both controllers have reached their setpoints
and change the main controller setpoint to "1200 l/h”.

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8. Wait for about 30 seconds and then click on the "Start/Stop" icon on the toolbar
of the OnlineTrendControl.

Evaluation
© Siemens AG 2019 All rights reserved

PV_Total- SP_Total- PV_-

stream stream YC_Coarse

The setpoint step from 800 l/h to 1200 l/h opens the valve for the fine stream
completely. The coarse stream controller registers the change of the fine stream
control valve and regulates the coarse stream valve accordingly. This leads to a
significant change of the total flow so that the controller for the total flow closes the
fine stream valve again until the total flow has reached the new setpoint value.

Note Typical a large disturbance moves the overall flow away from its setpoint. The
fine stream controller is supposed to react quickly and compensate the
disturbance, but will reach one of its manipulated variable limits. The coarse flow
controller slowly adapts to the situation and allows the fine stream controller to
return to the center of its manipulated variable range.

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5.9 Gradient limits in actuators "Gradient-Limit"

Numerous mechanical actuators in process plants, such as control valves, pumps
with variable speed or thermostatic baths, react only with limited speed to a change
in the manipulated variable. As a result, the valve position, the pump speed or the
bath temperature cannot be changed as quickly as required and the achievable
gradient of the controller’s manipulated variables is limited. Even with a linear
controller and an otherwise linear system, the behavior of the closed control loop in
this case is not independent of the amplitude, it depends on the signal form of the
manipulated variable.
There is no effect of gradient limitation for slow manipulated variable changes. The
steeper the signal edge, the stronger the delaying effect. This alters the visible
dynamics of the controlled system from the controller’s point of view. Since the
behavior is not known to the controller, integrator windup may occur in PID
controllers leading to strong overshoots.
If the speed of the actuator is sufficiently fast compared to the other time constants
of the controlled system, the control dynamics are hardly distorted. If the dynamics
are more strongly distorted, the controller is usually designed according to the
worst-case scenario, i.e. according to the largest occurring setpoint steps. In all
other scenarios, such as disturbance behavior, significant limitations of control
performance are imposed.
In the following, the problem is presented using a simple flow control loop,
consisting of PID controller and valve, and four methods for improving control
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dynamics are explained.

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Overview
Below, the structure in the P&ID is shown and all CMs and the simulation of the
equipment module are described. The structure is described in general for all
methods. The modifications of the respective method are explained in the
corresponding subchapter.

P&I Diagram
The P&ID below symbolically represents all of the components, such as field
devices and containers relevant to operation.

FIC YC
GradLimit GradLimit

Feed

CM and variants
The technical function "GradientLimit" consists of two interconnected CMs and a
© Siemens AG 2019 All rights reserved

simulation plan. The behavior of the controlled system is simulated in the

simulation plan.
The following table provides an overview of the CMs of the equipment module,
including the associated CMTs.
CM CMT Variant Description
FIC_GradLimit PIDCon • PV Flow controller
• PV_Scale#
YC_GradLimit VlvAn • IF_Ctrl# Control valve
• MV_Scale#
• RbkReturn
• YC

In the figure below, the structure with the cross-chart interconnections is shown in
simplified form.

Sim_GradLimit FIC_GradLimit YC_GradLimit

PV_In V
ValveGradSim
SimPV_In MV
In

PT1_2s to_Actor_Slave from_Ctrl

Out Out In

from_Actor_Slave to_Ctrl
In Out

The "FIC_GradLimit" controller detects the flow and controls it using the
"YC_GradLimit" control valve. In the CFC chart "SimGradLimit", the flow rate is
calculated from the control value for the valve and the gradient limitation.

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Structure and parameterization

Simulation "Sim_GradLimit"
The CFC "Sim_GradLimit" simulates the gradient limitation of the control valve and
the flow rate.
2 3

1. Calculation of the valve feedback (valve position in the range 0...100% and a
maximum travel speed of 3 %/s in both directions)
2. Calculation of the flow rate (100 % valve opening corresponds to an inlet of
2000 l/h)
3. Flow change delay (PT2 behavior with 15 seconds and 2 seconds delay)
4. Visualization of the position feedback in the WinCC Runtime
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CFC "Method_GradLimit"
In the CFC "Method_GradLimit" the different methods for considering the gradient
limitation of the actuator are selected and activated.
The respective methods are activated in sub-sheets 1 to 4, the description of the
individual methods can be found in the following sub-sheets. The methods are
selected in Subsheet 6.
1 2 3

1. Selection of the method from WinCC Runtime

2. Checking the input
3. Activation of the respective method for consideration of gradient limitation

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FIC_GradLimit
The instance has the following parameterization.
Block Connection Value Use
PV_Scale HiScale 2000.0 Scaling of the process value upper limit
PV_Unit In 1353 Unit of the process value l/h (liters per
hour)
C Gain.Value 5 Controller gain
C TI.Value 28 Controller lag
C SP_InHiLim 2000.0 Maximum value of the internal setpoint
to_Actor_Slave Out Connection to valve
(YC_GradLimit\from_Ctrl.In)
from_Actor_Slave In Interconnection for the valve
(YC_GradLimit\to_Ctrl.Out)
PV SimOn Activation of simulation on the channel
block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)
PV SimPV_In Interconnection for the simulated process
value
(Sim_GradLimit\PT1_2s.Out)
© Siemens AG 2019 All rights reserved

YC_GradLimit
The instance has the following parameterization.
Block Connection Value Use
V MV Interconnection for the simulation
(Sim_GradLimit\ValveGradLim.In)
from_Ctrl In Interconnection for the controller
(FIC_GradLimit\to_Actor_Slave.Out)
to_Ctrl Out Interconnection for the controller
(FIC_GradLimit\to_Actor_Slave.In)
YC SimOn Activation of simulation on the channel
block
(Equipment_Modules\\
Activate_Simulation\Sim_Act.Out)

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5.9.1 Control behavior without active method

Commissioning and operation

2. In the faceplate, change the operating mode to "Automatic".

3. Switch to the controller "FIC_GradLimit1" and change the operating mode of
the controller to "Automatic".
4. Enter a setpoint value of "300" L/h.

The new setpoint will be reached after approximately two minutes.

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5. Specify a new setpoint of "800" L/h for the controller.

6. Close the faceplate and observe the trend curve for about two minutes until the
new setpoint has been reached.

Evaluation
© Siemens AG 2019 All rights reserved

During the positive setpoint step, a significant difference between the manipulated
variable for the valve and the actual valve position (position readback signal,
green) is visible. The actual valve position cannot follow the commands of the
controller (red) fast enough due to the gradient limitation. Since the difference
between the manipulated variable for the valve and the actual valve position is not
known to the controller, an overshoot of more than 30% of the step height occurs,
which would not be acceptable in many applications.

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5.9.2 Method 1 "External Reset"

For controllers with an incremental algorithm that have an input variable for
external reset, setting the manipulated variable from the last sampling step (e.g.
PIDConR.ExtReset), the actual actuator position is connected to this reset input.
This prevents the controller manipulated variable from drifting too far away from the
position feedback signal.

Setup

NOTE Instead of the PIDConL controller, method 1 "External Reset" uses the PIDConR
controller from the Advanced Process Library.

