UniKL MICET

LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL

EDITION:
REVISION NO:
EFFECTIVE DATE:

1
1
29 SEPT
2014

AMENDMENT
DATE:

SECTION OF CHEMICAL ENGINEERING TECHNOLOGY

MALAYSIAN INSTITUTE OF CHEMICAL & BIOENGINEERING TECHNOLOGY

PROCESS CONTROL LABORATORY

LABORATORY INSTRUCTION SHEETS

COURSE CODE

CPB 30004 / CPD 20302 / CKB 20003

EXPERIMENT NO.

EXPERIMENT 4

EXPERIMENT TITLE

Air Flow Process Control Plant

DATE
GROUP NO.
LECTURER/INSTRUCTOR/TUTOR

1)
2)

DATE OF REPORT SUBMISSION

DISTRIBUTION OF MARKS FOR

LABORATORY REPORT:

ATTENDANCE/PARTICIPATION/DISIPLINE:

/5%

INTRODUCTION:

/5%

PROCEDURE:

/5%

RESULTS& CALCULATIONS
ANALYSIS
DISCUSSIONS:
ADDITIONAL QUESTIONS
CONCLUSION

/15%
/20%
/15%
/10%

SUGGESTIONS & RECOMMENDATIONS

/5%

REFERENCES:

/5%

TOTAL:
EXAMINER COMMENTS:

/15%

RECEIVED DATE AND STAMP:

/100%

UniKL MICET
LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL

EDITION:

1
1

REVISION NO:
EFFECTIVE DATE:

29 SEPT
2014

AMENDMENT
DATE:

STUDENT CODE OF ETHICS

SECTION OF CHEMICAL ENGINEERING TECHNOLOGY

MALAYSIAN INSTITUTE OF CHEMICAL &

BIOENGINEERING TECHNOLOGY
I hereby declare that I have prepared this report with my own efforts. I also admit to
not accept or provide any assistance in preparing this report and anything
that is in it is true.
1) Group Leader: ..
Name
: __________________________________
Matrix No. : __________________________________

(Signature)

2) Group Member 1: .
Name
: __________________________________
Matrix No
: __________________________________

(Signature)

3) Group Member 2:..

Name
:__________________________________
Matrix No. : __________________________________

(Signature)

4) Group Member 3:..

(Signature)

UniKL MICET
LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL

1.0

EDITION:
REVISION NO:
EFFECTIVE DATE:

1
1
29 SEPT
2014

AMENDMENT
DATE:

OBJECTIVES
a) To study gas volumetric flow rate measurement using orifice plate.
b) To study gas mass flow rate measurement using orifice plate and perfect gas
law to compute the gas density from the pressure and temperature
measurements.
c) To study gas mass flow rate (Fm) control using PID controller.

2.0

LEARNING OUTCOMES

At the end of the study, student will be able to:

a) To be familiar with the basic steps of machine from start-up to shut-down

with proper handling and setting.
b) To gain knowledge about pressure and temperature variation using Perfect
3.0

Gas Law
INTRODUCTION

UniKL MICET
LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL

EDITION:

1
1

REVISION NO:
EFFECTIVE DATE:

29 SEPT
2014

AMENDMENT
DATE:

The air flow process control training system uses air to simulate a gas or
vapor phase flow process. Gas/vapor volumetric flow can be measured either by
the differential pressure across orifice or by a variable area flow meter.
Compensation for pressure and temperature variation using Perfect Gas Law
can be made to the flow measurement by the differential pressure
measurement.
4.1
4.2

INSTRUMENTS /APPARATUS / CHEMICAL / REAGENTS

Gas volumetric/mass flow measurement system

a) Integral orifice flow element, FE91.

b) Differential pressure flow transmitter with square root function, FT91.
c) Absolute pressure transmitter, PT91.
4.3

d) RTD temperature transmitter, TE91/TIT911.

Apparatus
a) Air Flow process control training system. The schematic diagram is shown in
Figure 1.

5.0

PROCEDURE

The following steps constitute the start-up procedure. Go through these

steps before starting any experiment:

1. Switch the "PANEL, SCADA/DDC" selector switch at the front of the cubicle
to "PANEL, SCADA" position. Switch ON the main power supply at the front
of the cubicle. All the panel instruments will lit up.
2. From the process air supply, trace the two pipelines, PLI and PLII as follows:

Pipeline I (PLI):

UniKL MICET
LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL

EDITION:

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AMENDMENT
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AR900-MV900A-T90-MV900D-PLI-FI911-TE911-FE91/FT91-FCV91-FCV1-VF

