LAB 03 – SIM 2100 LEVEL CONTROL FEEDBACK CONTROLLER

PETROLEUM PROCESS SIMULATION LAB

PETR2163L-04

LAB DATE:04 TH OCTOBER, 2018.

SUBMITTED TO: LOREE D’ORSEY

SUBMITTED BY: JASKARAN SINGH CHAUHAN (20183319)

OBJECTIVE:

(a) To study the simulation level 2100 feedback controller.

(b) To study the behaviour of the model with disturbances.
(c) To study the affect of flow on level of the vessel.
(d) To study Ziegler Nichols formula.
(e) To study output values by changing different values of gain and error.

OBSERVATIONS:

1. THE SIM 2100 Simulation Model is feedback controller.

2. Two inlet feed lines are attached to the vessel to increase and decrease the level
of the vessel.
3. The level indicator is attached to the vessel to check the level of the vessel.
4. Flow indicator is attached to check and control the flow rate of the feed on feed
lines and outer lines.
5. The system is very sensitive if any variable of the system is change.
Assignment 1: Exploration of Model

Q.1.0) What is the minimum level for the liquid in the vessel with the level control valve
at 60%?

Answer: 41.85%.

Q.1.1) What valve opening is required to maintain the level at the same value as the
previous question?

Answer: 86.53%.

Assignment 2: Investigate controller response to change in inlet flow rate to vessel

Restart and plot only FI_101_02, LIC_101_03 MV, LIC_101_03 OP, LIC_101_03 SP, &
FI_101_04

Q.2.0) Before increasing the inlet flow, predict what will happen to the following values:

VARIABLES PREDICTION
FI_101_02 INCREASE
LIC_101_03 MV INCREASE
LIC_101_03 OP STABLE
FI_101_04 INCREASE

Q.2.1) How did your predictions compare to the actual response?

VARIABLES RESULT
FI_101_02 INCREASE
LIC_101_03 MV STABLE
LIC_101_03 OP INCREASE
FI_101_04 INCREASE

Q.2.2) How long does it take for the controller to reach steady state?

Answer: 4.13 sec.

Q.2.3) How much did the level overshoot?

Answer: Overshoot is 18.20.

Q.2.4) How much did the level oscillate before reaching the new steady state value?

Answer: After 9 oscillations to reach steady state level.

Q.2.5) Based on the answers to these questions, is this controller response to a step
change reasonable? Why?

Answer: No, controller response to a step change is not reasonable because according to
study the graph and values must be steady not vary. But the graph show under damped
condition of the controller.
Assignment 3: Investigate controller response to inlet and outlet disturbances

Restart and plot only FI_101_02, LIC_101_03 SP, LIC_101_03 MV, & LIC_101_03 OP.

Set inlet disturbance of 5 m3/h.

Q.3.0) What is the maximum level being reached?

Answer: 56.81%.

Q.3.1) What is the minimum level being reached?

Answer: 43.95%.

Picture of the Graph

Restart and plot only FI_101_02, LIC_101_03 SP, LIC_101_03 MV, LIC_101_03 OP, &
FI_101_04.

Set outlet disturbance of 0.2 bara.

Q.3.2) What is the maximum level being reached?

Answer: 51.59%.

Q.3.3) What is the minimum level being reached?

Answer: 48.34%.

Take picture of your graph (minimum 4 oscillations). Keep copy of the graph for
comparison in later labs.
Assignment 4: Investigate how to tune Ziegler Nichols formula values for (a)
proportional control, (b) proportional plus integral control, and (c) proportional plus
integral plus derivative control.

Restart and plot only FI_101_02, LIC_101_03 SP, LIC_101_03 MV, & LIC_101_03 OP.

(a) Proportional Control

Q.4.0) What is the steady state error (Set Point – Measured Value)?

Answer: Error= Set point- Measured Value

=27-7.9

=19.10

Q.4.1) What is the present gain setting for the controller?

Answer: Gain=2

Q.4.2) Does the equation match the output figures you are seeing in the controller
faceplate? (Hint – the answer is yes)

Answer: Yes, Controller O/P = GAIN*ERROR

GAIN = Controller O/P / ERROR

GAIN = 38.20/19.10

GAIN = 2.

