MANUAL FOR FLOW CONTROL

Objective

: To study the responses from different PID settings in the flow control

The System

: INFLOW (FT12) using LIC/FIC11

FT12-inflow, vortex flow meter
FIC11-loop2, PID2 of LIC/FIC11
LCY11/PP/LCV11-Control valve at inflow pipe, complete with
current-air converter (IP) and Positioner (PP)
OUTFLOW (FTll) using TIC11/FIC12
FE11-outflow orifice meter
FT11-outflow, DP flow transmitter with FIC12-loop2, PID2 of
TIC11/FIC12
TCY(EP)/TCV11-control valve complete with current-air Positioner
(EP)

Key Process : Inflow FT12 to tank T11

Process Variables:
Pump from T12 by P12
Outflow FT11 from tank T11
Pumped to heat exchanger by P11

EXPERIMENTAL PROCEDURES
1. Fill tank T12 with water till its level reaches the overflow Drain pipe outlet (D).
Check and top up later when is about half-full.
2. Turn on the main power supply switch at the electrical cubicle. The control panel
instruments lit up. The PANEL, SCADNDDC switch should be in the 'PANEL,
SCADA" position.
3. Locate the following external selector switches mounted near the panel controllers
LIC/FIC11 and TIC11/FIC12.
1-2-3 Position (Element) selector switch is for controller LIC/FIC11
1-2 position selector switch is for controller TIC11/FIC12
Switch both to position 2.
4. Set the two panel controllers to Manual (M) mode. Display FIC11 and switch it to
manual (M) mode. Manually adjust the output (MV) of FIC11 (loop 2 of LIC/FIC11)
to about MV = 35%.

5. Make sure TIC11/FIC12 is in position 2. Display FIC12 and switch to manual mode
Manually adjust the output of TIC11 to about 35%
6. Star the inflow pump P12. Check that the Inflow manual valve entering tank T11 at
the top is opened, but shut the bottom Inflow manual valve to T11.
7. Open the Other Demand valve fully and keep it opened throughout the experiment.
8. When the level tank T11 is more than 50%, start the outflow pump Pll. verify Pll is
pumping through the Heat Exchanger by visually checking its discharge into tank
T12.
9. Start the recorder LFTR11 and its chart drive by pressing ON the RCD pushbutton at
the front of the recorder with its swing cover opened.
10. Display both controllers FIC12 and FIC11, making sure that both are in position 2 at
their respective external selector switches. Manually regulate both control valves
TCV11 and LCV11 from their controllers FIC12 and FIC11 (in manual modes) so
that the water level in thank T11 remains almost steady.
11. Note that the inflow is channel 2-green pen: outflow channel 2-blue pen
12. Set Proportional (P) and Integral (I) control into FIC11 and FIC12 using the
following trial PID values for both controllers
PB2 : 150%
TI2
: 6 seconds
TD2 : 0 second
13. Display FIC11. Observe FT12, the Inflow rate PV2 at FIC11. Change its set- point
SV2 to 5 m3/hr.
Display FIC12. Observe FT11, the outflow rate PV2 at FIC12. Change its set- point
SV2 to 4.5 m3/hr
Note: The inflow FT12 must always be set higher than the outflow FT11 so that tank
T11 can overflow tank T12 but cannot run dry.
14. Press the Auto (A) button to switch both FIC11 and FIC12 to Auto mode
15. Observe the recorder output for the response and note the set-points and PID values.
(write the set-point and PID values on the recorder paper beside their response)
16. With the controller still in Auto mode, reduce the flow set-point SV2 as follows:
Inflow FT12 set-point at FIC11, SV2 to 3 m3/hr.
Outflow FT11 set-point at FIC12 SV2 to 2.5 m3/hr.
Watch the control response.

17. Repeat step 12, 13, 14 and 15 for PB2 100% and T12 6 seconds
18. Apply set-point disturbances to both the flow loops by changing their controllers setpoint SV2 as follows:
Inflow FIC11, SV2 = 5.0 m3/hr
Outflow FIC12, SV2 = 4.5 m3/hr
Observe the responses. Repeat step 16. Observe the responses.
19. The next few test are done with FIC11 but FIC12 must be left alone in Auto with Setpoint SV2 = 2.5 m3/hr and PB2 150% TI2 6 seconds TD2 0 sec
Test disturbances: The test are for the inflow Loop
1. FIC11, SV2 = 3 m3/hr, PB2 150%, T12 6 seconds, TD2 0 sec
a. Step SV2 to 3.5 m3/hr and observe effect of disturbance. Set SV2 back to 3.0
m3/hr
b. Open manual by-pass valve for 5 seconds then observe the effect of disturbances.
c. Switch FIC11 to manual and step increase MV by 10% switch back to auto mode
and observe the disturbance.
2. Repeat step 1 (test disturbances) using the following PID values:
a. PB2 at 100% and 200%
b. PB2 at 150% and T12 at 9999 seconds and TD2 at 0 sec
c. PB2 at 2%
d. PB2 at 20 %
e. PB2 at 40 %
f. PB2 at 60%
3. Re-adjust PB2 to 150%, T12 at 6 seconds and observe.
4. Set PB2 at 150%, TI2 at 6 seconds and TD2 at 30 to 60 seconds. Disturb the inflow
by opening/closing the by-pass valve of pump P12. When it oscillation is damped,
apply the load test disturbance as in step 1
5. Record all observations.

THEORY
A controller compares a measured value from a process with a set-point. The difference
between the values is called error and signal is being sent to system in order to bring the
value back to desired set point.
Generally, there are there basic types of controllers: proportional (P), proportionalIntegral (PI) and Proportional-Integral-Derivative (PID). Proportional controller is the
simplest controller among the three types and it does correction to the system based on
error calculated. However, this type of controller gives rise to offset or a steady state

error. For a proportional-integral (PI), an integral function is added to eliminate the

offset. A proportional-integral-derivative (PID) adds the derivative action whereby the
controller can calculate the derivative of error and hence able to anticipate the direction
of the process is heading.
A fast process like flow generally does not require a positioner. A positioner is actually a
high gain proportional controller and may even cause further instability when used with
high gain flow process. A positioner is however very useful to help overcome friction and
hysteresis in the control valve. A positioner ensures the control valve stroke
proportionally with controller signal if its actuator spring is not 3-15 psig. The
proportional band (PB%) of the flow controller may have to be increased to reduce the
overall higher loop gain, compensating for the positioner high gain.

RESULT
The recorder LFTR11 records the results of the experiments. At each set of PID values,
the response of flow control is different.
Study and compare the different response for different PID values.
a. Look for a damped and non-oscillatory response with OFFSET (no Integral control)
b. Look for a damped and non-oscillatory response without OFFSET (PI control).
c. Look for oscillatory response with inadequate damping (low PB)
d. Look for oscillatory response and instability caused by the Derivative action (TD2 is
not 0) of a full PID controller. Include the recorder chart response when the controller
has Derivative control gain.
Make a report of your observation. Comment and give your conclusions.