Effect of changing set points to the controllability of flow and mass flow control

PROCESS CONTROL PRACTISE ( CPE 622) 2011

ABSTRACT
This project is about the effect of changing the set point on FIC 31 and FIC 91. The set point change is change is in between 5%, 10 % and 20 %. While performing the open loop test, flow control is using the self regulating process. For the open loop test to FIC 31, the numerical method is used. While for FIC 91, the reformulated tangent method is used to calculate the optimum controller tuning, After performing the open loop, then data that is calculated before this is proceeded to do the closed loop test. The value of P& ID is calculated from the open loop test using the Ziegler Nichols method. In flow controller, the PI controller is used because of process response rate. PI controller is commonly used in tuning, this is because the derivative action is very sensitive to measurement noise and the absent of an integral value may prevent the system from reaching it target value due to control action. The responses of the controller can be described in the terms of the responsiveness of the controller to an error, the degree to which the controller overshoots the set point and the degree to the degree of the system oscillation. The set point change is tested during the process. The set point is changes from 5%, 10%, and lastly 20% for each controller which are FIC 31 and FIC91.tuning control loop is the adjustment of its control parameter which are gain, proportional band, integral/ reset, derivative/rate. It also the optimum values for the desired control process.

OBJECTIVE
To study the effect of the set point change to FIC31 and FIC91. To apply the numerical method (FIC31) and the reformulated tangent method (FIC 91) for the open loop test. To apply the Ziegler Nichols method for the closed loop test.

Effect of changing set points to the controllability of flow and mass flow control

PROCESS CONTROL PRACTISE ( CPE 622) 2011

PIPING AND INSTRUMENT DIAGRAM (P&ID)

FIC 31
I/P I/P FIC 31

Water reservoir T32

FT31

P32

FIGURE 1: P&ID DIAGRAM FOR FIC31

Process Description

Effect of changing set points to the controllability of flow and mass flow control
FIC 91

PROCESS CONTROL PRACTISE ( CPE 622) 2011

FIC I/P

FIC 91

PROCESS AIR SUPPLY

VENT

AIR HEATER

TO AP922

FIGURE 2: P&ID DIAGRAM FOR FIC91 PROCESS DESCRIPTION

Effect of changing set points to the controllability of flow and mass flow control

PROCESS CONTROL PRACTISE ( CPE 622) 2011

Experimental Methodology
START FIC31 FIC91

Open Loop Test

Open Loop Test

Numerical method

Reformulated tangent method

Calculate RR, Td, TC

Calculate PI (Z-N)

Calculate PI (Z-N)

Run closed Loop Test

Run closed Loop Test

Set point test 5%, 10%, 20% Combined Analysis TR, TS

Set point test 5%, 10%, 20%

END

Effect of changing set points to the controllability of flow and mass flow control

PROCESS CONTROL PRACTISE ( CPE 622) 2011

RESULTS AND CALCULATION

Control loops

parameters

Numerical method

FIC31

FIC91

Residence time, RR (1/s) 0.1786 Dead time, Td, (s) 5 Time constant, TC, (s) 10 Residence time, RR (1/s) Dead time, Td, (s) Time constant, TC, (s) Table 1: The Open Loop Result

Reformulated tangent method 0.5656 5.10 3.8

Control loops

parameters

Open loop tuning rule

Ziegler -Nichols Proportional band, PB % 99.21 Controller gain, KC 1.00 Integral time, I (s) 0.27 Proportional band, PB % 320 Controller gain, KC 0.31 Integral time, I (s) 17 Table 2: The Open Loop Result by Using Ziegler Nichols.

FIC31

FIC91

Effect of changing set points to the controllability of flow and mass flow control

PROCESS CONTROL PRACTISE ( CPE 622) 2011

Set point change Control loops Initial 1.8 5% 1.89 10% 2.07 20% 2.16 30.0

FIC31 FIC91

25 26.2 27.5 Table 3: The Set Point Change for Each Control Loop.