The following parameterization is required for the "External reset" method:

Block Connection Value Use
C ExtRstOn 1 Activate external reset

The following wiring is used in addition to the standard wiring:

Block Connection Target Description
C ExtReset Circuit for position Reset value for ExtRstOn = 1
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feedback of the valve

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Commissioning and operation

2. In the "YC_GradLimit1" valve faceplate, change the operating mode to

"Automatic".
3. Switch to the controller "FIC_GradLimit1" and change the operating mode to
"Automatic".
4. Also enter a setpoint of "300" L/h in the controller's faceplate.
The new setpoint will be reached after approximately two minutes.
5. Specify a new setpoint of "800" L/h for the controller.
6. Close the faceplate and observe the trend window for about two minutes until
the new setpoint has been reached.

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Evaluation
© Siemens AG 2019 All rights reserved

With the "External reset" method activated, a significantly better control response is
achieved for the same setpoint step, the overshoot is significantly smaller, and the
settling time is also shorter.

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5.9.3 Method 2 "Tracking output value in case of excessive deviation"

With the method "Tracking output value in case of excessive deviation", the
controller output is adjusted to the current position feedback signal as soon as the
difference between the controller output and the position feedback signal exceeds
a limit (e.g. 25% of the positioning range).

Setup
Three additional blocks ("Sub02", "AbsR" and "CopmAn02") from the Advanced
Process Library are required for the method "Adjust control value if deviation is too
large".
The following parameterization is required:
Block Connection Value Use
CompAn02 In2 25 Difference between output value and
position feedback signal at which the
output value is to be reset

The following wiring is used in addition to the standard wiring:

Block Connection Target Description
Sub02 In1 Connection to the Form difference between
manipulated variable of manipulated variable and position
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the valve feedback signal

Sub02 In2 Circuit for position
feedback of the valve
Sub02 Out AbsR.In Output of the difference between
manipulated variable and position
feedback signal
AbsR In Sub02.Out Form absolute value
AbsR Out CompAn02.In1 Output of the absolute difference
CompAn02 In1 AbsR.Out Compare difference independent
of direction
CompAn02 GT C.MV_TrkOn If the difference between the
output value and the position
feedback signal is large, adjust
the output value of the controller.
C MV_TrkOn CompAn02.GT Activating the output value
C MV_Trk Circuit for position Tracking value for manipulated
feedback of the valve variable MV

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Commissioning and operation

For commissioning and operation, it is assumed that the user program has been
loaded in the automation system (AS) or the S7-PLCSIM and that the OS (WinCC
Runtime) has been activated. You can find a guide for loading the user program
and activating the OS in chapter 2 "Preparation and commissioning".
Proceed as follows:
1. Enter the setpoint "2" at the faceplate "GradientLimit".
2. In the "YC_GradLimit2" valve faceplate, change the operating mode to
"Automatic".
3. Switch to the controller "FIC_GradLimit2" and change the operating mode to
"Automatic".
4. Also enter a setpoint of "300" L/h in the controller's faceplate.
The new setpoint will be reached after approximately two minutes.
5. Specify a new setpoint of "800" L/h for the controller.
6. Close the faceplate and observe the trend window for about two minutes until
the new setpoint has been reached.

Evaluation
© Siemens AG 2019 All rights reserved

After the difference between the manipulated variable and the position feedback
signal exceeds the parameterized limit value, the controller output (red) is set to the
position feedback signal (green). This limits the manipulated variable curve and
completely avoids overshoot. The method is not effective for smaller setpoint steps
because the difference between the controller output and the position feedback
signal does not exceed the limit value.

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5.9.4 Method 3 "Blocking integrator"

Another method of handling actuator gradient limitation is the method of blocking

the integrator. For this purpose, signals showing if manipulated variable limits are
reached, are read from the underlying valve positioner (e.g. Sipart PS) in order to
block the integrator in a direction-dependent manner. This method acts very
specifically against integrator windup and corresponds to what is proposed for
cascade control within the distributed control system (interconnection of the
function blocks for master and slave controllers, see templates of the PCS 7
Advanced Process Library). This assumes that binary feedback signals from the
actuator are available as soon as the actuator reaches its internal manipulated
variable limitation and the gradient limitation thus takes effect.
Setup
The following wiring is used in addition to the standard wiring:
Block Connection Target Description
C IntHoldPos Limitation of the Block integrator in positive
manipulated variable in direction
positive traverse
direction from the
downstream valve
positioner
C IntHoldNeg Limitation of the Block integrator in negative
manipulated variable in direction
negative traverse
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direction from the lower-

level valve positioner

Commissioning and operation

For commissioning and operation, it is assumed that the user program has been
loaded in the automation system (AS) or the S7-PLCSIM and that the OS (WinCC
Runtime) has been activated. You can find a guide for loading the user program
and activating the OS in chapter 2 "Preparation and commissioning".
Proceed as follows:
1. Enter the setpoint "3" at the faceplate "GradientLimit".
2. In the "YC_GradLimit3" valve faceplate, change the operating mode to
"Automatic".
3. Switch to the controller "FIC_GradLimit3" and change the operating mode to
"Automatic".
4. Also enter a setpoint of "300" L/h in the controller's faceplate.
The new setpoint will be reached after approximately two minutes.
5. Specify a new setpoint of "800" L/h for the controller.
6. Close the faceplate and observe the trend window for about two minutes until
the new setpoint has been reached.

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With the "Blocking integrator" method activated, the integrator windup can be
suppressed such that the overshoot is reduced during the setpoint step. The lower
part of the trend shows when the gradient limitation is active.
Direction-dependent blocking has the advantage that it works independently of the
step height, such that tracking behavior is less slowed down, and no
parameterization is required. However, the binary signals required for this are only
available for a few installations in the distributed control system.
One example is an electro-pneumatic valve positioner, which often operates
internally as a 5-point positioner. The so-called slow gear zone, in which an
approximately proportional control behavior is visible, covers only 1...10% of the
valve position range. As soon as the control deviation leaves this range, the
positioner opens the maximum air supply to the valve actuator, i.e. it operates at its
manipulated variable limit. This happens frequently during operation with large
setpoint steps. The corresponding binary signals are usually only available for
internal use within the field device and are not made available to the outside world
via a communication interface.

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5.9.5 Method 4 "Blocking integrator with gradient calculation"

The "Blocking integrator with gradient calculation" method allows directional

blocking of the integrator even in cases where no feedback can be received from
the actuator showing that the actuator is moving at maximum speed. For this
purpose, this information is reconstructed inside the process control system by
calculating the current gradient of the valve position and comparing it to the known
limit value of the maximum travel speed.
Typically position feedback is superimposed by measuring noise, therefore a low-
pass filtering with meaningful time constant must be performed in front of the
differentiator.

Setup
For the "Blocking integrator with gradient calculation" method, three additional
blocks ("Derivative" and twice "CopmAn02") from the Advanced Process Library
are required.
The following parameterization is required:

Block Connectio Value Use

CompAn02_pos In2 2.9 Comparison gradient in positive direction

CompAn02_neg In2 -2.9 Maximum gradient in negative direction
The maximum gradient must be parameterized so that it is just below the real
gradient limit. Otherwise the limitation would not be detected.