Pipeline II (PLII):
AR900-MV900A-T90-MV900D-PLII-FCV90-PG902-V

3. Open valves of the pipelines PLI and PLII at their various manual valves.
Close the manual by-pass valve of the control valve FCV91 and the ON/OFF
control valve FCV90.
4. The pipeline PLI has two discharge manual valves, VF and MV901. Open the
vent VF and close the valve MV901.
5. Make sure the valves MV900A and MV900D are open and valves MV900B
and MV900C are shut.
6. Place the panel controller FIC91 in the Manual (M) mode. Open fully the
control valve FCV91 by setting the MV of FIC91 to -6.3%.
7. Adjust the manual valve MV900A till the air flow rate is about 50 kg/hr
(Read the flow rate from PV of FIC91).
8. Check that vent valve and bottom drain valve of vessel T90 are shut. Set MV
= 106.3% at FIC91 to fully shut the control valve FCV91.
9. Check control valve FCV91 (in the plant) is fully shut and FI911 reads the
air volumetric flow rate as ZERO. Also check the mass flow rate Fm at FIC91
is ZERO.
10.Now set the MV = 50% at FIC91 and check control valve FCV91 (in the plant)
is 50% opened.

11.Note the variables that are recorded in each channel of the recorder FPTR91.
Red Pen - Mass flow rate (kg/hr)
Green Pen - Volumetric flow rate (m3/hr)

UniKL MICET
LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL

EDITION:

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AMENDMENT
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Blue Pen - Temperature (C)

A. AIR FLOW MEASUREMENT

1.
Set the MV = -6.3% (in Manual mode) so that control valve
FCV91 is fully opened. Record the reading/data in Table 1.
2.

shown in results section.

Data to be taken AT THE CONTROL PANEL:
i)

Access the following data by pressing the corresponding

push buttons in FIC91 and FIC90:

FIC91
PID1(main page): PV - Fm, kg/hr
I/O DATA:

X1 - FT91, % of , 0 - 100
X2 - TIT911, % of 0 - 120C
X3 - PT911, % of 0 - 60 psia

FIC90
P/T REGISTER: PO1 - Fv, m3/hr
ii)

At the Recorder: Fv (Channel 2, Green) and Fm (Channel

1, Red)

3.

Data to be taken AT THE PLANT:

Locate the rotameter FI911 and pressure gauge PG900. Take both
instruments readings and also note the units used. (Rotameter
reading should be taken as 0.5 Nm3/hr)

Now, take another sets of readings for MV = 50% and MV = 70% and
record them in the Table 1 in the results section.

UniKL MICET
LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL

EDITION:

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B. CONTROL OF AIR FLOW SYSTEM

1.
With FIC91 in Manual (M) mode, open the control valve FCV91
fully with MV = -6.3%. (For confirmation, check the stem position
indicator of control valve FCV91. FCV91 is an Air-To-Close (ATC)
2.

valve)
With FIC91 still in Manual mode, adjust its setpoint, SV = 25

3.

kg/hr.
Access the PID parameters of FIC91 and set the first (I) PID trial

4.

values:
PB = 200%, TI = 6 s, TD = 0 s
Start the recorder chart drive by pressing RCD pushbutton at

5.

FPTR91.
Switch FIC91 to Auto (A) mode and watch the recorder response

6.

(i.e. air flow response) until the air flow (red pen) is fairly steady.
Introduce a pulse disturbance by quickly opening and shutting
fully the by-pass valve at control valve FCV91. Observe the

7.

response till it becomes fairly steady.

Repeat step (5.2.6) (i.e. introducing pulse disturbance) with the
second (II) and third (III) sets of PID trial values:
II
PB = 150%
TI = 6s
TD = 0s

III
PB = 100%
TI = 6s
TD = 0s

DO NOT FORGET TO MARK THE PID VALUES AND THE SETPOINT ON THE CHART PAPER WHENEVER THE VALUES

UniKL MICET
LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL

EDITION:

1
1

REVISION NO:
EFFECTIVE DATE:

29 SEPT
2014

AMENDMENT
DATE:

ARE CHANGED. ALSO MARK ON THE CHART THE

BEGINNING OF EACH PART OF THE EXPERIMENT.

8.

Repeat the experiment for the above 3 sets of PID trial values
with step change in setpoint for the mass flow rate by changing
the present setpoint of FIC91 from SV= 25kg/hr to SV = 30
kg/hr. Observe and record the response till it becomes fairly

9.

steady.
Switch back the setpoint SV = 25 kg/hr. Use the first (I) PID
trial value but now with TD = 20 s. Mark the PID values on

10.

the chart paper simultaneously.

Apply the disturbance by opening and shutting fully the by-

pass valve at control valve FCV91 and observe the response.

C. PID CONTROLLER TUNING
1.
Set FIC91 in Manual (M) mode with setpoint SV = 25 kg/hr.
Adjust the PID values to the following:
PB = about 100%, TI = 9999 s (Maximum), TD = 0 s
(Minimum)
2.
By setting TI to maximum value and TD to minimum value, we
3.

can eliminate these two modes in a PID controller (use PB only).

Adjust MV in FIC91 until the PV value closes to the setpoint SV

4.

value (SV = 25 kg/hr).

