Laboratory Report Submission Form

CPB 30004 - PROCESS DYNAMICS & CONTROL

CPD 20302 - PROCESS CONTROL

Section: LO1-P2
To: DR NOR SHAHIRAH MOHD NASIR

Student Name: ID No.: Date of Submission: 02/03/2020

1) NI AZILAH BINTI SULAIMAN 1) 55213118201
2) NUR AMIRAH BINTI BAHARUDIN 2) 55213118191 Submitted by: MOHAMAD LUQMAN AL HAKIM
3) MOHAMAD LUQMAN AL HAKIM BIN MOHD SENARI 3) 55213118158
4) NIZAL IRFAN BIN AZLIN 4) 55213118190
5) MUHAMMAD ASYRAF BIN ZAINUDDIN 5) 55213118161

Title of Experiment: GAS FLOW PROCESS CONTROL Date of Experiment: 24/02/2020

CRITERIA V.POOR POOR GOOD V.GOOD EXCELLENT

OBJECTIVES (5%)
1 2 3 4 5
State the objectives of the experiment (preferably in point form).
INTRODUCTION & THEORY (20%)
1. Explain the background and processes in the experiment using P&ID. 4 8 12 16 20
2. Summaries of the theories and/or formulations involved in the experiment.
RESULTS & DISCUSSION (40%)
1. Data presented are appropriate with complete labels and units.
8 16 24 32 40
2. The presented data/tables/figures are well explained and justified based on theories.
3. The data/findings are discussed and infered based on the objectives of the experiment.
CONCLUSIONS (20%)
1. Summaries of the findings of the experiment and the related theories. 4 8 12 16 20
2. Recommendations of improvements in experimental apparatus/procedures/parameters.
REFERENCES (5%) 1 2 3 4 5
FORMAT/LANGUAGE/TIDINESS/PUNCTUAL SUBMISSION/INITIATIVES (10%) 2 4 6 8 10
Signature & Stamp:
TOTAL MARKS (100%)

COMMENTS:
OBJECTIVE
1. To study gas volumetric flow rate measurement using orifice plate.
2. To study gas mass flow rate measurement using orifice plate and perfect gas law to
compute the gas density from the pressure and temperature measurements.
3. To study gas mass flow rate (Fm) control using PID controller.
INTRODUCTION
Flow measurement is the quantification of movement of a fluid or a measure of bulk
fluid movement. In the instrumentation field, the oldest recorded work assumed is the flow
measurement. There are two ways in flow measurement which are basis of the weight and
volumetric basis. Unit for the flow measurement is mass per unit time or weight per unit time.
For liquid flow usually measured in the basis of weight or volumetrically. Meanwhile for
gaseous flow specially measured volumetrically. Example of pressure based flow meters are
multi hole pressure probe, differential pressure transmitters, pitot tube, dall tube, orifice meter
and venturi meter (Gill, 1979).
Flow meters are usually accurate and not affected by any other circumstances of
conditions. But in a practical case, the environmental factors and any other various factors must
be considered too. The factors must due to the improper installation of the startup. The others
factors of industrial flow measurements are often prone also lead to the error for calibrate the
flow meters. Most of the time for calibrating the flow meters, in situ methods are usually
employed (Peter, Chinedu, & Harcourt, 2016).
With disturbances of pressure and temperature, usually vapours and gases easily
changing their volume. This is mean by as the kinetic energy of the individual molecules is
reduced, a gas will yield to an increasing pressure by decreasing in volume as the gas molecules
are forced closer together and it will yield to a decreasing temperature by decreasing in volume.
By differential pressure across orifice or by a variable area flow rate, the vapour or gas can be
measured. The devices that used in this experiment is orifice plate which to measure the flow
rate. By using calculation of orifice plate, the mass flow rate and volumetric can be determined.
The relationship between the velocity of the fluid and the pressure has something to do with
Bernoulli’s principle. The principle is same as the venturi nozzle. When pressure decreases,
the velocity will increase. The reduced area of the orifice produces different pressure across
the orifice as increasing of the fluid flow velocities with the orifice plate mounted in the flow
stream (Peter et al., 2016).

The flow measurement by the differential pressure measurement was named Perfect
Gas Law. The Perfect Gas Law also called as ideal gas. We used PID controller to control the
gas mass flowrate. PID stands for ‘Proportional-Integral-Derivative’. The controllers produce
a control signal. PID controller maintains the output such that there is zero error between
process variable and set point/ desired output by closed loop operations. The design of Ziegler-
Nichols tuning rules specially for a ¼ amplitude decay response. Therefore, after a disturbance
or set point change, it results in a loop that overshoots its set point. The loop is only marginally
robust which can only withstand on small process condition change. The method was called
damped oscillation and continuous cycling method. The oscillation behavior is different but
the procedures for both methods are same. Until the system oscillates at constant amplitude,
the proportional gain will increase (Lu, J.,2001).

