PRESSURE CONTROL Laboratory Manual (Last Update: 18 Feb 2009)

302265 ChE381Process Lab Projects

Pressure Control: Close Loop PID Temperature Control Loop Tuning (Ziegler
and Nicholas Method)

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Laboratory Manual
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This manual is constructed by the teaching team of ChE381Process Lab Projects in the Department of Chemical Engineering of Curtin University of Technology according to the manufacturers instruction of the operation unit. Experiments are selected by the unit coordinator based on the suitability and time required for the project.

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PRESSURE CONTROL Laboratory Manual (Last Update: 18 Feb 2009)

OBJECTIVES i) ii) To demonstrate the characteristic of PB (Proportional Band) + I (Integral Action) + D (Derivative Action) on a pressure process control loop. To demonstrate the loop tuning procedures on a pressure process control loop

BACKGROUND AND EQUIPMENT The SOLTEQ Pressure Control Trainer (Model: SE401) is used in this experiment. It is made of industrial graded instrumentation and designed to exhibit a realistic working environment of standard industrial pressure control loop. It is used to demonstrate as well as give the student a hands on experience on how a pressure loop can be controlled using a microprocessor based controller. PID Control 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. Integral action avoids the offset created in proportional only control by bringing the output back to the set point. Proportional-plus-integral (PI) control is generally used on processes where no amount of offset can be tolerated. However, some processes are so difficult to control or so critical to maintain at set point, that the use of all three modes will be helpful in achieving desired control. Derivative control responds to the rate of range of error. Hence, combined PID control responds to all aspects of process errordirection, magnitude, duration, and rate of change. The output of a PID controller is a linear combination of P, I, and D modes of control. Processes that benefit most from PID control have rapid and large disturbances in which derivative action can respond to the rapidity of the changes, and integral action can respond to the duration of them.

Figure 1: System response to a process upset with different modes of analog Control

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PRESSURE CONTROL Laboratory Manual (Last Update: 18 Feb 2009)

Loop Tuning The closed-loop control system attempts to achieve a balance between supply and demand by comparing the controlled variable to the set point and regulating the supply to an amount that will maintain the desired balance. Tuning the controller adjusts the supply so that balance is achieved as quickly as possible. The performance criteria for a PID controlled can be evaluated by measuring the damped period. Optimum tuning generally results with a QAD-period that is approximately equal to the natural period. The damped period will be referred to as PID, and is equal to o. Recommendations for response setting are: Method: Ziegler and Nichols for closed loop
PB = 2(PB)* I = 0 /1.2 D = 0 /8 where (PB)* is the proportional-band setting that produces constant amplitude cycling.

GENERAL OPERATING PROCEDURES:

General Start-up Procedures

1. Start compressor and wait for sufficient air pressure to build up; recommended air supply pressure is 6 bar. Close HV1, set pressure regulators RG1 to 4 Bar or 4 kg/cm2 and do not adjust RG2. 2. Remove both caps of the red and green recorder pens. 3. Switch on instrument power supply. 4. Check recorder is working and the pens have ink. Then stop the recorder. 5. Set controller to manual with 0% output. 6. Check and make sure hand valves position are as follows: Close Open HV3,HV4 HV1, HV2

7. Open the isolation valve HV1. Air will start to charge into the receiver tankTN1 until pressure reaches 4 bar. Adjust RG1 if the pressure drop below 4 bar. Note: 1. For Yokogawa controller and recorder operations please refer to Appendix A. 2. Yokogawa recorder chart speed has been preset at 3600mm/hr.

General Shut Down Procedures 1. Close HV1.

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PRESSURE CONTROL Laboratory Manual (Last Update: 18 Feb 2009)

2. Put controller in "Manual" mode, and then set controller output to 50%. Release compressed air in the trainer system by opening globe valve HV2 to set the air flow rate at FI1 to 40 LPM. Wait until both pressure gauges PI1 and PI2 read 0 bar. 3. Shut off main compressed air supply. 4. Switch off the main power. Then, replace the caps of the recorder pens. Note: ALWAYS put on the caps to the pen after end of experiments, as the ink will dry rapidly with the tip exposed. Equipment Maintenance 1. 2. 3. 4. 5. 6. 7. ALWAYS put on the caps to the pen after end of experiments, as the ink will dry rapidly with the tip exposed. Release the air completely from both tanks when the unit is not in use. Wipe off any spillage on the unit immediately. Always check that all indicators are functioning. Always check that the pressure gauges are working properly. Clean the equipment with damp cloth every month. Replace the chart paper and the felt pens of the chart recorder whenever necessary.

