DIAGRAM AND DESCRIPTION OF APPARATUS- FLOW

MEASUREMENT AND CONTROL (MODEL WF 922)

The equipment used in this experiment is the air pressure process control training system,
Model WF922 (Figure 1). This liquid flow model, WF922 consists of a stainless steel tank
(T21), three (3) centrifugal pumps (P21, P22A/B) and the associated piping, valves and
fittings.
The flowmeters are:
a) FT22: Vortex flowmeter
b) FI22: Rotameter or variable area flowmeter
c) FE21: Orifice plate
FT21: Differential pressure flow transmitter. Square root linearization of differential pressure
signal (FT21) is required because FT21 measures the pressure drop (h) across the orifice plate
and flow F= k h. Two pressure gauges PG21 and PG22 are installed at the inlet and outlet of
the flow control valve, FCV21 to measure the valve pressure drop which is related to the
flowrate.

Sensor/ Transmitter
FE21/FT21

Controller
FIC21

Controlled Flow (CF)

PV1=FT21

Final Control Element

FCY21/FCV21

MV1 to FCY21/FCV21

Note that FIC21 is Single Loop Controller. For FIC21, its PV1 is always the Controlled Flow
CF.

METHODOLOGY
1) The following is checked quickly:

The main power supply (415V/50Hz/3 phase) is ON and the panel instruments are lit.
Tanks T21 is adequately filled with water up to almost the level of its lower overflow
pipe.

The pump manual by-pass valves B21, B22A and B22B are opened. Make sure all
the
pumps are switched OFF.

The Instrument air supply is set at the pressure indicated at the air pressure regulator
(IAS). Exact pressure adjustment of the air regulator (IAS) is not necessary. Once set,
it need not be readjusted frequently. The air regulator is purged using its bottom and
drain valve regularly.

The pipelines and control must be in normal operation position. First, manual valves
CF1/WF1 must be fully opened but CF2/WF2 are totally shut. Next, the Controller
selector switch is in Position 1: FT21=PV1=CF. Lastly, the interconnecting manual
valve MVX is fully shut.

Controller FIC21 is in Manual (M) mode with MV1=100% so that the control valve
FCV21 is fully opened. The control valve Positioner (PP) must be connected i.e. use
the positioned (PP).

2) FLOW MEASUREMENT BY THREE DIFFERENT FLOWMETERS

a) The three flow meters FI22, FE21/FT21, FT22 and control valve FCV21 must be
connected in series in the same pipeline from pump P21 as follows:P21-FE21/FT21-MVX-FI22-FT22-CF2-FCV21*-T21

*Make sure the selector switch is in Position 1: FT21=PV1=CF. Note*: FCV21

refers to FCY21/PP/FCV21
b) Switch off pumps P22A/B. Shut fully their manual discharge valves located at the
outlet pipelines of these pumps.
c) Trace the above pipeline and open or shut the appropriate valves as follows:

Discharge manual valve of Pump P21: Open fully

Interconnecting manual valve MVX: Open fully
Discharge manual valves of pumps P22A/B: Shut fully
CF1, WF1, WF2: Shut fully
CF2 and FCV21: Open fully

d) With FIC21 in Manual (M) mode, adjust MV1=100% to make sure FCV21 is fully
opened.
e) Press RCD at the recorder FR21 to start its chart drive.
f) Open fully B21, the manual by-pass valve of pump P21. Start pump P21 only. Shut
fully its manual by-pass valve B21 but open fully its manual discharge valve for
maximum flow. Note down the flow rates and pressure gauge readings of the
following:FI22 : Variable Area Flow meter, read at FI22.

Write down the reading at the recorder chart paper.

FE21/FT21 : Orifice/Differential Pressure (DP) Flow Transmitter.

Note down the reading at the recorder chart, beside the Red response.
Read FT21 at Channel 1.

FT22 : Vortex flow meter.

Note down the reading at the recorder chart, beside the Green
response.

Read FT22 at Channel 2.

PG21, PG22 : Pressure drop across the control valve FCV21 is PG21 PG22. Note

down the Pressure drop reading LAST (after reading FI22, FE21/FT21
and FT22) when they are steady, on the recorder chart paper.
Note that the flow rate is maximum if
- at FIC21, MV1 = 100% i.e. FCV21 is fully opened.
- discharge valve is fully opened.
- and by-pass valve B21 is fully shut.
Take readings only when they are stable and refer to the typical result sheets at the
results section. Take the pressure gauges readings last.

