UniKL MICET EDITION: 1

LABORATORY: PROCESS 1
REVISION NO:
CONTROL
29 SEPT
EFFECTIVE DATE:
EXPERIMENT:GAS PRESSURE 2014
PROCESS CONTROL 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 2

EXPERIMENT TITLE Gas Pressure Process Control

DATE
GROUP NO.
1)
LECTURER/INSTRUCTOR/TUTOR
2)
DATE OF REPORT SUBMISSION
ATTENDANCE/PARTICIPATION/DISIPLINE: /5%

INTRODUCTION: /5%

PROCEDURE: /5%
RESULTS& CALCULATIONS /15%
ANALYSIS /15%
DISTRIBUTION OF MARKS FOR DISCUSSIONS: /20%
LABORATORY REPORT: ADDITIONAL QUESTIONS /15%
CONCLUSION /10%

SUGGESTIONS& RECOMMENDATIONS /5%

REFERENCES: /5%

TOTAL: /100%

EXAMINER COMMENTS: RECEIVED DATE AND STAMP:

 UniKL MICET EDITION: 1
LABORATORY: PROCESS 1
REVISION NO:
CONTROL
29 SEPT
EFFECTIVE DATE:
EXPERIMENT:GAS PRESSURE 2014
PROCESS CONTROL 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: ………………………………………….. (Signature)

Name : __________________________________
Matrix No. : __________________________________

2) Group Member 1: ………………………………………. (Signature)

Name : __________________________________
Matrix No : __________________________________

3) Group Member 2:……………………………………….. (Signature)

Name :__________________________________
Matrix No. : __________________________________

4) Group Member 3:……………………………………….. (Signature)

Name :__________________________________
Matrix No. : __________________________________
 UniKL MICET EDITION: 1
LABORATORY: PROCESS 1
REVISION NO:
CONTROL
29 SEPT
EFFECTIVE DATE:
EXPERIMENT:GAS PRESSURE 2014
PROCESS CONTROL AMENDMENT
DATE:

1.0 OBJECTIVES
a) To identify the important components of the air pressure control system and to
mark them in the P&I Diagram To study single loop flow control using PID
controller
b) To control the pressure in single capacity and two capacity processes using
PID controller.
c) To tune the PID controller using Ziegler Nichols closed-loop method.

2.0 LEARNING OUTCOMES

At the end of the study, student will be able to:
2.1 To be familiar with the basic steps of machine from start-up to shut-down
with proper handling and setting.
2.2 To identify the major component of the Gas Pressure process control
training system
3.0 INTRODUCTION
Pressure vessels play an important role in chemical industries as storage vessels
for gas phase components, reaction vessels to carry out a gas phase reaction, etc.
Precise control of pressure in the pressure vessels is necessary in order to:
(i) Maintain a constant concentration of components in the vessel,
(ii) Maintain the number of moles in the vessel, and
(iii) Protect the vessel from being damaged due to very high pressures.

4.0 INSTRUMENTS /APPARATUS / CHEMICAL / REAGENTS

The control system consists of a microprocessor based PID controller with an inbuilt
ON/OFF controller. It is equipped with the necessary instrumentation and signal
transmission system.
Identify and mark the following major components of the system in the P&I block
diagram provided in the schematic diagram is shown in Figure 1.
 UniKL MICET EDITION: 1
LABORATORY: PROCESS 1
REVISION NO:
CONTROL
29 SEPT
EFFECTIVE DATE:
EXPERIMENT:GAS PRESSURE 2014
PROCESS CONTROL AMENDMENT
DATE:

5.0 PROCEDURE
5.1 STARTUP PROCEDURES
Go through these steps before starting any experiment.
1) Switch the "PANEL, SCADA/DDC" selector switch at the front of the
cubicle to the "PANEL, SCADA" position.
2) Switch ON the main power supply at the front of the cubicle. All the
panel instruments will lit up.
If the recorder chart drive is running, STOP it by pressing the `RCD'
pushbutton.
3) If any annunciator gets activated, press the ACKNOWLEDGE button
to silence the buzzer.
4) Set the instrument air supply regulator to the pressure indicated at
the air regulators at the pneumatic control valves PCV91 and PCV92.
Purge if there is any condensed water in the air regulators by opening
the bottom drain valves.
5) Make sure that the by-pass valves around the control valves PCV91
and PCV92 are shut fully and the pair of manual valves
upstream/downstream of these control valves are opened.
6) Check that the control valve positioner (PP) of PCV91 is connected
(ON) (i.e., not by-passed).
7) Make sure the compressed air is available at the pressure inlet air
regulator AR91.
8) Check that the vent valve (V) and bottom drain valve (D) of vessel T91
are shut.
9) SHUT fully the manual valves MV91B and MVIII.
10) SHUT fully the process inlet manual valve MV91.
11) Place the panel controller PIC91 in manual (M) mode and adjust its
MV = - 6.3% to open the control valve PCV91 fully.
12) Open fully the final discharge manual valve (VP). This valve is at
downstream of pressure control valve PCV91.
 UniKL MICET EDITION: 1
LABORATORY: PROCESS 1
REVISION NO:
CONTROL
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EFFECTIVE DATE:
EXPERIMENT:GAS PRESSURE 2014
PROCESS CONTROL AMENDMENT
DATE:

13) From the process air supply, trace the two pipe lines PLI and PLII as
follows: Pipeline PLI: Single capacity process:
AR91-MV91-T91-PLI-B92- FI92 -P CV9 1 –VP
Two-capacity process
AR9 1 -MV9 1 -T91 -PLI-MVI-T92-MV92-FI92 -PCV 9 1 –VP
Pipeline II (PLII):
AR9 1 -MV9 1 -T91-PLII-MVII-PCV92-MV92A/MV92B-V
14) Open fully the pipelines PLI (Single capacity process) and PLII at their
various manual valves.
15) Make sure the manual by-pass valve B92 around vessel T92 is opened
and the manual valves at the inlet MVI and outlet MV92 of T92 are
shut.
16) The pipeline PLII has two discharge manual valves, MV92A (globe
valve) and MV92B (gate valve). SHUT both the valves MV92A and
MV92B.
17) Check and adjust the pressure at AR91 is approximately at the
pressure indicated at AR91. Check MV91 is fully shut.
18) Slowly open MV91 and regulate it until the flow rate at the variable
area flow meter FI92 reads 35 Nm3/Hr
19) Check the pressure and flow rate setting:
a. Shut fully PCV91 from PIC91 in manual (M) mode with
MV=106.3%. Read the pressure at vessel T91 at the PV reading
of PIC91. If the pressure is about 22 – 27 psig, the pressure is
correctly set.
b. Open fully PCV91 from PIC91 in manual (M) mode with MV=-
6.3%. Read the pressure at vessel T91 at the PV reading of
PIC91. If the pressure is not more than 10 psig and the flow
rate at FI92 also reads 35 Nm 3/Hr, the air flow rate is correctly
set.
c. Now the process air supply pressure and flow rate are set. DO
NOT readjust AR91 and MV91 hereafter.
 UniKL MICET EDITION: 1
LABORATORY: PROCESS 1
REVISION NO:
CONTROL
29 SEPT
EFFECTIVE DATE:
EXPERIMENT:GAS PRESSURE 2014
PROCESS CONTROL AMENDMENT
DATE:

5.2 ON/OFF PRESSURE CONTROL

It uses the ON/OFF pressure controller PIC92 to control at the High
pressure limit of PIC91.
1) Make sure that you have gone through the START-UP procedures
very carefully.
2) Start the chart drive of the recorder by pressing the `RCD'
pushbutton at the front of the recorder.
3) Shut fully PCV91 from PIC91 in manual (M) mode with
MV=106.3%. Read PV at PIC91, the pressure at vessel T91. The
pressure should be in the range of 22-27 psig.
4) To open PLII: Open only the manual discharge globe valve MV92A
at the common vent of PLII. Keep the gate valve MV92B at the
common outlet of PLII closed.
5) Note the response of PT91 at the recorder PR91.
PCV92 opens when PT91 exceeds 21 psig and closes when PT91
drops below a fixed Dead Band (0.5 psig), i.e., 20.5 psig.
6) Try to repeat the ON/OFF action by opening and closing PC 91.
This is done from PIC91 in manual (M) mode by reducing the MV
such that pressure PV drops below 20 psig. Then shut PCV91
fully again with MV = 106.3%.
7) Stop the record chart drive and retrieve the relevant portions of
the chart
5.3 PID CONTROL OF PRESSURE IN SINGLE CAPACITY PROCESS
1) Make sure that you have gone through the START-UP procedures
very carefully.
2) Start the chart drive of the recorder by pressing the `RCD'
pushbutton at the front of the recorder.
3) Make sure that pipelines PLI and PLII are opened throughout.
4) Open only the manual discharge globe valve MV92A at the
common vent of PLII.
5) Close the gate valve MV92B at the common outlet of PLII
 UniKL MICET EDITION: 1
LABORATORY: PROCESS 1
REVISION NO:
CONTROL
29 SEPT
EFFECTIVE DATE:
EXPERIMENT:GAS PRESSURE 2014
PROCESS CONTROL AMENDMENT
DATE:

