TABLE OF CONTENT

NO CONTENT PAGE
1 Abstract 2
2 Introduction 3-4
3 Objective 5
4 Theory 6-8
5 Material and Apparatus 9-10
6 Methodology 11-13
7 Data And Results 14-17
8 Discussion 18-19
9 Conclusion 20
10 Recommendation 21
11 References 22
12 Appendices 23

Lab Report Process Control - Flow Measurement and Control System Page 1
1.0 ABSTRACT

The main objectives for this experiment are to understand the concept of process
control system and to perform the flow process control test in order to determine the P, I and
D behavior. The experiment is started for Close Loop Proportional Flow Control using P =
110%, I = 0 seconds, D = 0 seconds with SV = 50% in manual mode and 75% in auto mode.
Then, the experiment is repeated by changing the value P = 30% and 5% with I = 0 seconds,
D = 0 seconds and SV = 50% in manual mode and 75% in auto mode.

After that, the experiment is conducted for Close Loop Proportional plus Integral
Flow Control where firstly at P = 70%, I = 1 seconds, D = 0 seconds with SV = 50% in
manual mode and 75% in auto mode. The experiment is repeated by changing the value I = 5
seconds and 40 seconds with P = 70%, D = 0 seconds and SV = 50% in manual mode and
75% in auto mode.

Each after the SV, P, I or D value is changed, the students observe the process
response graph to determined the P, I and D mode behavior. Since flow process is self-
regulated process, the response curve stabilize after some time.

After the process becomes stabilize, the graph of the response curve is printed. The
students conclude that the higher value of P, the process and control value make less
oscillation while the lower P value, the process and control value make more oscillation and
the higher value of I, the time taken for the process and control value to be stabilize is faster
while the lower I value, the time taken for the process and control value to be stabilize is
slower.

Lab Report Process Control - Flow Measurement and Control System Page 2
 2.0 INTRODUCTION

Process control is defined as an engineering disciple that deals with architectures,

mechanisms and algorithms for maintaining the output of a specific process within a desired
range. In other word it is a method used to control process variables when manufacturing
products

The first experiment is conducted to demonstrate the characteristics of Proportional

control on a Flow Control Loop. Proportional control system is a type of
linear feedback control system. Two classic mechanical examples are the toilet bowl float
proportioning valve and the fly-ball governor.

The proportional control system is more complex than an on-off control system like a
bi-metallic domestic thermostat, but simpler than a proportional-integral-derivative (PID)
control system used in something like an automobile cruise control. On-off control will work
where the overall system has a relatively long response time, but can result in instability if the
system being controlled has a rapid response time. Proportional control overcomes this by
modulating the output to the controlling device, such as a continuously variable valve.

An analogy to on-off control is driving a car by applying either full power or no

power and varying the duty cycle, to control speed. The power would be on until the target
speed is reached, and then the power would be removed, so the car reduces speed. When the
speed falls below the target, full power would again be applied. The more powerful the
engine, the greater the instability. Stability may be expressed as correlating to the power-to-
weight ratio of the vehicle.

Proportional control is how most drivers control the speed of a car. If the car is at
target speed and the speed increases slightly, the power is reduced slightly, or in proportion to
the error (the actual versus target speed), so that the car reduces speed gradually and reaches
the target point with very little, if any, "overshoot", so the result is much smoother control
than on-off control.

Lab Report Process Control - Flow Measurement and Control System Page 3
 The second experiment is conducted to demonstrate the characteristics of Proportional
and Integral control on a Flow Control Loop. The PI controller is the most popular variation,
even more than full PID controllers. PI control is needed for non-integrating processes,
meaning any process that eventually returns to the same output given the same set of inputs
and disturbances.

The Proportional-Integral (PI) algorithm computes and transmits a controller output

(CO) signal every sample time to the final control element (valve). PI controllers have two
tuning parameters to adjust. While this makes more challenging to tune than a Proportional
controller, they are not as complex as the three parameter PID controller. A Proportional
controller is best suited to integrating processes. Integral action enables PI controllers to
eliminate offset, a major weakness of a Proportional controller. Thus, PI controllers provide a
balance of complexity and capability that makes them by far the most widely used algorithm
in process control applications.

The lack of derivative action may make the system more steady in the steady state in
the case of noisy data. This is because derivative action is more sensitive to higher-frequency
terms in the inputs. Without derivative action, a PI-controlled system is less responsive to real
(non-noise) and relatively fast alterations in state and so the system will be slower to reach
setpoint and slower to respond to perturbations than a well-tuned PID system may be.

Lab Report Process Control - Flow Measurement and Control System Page 4
 3.0 OBJECTIVE
1. To gain fundamental concept of the Process Control system.

