EXPERIMENTAL PRESSURE CONTROL TRAINER 1

PRESSURE CONTROL TRAINER

DESCRIPTION

The pressure control trainer is designed for teaching the basic pressure control
principles study in chemical and instrumentation engineering. For ease of
understanding, the product is described with its major components.

EXPERIMENTAL PRESSURE CONTROL TRAINER 2

INTRODUCTION

Pressure loops vary from very tight, fast loops (almost like flow control) to slow
averaging loops (almost like level control). An example of a fast pressure loop is the
case of a valve throttling the flow of a vapour from a vessel

THE CONTROL SYSTEM

An air stream entering the tank maintains the pressure of the air at a value P i. It is
desired to maintain (or control) the pressure of the air at P R by means of the
controller. If the measured pressure Pm differs from the desired pressure PR, the
controller senses the difference or error e = PR - Pm, and changes the valve position
in such a way that the desired liquid height P R is obtained in the tank.

COMPONENTS OF A CONTROL SYSTEM

EXPERIMENTAL PRESSURE CONTROL TRAINER 3

 Figure 1. Control System for a Pressure Loop

The system shown may be divided into the following components:

PT Pressure Transmitter
I/P Current to Pneumatic Converter
CV Pneumatic Control Valve
V Vent Valve
R Air Pressure Regulator
S Supply Pressure Gauge (I/P)
SP Set Point
PIC Pressure Indicator Controller

BLOCK DIAGRAM

For computational purposes, it is convenient to represent the control system shown

in Figure 1 by means of the block diagram shown in Figure 2. Such a diagram makes
it much easier to visualize the relationships among the various signals.

Set Point : The set point is synonym for the desired value of the controlled
variable.
Load : The load refers to a change in any variable that may cause the
controlled variable of the process to change.
In the example, the outlet (vent) valve position is a load variable.

The control system shown in Figure 2 is called a closed loop system or a feed back
system because the measured value of the controlled variable is returned to of “fed
back” to a device called the comparator. In the comparator, the controlled variable is
compared with the desired value or set point. If there is any difference between the
measured variable and the set point, an error is generated; this error enters a
controller, which in turn adjusts the final control element in order to return the
controlled variable to the set point.
Load
Vent Valve Controlled
PID Controller Variable, P
Comparator
Final Control Process
Controller Element (Pressure in
(Control Valve) Tank)
Set Point
PR

Measuring Element
(Pressure Sensor &
Transmitter)
Measured
Variable, Pm

Figure 2. Block Diagram of a Pressure Control System

EXPERIMENTAL PRESSURE CONTROL TRAINER 4
 FUNCTIONING OF THE SYSTEM

Figure 1 & 2 show that a pressure sensor is used to measure the pressure of air in
the tank; the signal from the pressure sensor is sent to the transducer (pressure
transmitter), which produces an output in the range of 4-20 mA, which is a linear
function of the input. The output of the transducer enters the controller where it is
compared to the set point to produce an error signal. The controller converts the
error to an output in the range of 4-20 mA according to the control law (P, PI, PD,
PID or On-Off) stored in the memory of the controller. The output of the controller
enters the I/P converter, which produces an output in the range of 3-15 psig, which is
a linear function of the input. Finally, the output of the converter is sent to the top of
the control valve, which adjusts the flow of air to the tank. The control valve used
here is linear and is pressure-to-open type. The external power of 230 V AC is
required for controller and I/P converter and 24 V DC for pressure transmitter. A
source of 20-psig airs is needed for the converter.

Valve for To see how the components interact with each other, consider the process to be
Pneumatic
Control operating at steady state with the outlet flow rate through the tank is equal to the set
generating
Valve
disturbance point. If the outlet flow rate from the tank increases, the following events occur.
Immediately the pressure sensor & pressure transmitter detects a decrease in the
pressure of the air in the tank and produces a change in the signal to the controller.
As soon as the controller detects decrease in the pressure, relative to the set point,
the controller output increases according to the control action chosen. The increase
in signal to the converter causes the output from the converter to increase and open
the valve in order to increase the flow of air. The increased flow will eventually
increase the pressure of air in the tank and move it towards the set point. From this
quantitative description, we see that the flow of signals from one component to the
next is such that the pressure of air in the tank should return to the set point. In a
well-tuned control system, the response of the pressure will oscillate around the set
point before coming to steady state.

