Name of student : Hameed Kadhim Mohsin

Number of student : (19)

Name of experiment : (( Pressure Control ))

Number of experiment : ( 2 )

Date of experiment : 26 \ 10 \ 2015

Group : ( A 2 )

The objective of the experiment

 To control the air pressure in the Process vessel using an on/off controller to
automatically start and stop the water feed pump as required to maintain the
required process in the process vessel (inflow control)
 Determine the variations in pressure due to he dead band inherent in an
on/off controller
 To change the air pressure inside the process vessel by changing the set
point on the set point on the on/off controller and to determine the effect of
disturbances to the process
 To investigate the effect of different ranges of inflow and outflow to / from
the process vessel
Introduction
Temperature, pressure, flow, and level are the four most common process
variables. Similar to temperature, pressure is another key process variable because
pressure provides a critical condition for boiling, chemical reaction, distillation,
extrusion, vacuuming, and air conditioning. Poor pressure control can cause major
safety, quality, and productivity problems. Overly high pressure inside a sealed
vessel can cause an explosion. Therefore, it is highly desirable to keep pressure in
good control and maintained within its safety limits.
Control In process industries refers to the regulation of all aspects of the process.
Precise control of level,
temperature, pressure and flow is important in many process applications. This
module introduces you to control in process industries, explains why control is
important, and identifies different ways in which
precise control is ensured.
The following five sections are included in this module:
❑ The importance of process control

❑ Control theory basics

❑ Components of control loops and ISA symbology

❑ Controller algorithms and tuning

❑ Process control systems

As you proceed through the module, answer the questions in the activities column
on the right side of each
page. Also, note the application boxes (double-bordered boxes) located throughout
the module. Application
boxes provide key information about how you may use your baseline knowledge in
the field. When you seethe workbook exercise graphic at the bottom of a page, go
to the workbook to complete the designated exercise
before moving on in the module. Workbook exercises help you measure your
progress toward meeting each section’s learning objectives
Theory
An on/off controller is a simple and effective way of controlling many
processes but does have disadvantages because its output can only be on or off. In
the case of the pressure process in this exercise the water pump is started and
stopped .
An on/off controller incorporates a dead band to avoid rapid switching of the
controlled variable when at the set pointi.e., in this case the pressure must rise
above the set point by a fixed amount before the pump switches off and the
pressure must fall below the set point by a fixed amount before the pump starts
again.
Note: On PCT53 an On/off controller with fixed dead band is created by setting the
Proportional Band to 0% in the PID controller. In a commercial On/off controller
the dead band can be varied to suit the process. This allows the choice of less
frequent switching but larger variations in the process variable closer control of the
process variable but more frequent switching with attendant wear etc.
Proportional term (P)
The Proportional Band, P, setting on a process controller makes a change to the
output (pump speed on PCT53) that is proportional to the current error value (the
difference between the measured pressure and the set point on the controller). The
proportional response can be adjusted by multiplying the error by a constant Kp,
called the Proportional Gain. This is related to the Proportional Band setting on the
controller as follows:Proportional Gain (Kp) - 1 00% / Proportional Band % i.e.
100% P term means unity gain (change in controller output = error at input) and
50% P term means a gain of 2 (change in controller output = 2x error at input) A
low setting of the P term (large gain) results in a large change in the output for 3
given change in the error. If the P term is too low, the system can become unstable.
In contrast, a large setting of the P term (low gain) results in a small output
response to a large input error, and a less responsive or less sensitive controller. If
the P term is too high, the control action may be too small when responding to
system disturbances resulting in slow response and offsets of the result process
variable from the set point A Proportional-only controller will not always settle at
the set point, but may retain a steady-state offset. Offset can be reduced in
Proportional-only control by reducing the P term setting. However. if the P-term is
set too small then hunting or oscillating will occur. The offset can be minimized by
adding a bias to the set point (setting the set point above or below the required
value to compensate for the offset) but this technique is only appropriate if the
system characteristics are known and fixed. A better solution is to remove the
offset by adding Integral action to the controller (Pl) as described below.
To control the air pressure in the process vessel using an on/off controller to
automatically start and stop the water feed pump as required to maintain the
required pressure in the process vessel (inflow control).
To determine the variations pressure due to the dead band inherent in an on/off
controller. To change the air pressure inside the process vessel by changing the set
point on the on/off controller and to determine the effect of disturbances to the
process.
To investigate the effect of different ranges of inflow and outflow to / from the
process vessel Method Using a PC to operate the process, the pump (water flow
into the process vessel) will be started and stopped by the controller in an attempt
to maintain steady air pressure in the process vessel. With outflow valve CV2 fully
open water will drain from the process vessel continuously, the rate determined by
the size of the orifice fitted. Disturbances can be applied to the process by opening
and closing the solenoid valve. This changes the outflow from the process vessel
resulting in a change in the water level inside the vessel.