The following wiring is used in addition to the standard wiring:

Block Connection Target Description
Derivative In Connection to the Calculation of the travel
manipulated variable of gradient
the valve
Derivative Out CompAn02_pos.In Output of the calculation of
CompAn02_neg.In the travel gradient
CompAn02_pos In1 Derivative.Out Comparison of maximum
travel speed in positive
direction
CompAn02_pos Out C.IntHoldPos Maximum travel speed
reached in positive direction
CompAn02_neg In1 Derivative.Out Comparison of maximum
travel speed in negative
direction
CompAn02_neg Out C.IntHoldPos Maximum travel speed
reached in negative direction
C IntHoldPos CompAn02_pos.Out Block integrator in positive
direction
C IntHoldNeg CompAn02_neg.Out Block integrator in negative
direction

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Commissioning and operation

For commissioning and operation, it is assumed that the user program has been
loaded in the automation system (AS) or the S7-PLCSIM and that the OS (WinCC
Runtime) has been activated. You can find a guide for loading the user program
and activating the OS in chapter 2 "Preparation and commissioning".
Proceed as follows:
1. Enter the setpoint "4" at the faceplate "GradientLimit".
2. In the "YC_GradLimit4" valve faceplate, change the operating mode to
"Automatic".
3. Switch to the controller "FIC_GradLimit4" and change the operating mode to
"Automatic".
4. Also enter a setpoint of "300" L/h in the controller's faceplate.
The new setpoint will be reached after approximately two minutes.
5. Specify a new setpoint of "800" L/h for the controller.
6. Close the faceplate and observe the trend window for about two minutes until
the new setpoint has been reached.

With the activated method "Blocking integrator with gradient calculation", the
integrator windup can also be suppressed such that the overshoot is reduced
during the setpoint step. Due to the delay caused by the low-pass filter, the effect
of the method is not quite as good as if the original binary signals are available.

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5.9.6 Methods comparison

In control loops with mechanical actuators whose moving speed is so strongly

limited that the delaying effect of the gradient limitation cannot be neglected
compared to the other time constants of the controlled system, a windup of the
integrator can be avoided by applying one of the four methods. This allows to
reduce the overshoot, especially with large setpoint steps, without generally tuning
the controller very sluggish and thus also impairing the disturbance compensation
of the control loop.
The following table compares the methods for suppressing integrator windup in
case of gradient limitations of the manipulated variable.
Method Requirements Parameters Effect
External reset Controller block None reduces divergence of
PIDConR setpoint and feedback
Analog position of the actuator in case
feedback from actuator of large setpoint steps,
reduces overshoot
Tracking output value in Analog position Switching threshold for Proportional step is
case of excessive feedback maximum deviation truncated, tracking
deviation e.g. 25%. behavior is slowed
down, slow settling
times
Blocking integrator Controller block None Avoids windup in case
© Siemens AG 2019 All rights reserved

PIDConL of active gradient

binary feedback from limitation, reduces
actuator when internal overshoots
manipulated variable
limitation is active (i.e.
gradient is limited)
Integrator blocking with Controller block maximum travel Avoids windup in case
gradient calculation PIDConL gradient of active gradient
Analog position Low pass filtering with limitation, reduces
feedback from actuator meaningful time overshoots
constant

The "External Reset" method has the advantage that it can be used for controllers
with incremental algorithms without further parameterization and without special
requirements on the feedback signals from the final control element.
The method "Tracking the output value in case of excessive deviation" has the
widest range of application. It does not require a special control algorithm, binary
feedback signals or high signal quality of the analog feedback signal. Only
application-specific limit values must be parameterized. The method slows down
the tracking behavior for large setpoint steps and remains completely ineffective for
small setpoint steps.
The "Blocking integrator" method achieves the highest overall control performance
for setpoint steps of different heights, but requires binary feedback signals from the
actuator when its internal manipulated variable signal limitation is active.
The "Blocking Integrator with gradient calculation" method allows the use of
directional integrator blocking with reduced precision even when there are no
binary feedback signals from the actuator. For this the maximum actuator gradient
and a meaningful filter time constant must be determined.

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Selecting the method

When selecting the method for considering gradient limits in final control elements,
the following sequence of criteria can be used:
1. If an incremental control algorithm is used, the "External Reset" method is
preferred.
2. If no incremental control algorithm is used, but the binary feedback signals of
the actuator are available when the internal manipulated variable limitation is
active, the "Blocking integrator" method should be selected.
3. If the binary feedback signals are not available, the method "Blocking integrator
with gradient calculation" must be selected as an alternative.
4. If sufficient smoothing of the position readback signal is not possible or the
filter time constant is not negligible small compared to the time constants of the
controlled system, use the method "Tracking output value in case of excessive
deviation".
© Siemens AG 2019 All rights reserved

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5.10 Instance-specific adaptations

Note No alarm, warning or tolerance limits are pre-parameterized in the equipment

modules. If you parameterize a limit value, you must also activate the
corresponding notification.
For example, parameter "PV_AH_En" for upper alarm limit "PV_AH_Lim".

Note Interconnection of the process variables depends on the selected variant of a

CM. In the configuration below, the control, process, and manipulated variables
are acquired via the "Pcs7AnIn" and "Pcs7AnOu" analog channel blocks.

The tables below contain the relevant parameters that you must either set or
interconnect.

C TI Integral action time in [s]

C SP_InHiLim (Upper) limit value of the internal
setpoint
C SP_InLoLim Limit (lower) of internal
setpoint
C PV_AH_En Alarm in case of upper limit value violation if PV ≥
PV_AH_Lim
C PV_WH_En Alarm in case of upper limit value violation if PV ≥
PV_WH_Lim
C PV_TH_En Tolerance in case of upper limit value violation if PV ≥
PV_TH_Lim
C PV_TL_En Tolerance in case of lower limit value violation if PV ≤
PV_TL_Lim
C PV_WL_En Alarm in case of lower limit value violation if PV ≤
PV_WL_Lim
C PV_AL_En Alarm in case of lower limit value violation if PV ≤
PV_AL_Lim
C ER_AH_En Alarm in case of upper control difference violation if ER ≥
(hidden) ER_AH_Lim
C ER_AL_En Alarm in case of lower control difference violation if ER ≤
(hidden) ER_AL_Lim
PV_Scale HiScale Scaling of the measured value (e.g. maximum container fill
LoScale level of 10000)
PV_Unit IN Unit of the scaled measured value (e.g. 1038 fill level in
liters)
PV PV_In Acquisition of the controlled variable, e.g. fill level

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Display
Block Connection Use
I PV_AH_En Alarm in case of upper limit value violation if PV ≥
PV_AH_Lim
I PV_WH_En Alarm in case of upper limit value violation if PV ≥
PV_WH_Lim
I PV_TH_En Tolerance in case of upper limit value violation if PV ≥
PV_TH_Lim
I PV_TL_En Tolerance in case of lower limit value violation if PV ≤
PV_TL_Lim
I PV_WL_En Alarm in case of lower limit value violation if PV ≤
PV_WL_Lim
I PV_AL_En Alarm in case of lower limit value violation if PV ≤
PV_AL_Lim
PV_Scale HiScale Scaling of the measured value (e.g. maximum container fill
LoScale level of 10000)
PV_Unit IN Unit of the scaled measured value (e.g. 1038 fill level in
liters)
PV PV_In Acquisition of the process variable, e.g. fill level

V MV_HiLim Upper and lower limit of the manipulated value

MV_LoLim
MV_Scale HiScale Scaling of the manipulated variable (manipulated value of
LoScale the valve block)
MV_Unit IN Unit of the scaled manipulated variable
MV_Out PV_Out or Channel blocks for linking a control valve
PV_ChnST Output of the manipulated variable or
Output of the manipulated variable including the signal
status

Note In the object properties of the message-type blocks, you can configure instance-
specific messages. You can find a guide to the procedure in the "SIMATIC
PCS 7 Process Control System; Operator Station (V9.0)" configuration manual
under https://support.industry.siemens.com/cs/ww/en/view/109746516.

