Instruments Controller I II III

MV = -6.3% MV = 50% MV = 70%

At the PANEL FIC91, I/O Data
FT91, √ℎ X1 - % of 0-100% H2O 78.7 42.9 25.5

TIT911, T X2 - % of 0 - 120oC 25.2 25.4 25.4

PT911, P X3 - % of 0 – 60 psia 67.1 84.4 92.0

FIC91 Main Face Plate

Fm PV, kg/Hr 50.3 30.7 19.1

FIC90, PT Register
Fv PO1, m3/Hr 20.1 11.0 6.5

Recorder FPTR91
Channel (Red 1) Fm, kg/Hr 50.3 30.7 19.1

3
Channel 2 Fv,m /Hr 20.1 11.0 6.5
(Green)
By Calculation Fvb,Nm3/Hr 19.63 16.12 13.03

Fm,kg/Hr 25.38 20.93 16.85

At the Plant

FI911, Nm3/Hr 48 28 17

PG900, psig 29.5 37.5 41.5

RESULT

There are different methods of controller tuning such as Ziegler-Nichols method which is used
and applied in this experiment. The values of parameter given during this experiment are
different in each process and no particular and specific for every plant. Theoretically, a good
combination of the P, I, D values can produce less oscillation and better settling time. All general
methods for control design can be applied to PID control. All of the different method is used to
consider the key elements of control, load disturbances, sensor noise, process uncertainty and
reference signals. But if unfamiliar with the system, it is need to the experimentation and selects
the controller settings, obtained from Ziegler-Nichols method as applied in this experiment. So,
Ziegler-Nichols method provides initial settings that will ensure good tuning of plant. The
Ziegler-Nichols tuning rules were created to give closed loop systems with load of disturbances.
.

Tn secs = measured period (mm) x 3600

Chart speed (500 mm/Hr)

= 1mm x 3600 s

500 mm

= 7.2 s

Approximate PI setting by Ziegler Nichols formula:

PB = 2 x PB*

TI = Tn / 1.2

TI = 7.2 / 1.2 = 6 s
Ziegler-Nichols method

The First Method

The first method is used and applied to a plant basis on Figure 1. This method is usually applied
to first order system. It is also used in a plant consist of a series of first order systems. The
response is characterized by two parameters, L the delay time and T the time constant. These are
found by drawing a tangent to the step response at its point of inflection and draw its
intersections with the time axis and the steady state value. The plant equation is

𝐾𝑒 −𝑠𝐿
𝐺 (𝑠) =
𝑇𝑠 + 1

Ziegler and Nichols derived the following control parameters based on this model:
PID Type Kp Ti=Kp/Ki Td=Kd/Kp
P 𝑇 ∞ 0
𝐿
PI 0.9𝐿
𝑇 𝐿 0
0.3
PID 𝑇 2L 0.5L
1.2𝐿

Figure 1: Response Curve for Ziegler-Nichols first method

The Second Method

The second method targets plants that can be assumed unstable under proportional control. The
technique is designed to result in a closed loop system with 25% overshoot. This is rarely
achieved as Ziegler and Nichols determined the adjustments based on a specific plant model.
The steps for tuning a PID controller via the 2nd method are as follows:

Using only proportional feedback control:

a) Reduce the integrator and derivative gains to 0.
b) Increase Kp from 0 to some critical value Kp=Kcr at which sustained oscillations occur.
If it does not occur then another method has to be applied.
c) Note the value Kcr and the corresponding period of sustained oscillation, Pcr

The controller gains are now specified as follows:

PID Type Kp Ti Td
P 0.5Kcr ∞ 0
PI 0.45Kcr 𝑃𝑐𝑟 0
1.2
PID 0.6Kcr 𝑃𝑐𝑟 𝑃𝑐𝑟
2 8
 Figure 2: Step response for system tuned via second method

Graphs obtained from recorder PIC91

APPENDIX

Without P/T compensation:

Fv = k1 √h

With P/T compensation:

√ℎ𝑃
Fvb = kvb 𝑇

The mass flow rate measurement is given by:

Assuming perfect gas law :