integral term (I) :

The contribution from the integral term is proportional to magnitude and duration
of the error. The Integral term in a PID controller is the sum of the instantaneous
error over time and gives the accumulated offset that should have been corrected
previously. The resulting controller output is thesum of the contribution from the
Integra! term and the contribution from the P term. When the I term is correctly
adjusted any residual offset in the process variable due to the P term
will be gradually reduced by the Integral term until the offset is eliminate. if the
time setting of the I term is too long then correction to any offset will be van slow.
However, since the integral term responds to accumulated errors from the past, it
can cause the present value to overshoot the setpoint value or to make the process
completely unstable if the time setting of the I term is too short. If this occurs the I
term makes adjustments to the controller output faster than the process can
respond, l.e. the I term winds up the controller output so that the process
overshoots considerably, hence the term Integral Wind-up or Integral saturation
Careful selection of the in the system
Experimental procedure
At the apparatus has been set up according to the Installation section, the sump
filled with clean water and the power supply connected to the socket marked 24V.
Before starting this exercise fully close vent valve CV4, open outlet valve CV2 and
fit a 15 mm diameter orifice below it. Fit a 2.0 mm orifice below the solenoid
valve. Connect the USB socket at the rear of the electrical enclosure a suitable PC
on which the PCT53 software has been installed using the USB cable supplied.
Check that the PC is switched on then run the PCT53 software and select
Experiment Exile: Inflow Control (PC Control). Ensure that the Virtual COM port
has been enabled using the red telephone icon in the top toolbar.
Before starting the exercise it is advisable to adjust inlet valve CV1 to give
appropriate flow into the process vessel as follows;
Fully open outlet valve CV2 and fully open inletwaive CV1.
Choose the '"^ icon (or View \ Diagram) to display a mimic diagram of the
process, Click Power On (in Controls). Open vent valve CV4 to relive any pressure
in the process vessel. If the pressure indicated on the
mimic diagram is not 0 bar click the zero button to zero the reading. Close vent
valve CV4. Set the pump speed to 70%. by typing in the value or by clicking the
up arrow, so that water is
pumped into the process vessel, As the water level rises adjust inlet value CV1
until the air pressure remains steady at approximately 02 bar inside the process
vessel (flow into the vessel CV1 matches flow out of the vesselCV2), Reset the
pump speed to 0 % on the mimic diagram, open vent value CV4 and allow the
vessel to drain via outlet valve CV2.
Procedure Choose the PID box on the mimic diagram: set the Proportional Band.^
Integral Timeand Dentation time to 0 then set the Set Point to 0.2 bar (default at
start up).
Ensure that the apparatus has been set up according to the Installation section, the
sump filled with clean water and the power supply connected to the socket marked
24V IN at the rear of the electrical enclosure.. Before starting this exercise fully
close vent value CV4. open outlet valve CV2 and fit a 1 5mm diameter orifice
below it. Fit a 2,0mm orifice below the solenoid value Connect the USB socket at
the rear of the electrical enclosure to a suitable PC on which the PCT53 software
has been installed using the USB cable supplied. Check that the PC is switched on
then run the PCT53 software and select Experiment Ex 1; Inflow Control (PC
Control). Ensure that the Virtual COM port has been enabled using the red
telephone icon in the top toolbar. Before starting the exercise it is advisable to
adjust inlet valve CV1 to give appropriate flow into the process vessel as follows:
Fully open outlet valve CV2 and fully open inlet valve CV1. Choose the L"1 icon
(or View \ Diagram) to display a mimic diagram of the process. Click Power On
(in Controls). Open vent valve CV4 to relive any pressure in the process vessel. If
the pressure indicated on the mimic diagram is; not 0 bar click the zero button to
zero the reading. Close vent valve CV4. Set the pump speed to 70%, by typing in
the value or byclicking the up arrow, so that water is pumped into the' process
vessel. As the water level rises adjust inlet valve CV1 until the air pressure remains
