Summary

Aim of Experiment
The main objective is to study the characteristics of flow control system, and
to determine the performance of P, PI and PID controllers. 4 different tasks
are performed during the experiment to determine open-loop behaviour and
limitation of process, to determine influence of disturbance to process, to
determine controller settings by using Ziegler-Nicholas Closed Loop Method
and to evaluate performance of P, PI and PID controllers
Materials and Equipment Used
In this experiment, RT 020 Flow Control experimental unit is used and is
connected to the computer for data input and output.

Task 1: To determine open-loop behaviour and limitation of process

Procedures
In order to begin the experiment, computer and equipment is switched on
and Manual operating mode is selected and disturbance, Z is set to be 0%.
Next, regulation ratio, Y is set to 20% (valve 20% open) and steady-state in
the flowrate, X is reached after a while. Step change of Y from 20% 30% is
performed and a new steady-state in the flowrate, X is reached after waiting.
Graph is paused and valve is closed (Y=0%) for safety purposes. Results are
taken and graph plotted from the computer is saved, printed and analysed.
(CTR2-1)
After obtaining first graph, the steps above are repeated with a steady
increase at 10% interval in the regulation ratio (Y) until the valve is fully
open (Y=100%). (CTR2-2)
Results

Figure 1: CTR2-1 Graph

 Figure 2: CTR2-2 Graph
Discussion
Task 1 (CTR2-1, CTR2-2)
From the graph of CTR2-1, it is shown that the response time is relatively
short, therefore we can conclude that it shows a First-Order Response. At a
time of around 2:23:28 PM, the moment when Y is set to change from 20%
30%, it has only around 1 second of delay for X to be increased from around
72L/hr to approximately 94L/hr.
CTR2-2 is plotted to determine the systems overall performance and
behaviour. Initially, when Y is at 20%, the flowrate is at around 72L/hr. As we
slowly increase Y with 10% interval, it can be seen that X increased
exponentially until it reaches a maximum of around 158L/hr. It is also shown
in the graph that at a change of Y from 80% 90%, X does not change. This
is most likely due to some error in the equipment or sensor that it couldnt
detect the change of flowrate. However, when the process continues with a
step change of Y from 90% 100%, X increased. Therefore, the statement
that flowrate increases exponentially is still valid.
Among the limitations of Open-Loop process is it has low accuracy and
reliability. Although its easily built, the system does not have any
mechanism of feedback and thus the result output are not very accurate.
Besides, since it has no feedback mechanism, it is most likely unable to
remove any disturbance which will be discussed in CTR2-3.

Task 2: To determine influence of disturbance to process

Procedures
In order to perform this experiment, Manual operating mode is selected
and disturbance, Z is set to be 0%. Regulation ratio, Y is set to 50% (valve
half open) and steady-state in the flowrate, X is reached after a while. Next,
Step change of Z from 0% 10% is performed and a new steady-state in the
flowrate, X is reached after waiting.
The steps above are repeated with a steady increase at 10% interval in the
disturbance variable (Z) until the maximum disturbance valve is reached
(Z=100%). Graph is paused and valve is closed (Y=0%) for safety purposes.
Finally, results are taken and graph plotted from the computer is saved,
printed and analysed.
Results
 Figure 3: CTR2-3 Graph

Discussion
According to graph CTR2-3, an observation can be made that when
disturbance is introduced, flowrate will decrease. The decrease of flowrate
starts when disturbance is at 30% (at time around 2:37:58). This is because
at 10% and 20%, the influence of disturbance is not that significant to
decrease the flowrate.
Among the possible influences of disturbance are blockage in the pipeline
due to impurities. As impurities build up in the pipeline of flowing fluid, it will
reduce the flowrate eventually, and as seen in the graph, the more the
amount of impurities blocking the pipeline, the lower the flowrate.
Other than blockage in pipeline, another possible influence is leakage in the
pipeline. It is possible that the pipe suffered from corrosion which will lead to
a crack in the pipeline. Fluid will then seep through the small crack and will
 start leaking. If it is left untouched, the crack will eventually grow which will
cause more fluid to be leaked and that will decrease the flowrate of the
pipeline.
Sudden change of pressure in the pipeline is also one of the possible
disturbance. If theres a sudden drop in pressure, it will decrease the flowrate
of fluid. Likewise, if theres a sudden increase in pressure, it will increase the
flowrate of fluid. This will cause the flowrate to be unstable over time.
Other than determining the possible disturbances, a signal block diagram of
this open-loop system is drawn and shown in the figure below.

Input Controlle Actuator Valve Flowrate

Signal r Output

Disturban
ce Input