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EXPERIMENT: GAS FLOW 2014
PROCESS CONTROL AMENDMENT
DATE:

SECTION OF CHEMICAL PROCESS

MALAYSIAN INTITUTE OF CHEMICAL & BIOENGINEERING TECHNOLOGY

PROCESS CONTROL LABORATORY

LABORATORY INSTRUCTION SHEETS

COURSE CODE
EXPERIMENT NO. EXPERIMENT 4

EXPERIMENT TITLE Gas Flow Process Control Plant

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 study gas volumetric flow rate measurement using orifice plate.
b) 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.
c) To study gas mass flow rate (Fm) control using PID controller.

2.0 LEARNING OUTCOMES

At the end of the study, student will be able to:
a) To be familiar with the basic steps of machine from start-up to shut-down with proper
handling and setting.
b) To gain knowledge about pressure and temperature variation using Perfect Gas Law
3.0 INTRODUCTION
The air flow process control training system uses air to simulate a gas or vapor phase flow
process. Gas/vapor volumetric flow can be measured either by the differential pressure across
orifice or by a variable area flow meter. Compensation for pressure and temperature variation
using Perfect Gas Law can be made to the flow measurement by the differential pressure
measurement.

4.0 INSTRUMENTS /APPARATUS / CHEMICAL / REAGENTS

4.1 Gas volumetric/mass flow measurement system
a) Integral orifice flow element, FE91.
b) Differential pressure flow transmitter with square root function, FT91.
c) Absolute pressure transmitter, PT91.
d) RTD temperature transmitter, TE91/TIT911.
4.2 Apparatus
a) Air Flow process control training system. The schematic diagram is shown in Figure 1.
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Figure 1: Schematic diagram of Air Flow Process Control Training System

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5.0 PROCEDURE
The following steps constitute the start-up procedure. Go through these steps before starting
any experiment:

1. Switch the "PANEL, SCADA/DDC" selector switch at the front of the cubicle to "PANEL,
SCADA" position. Switch ON the main power supply at the front of the cubicle. All the panel
instruments will lit up.
2. From the process air supply, trace the two pipelines, PLI and PLII as follows:

Pipeline I (PLI):
AR900-MV900A-T90-MV900D-PLI-FI911-TE911-FE91/FT91-FCV91-FCV1-VF
Pipeline II (PLII):
AR900-MV900A-T90-MV900D-PLII-FCV90-PG902-V

3. Open valves of the pipelines PLI and PLII at their various manual valves. Close the manual
by-pass valve of the control valve FCV91 and the ON/OFF control valve FCV90.
4. The pipeline PLI has two discharge manual valves, VF and MV901. Open the vent VF and
close the valve MV901.
5. Make sure the valves MV900A and MV900D are open and valves MV900B and MV900C are
shut.
6. Place the panel controller FIC91 in the Manual (M) mode. Open fully the control valve
FCV91 by setting the MV of FIC91 to -6.3%.
7. Adjust the manual valve MV900A till the air flow rate is about 50 kg/hr (Read the flow
rate from PV of FIC91).
8. Check that vent valve and bottom drain valve of vessel T90 are shut. Set MV = 106.3% at
FIC91 to fully shut the control valve FCV91.
9. Check control valve FCV91 (in the plant) is fully shut and FI911 reads the air volumetric
flow rate as ZERO. Also check the mass flow rate Fm at FIC91 is ZERO.
10. Now set the MV = 50% at FIC91 and check control valve FCV91 (in the plant) is 50%
opened.
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11. Note the variables that are recorded in each channel of the recorder FPTR91.
Red Pen - Mass flow rate (kg/hr)
Green Pen - Volumetric flow rate (m3/hr)
Blue Pen - Temperature (°C)

A. AIR FLOW MEASUREMENT

1. Set the MV = -6.3% (in Manual mode) so that control valve FCV91 is fully
opened. Record the reading/data in Table 1. shown in results section.
2. Data to be taken AT THE CONTROL PANEL:
i) Access the following data by pressing the corresponding push buttons
in FIC91 and FIC90:
FIC91
PID1(main page): PV - Fm, kg/hr
I/O DATA: X1 - FT91, % of , 0 - 100
X2 - TIT911, % of 0 - 120°C
X3 - PT911, % of 0 - 60 psia
FIC90
P/T REGISTER: PO1 - Fv, m3/hr
ii) At the Recorder: Fv (Channel 2, Green) and Fm (Channel 1, Red)
3. Data to be taken AT THE PLANT:

Locate the rotameter FI911 and pressure gauge PG900. Take both instruments’
readings and also note the units used. (Rotameter reading should be taken as ±0.5
Nm3/hr)

Now, take another sets of readings for MV = 50% and MV = 70% and record them in
the Table 1 in the results section.
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B. CONTROL OF AIR FLOW SYSTEM

1. With FIC91 in Manual (M) mode, open the control valve FCV91 fully with
MV = -6.3%. (For confirmation, check the stem position indicator of control
valve FCV91. FCV91 is an Air-To-Close (ATC) valve)
2. With FIC91 still in Manual mode, adjust its setpoint, SV = 25 kg/hr.
3. Access the PID parameters of FIC91 and set the first (I) PID trial values:
PB = 200%, TI = 6 s, TD = 0 s
4. Start the recorder chart drive by pressing “RCD” pushbutton at FPTR91.
5. Switch FIC91 to Auto (A) mode and watch the recorder response (i.e. air flow
response) until the air flow (red pen) is fairly steady.
6. Introduce a pulse disturbance by quickly opening and shutting fully the by-
pass valve at control valve FCV91. Observe the response till it becomes fairly
steady.
7. Repeat step (5.2.6) (i.e. introducing pulse disturbance) with the second (II)
and third (III) sets of PID trial values:

II III
PB = 150% PB = 100%
TI = 6s TI = 6s
TD = 0s TD = 0s

DO NOT FORGET TO MARK THE PID VALUES AND THE SET-POINT

ON THE CHART PAPER WHENEVER THE VALUES ARE CHANGED.
ALSO MARK ON THE CHART THE BEGINNING OF EACH PART OF
THE EXPERIMENT.
8. Repeat the experiment for the above 3 sets of PID trial values with step
change in setpoint for the mass flow rate by changing the present setpoint of
FIC91 from SV= 25kg/hr to SV = 30 kg/hr. Observe and record the response
till it becomes fairly steady.
9. Switch back the setpoint SV = 25 kg/hr. Use the first (I) PID trial value
but now with TD = 20 s. Mark the PID values on the chart paper
simultaneously.
10. Apply the disturbance by opening and shutting fully the by-pass valve at
control valve FCV91 and observe the response.
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C. PID CONTROLLER TUNING
1. Set FIC91 in Manual (M) mode with setpoint SV = 25 kg/hr. Adjust the PID
values to the following:
PB = about 100%, TI = 9999 s (Maximum), TD = 0 s (Minimum)
2. By setting TI to maximum value and TD to minimum value, we can eliminate
these two modes in a PID controller (use PB only).
3. Adjust MV in FIC91 until the PV value closes to the setpoint SV value (SV =
25 kg/hr).
4. Transfer FIC91 to Auto (A) mode. Introduce a setpoint pulse disturbance as
follows:
i) Set increase SV to 28 kg/hr
ii) Hold the value for a few seconds
iii)Bring back the SV to 25 kg/hr
5. Observe the mass flow rate (red pen) response. Repeat the Closed Loop
Tuning Method as above with a decreasing PB value until uniform oscillation
(constant amplitude) is observed. (To increase oscillation, decrease PB value
and vice versa)

Figure 1: Uniform oscillation

6. Examine the
chart response for the uniform oscillation. New PID value from tuning
procedures can be obtained as follows:
i. PB corresponds to uniform oscillation = PB* ultimate (correspons to
ultimate gain, Kcu)
ii. Distance between two adjacent peaks = Tn* ultimate (ultimate period, Pu)
Tn* can be calculated from this formula:

measurement (mm)x 3600

𝑇𝑛 ∗ = 500mm
chartspeed( hr
)
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iii. The approximate PI controller settings by using Ziegler Nichols formula
are:
PB = 2 X PB*, TI = Tn*/1.2
7. To test this new PI controller settings, set this value into FIC91 (in Auto
mode) perform the test with a pulse disturbance. Increase PB value to damp
the oscillation and fine tune the PB and TI values to get as close to Quarter
Amplitude Damping response.

Figure 2: Quarter Amplitude Damping Response (Blue pen)

D. SHUTDOWN PROCEDURE
1. Stop the recorder chart by pressing ”RCD” press button at recorder FPTR91.
2. Switch FIC91 to Manual mode with MV = 0%.
3. Switch off the main power supply.
4. Shut off the process air supply at AR900.
5. Shut off the instrument air supply.
6.
6.0 RESULTS & CALCULATIONS
A. The recorder FPTR91 records the results of the experiments. Suitable portions of the
recorder chart paper should be submitted as RESULTS of the experiment.
B. The report should contain:
i) The P&I Diagram with all major components marked clearly.
ii) The instruments readings taken simultaneously and recorded for different valve
opening positions.
iii) Comparison between direct instrument data with calculated data for Fvb and Fm
iv) The PID flow control responses for disturbances and setpoint changes for different
controller settings.
v) Discussion on the response characteristics for different controller settings.
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vi) Tuning by Ziegler Nichols method and its response.

Instrument Reading Controller I II III

MV=6.3% MV=50% MV=70%
At the panel FIC91, I/O Data
FT91, √ℎ X1 - %of 0-100mm
TIT911, T X2 - %of 0-120oc
PT911, P X3 - %of 0-60psia
FIC91, Main Face plate
Fm PV, kg/Hr
FIC91, Main Face plate
Fv PO1, m3/Hr
Recpder FPTR91
Channel 1(Red) Fm , kg/Hr
Channel 2(Green) Fvb , m3/Hr

By Calculation Fvb , Nm3/Hr

Fm , kg/Hr
At the Plant
FI911, Nm3/Hr
PG900 , psig

7.0 ANALYSIS OF THE RESULTS

Analysed critically each results obtain in section 6.0 by referring to the theory/introduction
parts. Find reasons (suggested reasons) on each occurrence shown in the results.

8.0 DISCUSSIONS
Discuss the overall experiment on data obtain based on your understanding. Discussion
should relate reasons for the phenomena/results obtained, theoretical parts, suggested reasons
(if necessary but back with sound theoretical knowledge) and your overview understanding.
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9.0 ADDITIONAL QUESTIONS
i. Water has been analysed for pH, conductivity and dissolve oxygen. What does each of this
measurement tell you about the water?
ii. Includes short essay on your understanding on pH, conductivity and dissolve oxygen. Relate
your discussion on the requirement of industrial effluent released (if applicable).

9.0 CONCLUSION
Conclusion is merely a summary of the important findings already reported in the discussion
section. It also relates to the objectives stated earlier.

10.0 SUGGESTIONS & RECOMMENDATIONS

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

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