Safety Precautions 1. 2. 3. 4. 5. The unit must be operated under the supervision of trained personnel. Do not adjust the pressure regulator RG2 unless the setting pressure drops below the required pressure as written in the specification plate. Check the relief valve every half year to make sure that it is in a good condition. Open valve V3 and V4 to drain any condensate collected every week. All operating manuals supplied with the unit must be completely read and understand before conducting any experiment on the unit.

REFERENCES 1. 2. 3. Perrys Chemical Engineers Handbook, 7th Edition, (Ed: R.H. Perry, Green, and J.O. Maloney), McGraw-Hill, New York, 1997 Principles and Practice of Automatic Process Control, 2nd Edition, Carlos A. Smith and Armando B. Corripio, Wiley, 1997 CE Refresher: Process Automation, McGraw-Hill, Inc. New York, 1985

EXPERIMENTAL PROCEDURES

Experiment 1: Close Loop P plus I & Derivative Control Objective: To demonstrate the characteristic of PB (Proportional Band) + I (Integral Action ) + D (Derivative Action) on a pressure process control loop
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PRESSURE CONTROL Laboratory Manual (Last Update: 18 Feb 2009)

Procedures: To start the experiment follows the start up procedures. 1. Put the control loop into "Manual Mode". Then adjust the output to 50%. Let the pressure build up in TN2. Manipulate HV2 to adjust FI1 to 20 L/min. 2. Enter a PB value of 200 %, I value of 3 sec and D value of 0 sec. 3. Adjust the output gradually so that the pressure of the tank matches the set point of 50%. Note: We recommend 50% as the initial output. From there, the output can be increased or decreased as appropriate. If the measurement is too far from set point, use HV2 to expedite the process. Closing HV2 will increase measurement input, and vice versa. 4. Start the recorder. Then, put the control loop into "Auto mode". 5. Simulate a load change by opening HV2 so that FI1 reads 40 L/min for 5 seconds; restore HV2 to its initial position. 6. Wait until the measurement exhibit a uniform pattern, and then stop the recorder. 7. Put the control loop into "Manual mode". Adjust the output gradually so that the measurement matches the set point. 8. Start the recorder, and then put the control loop into "Auto mode" Increase the set point to 75%, wail until the measurement exhibit a uniform pattern, then stop the recorder. 9. Maintain the PB and I values. Repeat Steps 2 to 8 by using the following D values. D (second) 0 5 20 Note: 1. For Yokogawa controller and recorder operations please refer to Appendix A. 2. Yokogawa recorder chart speed has been preset at 3600mm/hr.

Experiment 2: Loop tuning procedures on a pressure process control loop 1. Enter a PB value of 100, I value of 9999 seconds and D value of 0 second (setting I to its maximum and D to its minimum provides proportional-only control). Put the control loop into Manual mode. Adjust set point to 50 and slowly adjust the output so that the measurement matches the set point. (Approximate output value is 50, adjust as necessary). Make a step change in the controllers set point up to 60% and observe the resulting measurement cycle. Remain the value of D and I. Slowly reduces PB further if the measurement cycle damps out to a steady-state value, and, flowing this, make another change in the controllers set point.

2.

3. 4.

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PRESSURE CONTROL Laboratory Manual (Last Update: 18 Feb 2009)

Suggested values are as follows:

5.

Repeat steps 3 and 4 until the measurement cycles at a constant amplitude and period as shown in Figure 2.

Note: Be certain that the final actuator is not oscillating between its limits because such oscillation will yield erroneous results. 6. Based on the chart, determine the natural period using the following method Natural Period, T =

D X 3600 s TrendSpeed

Where D = Distance in mm between successive crests or valleys 7. Find the P, I and D values by using Ziegler and Nichols method.

PB = 2(PB)* I = 0 /1.2 D = 0 /8

where (PB)* is the proportional-band setting that produces constant amplitude cycling.
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PRESSURE CONTROL Laboratory Manual (Last Update: 18 Feb 2009)

8. 9.