6) For single capacity operation, only vessel T91 is used. Vessel T92
is by-passed
a. Open by-pass valve B92 around T92
b. Shut the manual valves at the inlet, MVI, and at the outlet,
MV92, of T92.
c. Make sure the air flow path T91-PLI-FI92-PCV91-VP is
opened through B92.
7) Set the set point of PIC91 as SV = 15 psig.
8) Set the PID controller with the first (I) trial values: PB1 =
70%, T11 = 40 secs, TD1 = 0 sec.
9) Transfer the controller to Auto (A) mode and wait for the
response to become almost stable.
10) Switch PIC91 to Manual (M) mode, decrease MV by about 5 to
10%, switch back to Auto (A) mode and observe the response for
a few minutes.
DO NOT FORGET TO MARK THE PID VALUES AND THE
SETPOINT ON THE CHART PAPER WHENEVER THE VALUES
ARE CHANGED. ALSO MARK ON THE CHART THE BEGINNING
OF EACH PART OF THE EXPERIMENT
11) If the response is slow to return to the set point SV = 15 psig,
reduce
TI1 to 20 secs. and repeat the step (10) again.
12) Now set the PID controller with the second (II) trial values:
PB1 = 45%, TI1 = 30 secs, TD1 = 0 sec.

13) Switch PIC91 to Manual (M) mode, decrease MV by about 5 to

10%, switch back to Auto (A) mode and observe the response for
a few minutes.
If the response is not oscillatory, proceed to step (15). If the
response is oscillatory, go to the next step, step (14).
14) Increase PB1 by 5% and repeat the step (13).
15) Try the third (III) trial values for the PID controller: --
PB 1 = 20%, TI1 = 10 secs, TD1 = 2 sec.
16) Introduce the disturbance in MV as in step (13) and observe the
response.
17) STOP the chart drive and retrieve the relevant portions of
the chart paper. Attach the chart paper along with the results .
 UniKL MICET EDITION: 1
LABORATORY: PROCESS 1
REVISION NO:
CONTROL
29 SEPT
EFFECTIVE DATE:
EXPERIMENT:GAS PRESSURE 2014
PROCESS CONTROL AMENDMENT
DATE:

6.0 SHUTDOWN PROCEDURE

1. Switch the controller PIC91 to Manual(M) mode, and set the MV=100%
2. Stop Recording by push the recorder “RCD” button
3. Switch Off the main power supply
7.0 RESULTS & CALCULATIONS

The recorder PR91 records the results of the experiments. Suitable

portions of the recorder chart paper should be submitted as RESULTS of
the experiment.

The report should contain

1. The P&I diagram with all major components marked clearly.
2. A detailed report of the start-up procedure.
3. The response curves of the ON/OFF controller with all particulars such
as Setpoint and Dead Band.
4. Response curves for single capacity and two-capacity processes with
different PID controller values. Include all the details such as setpoint,
PID controller values.
5. Discussion on the response characteristics.

8.0 ANALYSIS OF THE RESULTS

Analysed critically each results obtain in section 7.0 by referring to the

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

9.0 DISCUSSIONS

Based on your observation, comment/discuss on the following:

1. The choice of Air-to-Open or Air-to-Close control valve is determined by
safety consideration.
2. ON/OFF control is a two position control. Use of dead band is recommended
in ON/OFF controllers. Why?
3. Difference between single capacity and two-capacity processes.
 UniKL MICET EDITION: 1
LABORATORY: PROCESS 1
REVISION NO:
CONTROL
29 SEPT
EFFECTIVE DATE:
EXPERIMENT:GAS PRESSURE 2014
PROCESS CONTROL AMENDMENT
DATE:

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

11.0 SUGGESTIONS & RECOMMENDATIONS

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

12.0 REFERENCES
Minimum of at least 5 references (with 3 of them are paper/book/chapter base
CAMPUS : UniKL MICET EDITION: 1
LABORATORY: SECTION of 1
PROCESS CHEMICAL REVISION NO:
TECHNOLOGY
29 SEPT
EFFECTIVE DATE:
EXPERIMENT: LIQUID FLOW 2014
PROCESS CONTROL AMENDMENT
DATE: