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An extensive amount of the software in modem controllers is devoted to detecting and reporting a problem in the form of an alarm. The alarm takes the form of a visual signal (flashing light), an audible signal (beeping horn), or the actuation of a switch. Examples of the use of switch closures include turning on or off a pump motor or opening or shutting a valve. The alarms are classified as process alarms and diagnostic alarms. The diagnostic alarm detects a malfunction in the control equipment or the loss of communication. For example, if a wire connecting the output of a temperature transmitter to an analog input block breaks, a diagnostic alarm would go off indicating that the signal to the analog input block is out of range. The manufacturer of the control equipment provides all the software for detecting the problems that trigger diagnostic alarms. The engineer who configures the control blocks selects the variables that arc to trigger process alarms and specifies the alarm limits and the type of annunciation (flashing light, beeping horn, etc.) The alarms can be assigned a priority rating. Those variables in a process that are most critical arc given the highest priority; less critical variables are given a lower priority.
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The software provides basic mathematical functions such as summation, subtraction, multiplication, and accumulation (i.e., integration). These functions can be used along with other blocks in the design of a control system. A simple example of these functions is the calculation of mass flow rate of a gas from measurements of velocity, pressure, and temperature. These three measurements are combined according to the following relationship, which is based on the ideal gas law:
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w = vAPMIRT
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where w = the mass flow rate, mass/time v = the velocity P = pressure T = absolute temperature A4 = molecular weight of the gas R = the gas constant A = cross-sectional area for flow
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The signal from the math block that represents w can then be sent as the control variable to a control block that controls the mass flow of gas.
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Long-term storage of the transients can be obtained easily with a digital computer. This task is referred to as archiving. The automatic storage of critical processcontrol variables on disk or tape can be retrieved later to explain process operating difficulties. The computer can also be used to automatically record or log the type and location of an alarm, the time of a process alarm, the time of acknowledgment of an alarm, and the time it was cleared by operator intervention: this information is useful to supervisors in detecting violation of safety regulations or process malfunctions.
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SPECIAL FEATURES OF MICROPROCESSOR-BASED CONTROLLERS
In addition to the tasks just described, there are three special features available in modern microprocessor-based controllers that deserve attention. These are limiting, tracking, and anti-reset windup. Each will be discussed separately.
Limiting
In configuring a control system from basic control blocks, one can select lower and upper limits on controller output and set point. These limits are narrower than the limits inherently present in the hardware. Limits are often placed on a controller output for safety reasons or to protect equipment. For example, if one knows the flow rate of a liquid that causes a tank to overflow, one can set the limit on the output of a controller at a value less than the value that causes overflow. The limits on the controller output are active when the controller is in either automatic or manual mode. An example of a limit on set point is the selection of an upper limit on pressure for a steam-heated sterilizer to prevent damage to the equipment.
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