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SECTION OF CHEMICAL PROCESS TECHNOLOGY

MALAYSIAN INTITUTE OF CHEMICAL & BIOENGINEERING TECHNOLOGY

PROCESS CONTROL LABORATORY

LABORATORY INSTRUCTION SHEETS

COURSE CODE
EXPERIMENT NO. EXPERIMENT 2

EXPERIMENT TITLE Gas Pressure Process Control

DATE
GROUP NO.
1)
LECTURER/INSTRUCTOR/TUTOR
2)
DATE OF REPORT SUBMISSION
ATTENDANCE/PARTICIPATION/DISIPLINE: /5%

INTRODUCTION: /5%

PROCEDURE: /5%
RESULTS& CALCULATIONS /15%
ANALYSIS /15%
DISTRIBUTION OF MARKS FOR DISCUSSIONS: /20%
LABORATORY REPORT: ADDITIONAL QUESTIONS /15%
CONCLUSION /10%

SUGGESTIONS& RECOMENDATIONS /5%

REFERENCES: /5%

TOTAL: /100%

EXAMINER COMMENTS: RECEIVED DATE AND STAMP:

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STUDENT CODE OF ETHICS

SECTION OF CHEMICAL PROCESS TECHNOLOGY

MALAYSIAN INSTITUTE OF CHEMICAL & BIO

ENGINEERING TECHNOLOGY

I hereby declare that I have prepared this report with my own efforts. I also admit to

not accept or provide any assistance in preparing this report and anything

that is in it is true.

1) Group Leader: ………………………………………….. (Signature)

Name : __________________________________
Matrix No. : __________________________________

2) Group Member 1: ………………………………………. (Signature)

Name : __________________________________
Matrix No : __________________________________

3) Group Member 2:……………………………………….. (Signature)

Name :__________________________________
Matrix No. : __________________________________

4) Group Member 2:……………………………………….. (Signature)

Name :__________________________________
Matrix No. : __________________________________
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1.0 OBJECTIVES
a) To identify the important components of the air pressure control system and to mark them in the
P&I Diagram To study single loop flow control using PID controller
b) To control the pressure in single capacity and two capacity processes using PID controller.
c) To tune the PID controller using Ziegler Nichols closed-loop method.

2.0 LEARNING OUTCOMES

At the end of the study, student will be able to:
2.1 To be familiar with the basic steps of machine from start-up to shut-down with proper
handling and setting.
2.2 To identify the major component of the Gas Pressure process control training system
3.0 INTRODUCTION
Pressure vessels play an important role in chemical industries as storage vessels for gas phase
components, reaction vessels to carry out a gas phase reaction, etc. Precise control of pressure in the
pressure vessels is necessary in order to:
(i) Maintain a constant concentration of components in the vessel,
(ii) Maintain the number of moles in the vessel, and
(iii) Protect the vessel from being damaged due to very high pressures.

4.0 INSTRUMENTS /APPARATUS / CHEMICAL / REAGENTS

The control system consists of a microprocessor based PID controller with an inbuilt ON/OFF controller.
It is equipped with the necessary instrumentation and signal transmission system.
Identify and mark the following major components of the system in the P&I block diagram provided in
the schematic diagram is shown in Figure 1.
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Figure 1: Schematic diagram of Gas Pressure Process Control Training