2. To study the closed loop for flow control. We conduct the experiment by
using manual control and automatic control.

3. To conduct the experiment on Flow Control System for Close Loop

Proportional Flow Control and Close Loop Proportional plus Integral Flow
Control.

4. To study the behavior of the P and I mode towards the process response
curve for the flow control system.

Lab Report Process Control - Flow Measurement and Control System Page 5
 4.0 THEORY

A fundamental component of any industrial process control system is the feedback

control loop. It consists of a process, a measurement, a controller, and a final control element.
The information of flow provides the means for control, which allows efficient utilization of
raw materials and energy. If all these elements are interconnected which the information can
be passed continuously around the loop, this called as closed-loop control and if a loop is
interrupted for any reason, such as when the controller is placed on manual control, it is
considered to be open-loop control.

Set Point

Controller

Measurement

Input Output
(Manipulated Process (Controlled
Variable) Variable)
Final Control
Element

Figure 1: A Closed Control Loop

Set Point

Controller

Measurement


Input Output
(Manipulated Process (Controlled
Variable) Variable)
Final Control
Element

Lab Report Process Control - Flow Measurement and Control System Page 6
 Figure 2: An Open Control Loop
Proportional control attempts to stabilize the system and avoid fluctuations by
responding to the magnitude as well as the direction of the error. The relationship between
the output and the width of the measurement span is called the proportional band. For
example, a 20 percent proportional band is narrow; it provides sensitive control because 100
percent output change is produced by only 20 percent measurement change.

In operation, the proportional controller calculates the amount of error between the
measurement and set point, amplifies it, and positions the final control element to reduce the
error. The magnitude of the corrective action is proportional to the error. If the proportional
band is too wide (insensitive), the offset will be much larger, reducing the amount of control
over the process. Narrowing the proportional band (increasing the gain) can reduce the
amount of offset.

The integral term accelerates the movement of the process towards set point and
avoids the offset created in proportional only control. However, since the integral term
responds to accumulated errors from the past, it can cause the present value to overshoot the
set point value.. It is an automatic rebalancing of the system that operates as long as an error
exists. Integral control is almost combined with proportional control.

Lab Report Process Control - Flow Measurement and Control System Page 7
 Proportional-plus-integral (PI) control is generally used on processes where no
amount of offset can be tolerated. In a proportional-plus-integral controller, integral action
can be expressed in terms of minutes per repeat which is the amount of time necessary for the
integral controller to repeat the open-loop response caused by the proportional mode for a
step change in error. Smaller integral time value will yield faster integral action.

Lab Report Process Control - Flow Measurement and Control System Page 8
 5.0 MATERIAL AND APPARATUS

2 7

1
5
6

3
4

Figure 3: Instruments Construction for Flow Process Control (Model : SE270-1)

No Instrument No Instrument
1 Flow Transmitter 5 Hand Valve
2 Proportional Control Valve 6 Pressure Gauge
3 Process Pump 7 Flow Controller
4 Process Pump

Table 1 : Instruments Description for Flow Process Control Module (Model: SE270-1)

1. Specifications

a) Water Pump Tank

 Capacity : 10L
 Material : SS304
 Complete with level switch for protection cut off

Lab Report Process Control - Flow Measurement and Control System Page 9
 b) Centrifugal Pump
 Max flow : 30 LPM
 Max head : 30 M

c) Flowmeter
 Range : 0 - 2.5 LPM

d) Microprocessor Controller
 Type : PID
 Input : 4...20mA
 Output : 4...20mA
 Control : P,PI,PID and self tuning

2. Experimental Capabilities

 Demonstration of Proportional Control

 Demonstration of P + Integral Control
 Demonstration of PI+ Derivative Control
 PID Loop Tuning for Optimum Control

3. Overall Dimensions

 Height : 0.7 m
 Length : 0.6 m
 Depth : 0.22 m

4. General Requirement

 Electrical : 220-240 V/ 1-phase / 50Hz

 Pneumatic Air Supply : 10LPM @ 30psi
 Water Supply : Laboratory tap water

Lab Report Process Control - Flow Measurement and Control System Page 10
 6.0 METHODOLOGY

A. General Start-Up Procedure

1. Ensured that all valves are set according to Initial Valve Positions outlined as
follows:-

Close Partially open

HV 101 HV 102

HV 103

2. Sump Tank (T-101) is filled with water to 90% full. Close HV 104.

3. The control panel power supply is switched on.

4. P-101 is turned on and HV102 and HV103 is manually regulated until flow
reading reads 100%.

Warning! Extra care should be taken to ensure water level doesn’t

overflow or empty. Failure of doing so may result circulating
pump running dry.

