S-Lab Manual Exp 3 - Air Flow Process Control
S-Lab Manual Exp 3 - Air Flow Process Control
S-Lab Manual Exp 3 - Air Flow Process Control
LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL
EDITION:
REVISION NO:
EFFECTIVE DATE:
1
1
29 SEPT
2014
AMENDMENT
DATE:
COURSE CODE
EXPERIMENT NO.
EXPERIMENT 4
EXPERIMENT TITLE
DATE
GROUP NO.
LECTURER/INSTRUCTOR/TUTOR
1)
2)
ATTENDANCE/PARTICIPATION/DISIPLINE:
/5%
INTRODUCTION:
/5%
PROCEDURE:
/5%
RESULTS& CALCULATIONS
ANALYSIS
DISCUSSIONS:
ADDITIONAL QUESTIONS
CONCLUSION
/15%
/20%
/15%
/10%
/5%
REFERENCES:
/5%
TOTAL:
EXAMINER COMMENTS:
/15%
/100%
UniKL MICET
LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL
EDITION:
1
1
REVISION NO:
EFFECTIVE DATE:
29 SEPT
2014
AMENDMENT
DATE:
(Signature)
2) Group Member 1: .
Name
: __________________________________
Matrix No
: __________________________________
(Signature)
(Signature)
(Signature)
UniKL MICET
LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL
1.0
EDITION:
REVISION NO:
EFFECTIVE DATE:
1
1
29 SEPT
2014
AMENDMENT
DATE:
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
Gas Law
INTRODUCTION
UniKL MICET
LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL
EDITION:
1
1
REVISION NO:
EFFECTIVE DATE:
29 SEPT
2014
AMENDMENT
DATE:
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.
4.1
4.2
5.0
PROCEDURE
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):
UniKL MICET
LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL
EDITION:
1
1
REVISION NO:
EFFECTIVE DATE:
29 SEPT
2014
AMENDMENT
DATE:
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.
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)
UniKL MICET
LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL
EDITION:
1
1
REVISION NO:
EFFECTIVE DATE:
29 SEPT
2014
AMENDMENT
DATE:
FIC91
PID1(main page): PV - Fm, kg/hr
I/O DATA:
X1 - FT91, % of , 0 - 100
X2 - TIT911, % of 0 - 120C
X3 - PT911, % of 0 - 60 psia
FIC90
P/T REGISTER: PO1 - Fv, m3/hr
ii)
3.
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.
UniKL MICET
LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL
EDITION:
1
1
REVISION NO:
EFFECTIVE DATE:
29 SEPT
2014
AMENDMENT
DATE:
valve)
With FIC91 still in Manual mode, adjust its setpoint, SV = 25
3.
kg/hr.
Access the PID parameters of FIC91 and set the first (I) PID trial
4.
values:
PB = 200%, TI = 6 s, TD = 0 s
Start the recorder chart drive by pressing RCD pushbutton at
5.
FPTR91.
Switch FIC91 to Auto (A) mode and watch the recorder response
6.
(i.e. air flow response) until the air flow (red pen) is fairly steady.
Introduce a pulse disturbance by quickly opening and shutting
fully the by-pass valve at control valve FCV91. Observe the
7.
III
PB = 100%
TI = 6s
TD = 0s
DO NOT FORGET TO MARK THE PID VALUES AND THE SETPOINT ON THE CHART PAPER WHENEVER THE VALUES
UniKL MICET
LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL
EDITION:
1
1
REVISION NO:
EFFECTIVE DATE:
29 SEPT
2014
AMENDMENT
DATE:
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
9.
steady.
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
10.
4.
UniKL MICET
LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL
5.
EDITION:
1
1
REVISION NO:
EFFECTIVE DATE:
29 SEPT
2014
AMENDMENT
DATE:
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)
6.
Tn
measurement ( mm ) x 3600
500 mm
chartspeed (
)
hr
7.
UniKL MICET
LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL
EDITION:
REVISION NO:
EFFECTIVE DATE:
1
1
29 SEPT
2014
AMENDMENT
DATE:
D. SHUTDOWN PROCEDURE
1.
Stop the recorder chart by pressing RCD press button at
recorder FPTR91.
Switch FIC91 to Manual mode with MV = 0%.
Switch off the main power supply.
Shut off the process air supply at AR900.
Shut off the instrument air supply.
6.0
2.
3.
4.
5.
6.
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
iii)
iv)
Fvb and Fm
The PID flow control responses for disturbances and setpoint changes
v)
vi)
settings.
Tuning by Ziegler Nichols method and its response.
UniKL MICET
LABORATORY: PROCESS
CONTROL
EDITION:
REVISION NO:
At the panel
FT91,
Controller
29 SEPT
2014
EFFECTIVE DATE:
Instrument Reading
1
1
AMENDMENT
DATE:
II
III
MV=6.3%
MV=50%
MV=70%
TIT911, T
X2 - %of 0-120oc
PT911, P
X3 - %of 0-60psia
FIC91, Main Face plate
PV, kg/Hr
Fm
PO1, m3/Hr
Recorder 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
8.0
DISCUSSIONS
Discuss the overall experiment on data obtain based on your understanding.
Discussion should relate reasons for the phenomena/results obtained,
UniKL MICET
LABORATORY: PROCESS
CONTROL
EXPERIMENT: AIR FLOW
PROCESS CONTROL
EDITION:
1
1
REVISION NO:
EFFECTIVE DATE:
29 SEPT
2014
AMENDMENT
DATE:
theoretical parts, suggested reasons (if necessary but back with sound
theoretical knowledge) and your overview understanding.
9.0
ADDITIONAL QUESTIONS
i.
Includes short essay on comparison between Perfect Gas Law and air
flow measurement from instrument in the experiment.
ii.
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.
11.0 REFERENCES
Minimum of at least 5 references (with 3 of them are paper/book/chapter
based)