After taking the set of four (4) readings for Reading No1, proceed to the next
procedure for the next set of readings (Reading No.2). Then refer to the result sheet to
perform the calculation using the set of four (4) readings For Reading No.1 that were
just taken, allowing Reading No.2 to stabilize before taking them. The detailed
procedures are as follows,
Reading No. 1
Operate at maximum flow rate and record the 4 readings into the typical result
sheet. The pressure drop reading (PG21-PG22) should be taken last. Proceed to
the procedures below, described in Reading No.2.
Reading No. 2
Manually open the pump manual by-pass valve B21 by about 1 turn so that FI22
reads about 10% less flow. Perform the measurement calculation for Reading
No.1. Then record the 4 readings for Reading No.2, with the pressure drop
readings done last. Proceed to the procedures below, described in Reading
No.3.
Reading No. 3

With FIC21 in Manual (M) mode, adjust MV1 = 70% and check that FCV21 is
also about 70% opened. Perform the measurement calculation for Reading
No.2. Then record the 4 readings for Reading No.3, with the pressure drop
readings done last. Proceed to the procedures below, described in Reading
No.4.
Reading No. 4
With FCV21 at 50% opened, shut fully the pump by-pass valve B21. Perform the
measurement calculation for Reading No.3. Then record the 4 readings for
Reading No.4, with the pressure drop reading last. Proceed to the procedures
below, described in Reading No.5.
Reading No. 5
Manually shut the manual discharge valve of pump P21 until the Variable Area.
Flow meter FI22 reads about 1.2 m3/Hr. If the control valve Pressure drop is be
too low to be taken, take only the 3 flow meter readings. Perform the
measurement calculation for Reading No.4. Then record the readings for
Reading No.5, and perform the measurement calculation.
g) Switch off pump P21 and open fully its manual discharge valve.

3) PID SINGLE LOOP FLOW CONTROL

a) The PID flow controller is FIC21 (PID1) and the controlled variable PV1 is FT21.
The flow single loop is:FT21-FIC21-FCY21/PP/FCV21
b) Restore the pipelines and control to normal operation position i.e.

Open fully CF1/WF1, Shut fully CF2/WF2.

Shut the interconnecting manual valve MVX.
Open manual discharge valves of the pumps P21, P22A, P22B.
Controller selector switch is in Position 1: FT21=PV1=CF, SWC in Position 1.

Check that the adjacent upstream/downstream manual valves of FCV21 is fully

opened but its manual by-pass valve is fully shut. The Positioner (PP) at FCV21
must be connected i.e. ON, and not By-passed.
c) Switch ON only pump P21 and shut its manual by-pass valve B21.
d) With the controller FIC21 still in Manual (M) mode at MV1=100%, set its first (I)
trial PID values as follows:FIC21(PID1): PB1 = 100%, TI1 = 5 sec, TD1 = 0 sec
Ensure GW1 = 0.0%, GG1 = 1.0
Set the set point SV1 = 1.8 m3/Hr.
Manually adjust MV1 so that PV1 approaches SV1. Switch FIC21 to Auto (A)
mode. Make sure the PF key is OFF, else press it once.
The recorder FR21 chart drive should be at fast speed (500 mm/Hr) with RCD on.
Check the chart speed which is regularly printed out on the chart. Observe the
response of FT21 at the red pen until it is almost steady at the set point to within
0.02 m3/Hr, or continuous to oscillate even after 3 cycles. Write down the set
point (SV1) AND PID1 values on the Recorder chart paper besides its response.
These chart recordings constitute the results of the experiment. Refer also to the

typical results sheet in the results section.

e) Set point (SV1) step disturbance test
Make sure the pump P21 is ON and its by-pass valve B21 is fully shut. FIC21 must
remain in Auto (A) mode throughout the following tests.
Step increase the set point SV from 1.8 to 2.4 m3/Hr. This is a 0.6m3/Hr step
increase in set point. Observe the flow response (Red pen) patiently till it is stable
or shows oscillatory response even after 3 cycles.
Repeat the set point step test. Use the following set points SV1 = 2.8, 3.0, 3.2,
3.4,3.6, 4.0 and 4.2 m3/Hr, one at a time. Each set point change is a set point step
test at the new set point.
Note that the responses at different flow rates are not necessarily similar and may
appear more oscillatory (less damped) or less oscillatory (more damped). Look for
any specific set point or region of set points where the flow response is very irregular
or oscillatory signifying spurious flow meter signal or extreme nonlinearity with a
very high gain element in the loop at such particular flow rate, set point SV1 and
valve position MV1. Such set point SV1 shall be referred to here as Nm3/Hr, whilst
the valve position MV shall be referred to as NMV.
REMARKS
Note that NOT all oscillation are smooth. Some are jagged and irregular. Sometimes
limit cycle (of constant amplitude) may appear. Such pattern of oscillation is most
likely caused by friction (dead band) at the control valve, despite the fact that a valve
positioner (PP) is connected. Other possible contributing factors could be the higher
valve gain, the high dynamic gain of the positioner and even spiked and spurious
signals from the flow meter.
f) Repeat (e) but change the PID to the more damped second (II) trial PID values with

larger PB% and TI sec as follows:

FIC21 (PID1) : PB1 = 150%, TI1 = 10 sec, TD1 = 0 sec,
Step change the set point SV1 to 4.2 m3/Hr and observe the flow response (red
pen) till it is almost steady at its set point SV to within 0.02 m3/Hr, or continues
to oscillate even after 3 cycles.
Step decrease the set point SV1 to 4.0 m3/Hr and observe similarly.
Step decrease the set point SV1 to 3.8 m3/Hr and observe similarly.
Step decrease the set point SV1 to 3.6 m3/Hr and observe similarly.
Step decrease the set point SV1 to 3.4 m3/Hr and observe similarly.
Step decrease the set point SV1 to 3.2 m3/Hr and observe similarly.
Step decrease the set point SV1 to 3.0 m3/Hr and observe similarly
Step decrease the set point SV1 to 2.8 m/Hr and observe similarly.
Remember to do the test at set point SV1 = Nm3/Hr (TRY SV1 = 2.8, 3.0, 3.2,
3.4, 3.6, 3.8, 4.0, 4.2 m/Hr as above), checking whether the large PB% and TI sec
is able to damp down any high gain oscillation to within 0.02 or 0.05 m/Hr of
the SV1 value (Nm/Hr)
Each set point change is a set point step disturbance test at the new set point.
Summarizing, one set of PID (e.g. PB1 = 100%, TI1 = 5 sec, TD1 = 0 sec) may be
able to control flow at lower (e.g. 1.8 to 3.0 m/Hr) flow rate regions but not at all
regions. Around say 3.2 to 4.2m/Hr (referred to here as Nm/Hr), the flow response
may be too oscillatory!
Discuss how the oscillation at SV1 = Nm/Hr can be damped out.
4) PID SINGLE LOOP FLOW CONTROL USING DERIVATIVE CONTROL MODE
Make sure the selector Switch Position 1: FT21 = PV1 = CF
Open CF1/WF1, Shut CF2/WF2 and MVX.

a) Check that the manual discharge valve of pump P21 is fully opened.
b) Start pump P21 and shut its manual by-pass valve B21 fully.
Use the first (I) trial Linear PID values:
PB1 = 100%, TI1 = 5 sec, TD1 = 0 sec, GW1 = 0%, GG1 = 1.0
Change the set point at FIC21 to SV1 = 3.0 m/Hr.
Make sure the Recorder FR21 chart drive is running. Otherwise press its RCD
push button ON.
Check that the control valve Positioner (PP) is connected i.e. use the Positioner at
FCV21.
Switch FIC21 to Auto (A) mode and observe patiently the chart response (Red
pen) of FT21 for about 1 minute.
c) Introduce Derivative control mode to the PID controller by changing TD1 from 0 sec
to 5 sec i.e.
PB1 = 100%, TI1 = 5 sec, TD1 = 5 sec
Observe the chart response similarly for any oscillation due to the addition of
Derivative control mode. (If there is no oscillation, apply a load step disturbance by
switching FIC21 to Manual (M), step changing MV1 by about 10% and then
switching FIC21 back to Auto (A) mode. Observe for any oscillation).
d) If there is instability (oscillation), double the PB i.e. set PB1 from 100% to 200%.
Observe similarly if the instability can be damped.
e) Apply a load step disturbance test by switching FIC21 to Manual (M) mode, step
changing MV by about 10%, and then switching FIC21 back to Auto (A) mode.
Observe similarly, noting also whether the overall response and recovery to the set
point has been slowed down due to the larger PB1% required to damp the Derivativeinduced
oscillation.

f) Remove the Derivative control mode by setting TD1 to 0 sec, restoring back to the
first (I) trial Linear PID values:
PB1 = 100%, TI1 = 5 sec, TD1 = 0 sec, GW1 = 0%, GG1 =1.0
Apply a similar load step disturbance test as in the previous (e). Observe similarly. Is it
sound advice not to use Derivative mode for flow control?
5) To shut down WF922,
- Stop all pumps. Open fully their manual suction and discharge valves
- Switch the SWC selector switch back to Position 1.
- Check that the controller selector switch is at position : FT21 = PV1 = CF