EXPERIMENT 2: AIR FLOW PROCESS CONTROL (AF 922)

SUMMARY

The objective of this experiment is to identify the important components of the air flow
control system and to mark them in the P&1 diagram, to carry out the start-up procedure
systematically, study gas volumetric flow rate measurement using the orifice plate, study gas
mass flow rate measurement using the orifice plate and perfect gas, to compute the gas density
from the pressure and temperature measurements, To study gas mass flow rate (Fm) control
using PID controller, and to design a PID controller using Ziegler Nichols closed loop method.
In this experiment, the equipment used is the air flow process control training system (Model
AF922). The experiment was start with MV= -6.3% and the reading of PV, X1, X2, X3 and
P01 were taken. Then, different manipulated variables setting applied which were 50% and
70%. After that the set point was set to SV 25kg/hr and SV 30kg/hr. These experiments have
three sets of PB values which are 200%, 150% and 100%. Then, the result of experiment was
compared. From the results, the higher PB values the slower and more stable for the control.
The lower PB values gives faster and less stable on the control.

OBJECTIVES

 To identify the important components of the air flow control system and to mark them
in the P&1 Diagram.

 To carry out the start-up procedure systematically design a PID controller using Ziegler
Nichols closed loop method.

 To study gas volumetric and mass flow rate measurement using the orifice plate and
gas mass flow rate (Fm) control using PID controller. .

 Law to compute the gas density from the pressure and temperature measurements.

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EXPERIMENT 2: AIR FLOW PROCESS CONTROL (AF 922)

RESULT AND DISCUSSION

RESULT

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 78.6 66.6 49.0
29.2 29.3 29.3
TIT911, T X2 - %of 0-120oc
64.7 70.3 81.2
PT911, P X3 - %of 0-60psia
FIC91, Main Face
49.0 43.1 34.2
Fm plate
PV, kg/Hr
20.2 16.9 12.5
Fv FIC91, Main Face
plate
49.5 42.9 34.0
Channel 1(Red) PO1, m3/Hr 20.2 16.8 12.5
Channel 2(Green) Recorder FPTR91
Fm , kg/Hr 26.806 26.551 26.305
34.6545 34.325 34.007
By Calculation Fvb , m3/Hr

Fvb , Nm3/Hr
Fm , kg/Hr
At the Plant
FI911, Nm3/Hr 48.0 42.2 32.0
28.5 31.0
PG900 , psig 36.0

There is several different methods in controlling of tuning for example one of the method
is Ziegler-Nicholas method which is used to applied in the experiment. The values of parameter
are given during the experiment are different in each process and no specific for every plant.
In theory, a good combination of P,I, D values can produces less oscillation and better settling
time. In addition, all general methods for control design can be applied to PID control. All of
the different method is used to consider the key elements of control, load disturbance, sensor
noise, process uncertainty and reference signals. But if there’s unfamiliar system, its need to
be experimentation and selects the controller settings, obtained from Ziegler-Nicholas method
as applied in the experiments. Basically, Ziegler0Nicholas method provides an initial setting

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EXPERIMENT 2: AIR FLOW PROCESS CONTROL (AF 922)

that will ensure a good tunings of plant. Ziegler-Nicholas tuning rules were created to give
closed loop system with load of disturbance.

𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑑 𝑝𝑒𝑟𝑖𝑜𝑑 (𝑚𝑚)𝑥 3600

Tn secs = 𝑚𝑚
𝑐ℎ𝑎𝑟𝑡 𝑠𝑝𝑒𝑒𝑑 (500 )
𝐻𝑟

5𝑚𝑚 𝑥 36𝑜𝑜𝑠
= 500𝑚𝑚/𝐻𝑟

=36 s

Approximately PI setting by Ziegler Nicholas formula:

PB = 2 X PB*

TI = Tn / 1.2

TI = 36s / 1.2 = 21.67 s

ZIEGLER-NICHOLAS METHOD:

THE 1ST METHOD

First method is used and applied to a plant basis on figure 1. This method applied to first
order system. It’s also used in a plant consists of a series of first order system. The response is
characterized by two parameters, L the delay time and T the time constant. This can be found
by drawing a tangent to the step response at its point of inflection and draw its interaction with
the time axis and the steady state value. The plant equation is:

𝐾𝑒 −𝑠𝐿
G(s) = 𝑇𝑆+1

Ziegler-Nicholas derived the following control parameters based on this type of model:

PID Type Kp Ti = Kp / Ki Td = Kd / Kp

P T/L ∞ 0

PI 0.9 T / L L / 0.3 0

PID 1.2 T / L 2L 0.5L

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EXPERIMENT 2: AIR FLOW PROCESS CONTROL (AF 922)

Figure 1: Response Curve for Ziegler-Nicholas First method

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EXPERIMENT 2: AIR FLOW PROCESS CONTROL (AF 922)

THE 2ND METHOD

Second method targets the plant that can be assumed unstable under proportional control.
The technique is designed for the result in a closed loop system with 25% overshoot. This
rarely achieved as Ziegler-Nicholas determined the adjustment based on a specific plant model.
The steps for tuning a PID controller via 2nd method are:

Using only proportional feedback control:

 Reduce the integrator and derivative gains to 0

 Increase Kp from 0 to some critical value Kp = KCR at which sustained oscillations occur.

 Note the value Kcr and the corresponding period of sustained oscillation, Pcr

The controller gains are now specified as follow;

PID Type Kp Ti = Kp / Ki Td = Kd / Kp

P 0.5Kcr ∞ 0

PI 0.45Pcr Pcr / 1.2 0

PID 0.6Kcr Pcr/2 PCR/8

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EXPERIMENT 2: AIR FLOW PROCESS CONTROL (AF 922)

Figure 2: Step response for system tuned via second method

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EXPERIMENT 2: AIR FLOW PROCESS CONTROL (AF 922)

APPENDIX

Without P/T compensation:

Fv = Ki √ℎ

With P/T compensation:

√ℎ𝑝
Fvb = Kvb 𝑇

The mass flow rate measurement is given by;

1) Assuming perfect gas law:

√ℎ𝑝
Fm = Km 𝑇

Where

Fv = Volumetric flow rate, m3/ Hr

Fvb = Volumetric flow rate, Nm3/Hr

Fm = Mass Flow rate, Kg/Hr

h = Absolute pressure, psia

T = Temperature, K

For the given 6.35 mm bore orifice plate,

K1 = 0.256

Kvb = 1.356

Km = 1.753

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EXPERIMENT 2: AIR FLOW PROCESS CONTROL (AF 922)

CONTROLLER MV = -6.3% MV = 50% MV = 70%

Fvb, Nm3/Hr

√78.6×64.7 √66.6×70.3 √49×81.2

1.356 × 1.356 × 1.356 ×
29.2 29.3 29.3

√ℎ𝑝
= Kvb = 26.806 = 26.551 = 26.305
𝑇

Fm, Kg/Hr
√49×81.2
1.753 ×
√78.6×64.7 √66.6×70.3 29.3
1.753 × 1.753 ×
29.2 29.3

√ℎ𝑝
= 34.007
= Km = 34.6545 = 34.325
𝑇

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EXPERIMENT 2: AIR FLOW PROCESS CONTROL (AF 922)

DISCUSSION

The objective of this experiments is to study about the gas volumetric flow rate
measurements using orifice plate, gas mass flow rate measurements using orifice plate and
perfect gas and study gas mass flow rate (Fm) control using PID controller. A compressible
fluid is where fluid density changes when high pressure gradients. For gasses, changes in
density are accompanied in changes of temperature, and this considerably the analysis of
compressible flow. The difference between compressible and incompressible flow is the way
that forces are transmitted through the fluid.