Q.4.3) What is the new steady state error (Set Point – Measured Value)?

Answer: Error= SP- MV

Error= 25-15.35

Error = 9.65

Q.4.4) Does the equation again match the output figures you are seeing in the controller
faceplate?

Answer: Yes,

Controller O/P = GAIN*ERROR

GAIN = Controller O/P / ERROR

GAIN = 38.60/9.65

GAIN = 4.
Q.4.5) What is the new steady state error (Set Point – Measured Value)?

Answer: Error= SP- MV

Error= 25-18.53

Error = 6.47

Q.4.6)Does the equation again match the output figure you are seeing in the controller
faceplate?

Answer: Yes,

Q.4.7) What is happening when the gain is increased?

Flow Set Point Gain Level Error 100 – Controller

(Gain*Err Output
or)
10 25 2.0 5.96 19.04 61.92 61.80
10 50 2.0 30.29 19.71 60.58 60.58
10 75 2.0 54.69 20.31 59.38 59.38
20 25 2.0 14.78 10.22 79.56 79.56
20 50 2.0 39.11 10.89 78.22 78.22
20 75 2.0 63.51 11.49 77.09 77.01
10 25 4.0 15.35 9.65 61.4 61.38
10 50 4.0 40.02 9.98 60.09 60.08
10 75 4.0 6.73 10.27 58.92 58.92
20 25 4.0 failed to control
20 50 4.0 failed to control
20 75 4.0 failed to control
10 25 6.0 18.53 6.47 61.21 61.18
10 50 6.0 43.32 6.68 59.93 59.92
10 75 6.0 68.13 6.87 58.96 58.92
20 25 6.0 failed to control
20 50 6.0 failed to control
20 75 6.0 failed to control

Q.4.8) Why is the system failing to control at those settings?

Answer: the system is failed at those settings because system becomes unstable and gives
highest values at unstable modes. This leads to system failure.

Q.4.9) What is the critical gain Kcr for this system?

Answer: KCr = 7.589

Q.4.10) What is the critical period Pcr (in seconds) for this system?

Answer: Pcr = 10 sec.

Q.4.11) How long does it take for the system to stabilize?

Answer: 40 seconds to stabilize.

Q.4.12) What is the value of the steady state error signal?

Answer: Steady state error signal is 10.17%.

Q.4.13) What is the value of Kp?

Answer: Kp = Kcr /2.2

= 7.589/2.2

= 3.449

Q.4.14) What is the value of Ti?

Answer: Ti = Pcr/1.2

= 10/1.2

= 8.33 sec

Q.4.15) What is the steady state error now?

Answer: zero.

(C) Proportional Plus Integral Plus Derivative Control

Q.4.16) What is the required value of Kp?

Answer: Kp = Kcr /1.7

= 7.6/1.7

= 4.464
Q.4.17) What is the required value of Ti?

Answer: Ti = Pcr/2

= 10/2

= 5 sec.

Q.4.18) What is the required value of Td?

Answer: Td = Pcr/8
= 1.25 sec.

Q.4.19) What is the steady state error now?

Answer: Zero.

Q.4.20) How long does it take for the system to stabilize?

Answer: 50 seconds.

Q.4.21) How do these values compare with the Proportional + Integral system values in
the previous section?

Answer: Steady state error: Reduced in PID Controller as compared to PI controller

Kp: Less in PI controller, Higher in PID controller.

Ti : More in PI controller than PID controller.

Assignment 5: Investigate controller response to change in inlet flow rate to vessel.

Q.5.0) What other process variables could be controlled by using a feedback controller?

Answer: We can control temperature and pressure.

Q.5.1) Are there any processes that you think a PID based feedback controller would be
unable to control?

Answer: PID is sensitive and record and senses each vibration. The process in which valves
with vibration are present cannot be controlled by PID.

Q.5.2) Is there a disturbance that a feedback loop is best at dampening?

Answer: Feedback is very sensitive and square wave trend can give better result at damping.

Conclusion:

Simulation 2100 is the best model to control the process. In this model we see that gain
reduce the error of the process. Gain values can be increase by the help of increasing flow
rate. The different values of experiments show higher the flow higher the gain value and
lower the flow less the value of gain ultimately the system become steady after some time.