System
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5.0 PROCEDURE
5.1 STARTUP PROCEDURES
Go through these steps before starting any experiment.
1) Switch the "PANEL, SCADA/DDC" selector switch at the front of the cubicle to
the "PANEL, SCADA" position.
2) Switch ON the main power supply at the front of the cubicle. All the panel
instruments will lit up.
If the recorder chart drive is running, STOP it by pressing the `RCD' pushbutton.
3) If any annunciator gets activated, press the ACKNOWLEDGE button to silence the
buzzer.
4) Set the instrument air supply regulator to the pressure indicated at the air regulators
at the pneumatic control valves PCV91 and PCV92. Purge if there is any condensed
water in the air regulators by opening the bottom drain valves.
5) Make sure that the by-pass valves around the control valves PCV91 and PCV92 are
shut fully and the pair of manual valves upstream/downstream of these control valves
are opened.
6) Check that the control valve positioner (PP) of PCV91 is connected (ON) (i.e., not
by-passed).
7) Make sure the compressed air is available at the pressure inlet air regulator AR91.
8) Check that the vent valve (V) and bottom drain valve (D) of vessel T91 are shut.
9) SHUT fully the manual valves MV91B and MVIII.
10) SHUT fully the process inlet manual valve MV91.
11) Place the panel controller PIC91 in manual (M) mode and adjust its MV = - 6.3% to
open the control valve PCV91 fully.
12) Open fully the final discharge manual valve (VP). This valve is at downstream of
pressure control valve PCV91.
13) From the process air supply, trace the two pipe lines PLI and PLII as follows:
Pipeline PLI: Single capacity process:
AR91-MV91-T91-PLI-B92- FI92 -P CV9 1 –VP
Two-capacity process
AR9 1 -MV9 1 -T91 -PLI-MVI-T92-MV92-FI92 -PCV 9 1 –VP
Pipeline II (PLII):
AR9 1 -MV9 1 -T91-PLII-MVII-PCV92-MV92A/MV92B-V
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14) Open fully the pipelines PLI (Single capacity process) and PLII at their various
manual valves.
15) Make sure the manual by-pass valve B92 around vessel T92 is opened and the
manual valves at the inlet MVI and outlet MV92 of T92 are shut.
16) The pipeline PLII has two discharge manual valves, MV92A (globe valve) and
MV92B (gate valve). SHUT both the valves MV92A and MV92B.
17) Check and adjust the pressure at AR91 is approximately at the pressure indicated at
AR91. Check MV91 is fully shut.
18) Slowly open MV91 and regulate it until the flow rate at the variable area flow meter
FI92 reads 35 Nm3/Hr
19) Check the pressure and flow rate setting:
a. Shut fully PCV91 from PIC91 in manual (M) mode with MV=106.3%. Read
the pressure at vessel T91 at the PV reading of PIC91. If the pressure is about
22 – 27 psig, the pressure is correctly set.
b. Open fully PCV91 from PIC91 in manual (M) mode with MV=-6.3%. Read
the pressure at vessel T91 at the PV reading of PIC91. If the pressure is not
more than 10 psig and the flow rate at FI92 also reads 35 Nm 3/Hr, the air
flow rate is correctly set.
c. Now the process air supply pressure and flow rate are set. DO NOT
readjust AR91 and MV91 hereafter.