steady at approximately 0.2 bar inside the process vessel (flow into the vessel via
CV1 matches flow out of the vessel via CV2) Reset the pump speed to 0% on the
mimic diagram, open vent valve CV4 and allow the vessel to drain via outlet valve
CV2. Procedure - P only controller Choose the PID box on the mimic diagram, set
the Proportional Band, P, to 200%, the Integral Time to 0 and the Derivation time
D to 0 then set the Set Point to 0.2 bar (default at start up) Click Apply to enter the
changes to the settings. Choose the Automatic Mode of Operation. Select the ' icon
to begin data logging.The pump will start, the pressure will gradually rise andwater
will drain from the vessel via outlet valve CV2. The. pressure will continue to rise
until it reaches a steady pressure but this will not correspond with the setpoint of
0.2 bar on the controller because of the offset inherent in a P only controller. Open
the solenoid valve by clicking the button on the mimic diagram (1 indicates that
the valve is open) to disturb the process. Observe that the pressure falls slightly,
the pump speeds up slightly due to the increased error but a large offset remains.
When the pressure has settled close the solenoid valve and all6w the pressure to
settle. Adjust the set point to 0,3 bar then click apply and observe the response to a
requested increase in pressure. When the pressure has settled, return the set point to
0.2 bar and observe the response Adjust the P term to 100% in the PID controller
then click Apply Observe that the pump speeds up and the offset reduces slightly.
Open then close the solenoid valve as before to disturb the process and obscene/e
the response, the stability of the pressure and any reduction in offset. Adjust the P
term TO 5Cfyp and repeat the above steps. Adjust the P term to 2Q%'and repeat
the above steps. Adjust the P term to 10% and repeat the above steps Adjust the P
term to 5% and repeat theabove steps Adjust the P term to 2% and repeat the above
steps Choose the @ icon j6 finish data logging Results - P; only controller Choose
tie icon View \ Graph) to display a graph of the responses obtained. Choose
Format \,Graph Data and Plot Pressure Pl and Set point on 1 axis, and Controller
Output on the second’ axis. Obscene the changes in air pressure and the stability of
the responses for each change in P setting with a disturbance or change in set point.
Choose a setting for P that gives stable control with a reasonably small offset that
can be used in the next part of the exercise introducing Inlearal action. Procedure -
P+,1 Controller Create a new results sheet far this run by selecting the [mi icon in
the toolbar of the software. Choose the PID' on the mimic diagram, set the
Proportional Band, P, to the value selected
above, the Integral Time, I, to 0 seconds and the Derivation time D to 0 then set the
Set Point to 0.2 bar Click Apply. : ; Select the "-' icon to begin data logging.
Choose the Automatic mode of operation and allow the air pressure to stabilise.
Adjust the I term to 100 seconds in the P!D controller then click Apply. Observe
that the pumpspeed varies ‘very slowly to reduce the offset. When the pressure has
settled at the set point open the solenoid valve to disturb the process. Observe that
the pressure falls slightly, the pump speed varies and the pressure gradually returns
to the set point When the pressure has settled close the solenoid valve and allow
the pressure to settle again. Adjust the set point to 0.3 bar then click Apply and
observe the response to a requested increase in pressure, write the pressure has
settled return the set point to 0.2 bar and obscene the response Adjust the 1 fern’ its
5Q seconds in the PID controller then click Apply, Observe that the pressure
returns to the set point faster than before. When the pressure is settled at the set
point open then the solenoid valve as before to disturb the process. Adjust the set
point to 0 3 bar then click Apply and observe the response to a requested increase
in pressure. When the pressure has settled return the set point to 0.2 bar and
obscene the response Continue. Reducing (he. integral time setting and repeating
the disturbance and set point changes until the air pressure becomes unstable.
Results - P+lcontrollerChoose the 1&J Icon (or View \ Graph) to display a graph of
the responses obtained Choose Format \ Graph Data and Plot Pressure P1 and Set
point on 1 axis, and Controller output on the second
 02:42 02:06
02:33 02:00
01:54
Calculations

