Effect of changing set points to the controllability of flow and mass flow control

PROCESS CONTROL PRACTISE ( CPE 622) 2011

ABSTRACT
This project is about the effect of changing the set point on FIC 31 and FIC 91. The set point change is change is in between 5%, 10 % and 20 %. While performing the open loop test, flow control is using the self regulating process. For the open loop test to FIC 31, the numerical method is used. While for FIC 91, the reformulated tangent method is used to calculate the optimum controller tuning, After performing the open loop, then data that is calculated before this is proceeded to do the closed loop test. The value of P& ID is calculated from the open loop test using the Ziegler Nichols method. In flow controller, the PI controller is used because of process response rate. PI controller is commonly used in tuning, this is because the derivative action is very sensitive to measurement noise and the absent of an integral value may prevent the system from reaching it target value due to control action. The responses of the controller can be described in the terms of the responsiveness of the controller to an error, the degree to which the controller overshoots the set point and the degree to the degree of the system oscillation. The set point change is tested during the process. The set point is changes from 5%, 10%, and lastly 20% for each controller which are FIC 31 and FIC91.tuning control loop is the adjustment of its control parameter which are gain, proportional band, integral/ reset, derivative/rate. It also the optimum values for the desired control process.

OBJECTIVE
To study the effect of the set point change to FIC31 and FIC91. To apply the numerical method (FIC31) and the reformulated tangent method (FIC 91) for the open loop test. To apply the Ziegler Nichols method for the closed loop test.

Effect of changing set points to the controllability of flow and mass flow control

PROCESS CONTROL PRACTISE ( CPE 622) 2011

PIPING AND INSTRUMENT DIAGRAM (P&ID)

FIC 31
I/P I/P FIC 31

Water reservoir T32

FT3

P32

FIGURE 1: P&ID DIAGRAM FOR FIC31

Process Description

Effect of changing set points to the controllability of flow and mass flow control

PROCESS CONTROL PRACTISE ( CPE 622) 2011

FIC 91

FIC I/P

FIC 91

PROCESS AIR SUPPLY

VENT

AIR HEATER

TO AP922

FIGURE 2: P&ID DIAGRAM FOR FIC91 PROCESS DESCRIPTION

Effect of changing set points to the controllability of flow and mass flow control

PROCESS CONTROL PRACTISE ( CPE 622) 2011

Experimental Methodology
START FIC3 1 FIC9

Open Loop

Open Loop

Numerical method

Reformulated tangent method

Calculate RR, Td, TC

Calculate PI (Z-N)

Calculate PI (Z-N)

Run closed

Run closed

Set point test 5%, 10%, 20%

Set point test 5%, 10%, 20% 4

Effect of changing set points to the controllability of flow and mass flow control

PROCESS CONTROL PRACTISE ( CPE 622) 2011

Combine d
END

RESULTS AND CALCULATION

Control loops

parameters

Open loop tuning rule

Ziegler -Nichols

FIC31

Proportional band, PB % Controller gain, KC Integral time, I (s)

99.21 1.00 0.27 320 0.31 17 5

FIC91

Proportional band, PB % Controller gain, KC Integral time, I (s)

Effect of changing set points to the controllability of flow and mass flow control

PROCESS CONTROL PRACTISE ( CPE 622) 2011

Effect of changing set points to the controllability of flow and mass flow control

PROCESS CONTROL PRACTISE ( CPE 622) 2011

Table 1: The Closed Loop Result

Table 2: The Open Loop Result by Using Ziegler Nichols.

Set point change Control loops Control loops parameters 5% Numerical 10% Initial method Residence time, RR 0.1786 (1/s) Dead1.8 time, Td, (s)1.89 5 Time constant, TC, 10 (s) Residence time, RR 26.2 (1/s) 25 Dead time, Td, (s) Time constant, TC, (s) Reformulated 20% tangent method 2.07 0.5656 5.10 3.8 2.16

FIC31 FIC31

FIC91 FIC91

27.5

30.0

Table 3: The Set Point Change for Each Control Loop.

Effect of changing set points to the controllability of flow and mass flow control

PROCESS CONTROL PRACTISE ( CPE 622) 2011

Table 4: The Tuning Test for Each Control Loop.

SAMPLE OF CALCULATION
Closed loop FIC 31 PV 54.13 54.13 54.13 RR 0.1712 0.1786 Td (s) 5 TC (s) 10

62.19 0.0074 63.06 0 63.06 0 63.06 0 63.06 0 63.06 0 Control loop 0 parameters 63.06 63.06 Controller gain, KC FIC31 Integral time, I (s) Controller gain, KC FIC91 Integral time, I (s)

Tuning test 200 0.02 0.31 17.0

Table 5: The Table Obtained From Closed Loop at FIC 31 To calculate RRmax
PV1 PV
-1

/ 2h MV = (54.48-49.29 )/ 2(1)(5)

Effect of changing set points to the controllability of flow and mass flow control
= 0.519 To calculate Td Td = T1 2 h [ PV1 PV = 1.00 To calculate TC TC = 2h [ (PV = 3.25
nss oss

PROCESS CONTROL PRACTISE ( CPE 622) 2011

/ PV1-PV-1] = 3- 2(1) [(54.48-49.29 ) / 54.48-49.29 )]

- PV

OSS

)/ (PV1-PV-1 )]

Open loop

Table 5: Ziegler Nichols formula to calculate open loop

From table 1; 9

Effect of changing set points to the controllability of flow and mass flow control
FIC31 0.1786 5 10

PROCESS CONTROL PRACTISE ( CPE 622) 2011 FIC91 0.5656 5.1 3.108

RRmax TD TC

111.1 RR. TD 0.9/( RR.TD) 3.33 TD

FIC31 99.21 1 0.27

FIC91 320 0.31 17

DISCUSSION

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Effect of changing set points to the controllability of flow and mass flow control

PROCESS CONTROL PRACTISE ( CPE 622) 2011

CONCLUSION

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