5.2 ON/OFF PRESSURE CONTROL

It uses the ON/OFF pressure controller PIC92 to control at the High pressure limit of
PIC91.
1) Make sure that you have gone through the START-UP procedures very
carefully.
2) Start the chart drive of the recorder by pressing the `RCD' pushbutton at the
front of the recorder.
3) Shut fully PCV91 from PIC91 in manual (M) mode with MV=106.3%. Read
PV at PIC91, the pressure at vessel T91. The pressure should be in the range of
22-27 psig.
4) To open PLII: Open only the manual discharge globe valve MV92A at the
common vent of PLII. Keep the gate valve MV92B at the common outlet of
PLII closed.
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5) Note the response of PT91 at the recorder PR91.
PCV92 opens when PT91 exceeds 21 psig and closes when PT91 drops below a
fixed Dead Band (0.5 psig), i.e., 20.5 psig.
6) Try to repeat the ON/OFF action by opening and closing PC 91. This is done
from PIC91 in manual (M) mode by reducing the MV such that pressure PV
drops below 20 psig. Then shut PCV91 fully again with MV = 106.3%.
7) Stop the record chart drive and retrieve the relevant portions of the chart
5.3 PID CONTROL OF PRESSURE IN SINGLE CAPACITY PROCESS
1) Make sure that you have gone through the START-UP procedures very
carefully.
2) Start the chart drive of the recorder by pressing the `RCD' pushbutton at the
front of the recorder.
3) Make sure that pipelines PLI and PLII are opened throughout.
4) Open only the manual discharge globe valve MV92A at the common vent of
PLII.
5) Close the gate valve MV92B at the common outlet of PLI
6) For single capacity operation, only vessel T91 is used. Vessel T92 is by-
passed
a. Open by-pass valve B92 around T92
b. Shut the manual valves at the inlet, MVI, and at the outlet, MV92, of
T92.
c. Make sure the air flow path T91-PLI-FI92-PCV91-VP is opened through
B92.
7) Set the set point of PIC91 as SV = 15 psig.
8) Set the PID controller with the first (I) trial values: PB1 = 70%, T11 =
40 secs, TD1 = 0 sec.
9) Transfer the controller to Auto (A) mode and wait for the response to become
almost stable.
10) Switch PIC91 to Manual (M) mode, decrease MV by about 5 to 10%, switch
back to Auto (A) mode and observe the response for a few minutes.
DO NOT FORGET TO MARK THE PID VALUES AND THE SETPOINT ON
THE CHART PAPER WHENEVER THE VALUES ARE CHANGED. ALSO
MARK ON THE CHART THE BEGINNING OF EACH PART OF THE
EXPERIMENT
11) If the response is slow to return to the set point SV = 15 psig, reduce
TI1 to 20 secs. and repeat the step (10) again.
12) Now set the PID controller with the second (II) trial values:
PB1 = 45%, TI1 = 30 secs, TD1 = 0 sec.
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13)
Switch PIC91 to Manual (M) mode, decrease MV by about 5 to 10%, switch
back to Auto (A) mode and observe the response for a few minutes.
If the response is not oscillatory, proceed to step (15). If the response is
oscillatory, go to the next step, step (14).
14) Increase PB1 by 5% and repeat the step (13).
15) Try the third (III) trial values for the PID controller: --
PB 1 = 20%, TI1 = 10 secs, TD1 = 2 sec.
16) Introduce the disturbance in MV as in step (13) and observe the response.
17) STOP the chart drive and retrieve the relevant portions of the chart
paper. Attach the chart paper along with the result
6.0 SHUTDOWN PROCEDURE
1. Switch the controller PIC91 to Manual(M) mode, and set the MV=100%
2. Stop Recording by push the recorder “RCD” button
3. Switch Off the main power supply
7.0 RESULTS & CALCULATIONS

The recorder PR91 records the results of the experiments. Suitable portions of the
recorder chart paper should be submitted as RESULTS of the experiment.

The report should contain

1. The P&I diagram with all major components marked clearly.
2. A detailed report of the start-up procedure.
3. The response curves of the ON/OFF controller with all particulars such as Setpoint
and Dead Band.
4. Response curves for single capacity and two-capacity processes with different PID
controller values. Include all the details such as setpoint, PID controller values.
5. Discussion on the response characteristics.

8.0 ANALYSIS OF THE RESULTS

Analysed critically each results obtain in section 7.0 by referring to the theory/introduction parts.
Find reasons (suggested reasons) on each occurrence shown in the results.
9.0 DISCUSSIONS

Based on your observation, comment/discuss on the following:

1. The choice of Air-to-Open or Air-to-Close control valve is determined by safety
consideration.
2. ON/OFF control is a two position control. Use of dead band is recommended in ON/OFF
controllers. Why?
3. Difference between single capacity and two-capacity processes.
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10.0 CONCLUSION
Conclusion is merely a summary of the important findings already reported in the discussion section.
It also relates to the objectives stated earlier.

11.0 SUGGESTIONS & RECOMMENDATIONS

Your ideas of suggestion & recommendation to improve the learning process for this experiment or
anything related to the experimental procedure etc.

12.0 REFERENCES
Minimum of at least 5 references (with 3 of them are paper/book/chapter base)
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