B. General Shut-Down Procedure

1. P-101 is switched off.

2. HV 101 is opened to drain all the water.

3. The control panel power supply is switched off.

Lab Report Process Control - Flow Measurement and Control System Page 11
EXPERIMENTAL PROCEDURE

 Close Loop Proportional Flow Control

Objective: To demonstrate the characteristics of Proportional control on a Flow

Control Loop

Procedure:

1. PB value of 110%, I value of 0 seconds, and D value of 0 seconds in FIC-

101 control loop is entered.

2. Adjusted the set point to 50% while the control loop is in "Manual" mode.

3. The MV is gradually tune, so that the level measurement, PV matches the

set point at 50%.

4. Put the FIC-101 control loop into "Auto" mode.

5. Observed the response of the controlled and manipulated variables by

increasing the set point to 75%.

6. Put the FIC-101 into “Manual Mode”, and manually adjusted the set point
to 50%.

7. The MV gradually adjusted manually so that the level measurement

matches the set point of 50%.

8. Repeated step 2 - 7 with the I and D values maintained, using the following
PB value:

PB

30

Note: Compare all the results, and comment on the differences.

Lab Report Process Control - Flow Measurement and Control System Page 12
  Close Loop Proportional plus Integral Flow Control

Objective: To demonstrate the characteristics of Proportional and Integral control on

a Flow Control Loop

Procedure:

1. PB value of 70%, I value of 1 seconds, and D value of 0 seconds in FIC-101

control loop is entered.

2. Adjusted the set point to 50% while the control loop is in "Manual" mode

3. The MV is gradually tune, so that the level measurement, PV matches the set
point at 50%.

4. Put the FIC-101 control loop into "Auto" mode.

5. Observed the response of the controlled and manipulated variables by

increasing the set point to 75%.

6. Put the FIC-101 into “Manual Mode”, and manually adjust the set point to
50%.

7. The MV gradually adjusted manually so that the level measurement matches

the set point of 50%.

8. Repeated step 2 - 7 with the I and D values maintained, using the following I
value:

40

Note: Compare all the results, and comment on the differences.

Lab Report Process Control - Flow Measurement and Control System Page 13
 7.0 DATA AND RESULTS

1. Close Loop Proportional Flow Control Experiment

Proportional Integral Mode Derivative Mode Set Point (%)

Mode (%) (seconds) (seconds)
110 0 0 75

Proportional Integral Mode Derivative Mode Set Point (%)

Mode (%) (seconds) (seconds)
30 0 0 75

Lab Report Process Control - Flow Measurement and Control System Page 14
 Proportional Integral Mode Derivative Mode Set Point (%)
Mode (%) (seconds) (seconds)
5 0 0 75

Lab Report Process Control - Flow Measurement and Control System Page 15
 2. Close Loop Proportional plus Integral Flow Control Experiment

Proportional Integral Mode Derivative Mode Set Point (%)

Mode (%) (seconds) (seconds)
70 1 0 50

Proportional Integral Mode Derivative Mode Set Point (%)

Mode (%) (seconds) (seconds)
70 5 0 50

Lab Report Process Control - Flow Measurement and Control System Page 16
 Proportional Integral Mode Derivative Mode Set Point (%)
Mode (%) (seconds) (seconds)
70 40 0 50

Lab Report Process Control - Flow Measurement and Control System Page 17
 8.0 DISCUSSION

SP e MV CV
Flow Cotrol
Controller Valve Process

PV

Flow
Transmitter

Figure 4 – The Blocks Diagram Of Flow Control System

SP Set Point MV Manipulated Variable

e Error PV Process Variable
CV Controlled Variable D Disturbance

Since the experiment is done directly on the computer located beside the equipment
which automatic controller is used to control the system, therefore the flow control system is
the closed loop control system. Based on the blocks diagram, it is determined that all of the
block is connected, thus the process is controlled automatically.

From the experiment, we use an automatic controller that only use Proportional and
Integral mode for flow of water. This is because Proportional and Integral mode of control is
used for fast process response and noisy processes like flow, pressure and level control. In an
closed loop system, the quantity of the output being measured is called the “feedback signal”,
and automatically achieve and maintain the desired output condition by comparing it with the
actual condition.

From first experiment, we begin by set the Proportional value and the set point to 110%
and 75% respectively. At the beginning, we manually adjusted the MV value so that PV value

Lab Report Process Control - Flow Measurement and Control System Page 18
approaches set point before change the system in automatic mode. This step is repeated with
different Proportional value. From the graph, the set point is maintained at 75% while the
Proportional value is different causing the graph behavior to change. For the Proportional value
at 110%, the rise time is shorter and there is no oscillation. For the Proportional value at 30% and
at 5%, the rise time increase and there is more oscillation because the factor of more disturbance
that disturbs the system.