Figure 1: The Ziegler-Nichols Closed-Loop Tuning Method

RESULT
Instrument Readings Controller I II III
MV= -6.3% MV=50% MV=70%
At the PANEL FIC91, I/O Data 86.5 49.7 31.2
FT91 X1 - % of 0-100%
H2O

TIT911, T X2 - % of 0 – 120oC 27.0 27.4 27.4

PT911, P X3 - % of 0 – 60 psia 74.7 93.4 102.6

Fm FIC91 Main Face 52.1 37.2 24.7
Plate
PV, kg/Hr

Fv FIC90, PT Register 22.1 12.6 7.9

PO1, m3/Hr

Channel 1 (Red) Recorder FPTR91 25.0 21.8 28.2

Fm, kg/Hr

Channel 2 (Green) Fv, m3/Hr 22.1 12.7 8.0

By Calculation Fvb, Nm3/Hr 58.5 37.6 24.7

Fm, kg/Hr 75.6 48.6 32.0

At the Plant 50.0 29.0 78.0

FI911, Nm3/Hr

PG900, psig 43.5 44.0 49.8

 Ziegler-Nichols method of controlling tuning was used and applied in this experiment.
The values of parameter given for this experiment are different in each process and no specific
value for every plant. Theoretically, a good combination of the P,I,D values can produce less
oscillation and better settling time. In this method, there were several considerations to the key
of the element of control, load disturbance, sensor noise, process uncertainty and reference
signals. But if unfamiliar with the system, it is need to thee experimentation and selects the
controller settings, obtained from Ziegler-Nichols method as applied in this experiment. So,
Ziegler-Nichols method provides initial setting that will ensure good tuning of plant. The
Ziegler-Nichols tuning rules were created to give closed loop system with load of disturbance.

Tn secs = measured period (mm) x 3600

Chart speed (500 mm/Hr)
= 35mm x 3600 s
500 mm
= 252 s
Approximate PI setting by Ziegler Nichols formula:
PB = 2 x PB* = 2 x 20 = 40
TI = Tn / 1.2
TI = 252 / 1.2 = 210s
DISCUSSION

The equipment used was the gas flow process control training system, Model AF 922.
This gas flow process control experiment was done to identify the important components of
the air pressure control system, to study gas volumetric flow rate measurement by using orifice
plate, to determine the gas mass flow rate measurement using orifice plate and perfect gas law
to complete the gas density from the pressure and temperature measurements, to study gas mass
flow rate (Fm) control using PID controller by using Ziegler Nichols closed loop method. In
this experiment, in order to detect the differential pressure throughout the flow orifice plate
was used and the differential pressure measurement was calculated. The volumetric flow rate
and mass flow rate was recorded in the chart by the gas flow process control training system,
where the RED colour in the chart showed the mass flow rate (kg/hr) and the GREEN colour
showed the volumetric flow rate (m3/hr) throughout the experiment.

The experiment was conducted by control the air flow system by using the different set
of PID parameters. In manual mode (M), the control valve FCV91 was fully open with MV
value was -6.3% and the SV value was set at its set point which is 25 kg/hr. This experiment
was run in three different trial values. For the first set (I), the PB was set at 200%, TI at 6s and
TD at 0s. The experiment then was set in auto mode (A) and waited until the recorder response
of the air flow (red pen) was fairly steady. Then, a pulse disturbance was introduced by quickly
opening and shutting fully the by-pass valve at control valve FCV91. The same steps were used
for set II and set III with the same values of TI and TD but different in values of PB which
were 150% and 100 % respectively.

Based on the result in table 1, the value of mass flow rate and volumetric flow rate were
taken from the panel and also were calculated by using the formula at different values of MV.
Form the results obtained from the experiment, the reading of the mass flow rate from the panel
showed that, the increased the values of MV, the increased the mass flow rate (Fm). From the
calculation result, the values of mass flow rate also decreased when then MV value increased.
On the other hand, the result obtained from the experiment for volumetric flow rate (Fvb) on
the panel decreased when the values of MV increased. The values for volumetric rate also
decreased in calculation when the values MV increased.
 The proportional control mode is the main driving force in a controller (Didactic, 2013).
It changes the controller output in proportion to the error. When the error is bigger, the action
will become bigger since more control action needs to be correct the larger errors (Prada, 1973).
If the proportional band, PB is set too high, the control loop will begin oscillating and become
unstable. However, if the PB is set too low, it will not respond adequately to disturbance
changes. Based on the Figure 1 (Result for trial I, II and II at SV = 25 kg/hr), the set for trial I
showed the longest peak of disturbance while the set for trial III showed the shortest peak for
the disturbance. The proportional band, PB for trial I is higher compared to trial I and II. Based
on the result showed in chart, its follow the method where the trial I had longest peak with the
highest PB value which is 200%.