02:24
01:48
02:15
01:42
02:06 01:36
01:57 01:30
01:48 01:24
01:39 01:18
01:12
01:30
01:06

Time
Time
01:21 01:00
01:12 00:54
01:03 00:48
00:54 00:42
00:36
00:45
00:30
00:36 00:24
00:27 00:18
00:18 00:12
00:09 00:06
00:00
00:00
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35

-0.05

0.00
0.05
0.10
0.15
0.25

0.20

-0.05
ON\Off _set point 0.2 _solenoid valve open

Pressure

ON\Off _set point 0.2 _solenoid valve Closed

Pressure
 01:54 01:48 02:13
01:48 01:42 02:06
01:42 01:36 01:59
01:36 01:30 01:52
01:30 01:24 01:45
01:24 01:18 01:38
01:18 01:12 01:31
01:12 01:24
01:06
01:06 01:17
01:00
01:00 01:10
00:54

Time
Time
Time

00:54 01:03
00:48
00:48 00:56
00:42 00:42
00:49
00:36 00:36 00:42
00:30 00:30 00:35
00:24 00:24 00:28
00:18 00:18 00:21
00:12 00:12 00:14
00:06 00:06 00:07
00:00 00:00 00:00

ON\Off _set point 0.7 _solenoid valve Closed

ON\Off _set point 0.3 _solenoid valve Closed

0.05
0.10
0.15
0.20
0.25

0.00
-0.05
0.38
0.40
0.42
0.44
0.46
0.48
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40

Pressure Pressure Pressure

Proportional Band 5_integral 50_set point 0.2 _solenoid valve Closed

 02:00 01:48
01:54 01:42 01:42
01:48 01:36 01:36
01:42 01:30 01:30
01:36 01:24 01:24
01:30 01:18 01:18
01:24 01:12 01:12
01:18
01:06 01:06
01:12
01:00 01:00
01:06
01:00 00:54 00:54

Time
Time
Time

00:54 00:48 00:48

00:48 00:42 00:42
00:42 00:36 00:36
00:36 00:30 00:30
00:30
00:24 00:24
00:24
00:18 00:18
00:18
00:12 00:12 00:12
00:06 00:06 00:06
00:00 00:00 00:00