Control loop

parameters Proportional Band, PB (%)

Tuning test 200 0.02 0.31 17.0

FIC31 Integral time, I (s) Controller gain, KC FIC91 Integral time, I (s) Table 4: The Tuning Test for Each Control Loop.

Effect of changing set points to the controllability of flow and mass flow control

PROCESS CONTROL PRACTISE ( CPE 622) 2011

SAMPLE OF CALCULATION
Closed loop FIC 31 PV 54.13 54.13 54.13 62.19 63.06 63.06 63.06 63.06 63.06 63.06 63.06 RR 0.1712 0.1786 0.0074 0 0 0 0 0 0 Td (s) TC (s)

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Table 5: The Table Obtained From Closed Loop at FIC 31 To calculate RRmax
PV1 PV -1 / 2h MV = (54.48-49.29 )/ 2(1)(5) = 0.519 To calculate Td Td = T1 2 h [ PV1 PV oss / PV1-PV-1] = 3- 2(1) [(54.48-49.29 ) / 54.48-49.29 )] = 1.00 To calculate TC TC = 2h [ (PV nss - PV OSS )/ (PV1-PV-1 )] = 3.25

Effect of changing set points to the controllability of flow and mass flow control

PROCESS CONTROL PRACTISE ( CPE 622) 2011

Open loop

Table 5: Ziegler Nichols formula to calculate open loop

From table 1; FIC31 0.1786 5 10 FIC91 0.5656 5.1 3.108

RRmax TD TC

111.1 RR. TD 0.9/( RR.TD) 3.33 TD

FIC31 99.21 1 0.27

FIC91 320 0.31 17

Effect of changing set points to the controllability of flow and mass flow control

PROCESS CONTROL PRACTISE ( CPE 622) 2011

DISCUSSION
After performing open loop test, close loop test were performed by using Ziegler-Nichols tuning rule. Value of PB= 99.21 % I= 0.27s Kc= 1 for FIC31 and value of PB= 320% I= 17s Kc= 0.31 for FIC91.The process is performing using several of set point values which is 5%,10% and 20%. For the FIC31, when doing the set point test, there are oscillation occur when we insert the value of PB and I that calculated from the open loop calculation using Ziegler-Nichols tuning rule which is 99.21% and 0.27s respectively. It because the PB value may be too small whereas the I value is too big. So we retune the PB value by increase it and decrease the I value until we get the process response without oscillation. And finally the new PB is 200% and I is 0.02s. Then we try for several set point changes which is 5%, 10% and 20% for the new PB and I value. The graph show that the value of PB =200% and I =0.02s is satisfy the process response for various set point change. For the FIC91, the value of Kc and I calculated from the open loop calculation using Ziegler-Nichols tuning rule are 0.31 and 17s respectively. When we enter these value for set point test, there is a little bit of oscillation which is about 0.8% oscillate. It is because the Kc value may slightly bigger than the value that supposed to. When trying for the different sets of set point changes which is 5%, 10% and 20%, the graph give the same kind of oscillation but difference of process response. For set point 5% the process response is fastest compare to 10% and 20% set point changes and takes a less time to stabilize the process compare to other sets of set point changes. The process response is changing due to the changes of the set points.

Effect of changing set points to the controllability of flow and mass flow control

PROCESS CONTROL PRACTISE ( CPE 622) 2011

CONCLUSION
In conclusion the results from calculation part according to numerical methods are slightly difference from conventional tangent analysis. A faster sampling time of data capturing has been suggested to reduce the difference. As the set point value is increasing, the difference process response can obtained. The Ziegler-Nichols tuning rule gives the value of PB, Kc, and I which determined how the graph or process will oscillate. The right tuning of this value will give graph with no oscillation even though the set point change is different. For the FIC91, the bigger the set point change, the slower the process response which is takes more time to stabilize.

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