In addition to control modules for the motors, valves, and so on, there are five modules (in Simulation.fhx) to simulate conditions so that you can run the batch application and manipulate the process. These modules are initially imported into a separate area, Simulation, in the System Configuration/Control Strategies part of the database. Later in the tutorial, when we are ready to run the batch application, we will move the modules from the Simulation area to the EXTERIOR_PAINT/PAINT_BLEND process cell.
The simulation modules, which are imported as part of the Startup.fhx and Complete.fhx files, are listed below.
- TANKSIM - This module simulates the level of the color tanks. It determines whether the inlet and outlet valves for the color tanks are open and keeps track of the tank levels. It also calculates the cumulative discharge from the color tanks to the blenders based on a flow of 100 GPM from the color tank outlet valves.
- LEV500_SIM - This module calculates the level in UM_BLEND_500 by integrating the flow from the base tank and the color tanks into UM_BLEND_500 with the discharge rate from the blender. The level is input to the LI_500 module, the blender level indicator.
- LEV600_SIM - This module is the same as LEV500_SIM, but for UM_BLEND_600.
- RESET_SIM - This module resets the blender tank and color tank levels to 0 so that you can quickly retest the phases without having to first drain the tanks.
- FLOWSIM - This module simulates the flow for all of the FLOW_CONTROL modules. It simply takes the value of the valve output, adds deadtime, and ties it back to be the PV of the loop.