0.00
0.05
0.10
0.15
0.00
0.05
0.10
0.20
0.11
0.12
0.12
0.13
0.13
0.14
0.14
0.15

0.15
Proportional Band 5_set point 0.2 _solenoid valve Open

Proportional Band 5_set point 0.2 _solenoid valve Closed

Proportional Band 10_set point 0.2 _solenoid valve Closed

Pressure Pressure Pressure
 0.04
0.03
0.03

Pressure
0.02
0.02
0.01
0.01
0.00
01:25

00:50
01:20
01:15
01:10
01:05
01:00
00:55

00:45
00:40
00:35
00:30
00:25
00:20
00:15
00:10
00:05
00:00
Time

Proportional Band 25_set point 0.2 _solenoid valve Closed

0.00

0.00

0.00
Pressure

-0.01

-0.01

-0.01

-0.01
Time

Proportional Band 50_set point 0.2 _solenoid valve Closed

DISCUSSIONS

 An on/off controller
When the control type is ( ON\Off), the process of controlling the air pressure
depends on the state of the control valve .In the control condition ( ON\Off), the
fluid flow is turbulent and the payment of the pump in this case, as the frequency
and this leads to increase the load on the pump, as well as to increase the pressure
on the pump

In the case of the control valve is open and control type (ON\Off) and Set point
(0.2 ) .The air pressure in this process is disturbed, as is evident in (Figure 1) in
this case, the pressure boil a little and pump load on the pump will be less and be a
form of drawing in this case winding

In the case of the control valve is closed .The air pressure is in this case almost
streamlined and be a little turmoil, as is evident in (Figure 2) in the case of the
LED closed and Set point (0.2) the pressure at the pump is large, as well as
increasing the load on the pump .Increase in set point to 0.3 and the survival of the
control valve in this case is closed, the pressure in this case, the troubled and the
form of fee to be almost zigzag in case the situation is getting pregnancy hanging
on the pump and the flow of fluid in this case intermittently

0.35
0.30
0.25
0.20
Pressure

0.15
0.10
0.05
0.00
00:48
02:06
02:00
01:54
01:48
01:42
01:36
01:30
01:24
01:18
01:12
01:06
01:00
00:54

00:42
00:36
00:30
00:24
00:18
00:12
00:06
00:00

-0.05

Time

ON\Off _set point 0.2 _solenoid valve open

(Figure 1)
 0.25
0.20
0.15

Pressure
0.10
0.05
0.00
02:42
02:33
02:24
02:15
02:06
01:57
01:48
01:39
01:30
01:21
01:12
01:03
00:54
00:45
00:36
00:27
00:18
00:09
00:00
-0.05

Time

ON\Off _set point 0.2 _solenoid valve Closed

(Figure 2)

 Proportional Band controller

When the control is a type of type (Proportional Band), the process of controlling
the air pressure in this process depends on the speed of the pump and pay depends
on the nature of the control valve if the valve is open or closed if the LED

If (Proportional Band) is different from the case of (ON\Off) in the case of

(Proportional Band) a payment in the case of a continuous pump reverse
(Proportional Band) Payment will be intermittent and continuous payment
generates little push on the pump does not lead to increased pressure

In the case of the Proportional Band )5 ( and set point (0.2) of control in this case,
the turbulent air pressure almost less load on the pump Unlike previous operations
and have the form of a continuous flow almost as shown in (Figure 3)

If the control valve is closed and Proportional Band )5 ( and set point (0.2) the
flow pressure in this case is that almost smooth and linear and the pressure off on
the pump in this case as well as the high and increasing the load on the pump

In the case of increase Proportional Band (25 ( , the air pressure in this process is
almost a troubled because of the increasing proportion of (Proportional Band) to
(25), because in this process will increase pregnancy
When increasing the proportion of (Proportional Band) to (50), the pressure in the
form of this process will be a turbulent and winding compared to the previous
cases because of the increased proportion (Proportional Band) to (50)

0.15
0.14
0.14

Pressure
0.13
0.13
0.12
0.12
0.11

00:30
01:48
01:42
01:36
01:30
01:24
01:18
01:12
01:06
01:00
00:54
00:48
00:42
00:36

00:24
00:18
00:12
00:06
00:00
Time

Proportional Band 5_set point 0.2 _solenoid valve Open

(Figure 3)

0.00

0.00

0.00
Pressure

-0.01

-0.01

-0.01

-0.01
Time

Proportional Band 50_set point 0.2 _solenoid valve Closed

(Figure 4 )