EXPERIMENT 11 Ratio Control

11.1 Objectives

(i)

To demonstrate the characteristics of Proportional Band, Integral Action and Derivative Action on a flow process control loop.

(ii)

To demonstrate the characteristics of ratio control.

11.2 Introduction The experiment is designed for the ratio control in relation to a single loop flow control. The tank, pump, instrumentation and valves are strategically located for easy access. For safety reason, the control panel shall be protected against water splashes. The process piping shall be made of industrial pipes.

11.3 Experimental Equipment

The ratio control model is a water process. Water is pumped from tank T-520 via pump P-520 and is directly circulated back to the tank. Water is pumped out T-520 via pump pump P-525 going through a control valve FCV-520 before being pumped back into tank T-520. Water is pumped through pump P-520 passing through an orifice differential pressure transmitter is used to feed the controller FIC-521, which will then transmit a signal for the required control valve opening for FCV-520 as water is being pumped back to T-520. This opening will be based on the preset ratio of flow from P-520 and P-525 that is entering the tank T-520.

Table 11.1 Instrument function and capabilities No 1 Instrument PID controller Tag No FIC-521 Description Microprocessor based PID Range -

controller, flow control

Solenoid valves

HV-522 HV-523

Faults simulation

3 4

Recorder Pump

FR-521 P-520 P-525

Continuous 2 pen chart recorder Water circulation pumps

100 LPM

Table 11.1 Instrument function and capabilities No 5 Instrument Control valve Tag No FCV-520 Description Globe type control valve 0-100% 6 Pressure Indicator PI-520 PI521 7 Process Tank T-520 Dial gauge pressure indicator for local pressure indication Sump tank 80 L 0-4 bar Range

Flow transmitter

FT-520 FT-521

Integral orifice D/P transmitter Vortex flowmeter 0-100 LPM

Hand valve

HV521HV531

Input/Output isolation valves.

10

Control Panel

Mounting/installation of controller, alarm annunciator , recorder, push button power supply switch and changeover switch and changeover switch between the DCS and local control

11

Faults Switches

HS-521 HS-522 HS-523

Loss of flow measurement signal Leakage at pipe Loss of instrument air supply -

11.4

THEORY

11.4.1 On/Off Control Student may refer to section 0.3.2 for theory of On/Off Control

11.4.2 PID Control

Student may refer to section 0.3.5 for theory of PID control

11.4.3 Loop tuning

Student may refer to section 0.3.6 for theory of loop tuning

11.4.4 Ratio Control

Student may refer to section 0.3.9 for theory of ratio control

11.5 Procedure
Table 11.2 Start up procedure STEP ACTION Ensure that all valves are set according to Initial Valve Positions outlined in Table below. Open HV532 1 HV533 HV535 HV537 HV538 HV540 2 Open HV534 to fill in Water Tank T-520. Then close the valve once the tank is full. The instrument air regulator RG1 has been set to 2.8 bar (40 3 psi). Check that the RG1 pressure is correct and adjust if necessary to set it at 2.8 bar. 4 Switch on the main panel Close HV531 HV534 HV536 HV539 Hand valves to be Open/Closed Fully. REMARKS

Table 11.3 PID Flow control STEP ACTION Enter the following values: 1 PB = 200, I = 6 s and D = 1 s Put the control loop into manual mode and then adjust the set point to 50 LPM Switch on pump P525 and open control valve manually so that the measurement matches the set point of 50 LPM flow. Turn on the recorder then put the control loop into auto mode REMARKS

Stimulate load changes by closing HV537 for 3 seconds and then return it to its original position.

Once the measurement stabilize, turn off the recorder. Put the control loop back into manual mode.

Tune the output gradually so that the flow measurement matches the set point of 50 LPM. Turn on the recorder and then put the control loop into auto mode. Stimulate set point changes by increasing the set point to 75 LPM. Once the measurement stabilized, turn off the recorder. Put

10

the control loop back into manual mode. With the PB and I values maintained, repeat step 2 to step 10

11

with the following D values Compare the results and D 3 5 comment the differences.

Table 11.4 PID control loop tuning STEP ACTION Put the control loop into manual mode and then adjust the 1 output gradually so that temperature matches the set point of 50 LPM. Enter the following values: PB = 1000, I = 1000 s and D = 0 s Turn on the recorder then put the control loop into auto mode. Stimulate load changes by closing HV537 for 3 seconds and then return it to its original position. With the I and D values maintained, repeat step 3 and step 4 with reduced PB until the measurement oscillates about the set point. The suggested values are as follows: PB 500 5 200 100 50 10 Determine the natural period using the following method This provides proportional only control REMARKS

Natural
6 where

period , T

D Trend Speed

60 min

D = distance in mm between successive crests or valleys Maintain the PB value at which the measurement oscillates about the set point. Set I to natural period. Repeat step 2 and 7 4 and observe the response. There should be a 40% decrease in period. If the new period of the oscillation is longer than this, increase the interval time if the period is shorter decrease integral time. 8 Finally adjust (increase) the PB until the desire degree of damping is achieved

Table 11.5 Ratio control STEP ACTION REMARKS

Put the control loop into manual mode

Use selector switch to select ratio control mode

Switch on Pump P520 and adjust FT520 to about 40 LPM using HV533.

Turn on the recorder. Put the control loop into Auto mode.

Stimulate a change by adjusting FT520 to 50 LPM using HV533.

11.6 REFERENCES Seborg D.E., T.F. Edgar and D.A. Mellichamp, Process Dynamics and Control, John Wiley and Sons, 2
nd

edition, New York, 2004, pp 116-118.

Piping and Instrumentation Diagram