√ℎ𝑃
Fm = km 𝑇

Where Fv = Volumetric flow rate, m3/Hr

Fvb = Volumetric flow rate, Nm3/Hr

Fm= Mass flow rate, kg/Hr

h = Absolute pressure, psia

 T = Temperature, K

For the given 6.35 mm bore orifice plate,

k1 = 0.256

kvb = 1.356

km = 1.753

Controller I) MV= -6.3% II) MV= 50% III) MV= 70%

Fvb, Nm3/Hr =1.356√78.7 x 67.1 =1.356√42.9 x 84.4 =1.356√25.5x 92.0

=kvb=
√ℎ𝑃 25.2 25.4 25.4
𝑇
= 19.63 = 16.12 = 13.03

Fm kg/Hr =1.753√78.7 x 67.1 =1.753√42.9 x 84.4 =1.753√25.5x 92.0

Fm = km
√ℎ𝑃 25.2 25.4 25.4
𝑇
= 25.38 = 20.93 = 16.85
 Discussions

A compressible fluid is one in which the fluid density changes when it is in the high
pressure gradients. For gasses, changes in density are accompanied by changes in temperature, and
this complicates considerably the analysis of compressible flow. The main difference between
compressible and incompressible flow is the way that forces are transmitted through the fluid. For
an example, in a long, completely filled piping system, if a pump is turned on at one end, the water
will immediately begin to flow out of the other end of the pipe.

Based on the experiment, there are three different test was done to observe the process
response. For the first experiment, gas mass flow rate control was observed by using PID control
mode with pulse load disturbance and set point disturbance were applied to bother the process flow
response. In this experiment, three different value of PB was tests which are 200, 100 and 150 .PB
at 100 is the best value compare with others in order to the time it takes to regain constant and it
show that the lower value of PB, the faster the time it takes to stable. For the control value non-
linearity test (with PP) and observation control value response without positioner, there are two
trials were tests.
 Set point is the desired value of the controlled variable. It is important for maintained or
controlled at some desired value. For the first trial, the set point disturbance was introduced with
25kg/hr interval unit 50 kg/hr. Set point (SV) was change to 30 to observe the response. TI is
integral time. TI equal with 6 seconds was used when PB value was change from 200 PB to 100
PB. TI is related with KC, which is TI inversely proportional with KC. When KC increases it will
reduce steady state error time. TD is a settling time. In this experiment, TD was set to 0 second.
Settling time is a time required for the process output reach and remain inside a band. Next, when
the derivative time increase, settling time will decrease.

Rangeability is usually stated as the ratio of maximum to minimum flow. There are two
definition of maximum flow, which are commonly used in specifying the rangeability of a
flowmeter. It is important to understand the two methods of defining the maximum flow. It can
mean the difference between a flowmeter that can measure the flow range of interest, and one that
cannot.the first way to define the maximum flow is the maximum flow rate that the flowmeter can
measure. This is how the newer flowmeters specify the rangebility in their sales literature. The
other way to define the maximum flow is the maximum flowrate that actually occurs in a particular
application. This is how most DP flowmeter are specified.

Flow process is a very a fast with negligible capacity lag or dead time. The moment the
control valve is adjusted, the flow controller will be receiving the updated signal for flow
measurement. Thus, flow process can be considered as a high dynamic gain process compared to
level and temperature control. However, flow always characterized by noise, which can be
recorded as spurious fluctuation. This noise may be contributed by random pressure fluctuation
inside the pipeline and also can be from the pump vibration, turbulence flow and pressure drop at
the pipe fittings, valves and flowmeter.
 Gain can be defined as the change in input divided by the change in output. A process with
high gain will react more to the controller output changing. Flow process is fast and high gain
process because the process is stabilized faster after putting the input. The graph shows the process
is stabilized faster even after introducing the disturbance to the process.

Derivative gain is defined as larger values decrease overshoot, but slow down transient
response and may lead to instability due to signal noise amplification in the differentiation of the
error. For the flow process control, derivative control mode is not used because the flow process
is fast and high gain process which means it doesn’t usually overshoot. Overshoot is means when
a signal exceeds its steady state value.

REFERENCES

1. Dale E. Seborg, thomas F. Edgar, Duncan A. Mellichamp. Process dynamics and control,
second edition
2. Carlos A. Smith, C. Armando. Principles and practice of automatic process control, third
edition.