Then substitute the optimized P, I and D values into the loop controller. Put the control loop into Manual mode. Adjust set point to 50 and slowly adjust the output so that the measurement matches the set point. (Approximate output value is 50, adjust as necessary). 10. Simulate a load change and a set point change with this PID setting. Observe the response from chart recorder. Note: 1. For Yokogawa controller and recorder operations please refer to Appendix A. 2. Yokogawa recorder chart speed has been preset at 3600mm/hr.

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PRESSURE CONTROL Laboratory Manual (Last Update: 18 Feb 2009)

Flow diagram of the unit

PRESSURE CONTROL TRAINER (MODEL: SE 401)

PR1

PIC1

I/P1

RG2 CV1

AIR

VENT

FI 1 COMPRESSED AIR

HV 2
PT1 PI2

ATM PSV 2
PI1

ATM PSV 1

HV1

RG1

CONTROL TANK TN 2

RECEIVER TANK TN 1

HV4

HV 3 DRAIN

DRAIN

Instruments Functions 1 2 3 Air Regulator (RG1) Air Regulator (RG2) Hand Valves (HV1-HV4) Pressure gauge (PI1, PI2) Relief Valve (PSV1, PSV2) Supply 4 Bar or 4 kg/cm2 air to Receiver Tank (TN1). Supply 2.8 bar instrument air to I/P positioner. Do not change it unless air pressure drop below 2.8 bar. Input / Output isolation valves. HV2 is used to regulate the desired airflow and also act as a load change valve for testing purposes. Direct pressure measurement sensor, indicates pressure in the receiver and control tank. Mechanical activated device, the spring loaded normally closed valve, open prior to pressure greater than its spring tension. In case of over pressure in the tank this relief will open and purge the air to the atmosphere. For safety reason, do not adjust this valve. PSV1 and PSV2 are factory set at 5.0 Bar and 2.5 Bar, respectively. The tank is used as a buffer tank to stabilize the air supply pressure. Release the air completely when finished using
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4 5

Air Receiver Tank (TN1)

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PRESSURE CONTROL Laboratory Manual (Last Update: 18 Feb 2009)

the trainer. 7 Control Tank (TN2) Rotameter (FI1) The pressure in this tank will be controlled by a complete closed loop control system. Release the air completely when not in used. It is a direct airflow instrument used to indicate flow rate of the air. The process airflow rate is indicated by a float position to the scale of the tube. A transducer is used to convert process variable (Pressure in the control tank) to 4-20 mA analog signal that feeds to the controller. Final control element, the valve reacts proportionally to the controller output to control the pressure in the tank. Microprocessor based controller. This controller receives 4-20 mA signal from PT1 transmitter and also output 4-20 mA to the I/P positioner on the valve actuator Final control element, the valve reacts proportionally to the controller output to control the pressure in the tank. The pressure recorder is used to record the process measurement PT1 and controller (PIC1) set-point value. It is very useful for studying the dynamics of the process control loop and for tuning purposes.

Pressure Transmitter (PT1) Pressure Controller (PIC1)

10

11 12

Control Valve (CV1) Pressure Recorder (PR1)

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PRESSURE CONTROL Laboratory Manual (Last Update: 18 Feb 2009)

Appendix Instrument Operation Guide

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PRESSURE CONTROL Laboratory Manual (Last Update: 18 Feb 2009) Appendix A.1: YOKOGAWA Loop Controller Operation i. Selection of Operation Panel Group 1. 2. When power is turned on, initialization of the controller is carried out. Then, the controller shows the operation panel group. key while holding down the Press the one after another in the following sequence: Operation Panel Group Tuning Panel Group Engineering Panel Group key, the LCD display panel group is selected

The controller shows the operation panel group again by pressing the key. ii. Selection Operation of the Operation Panel 1. 2. key while holding down the Press the an operation panel will be displayed.

key while holding down the

key to select the Operation Panel Group, and button as shown

The operation panel changes from current to next one every time you press the below:

Loop 1 & Loop 2

Trend 1 & Trend 2

Alarm

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PRESSURE CONTROL Laboratory Manual (Last Update: 18 Feb 2009) iii. Auto/Manual Mode Selection 1. 2. Select the Loop 1 panel (as described in Section ii). / mode key to select the desired control operation mode. The LED indicator in the Press key which corresponds to the selected operation mode key is lit. : A Mode Key Selects the A (Automatic) control operation mode : M Mode Key Selects the M (Manual) control operation mode iv. Change of Output/Manipulated Value (MV) 1. Select the (Manual) control mode (as described in Section iii), use the keys to operate the output / Manipulated Value (MV) manually. 2. An increase or decrease of the MV value can be accelerated by holding down the pressing the MV operation key. : MV Operation Increasing Key Increases the MV value : MV Operation Decreasing Key Decreases the MV value v. Change of Set Point/Set Value (SV) 1. / key to change the set value (SV) of the control loop. This function is available in Use the the A (Automatic) and M (Manual) control operation mode. : SV Operation Increasing Key Increases the SV value : SV Operation Decreasing Key Decreases the SV value key, then and

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PRESSURE CONTROL Laboratory Manual (Last Update: 18 Feb 2009) vi. Change of PB, I and D Value 1. 2. 3. 4. 5. Press the key while holding down the key to display the Tuning Panel Group.

Press the push button to observe PID 1 pull-down menu. The PID menus provide detailed information regarding the PID function blocks. and keys (adjacent to the The downward through the menu. The and & keys) allow you to step upward or

keys permit changes to the selected line.

key until PB1 (Proportional Band Value) is highlighted. To change the PID value, first toggle the PB1 is shown at the top of the display below the PID1 title. The PB1 value can be changed by holding or keys until the desired value is set. Then toggle the key to select TI1 down the and TD1 to change the value of the Integral Action and Derivative Action, respectively.

6. 7.

Pressing the Finally, press the Panel.

button transfers the display to the Tuning Menu Group menu. key while holding down the key again to get back to the Operation

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PRESSURE CONTROL Laboratory Manual (Last Update: 18 Feb 2009) vii. Auto Tuning/Self-Tuning Control (STC) 1. 2. 3. 4. First, set the control operation mode to Press the key while holding down the (Manual Mode). key to display the Tuning Panel Group.

Press the push button to observe STC 1 pull-down menu. The STC menus provide detailed information regarding the PID function blocks. Toggle the key until MI 1 (Signal Defection applied to MV Value) is highlighted. MI1 is shown at or

the top of the display below the STC 1 title. Change the MI 1 to 20 % by holding down the

keys. The MI 1 value designated will shift the process variable by about 20 % during the auto tuning process. 5. Toggle the key until the STC is highlighted. Set the STC mode to ATSTUP by holding down the

key for 3 seconds. 6. 7. Pressing the Then, press the button transfers the display to the Tuning Menu Group menu. key while holding down the key again to get back to the Operation

(Automatic Mode) and now, the automatic tuning Panel. Set the control operation mode to the begins. ATSTUP appears on the control status display position of the loop panel. With the automatic tuning, PID control has not been started yet. After 30 seconds, the controller applies the step variation (MI %) automatically to the manipulated output. 8. When the process variable has been stabilized, the controller will automatically set the manipulated output back to the previous setting. 9. When all setting items are prepared, the mode is automatically set to STC=ON, and the PID control is started. At the same time, the control status display of the loop panel changes to STC-ON. 10. To turn off the STC mode, go to the STC1 pull down menu and set the STC mode to OFF. 11. Another way to turn off the STC mode is to change the PB, TI and TD value to any desired value.

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PRESSURE CONTROL Laboratory Manual (Last Update: 18 Feb 2009) Appendix A.2: YOKOGAWA Chart Recorder Operation i. Changing the Chart Speed 1. 2. 3. 4. 5. ii. Hold down the MENU key for 3 seconds to enter the Setting Mode. Press the key to show Chart and then press the key.

key to select the desired speed. Then press to enter the set value. Press the When the Setting complete screen appears, the new chart speed is applied. Press the ESC key to change the chart speed again or hold down the MENU key for 3 seconds to return to Operation Mode.

Starting/Stopping the Recorder 1. 2. 3. 4. Turn on the Power Switch of the recorder. Check that the recorder pens and chart paper have been installed properly. Press the RCD key to start recording. The status display shows the word RECORD. While the recording is in progress, press the RCD key to stop recording. The word RECORD on the status display clears.

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PRESSURE CONTROL Laboratory Manual (Last Update: 18 Feb 2009) Appendix A.3: Temperature Controller Operation iii. Changing the Set Point 1. 2. 3. Press button to select the set point setting mode.

/ button to set the desired temperature. The set point is indicated on the SV display (yellow digit LED display) Press button again to register the setting value.

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