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6 Additional information
6.1 General Information
Automation technology
Industrial processes in the chemicals or pharmaceuticals sectors, for example, are
controlled and regulated using automation technology.
The degree of automation of systems varies considerably and depends on the
system type and the process.
In general, an automation solution includes the following aspects:
• Measurement and control
• Possibly, control of higher quality control strategies
• Transferring, processing and representing information
• Complying with defined steps and procedures
• Observing complex contexts
• Guaranteeing constant product quality
• Strategies in the case of deviations from or exceeding of process parameters
or of component failures

The operator’s main task is to carry out operative process control on the basis of
process and plant information with respect to production process and its logistics
and auxiliary processes.
The task of process control is to guarantee that operating conditions are are kept
in, compliance with defined tolerance ranges for process safety and product quality,
in a selective and reproducible way. In case of disturbances, the process has to be
driven back to the desired operating state. In addition, the production sequence
should be continuously optimized with regard to costs, quality, and safety.
Using SIMATIC PCS 7 Advanced Process Graphics (APG), it is possible to make
process visualization more efficient for operators. When doing this, the system
shows the information in the plant overview that is relevant for orientation and
navigation. The information that is necessary for operator control and monitoring of
a plant unit, e.g. a reactor, is made available in a lower-level process picture. This
procedure provides the great advantage of dispensing information in a task-
oriented way that is optimized for process operation.

Note You can find detailed information and the procedure for configuring APG in the
Siemens Industry Online Support in the entry entitled "Integration of Advanced
Process Graphics in SIMATIC PCS 7" under
https://support.industry.siemens.com/cs/ww/en/view/89332241.

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6.2 Standardized plant units

Partial automation solution
The figure below shows the components of an automation solution for a process
plant. The production process is divided into several steps, e.g. fermentation and
distillation. In this connection, one process step corresponds to one plant unit,
which, for its part, can consist of different equipment modules, e.g. addition of
starting material or agitation.

The term plant unit represents an apparatus (device) in process plants (e.g. stirred
tank reactor, fermenter) which includes sensor technology, actuators and
automation (hardware and software).
There are structured units for both continuous and discontinuous processes.
Package units are variants of a plant units. Examples of package units include
refrigeration systems, vacuum systems and packaging machines. In this case, the
manufacturer of the mechanical or technical device includes automation
technology, specially tailored for this device, which is mounted locally on the device
on a separate hardware platform. The package unit is integrated as a whole into a
higher-level process control system.

Equipment module
An equipment module forms part of a unit and contains sensors, actuators and the
automation system (hardware and software). Equipment modules are designed
and configured for use in concrete applications, such as process technology
(dosing device, level or temperature control).
The automation solution of an equipment module is structured as follows:
• Connected and parameterized process tags
• Elementary simulation to demonstrate the mode of operation for virtual
commissioning, not necessary for plant operation
Each equipment module is combined in a hierarchy folder and can be integrated
into existing projects.

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Control module
Actuators and sensors are used at the control module level as control modules.
In PCS 7, the control module is implemented with software typicals
(control module types) such as a valve, motor, or controller, for example.
The implementation in the CFC contains all the relevant building blocks,
interconnections, and basic parameters. A control module type is produced from
the CFC, which is then stored in the PCS 7 master data library. You can create as
many instances as you like from this control module type using the Automation
Interface, for example. There can be major differences between the instances, e.g.
you can select options for functions as well as for the process link.
Each designation of a control module follows a uniform naming convention. This
means that the name provides information about the function and the job of the
control module.

Unit Template
A Unit Template is composed of several equipment modules. In a Unit Template,
equipment modules are grouped into a partial automation solution.
In addition, it is possible to display other information in a Unit Template, such as
economic or process engineering parameters (KPIs) or the operating times of
equipment.
A Unit Template is grouped in a hierarchy folder and you can easily integrate it into
existing projects and adapt it.
© Siemens AG 2019 All rights reserved

In contrast to package units, no local isolated control systems with their own
hardware are set up; rather, in the Unit Template concept, pre-assembled software
solutions are created in a central process control system for frequently occurring
unit types. Partial automation solutions for process plants are provided on a
uniform pre-assembled basis and can be edited by users. This means that it is
sufficient to adapt the templates to the existing process plant and automation
hardware. This significantly reduces the engineering effort required for several
similar automation tasks.

Configuration with templates

You can carry out configuration using templates at the equipment module or control
module level.
At the control module level, you use control module types in PCS 7 to create a
template for creating instances. It is possible to compare and match the instances
of the control module types with the PCS 7 Automation Interface.
Equipment modules or plant units are duplicated as a unit and adapted to the
corresponding process engineering.
The equipment modules and the Unit Template contain all functions that are
needed for automation in form of:
• CFCs (instances of control module types)
• SFCs
• OS pictures

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6.3 Design and structure

6.3.1 CFC naming convention

A uniform naming convention was used to identify the control modules with the
function being named according to European standard EN 62424 or to ISO 3511.
The figure below shows how a label is composed:
FIC_Reflux
Function Designation
F = Flow (First letter)
I = Indication (Next letter)
C = Control (Next letter)

The table below contains all of the letters that are used in the Application Example
and their meanings:

First letter Meaning

N Motor
P Pressure
Q Amount, quantity or quality
S Speed
T Temperature
W Weight
X Freely selectable first letter
Y Control valve

Subsequent letter Meaning

A Alarming/Messages
C Control
F Fraction
I Indication
R Recording/Storage
S Binary control function or switching function (not safety-
oriented) ("switching")
T Monitoring (transmitter, analog value processing)
H High
L Low

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6.3.2 Plant view

In the plant view, the equipment modules are implemented on two hierarchy levels.
In the "EquipmentModules_AS_Prj" AS project, the first hierarchy level is empty
and on the lower hierarchy level there is one hierarchy folder for each equipment
module that contains the necessary CFC.
On the first hierarchy level of the "EquipmentModules_OS_Prj" OS project, there is
the overview picture of all the equipment modules "EquipmentModules.pdl”. On the
lower hierarchy level there is one hierarchy folder for each equipment module that
contains a process picture. The illustration below shows the folder structure on a
schematic basis, i.e. the designations of the sub-folders differ from the folder
designations of the PCS 7 project.

EquipmentModules OS Project

PDL
Overview picture

EquipmentModule 1

EquipmentModule 2

PDL
EquipmentModule 2

EquipmentModules AS Project

EquipmentModule 1

User program Simulation

CFC CFC CFC

LIC_RefluxDrum LIC_Level Simulation

EquipmentModule 2
User program Simulation

CFC CFC CFC

PI_Tank PIC_Split Simulation

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6.4 Controllers and control response

The aim of this chapter is to give you an understanding of controller response and
the principle of operation in the case of faults or maintenance. To do this, we
describe tracking of the manipulated variable in picture form and display the
messages or displays on the faceplates in the case of faults.

6.4.1 Tracking standard and cascade controllers

Tracking of the manipulated variable is explained using the temperature flow

cascade as an example by changing the (internal/external) setpoint specification
from the control valve to the master controller and the (manual/automatic)
operating mode.
The following applies, in general: A controller must always be set to tracking mode
if it does not have access to the following block (follower controller or actuator),
because otherwise windup problems occur with controllers with an I component. A
controller always has no access to the following block if the following block is not in
automatic mode and uses the external setpoint. The tracking value is always
selected in such a way that the cascade can be closed again later without jolts.

