CDB 3062

CHEMICAL ENGINEERING LABORATORY III

MAY 2016

EXPERIMENT

: 6-RATIO CONTROL

GROUP

: 17

GROUP MEMBERS

: ROSLINA AIFAR BINTI ROSLI

19414

MOHD NOOR HADEEF BIN NOOR AZLAN

19431

KOI ZI KANG

18868

MUHAMMAD AMIRUL MUKMIN BIN MARZUKHI

19030

NUR AMALINA BINTI DAWI CAHYONO

19092

LAB INSTRUCTOR

: MR UMAIR

DATE OF EXPERIMENT

: 18th JULY 2016

Table of Contents
1.0 Summary ........................................................................................................................................... 1

2.0 Theory ............................................................................................................................................... 1

3.0 Objectives ......................................................................................................................................... 3

4.0 Procedures ........................................................................................................................................ 3

5.0 Results ............................................................................................................................................... 5

6.0 Discussions ........................................................................................................................................ 9

7.0 Conclusion ....................................................................................................................................... 11

8.0 References...11

9.0 Appendix.....12

1.0 SUMMARY
The ratio control experiment is conducted to demonstrate the characteristic of ratio
control and the characteristic of Proportional Band, Integral Action and Derivative Action on
a flow process control loop. In this experiment, we do the tuning in derivative time control
settings, PID flow control loop tuning and ratio control. There are two different flow loops in
the system for the application of ratio control. Based on the theory, the PID controller is the
most effective controller among all controller in tuning system. It shows a rapid response
with no offset. For ratio control method, it is a blending method of two or more variables in
adjustable proportions to obtain a desire mixture at stable condition of the system. From
the results that we obtained, we can see that the lower the derivative value in the PID
controller, the more accurate and efficient the controller is. The time lag of the system is
also minimal and thus gives faster response of the system. For the second part of the
experiment, we conducted loop tuning so that the optimum values of the controller settings
can be obtained. For the third part of the experiment, we used ratio control mode with
optimum value settings and the ratio factor obtained is 0.4. The controller has high
efficiency in ratio control as the ratio factor is well maintained at different flow rate.

2.0 THEORY
2.1 PID CONTROLLER
Each of the three basic control modes and the combinations discussed so far,
proportional (P), proportional plus integral (PI) have limitations which may not be significant
if the process and controller are carefully matched. However some processes are so difficult
to control or so critical.
To achieve good control performance, additional insight into the system might
sometimes be needed. For example, the derivative of the control error gives an estimate of
future error values. By letting the control signal depend also on the error derivative, one
obtains a control law where the control signal increases when the error is growing and vice
versa. This can be used to counteract growing control errors in a faster manner and give
smoother control action in the vicinity of the reference. If we expand the control law to
incorporate derivative action, we obtain the PID controller with control law
12 | P a g e

1
de
p (t ) p K c e(t ) e(t )dt D
I 0
dt

The control signal now consists of a P part, and I part and a D part. The D part is given by
(

). The constant Td is the derivative time of the controller. It can be interpreted as

the prediction horizon for a linear error estimator.

Thus, the advantage of PID controller is that it shows a rapid response with no offset.
However, PID controller is the most complex and difficult to tune, and it will be the best
controller if it is properly tuned.

2.2 LOOP TUNING

The closed loop control system attempts to achieve a balance between supply and demand
by comparing the controlled variable to the set point and regulating the supply to an amount
which will maintain the desired balance. Tuning the controller adjusts it so it can achieve that
balance as quickly as possible.

2.3 RATIO CONTROL

Ratio control systems are used extensively throughout industry to optimize the
relationship of the mixture between two flows in a processing plant. It provides a means a
blending two or more variables in adjustable proportions to obtain a desire mixture. The
measurement of the load (wild or uncontrolled flow) is the set point to the ratio controller
which adjusts the flow of the controlled variable. Using the remote set point facility, the
relationship between any two flows can be set and controlled automatically to minimize
wastage. A preset ratio regulates the flow of the controlled variable for example if the ratio
is 2 to 1 for every gallon of the uncontrolled variable flowing, two galloons of the controlled
variable is allowed to flow. Automatic control of systems allows the plant to operate
independently to maximize output.