Based on experiments, there are three different test was done observe the process
response. For first experiments, gas mass flow rate control was observed by using PID control
mode with pulse load disturbance and set point disturbance were applied to bother the process
flow response. In this experiment, three different value of PB, was test which are 200, 100, and
150. PB at 100 is the best value compare with others in order to the time it takes to regain
constant and it show that higher value of PB, the slower time it takes to constant. For the
control value non-linearity test with PP and observation control value response without
positioner.

The meaning of set point is the desired value of controlled variable and It is
important to maintain or controlled some desired value. For the first trial 25 kg/hr interval unit
50kg/hr was used for disturbance. The set point (SV) was changed, Ti is integral time, Ti equal
to 6 seconds was used when PB value change. Ti related with Kc, which Ti is inversely
proportional to Kc. When Kc increase it will reduce steady state error time. TD is settling time,
In this experiments TD was set to 0 second. Settling time was required for the process output
reach and remains inside a band. Next, when derivatives time increase, settling time will
decrease.

Range ability is usually stated as a ratio of maximum to minimum flow. There are
two definition of maximum flow, firstly maximum flow rate that the flow meter can measure,
and other definition is that actually occurs in a particular application, this how ,most DP flow
meter are specified. It is important to identify the definition of range ability because it can be
mean different between flow meter that can measure the flow range of interest.

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EXPERIMENT 2: AIR FLOW PROCESS CONTROL (AF 922)

Flow process is a very fast with negligible capacity lag or dead time. The moment
the control valve is adjusted, the flow controller will be receiving the updated signal for the
flow measurements. Thus, flow process can be considered as a high dynamic gain process
compared to level and temperature control. However, flow always characterized by noise,
which can be recorded as spurious fluctuation. This noise contributed with random pressure
fluctuation inside the pipeline and also can be from pump vibration, turbulence flow and
pressure drop at the fitting, valves and flow meter.

Gain can be defined as changes in input divided by the change in output. A process
with high gain will react more to the controller output changing. Flow process is fast and high
gain process because the process is stabilized faster even after introducing the disturbance to
the process.

Derivatives gain defined as larger decrease overshoot, but slowdown transient

response and may lead to instability due to signal noise amplification in the differentiation of
the error. For the flow process control, derivatives control mode is not used because the flow
process is fast and high gain process control, derivatives control is used because the flow
process is fast and high gain process which it doesn’t usually overshoot. Overshoot is means
when a signal exceeds its steady state value.

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EXPERIMENT 2: AIR FLOW PROCESS CONTROL (AF 922)

CONCLUSION & RECCOMENDATION

In a nutshell, the experiment is divided into two parts. Part one is PID single loop flow
control that include single loop control, set point step test and PID controller tuning. Plus, part
two of the experiment is flow, ratio, control linear PID that consist of three different test using
one or more WF pump with ratio 1 – 1.8. The objectives of this experiment is to identify the
major components of flow ration process control system, to perform start-up and shutdown
procedure systematically, to study single loop flow control using PID controller and to study
flow ratio control using linear PID.

A gas mass flow rate was observed using PID control, the PB value was manipulated
in each test which is 200,150 and 100. It is found that, as PB value is increase, the time to reach
steady state is longer. However, during the non-linearity test with PP, the observation control
value response without positioner. Thus, the result is uncertain. To test the set point step test,
value of disturbance was changed between the first and second trial which is 25kg/hr and
50kg/hr. The set value is changed and the integral time is set to 6 seconds. As integral time is
inversely proportional to control gain, the steady state error time will decrease as control gain
increase. Moreover, flow process is a very fast process with negligible capacity lag or dead
time. But, it can be affected by noise that can contributed with fluctuation inside pipeline.
Because flow process is a very fast and high gain process, the process is stabilized faster than
the disturbance was introduced, due to it ca expect the disturbance so prevention was taken
earlier.

There are a few recommendation to improve the quality and result of the experiment.
First, make sure that the marker is functioning well. Next, the paper should be clotted.
Therefore, it will not affected the result of the experiment. Next, ensure that the by-pass valve
PL1 and PL2 is fully open, so the flow of gas will not be interrupted. Plus, ensure that each
value of setting is changed between each trial to avid error in result.

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