Slave controller

Control valve

No. Master controller Slave controller Control valve Comment

1. Manual/Internal Manual/Internal Manual/Internal
(Forcing active) (Forcing active)
2. Manual/Internal Manual/Internal Manual/Internal Manipulated value
(Forcing active) (Forcing active) specification 20% in
Manipulated value Manipulated value Manipulated value control valve
1t/h 20% 20% The manipulated values
are tracked automatically
3. Manual/Internal Manual/Internal Automatic/External Operating mode
(Forcing active) (Forcing canceled) changed in control valve.
Manipulated value 1t/h Manipulated value Manipulated value The control valve applies
20% 20% the tracked (external)
manipulated variable on
a bumpless basis from
the slave controller
4. Manual/Internal Automatic/Internal Automatic/External Operating mode
(Forcing active) changed in slave
Manipulated value 1t/h Manipulated value Manipulated value controller. No change in
20% 20% behavior.

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No. Master controller Slave controller Control valve Comment

5. Manual/Internal Automatic/External Automatic/External Setpoint specification
(Forcing canceled) changed in slave
Manipulated value 1t/h Manipulated value Manipulated value controller. The slave
20% 20% controller applies the
tracked (external)
manipulated variable on
a bumpless basis from
the master controller

6.4.2 Tracking ratio controllers

Tracking of the manipulated variable is explained using the "Ratio control”

equipment module as an example by changing the (internal/external) setpoint
specification from the control valve to the master controller and the
(manual/automatic) operating mode.

Master controller Control valve

Master controller

Slave controller Control valve

Slave controller 2

No. Master Slave controller Control valve Control valve Comment

controller master slave
controller controller
1. Manual/Internal Manual/Internal Manual/Internal Manual/Internal
(Forcing active) (Forcing active)
2. Manual/Internal Manual/Internal Manual/Internal Manual/Internal Manipulated value
(Forcing active) (Forcing active) specification 20%
Manipulated Manipulated Manipulated Manipulated in control valve2
value 0.00 l/h value 100 l/h value 0% value 20% The manipulated
variable is tracked
automatically
3. Manual/Internal Manual/Internal Manual/ Manual/ Manipulated value
(Forcing active) (Forcing Internal Internal specification 30%
Manipulated canceled) in control valve1
value 600 l/h Manipulated Manipulated Manipulated The manipulated
value 100 l/h value 30% value 20% variable is tracked
automatically
4. Manual/Internal Manual/Internal Manual/ Automatic/ Operating mode
(Forcing active) (Forcing External External changed in control
Manipulated canceled) valve2.
value 600 l/h Manipulated Manipulated Manipulated

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No. Master Slave controller Control valve Control valve Comment

controller master slave
controller controller
value 100 l/h value 30% value 20%
5. Manual/Internal Manual/Internal Automatic/ Automatic/ Operating mode
(Forcing (Forcing External External changed in control
canceled) canceled) valve1.
Manipulated Manipulated Manipulated Manipulated
value 600 l/h value 100 l/h value 30% value 20%
6. Manual/Internal Automatic/ Automatic/ Automatic/ Operating mode
(Forcing External (forcing External External changed in slave
canceled) canceled) controller. The
Manipulated Manipulated Manipulated Manipulated manipulated
value 600 l/h value 150 l/h value 30% value 30% variable is tracked
automatically

6.4.3 Tracking split range temperature

Tracking of the manipulated variable is explained using the split range temperature
as an example by changing the (internal/external) setpoint specification from the
control valve to the master controller and the (manual/automatic) operating mode.
The front part of the cascade with the interaction of master and slave controller
works exactly like the normal cascade control in section 6.4.1. In tracking
operation, the split-range controller uses the neutral position as the tracking value,
because in manual operation or with an internal setpoint of both actuators,
© Siemens AG 2019 All rights reserved

combinations of output values can be set that cannot be mapped via the split-
range.

NOTE When using a split-range rule structure, it is not ensured that bumpless return to
normal operation is possible.

Master controller

Slave controller
Control valve 1

Control valve 2

No. Master Slave Control Control valve2 Comment

controller controller valve1
1. Manual/Internal Manual/Internal Manual/ Manual/
(Forcing active) (Forcing active) Internal Internal
2. Manual/Internal Manual/Internal Automatic/ Automatic/ Operating mode
(Forcing active) (Forcing External External changed for control

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No. Master Slave Control Control valve2 Comment

controller controller valve1
canceled) valves. No change in
behavior.
3. Manual/Internal Automatic/ Automatic/ Automatic/ Operating mode
(Forcing External External External changed with slave
canceled) (Forcing controller. No change
canceled) in behavior.

4. Automatic/ Automatic/ Automatic/ Automatic/ Operating mode

Internal External External External changed with master
(Forcing controller.
canceled) Manipulated variable
Manipulated specification 30 °C in
variable 30°C master controller.
The slave controller
applies the tracked
(external)
manipulated variable
on a bumpless basis
from the master
controller.
5. Manual/Internal Automatic/ Automatic/ Automatic/ Setpoint specification
(Forcing External External External changed in slave
canceled) controller. The slave
Manipulated Manipulated Manipulated Manipulated controller applies the
© Siemens AG 2019 All rights reserved

variable 30°C variable 50°C variable variable >=0% tracked (external)

>=0% manipulated variable
on a bumpless basis
from the master
controller.

6.4.4 Faults and maintenance for temperature throughflow cascade

In general, a controller can not work if it does not receive correct actuacl value of
the measured values due to wire break, loose contact, short circuit, bus error,
sensor failure or similar. The error case is signaled at the channel block by the
output "Bad = true".
The controller is then put into the fault state (CSF: Control System Fault) by means
of an interconnection and allows the operator to set manually the manipulated
variable in order to be able to influence at least the process. In case of a fault in the
channel to the actuator even this possibility of intervention is no longer available.
For the tracking of the master controller, the general rules also valid here: as soon
as the slave controller is no longer able to follow commands of the master
controller (no matter why, even with CSF in slave controller), the master controller
must be taken in tracking to enable later bumpless switching to normal operation.
The tables below describe the way of functioning and generated messages of the
individual process tags using the temperature throughflow cascade in case of
errors as an example.
The error on the channel block (the Bad output is active) occurs if there is a short-
circuit or a wire break on the device, for example.
Maintenance status OoSAct (lies: "Out of Service") occurs if maintenance is being
carried out on the device. From the controller's point of view, the sensor state "Out
of service" has the same consequences as the measurement loss.

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Faulty slave controller

Master controller

Slave controller
Control valve

Master controller Slave controller Control valve

Control or manipulated CSF puts the controller into No change in operating
variable specification is not disturbance status mode. The manipulated
possible since the CSF with (external error). variable of the slave
the slave controller is forced Controller switches to controller still matches the
manual mode. The manipulated variable, MV.
manipulated variable for
the control valve can be
changed
© Siemens AG 2019 All rights reserved

Note As soon as the CSF on the slave controller is no longer active, it can be switched
back to the original operating status (automatic/external).

Faulty master controller

Master controller

Slave controller
Control valve

Master controller Slave controller Control valve

CSF puts the controller into The slave controller The control valve continues
disturbance status (external continues to receive the MV to receive the MV from the
error). The manipulated from the master controller slave controller
variable (MV) can be
changed.

Note As soon as the CSF on the master controller is no longer active, it can be
switched back to the original operating status (automatic/external).