EXPERIMENTAL PRESSURE CONTROL TRAINER 5

 PRESSURE CONTROL TRAINER
OPERATIONAL MANUAL

STARTUP PROCEDURE:

 Check that the air pressure regulator supplying air to the control valve (fitted
at the back of the equipment) and pressure regulator supplying air to the I/P
converter (fitted on the front panel) are shut off properly.
 Check that the drain valve of the air compressor provided beneath the air
supply valve of the pressure tank of the air compressor and the air supply
valve itself is also shut off.
 Switch ON the air compressor motor and allow the air pressure to build up in
the compressor’s pressure tank up to about 7-kg/ cm 2 (g).
 Now open the air supply valves provided on the compressor’s pressure tank
and allow the air to reach the pressure regulators.
 Slowly open the air pressure regulator provided for the pneumatic control
valve (fitted at the back of the equipment) and set the pressure near to 1.5 kg/
cm2 (g) as indicated by the pressure gauge provided on the pressure regulator
and pneumatic control valve also.
 Now open the pressure regulator provided for the I/P converter (fitted on the
front panel) and set the pressure to 1.4 kg/ cm 2 (g) as indicated by the
pressure gauge fitted along with it.
 In control panel you can have recorder output ( in the range of 0 – 100 % )
( 4 – 20 mA) to which you can attach recorder of same input type. (i.e. 4 – 20
mA.) The current meters at the top panels indicates E/P Converter input and
Transmitter output in the range of 4 –20 Ma respectively.
 Check all the air connections for any sort of leakage and in case any leakage
is observed tighten it immediately to prevent the loss of compressed air.
 Open the disturbance valve (needle valve) provided on the pressure tank
slightly/ to the desired degree.
 Now switch on the PID controller.
 Switch ON the computer and start the software for Pressure Control Trainer
by executing the respective executable file (pressure.exe).

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  Open the Citect explorer and run the program and select the pressure control
trainer.
 Choose the Mode of Operation or Control action of interest, apply the
disturbance/ change of set point and log the data to the computer and analyze
it.

SHUTDOWN PROCEDURE:

 First of all shutting down the system after experiment, Shutdown the
programme.
 Close the air supply to the E/P Converter /control valve by closing the
regulator provided.
 Switch off the air compressor and shut off the discharge valve of it. Drain
the filled air from the cylinder of compressor by opening the drain coke at
the bottom of the compressor. Close the air supply valve to the control
trainer.
 Adjust the set point of the PID Controller to a lower value. Switch off the
power supply to the trainer.
 Fully open the needle valve (vent valve) provided on the top of the
pressure vessel to remove any air quantity of air from the system.
 Switch off the power supply to the trainer.

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PRECAUTIONS:

 For proper operation read the instruction provided and then follow it step
by step.
 Do not apply very high set point to the PID controller (not above range) as
it may damage it may damage the pressure vessel/transmitter after long
time through the vessel is tested to the high pressure.
 Do not apply higher pressure to E/P Converter (Greater than 1.4 Kg/cm 2)
as it may damage it. Also the lesser pressure (less than 1.4 Kg/cm 2) may
not give accurate functioning of it.
 Do not change link position of the control panel terminals.
 Do not alter the wiring of instrument.
 Do not alter or modify the components of the trainer.
 Use standard parts provided by D. K. Scientific Industries.
 Carefully read the manuals of each component fitted in the trainer and
understand the product working. Refer the individual manual of each
proper maintenance and precautions.
 If possible put trainer in Air-conditioned room.
 Do not put instrument idle for a longer time. Run it once in a week.
 Give routine maintenance to it.
 Remove dust periodically from the trainer.
 Any problem encountered during the use of the set up, first refer
instruction manual. If problem persists, contact us immediately. We provide
support for your specific questions or any up gradation.

ROUTINE MAINTENANCE:

 Check the working of control panel when not in use.

 Disconnect the electric supply to the control panel when not in use.
 Drain the water content in the air filter regulator regularly.
 Do not allow the pressure in the pressure tank to cross the pressure of 10
Kg/cm2 (Max. limit of pressure tank) as it may damage the pressure sensor
transmitter/pressure tank.

EXPERIMENTAL PRESSURE CONTROL TRAINER 8

TROUBLESHOOTING:

SR.
PART NAME PROBLEM CORRECTIVE MEASURES
NO.
 If Indication deviates
above + / - 3 % from
Wrong display of actual Value, calibrate
1 PID Controller
the Control value. the Controller as
mentioned in controller
manual.
 Ensure pneumatic air
pressure 1.4 Kg/cm2 is
available from the
pressure regulator to
the I/P Converter as
indicated by the
pressure gauge
provided along with the
regulator on the front
panel.
 Check the leakage
from the valve
Diaphragm.
Control valve not  Proportional Band (Pb)
2 Control valve
operating. value in the PID
controller is not very
low as it may Cause
oscillation of the control
valve for the fractional
value of error.
 Check the transmitter
connection to PID
controller.
 Leakage in the airline
running from the E/P
Converter to pneumatic
control valve, change
the pipeline.
Not give the  Ensure that the proper
3 Valve positioner proper output to air supply 1.4 Kg/cm2 is
the control valve. come to the positioner.
4 Pressure Does not give  Ensure that 24 V DC
Transmitter output. Comes to the
Transmitter.
 Ensure that link on the
panel is properly
EXPERIMENTAL PRESSURE CONTROL TRAINER 9
 connected.

 Switch off the

computer.
 Ensure all cable
connection.
No  Ensure connection of
Software
5 communication RS 232 /485 Converter.
programme.
With computer. Ensure PID is ON.
 Check the data
connection port For
computer.