The increasing of oscillation also mean that there is overshoot and undershoot occur in
the graph. When the number of oscillation increase the time taken for the system to achieve the
set point is increase because it need more time to stabilize. In this graph, the of overshoot is
shorter but the undershoot is higher. The time interval between the two successive peak is also
increase as decreasing the proportional value. The rise time indicate the time taken for the
process to achieve the set point. From the graph, we can observed that the rise time decrease as
the increasing of Proportional value. This is because happen due to the proportional behavior.

For the second experiment, we start by set the Proportional value, Integral value and the
set point to 70%, 1 seconds and 75% respectively. At the beginning, we manually adjusted the
MV value so that PV value approaches set point before change the system in automatic mode.
This step is repeated with different Integral value. From the graph, the set point and Proportional
value is maintained at 75% and 70% while the Integral value is different causing the graph
behavior to change. For the Integral value at 1 seconds, the rise time shorter but there is an
oscillation. For the Integral value at 5 seconds and at 40 seconds, the rise time decrease and there
is no oscillation.

The decreasing of oscillation also mean that the decreasing of overshoot which mean
that the integral is eliminate the offset from the graph. The number of overshoot is decrease as
the Integral value increase. When the number of oscillation decrease the time taken for the
system to achieve the set point is shorter because it need less time to stabilize. In this graph, the
higher the Integral value cause the time taken to stabilize and achieving the set point is shorter.
The rise time indicate the time taken for the process to achieve the set point. From the graph,
we can observed that the rise time decrease as the increasing of Integral value. The time interval
between the two successive peak is also decrease as decreasing the Integral value since the
oscillation decreases. This is because happen due to the integral and proportional behavior.

Lab Report Process Control - Flow Measurement and Control System Page 19
 9.0 CONCLUSION

These experiments had successfully achieved their objectives. Although the

experiments which was estimated to be about and a half an hour yet becomes one hour and
half, the students succeed in getting the experiments done and get to know more about the
process response when Proportional and Integral mode is applied to the flow control system.

The experiment shows that flow control system is a self-regulating process based on
the process response curve which shows that the process will stabilize after some time.
However, the time for the system to be stabilize can only be seen at flow measurement using
proportional and integral mode graph only due to less oscillation. For the flow measurement
using proportional mode graph, the time taken for the system to stabilize is longer causing the
time cannot be determine in the graph.

The higher value of Proportional value make less oscillation while higher value of
Integral value also make less oscillation. The calculation is neglected since the students only
requires to observes the behavior of the P and I mode acted on the process response curve of the
flow control system.

Lab Report Process Control - Flow Measurement and Control System Page 20
 10.0 RECOMMENDATIONS

The students should prepare and fully understands about the purpose of the
experiment and also how to conduct the experiment flow control process beforehand. This
allows the students to be able to conduct the experiment smoothly without any problem rises
such as confusion of what the next step to be done in the experiment process. Furthermore,
throughout the experiment will enable the student to identify the equipment and its function.

During the briefing of how to handle and conduct the experiments, students should
give full attention towards the in-charged person and write down the necessary points about
the experiment procedure. This is very important since the equipment is very sensitive and
need to be handle with care. This also allows the students to get full idea of how the
experiments should have been done.

During the experiments process, students should not play around and be serious
in order to get the most accurate results. Students should conduct the experiments
without causing any accidents and disturbing other person. Any wrong step will result the
repeating the experiment from the beginning. This will cause the waste of time. This
also helps in eliminating the human error that could happen due to the students misconduct
the experiment flow control process.

Lab Report Process Control - Flow Measurement and Control System Page 21
 11.0 REFERENCES

1. https://en.wikipedia.org/wiki/PID_controller
2. UiTM, Faculty of Chemical Engineering, Lecturing Slide, PROCESS CONTROL &
INSTRUMENTATION, Chapter 1.5, Operation and Responce Control System
3. https://en.wikipedia.org/wiki/Proportional_control
4. http://controlguru.com/integral-action-and-pi-control/
5. http://apmonitor.com/pdc/index.php/Main/ProportionalIntegralControl
6. http://kurser.iha.dk/m/mtpri1/control/3_PID/c_PI_control/pi_main_intro.html
7. SE270-1 Lab Manual Flow Process Control
8. https://www.academia.edu/24688603/CHE239_-
_Lab_Report_Simulation_Automatic_Flow_Control_System_2016_

Lab Report Process Control - Flow Measurement and Control System Page 22
12.0 APPENDICES

Figure 5 – The Flow Control System

Lab Report Process Control - Flow Measurement and Control System Page 23