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Faulty control valve

Master controller

Slave controller
Control valve

Master controller Slave controller Control valve

The controller receives the The controller receives the CSF puts the valve into
MV in the case of a manual MV in the case of a manual disturbance status
change on the control valve change on the control valve (external error)
The manipulated variable
(MV) can be changed
(manual)

Maintenance status on slave controller

Master controller

Slave controller
Control valve

Master controller Slave controller Control valve

The controller maintains the The controller cannot be The control valve retains the
old MV until normal operated due to old value while there is no
operation is re-established maintenance. new MV from the slave
or the operator specifies a The user can switch to controller
different MV on the slave manual mode and specify
controller manually. the MV for the control
valve.

Note As soon as the maintenance status is no longer active, the slave controller can
be switched back to the original operating status (automatic/external).

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6 Additional information

Maintenance status on master controller

Master controller

Slave controller
Control valve

Master controller Slave controller Control valve

The controller cannot be The controller retains the The control valve retains the
operated due to old value while there is no old value while there is no
maintenance. new MV from the master new MV from the slave
The user can switch to controller. controller.
manual mode and specify
the MV for the slave
controller.

be switched back to the original operating status (automatic/external).

Maintenance status on control valve

Master controller

Slave controller
Control valve

Master controller Slave controller Control valve

Normal operation is possible Normal operation is possible Normal operation is still
possible. The
maintenance status is
displayed.

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6 Additional information

6.4.5 Faults and maintenance for ratio controllers

The tables below describe the way of functioning and generated messages of the
individual process tags using the ratio controllers in case of errors as an example.
The error on the channel block (the Bad output is active) occurs if there is a short-
circuit or a wire break on the device, for example.
Maintenance status OoSAct occurs if maintenance is being carried out on the
device.

Note In the chapter below, we will not consider the second slave controller with control
valve, since the behavior matches that of the first slave controller with control
valve.

Faulty slave controller

Master controller Control valve

Slave controller 1
Control valve
Slave controller 1

Slave controller 2
Control valve
Slave controller 2

Master controller Control valve Slave controller 1 Control valve slave

master controller controller 1
The controller The control valve CSF puts the The control valve
functions without functions without controller into retains the old MV
limitations. limitations. malfunction status. until the slave
The MV can be controller specifies a
changed. new value.

Note As soon as the CSF on the slave controller is no longer active, it can be switched
back to the original operating status (automatic/external).

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Faulty master controller

Master controller Control valve

Master controller

Slave controller 1
Control valve
Slave controller 1

Slave controller 2
Control valve
Slave controller 2

Master controller Control valve Slave controller 1 Control valve slave

master controller controller 1

CSF puts the The control valve The controller The control valve
controller into functions without functions without functions without
malfunction status. limitations. limitations. limitations.
The manipulated
variable can be
changed.

Note As soon as the CSF on the master controller is no longer active, the master
controller is back in operating condition

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6 Additional information

Faulty control valve of master controller

Master controller Control valve

Master controller

Slave controller 1
Control valve
Slave controller 1

Slave controller 2 Control valve

Slave controller2

Master controller Control valve Slave controller Control valve slave

master controller controller

The controller CSF puts the The controller The valve functions
functions without control valve of the functions without without limitations.
limitations. master controller limitations.
into malfunction
status.
The valve
functions without
limitations.

Note As soon as the CSF on the master controller's control valve is no longer active, it
is back in Automatic/External mode.

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6 Additional information

Faulty control valve of slave controller

Master controller Control valve

Master controller

Slave controller 1 Control valve

Slave controller 1

Slave controller 2 Control valve

Faulty control valve of slave controller

Master controller Control valve Slave controller Control valve slave
master controller controller
The controller The valve functions The controller CSF puts the
functions without without limitations. functions without control valve of the
limitations. limitations. slavce controller
into malfunction
status.
The valve
functions without
limitations.

Note As soon as the CSF on the slave controller's control valve is no longer active, it
is back in Automatic/External mode.

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6 Additional information

Maintenance status on slave controller

Führungsregler
Master controller Control
Stellventil
valve
Master
Führungsregler
controller

SlaveFolgeregler
controller 11 Stellventil
Control valve
Slave controller 11
Folgeregler

SlaveFolgeregler
controller 22 Control
Stellventil
valve
SlaveFolgeregler
controller 2

Master controller Control valve Slave controller Control valve slave

master controller controller

The controller The valve functions The controller The control valve
functions without without limitations. cannot be retains the old value
limitations. operated due to until the slave
maintenance. controller specifies a
The user can new MV.
switch to manual
mode and change
the MV.

Note As soon as the maintenance status is no longer active, the slave controller can
be switched back to the original operating status (automatic/external).

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6 Additional information

Maintenance status on master controller

Master controller Control valve

Master controller

Slave controller 1 Control valve

Slave controller 1

Slave controller 2
Control valve
Slave controller 2

Master controller Control valve Slave controller Control valve slave

master controller controller

The controller The control valve The controller The valve functions
cannot be operated retains the old value functions without without limitations.
due to maintenance. until the slave limitations.
The user can switch controller specifies a
to manual mode and new MV.
change the MV.

Note As soon as the maintenance status is no longer active, the master controller can
be switched back to the original operating status (automatic).

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6 Additional information

Maintenance status on control valve of master controller

Control valve
Master controller
Master controller

Slave controller 1 Control valve

Slave controller 1

Slave controller 2 Control valve

Slave controller 2

Master controller Control valve Slave controller Control valve slave

master controller controller

The controller The valve displays The controller The valve functions
functions without the maintenance functions without without limitations.
limitations. status and limitations.
functions without
limitations.

Maintenance status on control valve of slave controller

Control valve
Master controller
Master controller

Slave controller 1 Control valve

Slave controller 1

Slave controller 2 Control valve

Slave controller 2

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6 Additional information

Master controller Control valve Slave controller Control valve slave

master controller controller
The controller The valve functions The controller The valve displays
functions without without limitations. functions without the maintenance
limitations. limitations. status and
functions without
limitations.

6.4.6 Faults and maintenance of split range temperature

The tables below describe the way of functioning and generated messages of the
individual process tags using the split range temperature controller in case of errors
as an example.
The error on the channel block (the Bad output is active) occurs if a short-circuit or
a wire break occurs on the device, for example.
Maintenance status OoSAct occurs if maintenance is being carried out on the
device.

Faulty slave controller

Slave controller
Control valve 1

Control valve 2

Master controller Slave controller Control valve1 Control valve2

The controller CSF puts the The valve functions The valve functions
functions without controller into without limitations. without limitations.
limitations. malfunction status.
The MV can be
changed.

Note As soon as the CSF on the slave controller is no longer active, it can be switched
back to the original operating status (automatic/external).

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6 Additional information

Faulty master controller

Master controller

Slave controller Control valve 1

Control valve 2

Master controller Slave controller Control valve1 Control valve2

CSF puts the The controller The valve functions The valve functions
controller into retains the last without limitations. without limitations.
malfunction status. manipulated
The MV can be variable that was
changed. present until the
© Siemens AG 2019 All rights reserved

master controller
specifies a new
value.

Note As soon as the CSF on the master controller is no longer active, it can be
switched back to the original operating status (automatic).

Faulty control valve 1

Master controller

Slave controller Control valve 1

Control valve 2

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6 Additional information

Master controller Slave controller Control valve1 Control valve2

The controller The controller CSF puts the valve The valve functions
functions without functions without into malfunction without limitations.
limitations. limitations. status.
Operation and the
MV can be
changed.