13 | P a g e

3.0 OBJECTIVES
The aims for the experiment are:
1. To demonstrate the characteristic of Proportional Band, Integral Action and
Derivative Action on a flow process control loop.
2. To demonstrate the characteristic of ratio control.
Problem Statement: How do different controller settings affect response graph and what
is the ratio control factor of this experiment?

4.0 PROCEDURES
Startup Procedure
1. The check up for the valves was done to ensure which valves needed to be opened or
closed based on the table below. Every valve was either closed or opened fully.
Closed

HV532, HV533, HV535, HV537, HV538, HV540

Opened

HV531, HV534, HV536, HV539,

2. Tank T-520 was fully filled with water by opening valve HV534.
3. Before switching on the main panel, the air regulator RG1 was set to 2.8 bar.
4. Finally, the main switch panel was switched on.
Part 1: PID Flow Control
1. These values were keyed; PB=200, I=6s, and D=1s
2. 50 LPM of set point was used. The control loop was put into manual mode before
adjusting the set point.
3. The flow of the water was gradually set till it reached 50 LPM by tuning the output
flow rate.
4. The recorder was switched on while the control loop was put into automatic mode.
5. The output was progressively tuned to match the set point.
6. Once the output reached the desired value, a simulation of load changes was
introduced by closing the valve HV537 for about 1 second.
7. The experiment was then repeated for a set point of 75 LPM.
8. Steps 1-7 were repeated with D=4s and 7s, while retaining the PB value and I value.

14 | P a g e

Part 2: PID Flow Control Loop Tuning

1. 50 LPM of set point was used. The control loop was put into manual mode before
adjusting the set point.
2. These values were keyed; PB=1000, I=1000s, and D=0s. The 0 value of D indicates that
we are using the PI Controller.
3. The recorder was switched on while the control loop was put into automatic mode.
4. The output was progressively tuned to match the set point.
5. Once the output reached the desired value, a simulation of load changes was
introduced by closing the valve HV537 for about 1 second
6. Step 1-5 was repeated to till measurement oscillates about set point. To obtained the
oscillation. 6 values of PB: 1000, 500, 200, 100, 50 and 30 were used in decreasing
manner, while preserving the values of I and D.
7. To obtain a natural period, the time between troughs was measured.
8. PB values was maintained, while setting I = natural period which has been obtained
from the calculation.
9. PB values was adjusted till a desired magnitude of damping was achieved.
Part III: Ratio Control
1. Control loop was put into manual mode.
2. Selector switch was set to ratio control, where both of the flow was activated.
3. Flow rate was attuned to 40 LPM.
4. Control loop was put into automatic mode and the recorder was turned on.
5. To introduce a change on the system, the flow rate was adjusted to 60 LPM via valve
HV533.
6. From the data, the efficiency of the ratio control was analyzed.

15 | P a g e

5.0 RESULTS

i) Table
Loop 1 Flow Rate (L/min)

Loop 2 Flow Rate (L/min)

16

40

20

50

24

60

Table 5.1: Flow Rates of Loop 1 and Loop 2

ii) Graphs

16 | P a g e

Graph 5.1: Response Graph for Different Derivative Time Setting

17 | P a g e

Graph 5.2: Response Graph for Different Proportional Band Setting

18 | P a g e

Graph 5.3: Response Graph for Loop Tuning Process

19 | P a g e

iii) Calculation

3600

(Eq. 5.1)

Given Speed of Graph = 1200 mm/hour and from graph 5.2, D = 2.5 mm, thus
=

2.5

3600
= 7.5
1200

6.0 DISCUSSIONS
The purpose of this experiment is to demonstrate the characteristic of Proportional
Band, Integral Action and Derivative Action on a flow process control loop as well as to
demonstrate the characteristic of ratio control. This experiment was divided into three parts:
tuning derivative time control settings, PID flow control loop tuning and ratio control. There
are two different flow loops in the system for the application of ratio control.
For the first part of the experiment, the control settings were set as such: PB = 200, I
= 6s and D = 1s. The values of PB and I were maintained. The D value was then changed to 4s
and consequently 7s. These 2 values were chosen within the range of 1-10 in order to
compare the response between a low, medium and high D value. From response graph 5.1,
we can see that with D =1, the response is the fastest among all and it has the minimum time
lag, least oscillation and least overshoot when a disturbance was applied. Therefore, we can
deduce that the lower the value of D, the lesser the time lag and the faster the response of
the system.
For the second part of the experiment, the control settings were set as such: PB =
1000, I = 1000s and D = 0s. The values of I and D were maintained whereas PB value was
changed to 500, 200, 100, 50 and 30 subsequently. The integral time was set at maximum and
the derivative time was set at its minimum in order to provide proportional only control. This
setting is used to determine the nature period of oscillation of the process for loop tuning.
The PB value was adjusted until a continuous and uniform oscillation was obtained. The
natural period was then calculated using equation 5.1 and the value obtained is 7.5s. This
value was then used for the integral time. Theoretically, there should be a 40% decrease in