Transfer FIC91 to Auto (A) mode. Introduce a setpoint pulse
disturbance as follows:
i) Set increase SV to 28 kg/hr
ii) Hold the value for a few seconds
iii)Bring back the SV to 25 kg/hr

UniKL MICET
LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL

5.

EDITION:

1
1

REVISION NO:
EFFECTIVE DATE:

29 SEPT
2014

AMENDMENT
DATE:

Observe the mass flow rate (red pen) response. Repeat the
Closed Loop Tuning Method as above with a decreasing PB
value until uniform oscillation (constant amplitude) is observed.
(To increase oscillation, decrease PB value and vice versa)

6.

Figure 1: Uniform oscillation

Examine the chart response for the uniform oscillation. New
PID value from tuning procedures can be obtained as follows:
i. PB corresponds to uniform oscillation = PB* ultimate
(correspons to ultimate gain, Kcu)
ii. Distance between two adjacent peaks = Tn* ultimate
(ultimate period, Pu) Tn* can be calculated from this formula:

Tn

measurement ( mm ) x 3600
500 mm
chartspeed (
)
hr

iii. The approximate PI controller settings by using Ziegler

7.

Nichols formula are:

PB = 2 X PB*, TI = Tn*/1.2
To test this new PI controller settings, set this value into FIC91
(in Auto mode) perform the test with a pulse disturbance.
Increase PB value to damp the oscillation and fine tune the PB
and TI values to get as close to Quarter Amplitude Damping
response.

UniKL MICET
LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL

EDITION:
REVISION NO:
EFFECTIVE DATE:

1
1
29 SEPT
2014

AMENDMENT
DATE:

Figure 2: Quarter Amplitude Damping Response (Blue pen)

D. SHUTDOWN PROCEDURE
1.
Stop the recorder chart by pressing RCD press button at
recorder FPTR91.
Switch FIC91 to Manual mode with MV = 0%.
Switch off the main power supply.
Shut off the process air supply at AR900.
Shut off the instrument air supply.

6.0

2.
3.
4.
5.
6.
RESULTS & CALCULATIONS
A. The recorder FPTR91 records the results of the experiments. Suitable
portions of the recorder chart paper should be submitted as RESULTS of
the experiment.
B. The report should contain:
i)
The P&I Diagram with all major components marked clearly.
ii)
The instruments readings taken simultaneously and recorded for
iii)

different valve opening positions.

Comparison between direct instrument data with calculated data for

iv)

Fvb and Fm
The PID flow control responses for disturbances and setpoint changes

v)

for different controller settings.

Discussion on the response characteristics for different controller

vi)

settings.
Tuning by Ziegler Nichols method and its response.

UniKL MICET
LABORATORY: PROCESS
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EDITION:
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At the panel
FT91,

Controller

29 SEPT
2014

EFFECTIVE DATE:

EXPERIMENT: AIR FLOW

PROCESS CONTROL

Instrument Reading

1
1

AMENDMENT
DATE:

II

III

MV=6.3%

MV=50%

MV=70%

FIC91, I/O Data

X1 - %of 0-100mm

TIT911, T

X2 - %of 0-120oc

PT911, P

X3 - %of 0-60psia
FIC91, Main Face plate

PV, kg/Hr

Fm

FIC91, Main Face plate

Fv

PO1, m3/Hr
Recorder FPTR91

Channel 1(Red)

Fm , kg/Hr

Channel 2(Green)

Fvb , m3/Hr

By Calculation

Fvb , Nm3/Hr
Fm , kg/Hr

At the Plant
FI911, Nm3/Hr
PG900 , psig

7.0

ANALYSIS OF THE RESULTS

Analysed critically each results obtain in section 6.0 by referring to the

theory/introduction parts. Find reasons (suggested reasons) on each
occurrence shown in the results.

8.0

DISCUSSIONS
Discuss the overall experiment on data obtain based on your understanding.
Discussion should relate reasons for the phenomena/results obtained,

UniKL MICET
LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL

EDITION:

1
1

REVISION NO:
EFFECTIVE DATE:

29 SEPT
2014

AMENDMENT
DATE:

theoretical parts, suggested reasons (if necessary but back with sound
theoretical knowledge) and your overview understanding.
9.0

ADDITIONAL QUESTIONS
i.

Includes short essay on comparison between Perfect Gas Law and air
flow measurement from instrument in the experiment.

ii.

Gas flow measurement tends to produce noise? Comment on this

statement

9.0

CONCLUSION
Conclusion is merely a summary of the important findings already reported
in the discussion section. It also relates to the objectives stated earlier.

10.0 SUGGESTIONS & RECOMMENDATIONS

Your ideas of suggestion & recommendation to improve the learning process
for this experiment or anything related to the experimental procedure etc.

11.0 REFERENCES
Minimum of at least 5 references (with 3 of them are paper/book/chapter
based)