Faulty control valve 2

Master controller

Slave controller Control valve 1

Master controller Slave controller Control valve1 Control valve2

The controller The controller The valve functions CSF puts the valve
functions without functions without without limitations. into malfunction
limitations. limitations. status.
The operating
mode and the MV
can be changed.

Maintenance status on slave controller

Master controller

Slave controller
Control valve 1

Control valve 2

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6 Additional information

Master controller Slave controller Control valve1 Control valve2

The controller The controller The valve functions The valve functions
cannot affect the cannot be without limitations. without limitations.
process while the operated due to
slave controller is maintenance.
being maintained. The user can
switch to manual
mode and specify
the MV for the
control valve.

Note As soon as the maintenance status is no longer active, the slave controller can
be switched back to the original operating status (automatic/external).

Maintenance on master controller

Master controller

Slave controller Control valve 1

Control valve 2

Master controller Slave controller Control valve1 Control valve2

The controller The controller The valve functions The valve functions
cannot be operated retains the old value without limitations. without limitations.
due to maintenance. while there is no
The user can switch new MV from the
to manual mode and master controller.
specify the MV.

Note As soon as the maintenance status is no longer active, the master controller can
be switched back to the original operating status (automatic).

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6 Additional information

Maintenance on control valve 1

Master controller

Slave controller Control valve 1

Control valve 2

Master controller Slave controller Control valve1 Control valve2

The controller The controller The valve displays The valve functions
functions without functions without the maintenance without limitations.
limitations. limitations. status and
functions without
limitations.
© Siemens AG 2019 All rights reserved

Maintenance on control valve 2

Master controller

Slave controller
Control valve 1

Control valve 2

Master controller Slave controller Control valve1 Control valve2

The controller The controller The valve functions The valve displays
functions without functions without without limitations. the maintenance
limitations. limitations. status and
functions without
limitations.

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6 Additional information

6.5 Block description of "pHTitrBlock"

Function description
The block is used to to convert pH values to concentration differences. To do this, you
must enter process-specific characteristics of the titration curve in the form of
parameters for the pH amplitude and buffer effect (α). The titration curve describes the
relationship between the pH value and the concentration difference between H + (or
H3O+) ions (acidic) and OH- ions (alkaline) in the solution. For a given combination of
chemicals, you can determine them in an experiment by adding an acid or an alkali
(neutralizer) in small steps. After each small dose, you mix the solution well, wait for
the neutralization reaction, and make a note of the new pH value.

For the equipment modules for pH value control, you use the trigonometric function
below as an approximation of the titration curve for conversion:
2𝑝𝐻𝑎𝑚𝑝𝑙 ∆𝑐
𝑝𝐻 = 7 + ∙ arctan (𝛼 ∙ 6 )
𝜋 10
This characteristic curve is inverted to convert pH values to concentration
differences.
1 𝜋
∆𝑐 = ∙ tan ( ∙ (𝑝𝐻 − 7)) ∙ 106
𝛼 2𝑝𝐻𝑎𝑚𝑝𝑙
© Siemens AG 2019 All rights reserved

Note Conversion is carried out in the two blocks below that are a component of the
"pHTitrBlock" and are included in the master data library:
• FB1025 "Titr_pH" for converting the concentration difference to the →pH
value
• FB1026 "TitrDeltaC" for converting the pH value to the →concentration
difference

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6 Additional information

Titration curve for various highly buffered solutions; pHampl=5

pH
12

11 alpha=3500
alpha=12000
10

2
-1 -0.8 -0.6 -0.4 -0.2 0 0.2 0.4 0.6 0.8 1
delta c 4
x 10
In the titration curve illustration, the neutral zone is at 7 pH with the maximum
excursion (amplitude) of 5. Typical values of between 3500 and 12000 are present
for the steepness of the characteristic curve in the neutral point (parameter α).

NOTICE Use in a productive environment is conditional upon knowing the titration

curve that must be entered in the block.
The parameters include:
• the amplitude area pHampl to be passed through on the pH value scale
• the buffer parameter α (alpha) as a measure of the steepness of the
characteristic curve in the neutral point

Inputs
Input Data type Description

CV STRUCT pH actual value

->Real
->Byte
DV STRUCT pH value of the disturbance variable
->Real
->Byte
SP STRUCT pH setpoint (specified by OpAnL operator control block
->Real oper SFC, for example)
->Byte

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6 Additional information

Input Data type Description

Alpha STRUCT Measure of the steepness of the characteristic curve in

->Real the neutral point
->Byte
Ampl_pH STRUCT The amplitude range that is to be crossed
->Real
->Byte
MV STRUCT Manipulated variable of the controller
->Real
->Byte
Feed_PV_Out STRUCT Inflow of the input material (disturbance variable)
->Real
->Byte
Feed_Scale STRUCT Scaling of the inflow (ScaleOut)
->Real
->Real

Conversion of the concentration differences for inputs "CV", "DV", and "SP" is
carried out based on parameters "Alpha" and "Ampl_pH".

CV_Out STRUCT Concentration difference of the pH actual value

->Real
->Byte
DV STRUCT Concentration difference of the pH value of the
->Real disturbance variable
->Byte
SP STRUCT Concentration difference of the pH setpoint
->Real
->Byte
MVHiLim STRUCT Variable upper limit value of manipulated variable MV
->Real depending on the feed amount of input material
->Byte (MVHiLim = 100/Feed_PV_Out/Feed_Scale.Max)
MV_Valve STRUCT Variable manipulated variable (to the valve process tag)
->Real depending on the feed amount of input material
->Byte (MV_Valve = Feed_PV_Out/Feed_Scale.Max * MV)

Interconnection of the inputs and outputs of the manipulated variables/disturbance

variables ("MV", "Feed_PV_Out", "Feed_Scale", "MVHiLim", "MV_Valve") is carried
out if it is intended to compensate the feed amount as a disturbance variable.

Note The output variable of the controller (what you can think of as a "concentration")
is multiplied by the (standardized) feed amount of the waste water (input
material) to calculate a measure of the required amount of neutralizer. If
manipulated variable limitation in the controller itself were to be constant, this
would result in it only being possible to use the dosing valve for complete control
at maximum waste water flow through. One remedy is to to interconnect
MV1HiLim dynamically in dependence on the feed amount.

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6 Additional information

6.6 Block description of "SimpHTitr"

Function description
The block is used to calculate a pH value based on process-specific characteristics
like the titration curve of the process, the inflow amounts, and the pH values of the
input material and the neutralizer, for example. The titration curve describes the
relationship between the pH value and the concentration difference of the supplied
neutralizer.

Inputs
Input Data Description
type
Feed_pH STRUCT pH value of the input material
->Real
->Byte
Alpha STRUCT Measure of the steepness of the characteristic curve in the
->Real neutral point
->Byte
Ampl_pH STRUCT The amplitude range that is to be crossed
->Real
->Byte
Neutr_MV STRUCT Manipulated variable of the controller for the neutralizer
->Real
© Siemens AG 2019 All rights reserved

->Byte
Neutr_Lag Real Delay of the manipulated variable (neutralizer)
Neutr_Factor Real Factor value for inflow of the neutralizer
Feed_PV STRUCT inflow amount of the input material
->Real
->Byte
pH_DeadTime Real Time-delayed signal output in seconds (deadtime)

NOTICE When using the deadtime (pH_DeadTime > 0), you must use a multi-
variable controller (ModPreCon block) for compensation and feedforward
injection of disturbance variable.