Figure1: Result for trial I, II and III at SV = 25 kg/hr

Lastly, the last testing of this experiment is PID controller tuning where Ziegler Nichols
method by setting the controller as below:

PB TI TD
100% 9999s 0s

The set point pulse disturbance was given to the process by increase the SV value from
25 kg/hr to 28 kg/hr for five second and change back to its original SV which is 25 kg/hr. Auto
mode (A) was done to ensure the turning process done by the system itself. The PB was
decrease from 100% to 50% and last to 30% in order to get the uniform oscillation. The
response form is shown in Figure 2 (The increasing of SV from 25 kg/hr to 28 kg/hr with PB
decrease from 100% to 30%). The result showed there were the oscillation on the chart. The
new value of PID controller can be calculated as there was oscillation showed in chart. Based
on the calculation, the new value of PID controller for Tn was 252 s for PB was 40 and TI was
210 s.

Figure 2: The increasing of SV from 25kg/hr to 28kg/hr with PB decrease from 100% to
30%.
Ziegler Nichols method has two methods in order to tuning the process control that was
developed in 1940s. The first method is being used in this experiment. It is a direct
measurement on the controller parameter or closed loop tuning method. The integral and
derivative gain, TD is set to zero. The proportional gain is decreased until the system start to
form the uniform oscillatory response. Based on oscillatory response, the critical value of Kc
= Kcu and the period of oscillation, Tc = Tn are formed. Figure 3 (Closed loop tuning method
response), shows the example of closed loop tuning method response:

Figure 3: Closed loop tuning method response (N.B. Nichols, 1942)

 Next, the second method of Ziegler Nichols method is based on the determination of
the open loop step response of the process. By applying the step input to the process and
recording the process, the step response is measured. The response is scaled to correspond to a
unit step input and characterized by parameter a and Tdel. Tdel is the time delay of the system
and a/ Tdel is the steepest slope of the step response. Figure 4: (Open loop tuning method
responses) showed the example of open loop tuning method response:

Figure 4: Open loop Tuning method response (Ziegler, 1942)

There were a few errors that occurred during conducting the experiment. The control
valve FCV91 not opened half when MV was set at 56.3%. Supposedly, the control valve can
open half.
CONCLUSION & RECOMMENDATION

As a conclusion, this experiment was being conducted by controlling the air flow
system by using the different set of PID controller to measure the volumetric flowrate as well
as the mass flowrate measurement which the result can be obtained through the chart printed
from the air flow process control training system. Initially, the PID controller was set in a
Manual (M) mode, and SV was set at its set point which 25kg/hour. Besides that, the control
valve FCV91 was fully open with by adjusted MV to -6.3%. After that, three different trials
were run with different values of PB of 200%, 150% and 100% respectively and with same
value of TI = 6 second and TD = 0 second. The auto mode was then set and waited until the
recorder response of the air flow of red pen (Mass Flow rate) was fairly steady and pulse
disturbance was introduced into the flow to observed any response. Based on the result
obtained, trial III has the shortest peak of disturbance and trial I has the longest peak for the
pulse disturbance. The proportional band, PB for trial I is higher compared to trial I and II.
Based on the result showed in chart, its follow the method where the trial I had longest peak
with the highest PB value which is 200%. Lastly, the Ziegler Nichols method was run to
obtained new values of the PID system which was the close loop system and also open loop
system. Based on the calculation, the new value of PID controller for Tn was 252 s for PB was
40 and TI was 210 s. The recommendation to be proposed to overcome the errors occurred
during the experiment is that every valve and control system should be set accordingly and
should be double inspection so that the control valve FCV91 would be fully open and set the
F1911 to -6.3%. Besides that, the by-pass valve on the pipeline PLI and PLII should be fully
open so that the flow of gas will not be interrupted.
REFERENCES

Gill, R. W. (1979). Pulsed Doppler with B-mode imaging for quantitative blood flow
measurement. Ultrasound in Medicine and Biology, 5(3).

Peter, U. C., Chinedu, U., & Harcourt, P. (2016). Model prediction for constant area, variable
pressure drop in orifice plate characteristics in flow system. Chemistry Internatioanl,
2(2), 80–88.

Lu, J., Chen, G., & Ying, H. (2001). Predictive fuzzy PID control: theory, design and
simulation. Information Sciences, 137(1-4), 157-187.

Didactic, F. (2013). Process Control - Process Control Air, Pressure, and Flow, Model 3533.

N.B. Nichols. (1942). Ziegler-Nichols Closed-Loop Tuning Method | Control Notes.

Retrieved February 29, 2020, from https://blog.opticontrols.com/archives/131

Prada, P. C. De. (1973). Process Control. 112.

Ziegler, J. G. (1942). Ziegler-Nichols Open-Loop Tuning Rules | Control Notes. Retrieved

February 29, 2020, from https://blog.opticontrols.com/archives/477