20 | P a g e

period but the response graph does not show such decrease which might need an increase in
terms of integral time. The PB value was then increased until it reached a desired degree of
damping which was at PB = 45. The values at this point, PB = 45, I = 8s and D = 0s are the
optimum values for the desired control response which is the purpose of loop tuning.
After loop tuning was finished, the third part of the experiments was continued. The
efficiency of the ratio control was tested by adjusting the flow rate of loop 2 and the flow rate
of loop 1 was checked. From table 5.1, we can see that the ratio factor obtained is 0.4 in which
for every 0.4L/min of loop 1 flowing, 1L/min of loop 2 is allowed to flow. The ratio control of
the system is very efficient as the ratio factor is maintained at every different flow rate of loop
2 applied. PID controller suits best for ratio control if we can tune it properly as it eliminates
offset and is more stable.
ERRORS & RECOMMENDATIONS
1) Human error: In Part I and II, the valve HV537 needed to be closed for about 1 second
manually. The error possibly occurs when it takes more or less than 1 second of closing
the valve.
Recommendation: Modification can be made to the machine which is by adding a system
that can automatically close the valve for exactly 1 second or any desired value.

2) Human error: Another error that can be made during this experiment is to leave some
space between each graph so that the graph does not get recorded together which will
lead into confusions when reading the graph.
Recommendation: Modification that can be made is to leave some space in the graph
after each step of the experiment to get clear results. Labelling can also be added to
differentiate the graph.

3) Systematic error: The flow of the water needed to be set until it reaches its set point by
tuning the output flow rate. The error occurred when the flow of water cannot reach or
equal to the set point and sometimes it exceeds the set point.
Recommendation: The machine need to be fixed or serviced so that this type of error can
be avoided.
21 | P a g e

7.0 CONCLUSION
The experiment is divided into three parts, which are the tuning derivative time
control settings, PID flow control loop tuning and ratio control. For the tuning derivative time
control settings, the controls settings were set at PB = 200, I = 6s, and D = 1s. Based on the
graphs obtained, it can be deduced that the lower the value of D, the lesser the time lag and
the faster the response of the system. For PID flow control loop tuning, the control settings
were set at PB = 1000, I = 1000s and D = 0s initially and PB value was adjusted till continuous
uniform oscillations were obtained. The natural period was calculated as 7.5s and it was used
for the integral time setting. The PB value was calibrated until it reached a desired value of
PB = 45. The most optimum values of the control settings after loop tuning is PB = 45, I = 8s
and D = 0s. For the ratio control, the efficiency of the ratio control was tested by adjusting the
flow rate of loop 2 and the rate of loop 1. From the data obtained, we can deduce that the
ratio factor obtained is 0.4 and the system is efficient enough in maintaining the ratio factor.
PID controller suits best for ratio control if we can tune it properly as it eliminates offset and
is more stable. All in all, the objectives of this experiment were achieved.

8.0 REFERENCES
Guwahati, I. (2013). Ratio Control. NPTEL. Retrieved 22 July 2016, from
http://nptel.ac.in/courses/103103037/31
PID Controller. (n.d.). Retrieved 22 July 2016, from
https://en.wikipedia.org/wiki/PID_controller#Loop_tuning
Seborg, D. E., Edgar, T. F., Mellichamp, D. A. & Doyle, F. J. (2004). Process Dynamics and
Control (3rd ed.). United States of America: John Wiley & Sons, Inc.

22 | P a g e

9.0 APPENDIX

Figure 1: The control valve

Figure 2: The control panel and the process tank

23 | P a g e