Outputs
Output Data Description
type
pH STRUCT pH simulation value
->Real
->Byte

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6 Additional information

To calculate the pH value, you carry out the following calculation steps:
1. Determine the products (multiplication) from the concentration differences and
inflow amounts of the input material and the neutralizer
2. Determine the overall inflow amount
3. Calculate the factor (proportional concentration difference) from the products
and the overall inflow amount
4. Convert the concentration difference to the pH actual value

In the simulation, you can adapt both the process-specific characteristics of the
titration curve and the effect of the values of feedforward injection of disturbance
variable (change the pH values of the input material by ± 1) and the variable
throughflow amounts (change the inflow amount by ±500 mol/L).
© Siemens AG 2019 All rights reserved

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6 Additional information

6.7 Block description of "ComStruIn" and "ComStruOut"

Function description
The blocks are used for standardized interconnection of process tags (controllers
with a valve process tag) or for setting up cascade controllers. All relevant signals
from a process tag are grouped into one structure, so that only a single
interconnection (of the structure) is required, instead of numerous individual cross-
system interconnections.
Connections from the valves or controllers are present at the inputs of the blocks,
which are then connected via the cross-chart interconnections outputs structrue to
the target process tag (i.E. slave controller or valve).

Inputs "ComStruIn"
Input Data type Description
ReStru1 bis STRUCT e.g. transmission von process-, parameter- or limit values
ReStru6 ->Real
->Byte
BoStru1 bis STRUCT e.g. setpoint, out of service and interlock
BoStru6 ->Bool
->Byte
Int1 and Int2 INT e.g. process value unit
Scale1 and STRUCT e.g. process value scale
© Siemens AG 2019 All rights reserved

Scale2 ->Real
->Real

Outputs "ComStruIn"
Output Data type Description
Out. STRUCT Structure for connection to Control module
BoStru1-6 ->Real
Int1-2 ->INT
ReStru1-6 ->Real
Scale1-2 ->Real

The ComStuOut block is the oppenside to ComStruIn. It deconstructs the cross-

chart interconnections input structure from the signal source into the original
individual variables, which can be used individually in the target process tags.

Inputs "ComStruOut"
Input Data type Description
In. STRUCT Structure for connection to Control module
BoStru1-6 ->Real
Int1-2 ->INT
ReStru1-6 ->Real
Scale1-2 ->Real

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6 Additional information

Outputs "ComStruOut"
Output Data type Description
ReStru1 bis STRUCT e.g. transmission von process-, parameter- or limit values
ReStru6 ->Real
->Byte
BoStru1 bis STRUCT Condition of MV output drive/channel block
BoStru6 ->Bool
->Byte
Int1 and Int2 INT e.g. process value unit
Scale1 and STRUCT e.g. process value scale
Scale2 ->Real
->Real
© Siemens AG 2019 All rights reserved

Equipment modules
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7 Appendix

7 Appendix
7.1 Service and support
Industry Online Support
Do you have any questions or need assistance?
Siemens Industry Online Support offers round the clock access to our entire
service and support know-how and portfolio.
The Industry Online Support is the central address for information about our
products, solutions and services.
Product information, manuals, downloads, FAQs, application examples and videos
– all information is accessible with just a few mouse clicks:
support.industry.siemens.com

Technical Support
The Technical Support of Siemens Industry provides you fast and competent
support regarding all technical queries with numerous tailor-made offers
– ranging from basic support to individual support contracts. Please send queries
to Technical Support via Web form:
www.siemens.com/industry/supportrequest
© Siemens AG 2019 All rights reserved

SITRAIN – Training for Industry

We support you with our globally available training courses for industry with
practical experience, innovative learning methods and a concept that’s tailored to
the customer’s specific needs.
For more information on our offered trainings and courses, as well as their
locations and dates, refer to our web page:
www.siemens.com/sitrain

Service offer
Our range of services includes the following:
• Plant data services
• Spare parts services
• Repair services
• On-site and maintenance services
• Retrofitting and modernization services
• Service programs and contracts
You can find detailed information on our range of services in the service catalog
web page:
support.industry.siemens.com/cs/sc

Industry Online Support app

You will receive optimum support wherever you are with the "Siemens Industry
Online Support" app. The app is available for Apple iOS, Android and Windows
Phone:
support.industry.siemens.com/cs/ww/en/sc/2067

Equipment modules
Entry-ID: 53843373, V5.0, 05/2019 160
7 Appendix

7.2 Links and literature

No. Topic
\1\ Siemens Industry Online Support
https://support.industry.siemens.com
\2\ Link to this entry page of this application example
https://support.industry.siemens.com/cs/ww/en/view/53843373
\3\ SIMATIC PCS 7 overview (collection of links for FAQ, manuals, compendium,
forum, application examples and multimedia)
https://support.industry.siemens.com/cs/ww/en/view/63481413
\4\ Controller optimization with the PID Tuner
https://support.industry.siemens.com/cs/ww/en/view/8031495
\5\ Model Predictive Control including integral transfer functions
https://support.industry.siemens.com/cs/ww/en/view/42200753
\6\ Configuration of Cascade Control
https://support.industry.siemens.com/cs/ww/en/view/43033319
\7\ PCS 7 Unit Template "Stirred Tank Reactor" using the example of the Chemical
Industry
https://support.industry.siemens.com/cs/ww/en/view/60546560
\8\ PCS 7 Unit Template "Fermenter" using the example of the Chemical Industry
https://support.industry.siemens.com/cs/ww/en/view/68098270
\9\ PCS 7 Unit Template "Distillation Column" using the example of the Chemical
© Siemens AG 2019 All rights reserved

Industry
https://support.industry.siemens.com/cs/ww/en/view/48418663
\10\ PCS 7 Unit Template "Dryer" using the example of the Chemical Industry
https://support.industry.siemens.com/cs/ww/en/view/74747848
\11\ PCS 7 Unit Template "Polymerization Reactor" using the example of the Chemical
Industry
https://support.industry.siemens.com/cs/ww/en/view/84061788
\12\ How do you procure documentation for PCS 7 (including the PCS 7 Manual
Collection)?
https://support.industry.siemens.com/cs/ww/en/view/59538371

Equipment modules
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7 Appendix

7.3 Change documentation

Version Date Modifications
V1.0 12/2011 First version
V1.1 04/2012 Valid for PCS 7 V7.1.3 and PCS 7 V8.0
V1.2 06/2012 Corrections and comments from suggestions
V2.0 06/2013 Expansion of the Val process tag type, new CTRL process
tag types, additional equipment modules for pH value control
V2.1 10/2013 New process tag types (CTRL; AMon and MOT) for multi-
variable control and drives inserted. Additional Links.
V2.2 04/2014 Equipment module "Temperature-Flow-Cascade" added.
V3.0 09/2016 Update for PCS 7 V8.2
V4.0 11/2017 Update for PCS 7 V9.0
Modification of the "Level control" equipment module
New equipment modules added:
• Buffer level control by means of "Buffer-Control"
feedforward control
• "Stream-Control" coarse/fine flow control
V5.0 05/2019 Update for PCS 7 V9.0 SP1, cross reference for the CMT on
the BPCM Library, new equipment module Gradient limits in
actuators "Gradient-Limit"
© Siemens AG 2019 All rights reserved

Equipment modules
Entry-ID: 53843373, V5.0, 05/2019 162

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