DESCRIPTION OF APPARATUS :-

PID CONTROLLER :

 Procedure for entering the values of P,I and D : To enter the values of

P, I and D into the PID controller press 1st and 3rd key at a time, then

after some time another screen will open, in this screen you can see like

(----- or AT ). In this screen if you want to select auto tuning press Up /

Down arrow key, then select (AT) option, then press 3rd key for next,

now you will find the screen for entering the value of P. Here you can

change the value by Up / Down arrow keys. Then press 3rd key for the

next option. When all the options will complete, then it will show the main

screen of process value(PV) and set point(SP). If you have selected the

auto tuning(AT) option, then you cannot appear the option of P,I and D

by the 3rd (next / enter) key. If you have selected the (-----) option then

and then you will find the another options of P,I and D. This whole

procedure is appeared in the Operation Flowchart in the manual of PID

EXPERIMENTAL PRESSURE CONTROL TRAINER 10

 controller.

 If you want to change the valve position by manually, then press the

fourth key of the PID controller, Now you will get the different screen and

it will appear like M 30. Here 30 indicates that, now the 30% of valve is

open. You can change that value by UP and DOWN arrow keys. Now if

you want to go to the normal screen press this fourth key again.

PID algorithm is a bit more sophisticated, effective control modules can be

built with just afew simple building blocks. Typical autopilots are built using a

PID algorithm. PID stands for proportional, integral, and derivative. Typically a

PID controller manipulates one control output to force a process value towards

a reference point. Let me say that again an a bit different way. Imagine a

cruise contro on a car. We know the current speed. We know the target

speed. And we know the accelerator position. The cruise control will

manipulate the accelerator position (control output) to try to make the current

speed (process value) equal to the target speed (reference point.) How the

cruise control calculates what accelerator position is needed to hold the

desired speed (even going up and down hills) is where the magic happens.

Proportional

All three components of the PID algorithm are driven by the difference

between the process value (i.e. the current speed) and the reference point

(i.e. the target speed.) We will call this difference (of error) for one particular

time step . For that same time step, we call the process value and the

reference point .

EXPERIMENTAL PRESSURE CONTROL TRAINER 11

The output value (i.e. the accelerator position) is called . The proportional

component simply calculates based on the size of the error term by

simply multiplying it by a constant, .

For simple situations, this all by itself can be a very effect control algorithm.

Typically this works best when you know that when then . For

example, imagine a simple wing leveler in an aircraft. The process value is

going to be bank angle, the reference point is going to be zero (zero bank

angle means the wings are level.) Assume a well trimmed aircraft with neutral

stability so that when the ailerons are zero there is no change in bank. A

proportional only control would set the aileron deflection inversely proportional

to the bank angle. As the bank angle gets closer to zero, the aileron deflection

gets closer to zero. Something as simple as this (a formula with one multiply

operation) can be an amazingly effective and stable controller.

Integral

Unfortunately life is often more complicated than we'd like, and even in the

case of a simple wing leveler, you encounter situations where the aircraft isn't

perfectly trim and zero aileron deflection does not always equal zero roll

motion. In an aircraft such as a Cessna 172, the amount of aileron deflection

needed to keep the wing level can vary with speed. In these cases, a

proportional only controller will stabilize out quickly, but will stabilize to the

wrong value. We need a way to drive the error in the proportional only

controller to zero. Enter the Integral component of the PID algorithm.

EXPERIMENTAL PRESSURE CONTROL TRAINER 12

Remember back to your calculus days, integral refers to the area under a

curve. If you have a function, the integral of that function produces a second

function which tells you the area under curve of the first function.

Fortunately we usually don't have a formula for the first function since it

changes depending on external conditions (i.e. current speed in a car.) That

means we can't integrate this function directly and we are spared all the

potentially messy calculus. So we use an alternative approach to approximate

the error under the process value curve. At each time step we know which

is the difference between the process value and the reference point. If we

multiply this distance times (the time step) we get an area which

approximates the error under the curve just for this time step. If we add these

areas up over time, we get a very reasonable approximation of the area under

the curve. Essentially what this does is that the longer time passes with us not

at our target value, the larger the sum of the (error dt)'s becomes over time.

If we use this sum to push our output value (i.e. our accelerator position) then

the longer we don't quite hit our target speed, the further the system pushes

the accelerator pedal. Over time, the integral component compensates for the

error in the proportional component and the system stabilizes out at the

desired speed.

Derivative

Hopefully someone else can chip in and add more explanation to this section.

But going back again to calculus. The derivative of a function implies the rate

of change of the function output. If you know the function, you can take the

derivative of that function to produce a second function. For any point in time,

EXPERIMENTAL PRESSURE CONTROL TRAINER 13

the derivative function will tell you the rate of change (or slope) of the first

function.

Conceptually, this makes sense in the context of a controller. How quickly we

are closing on our target value (i.e. the rate of change from each time step to

the next) is an important piece of information that can help us build a more

stable system that more quickly achieves the target value.

For a car cruise control, we are measuring velocity at each time step. The rate

of change of velocity is defined as acceleration (for those that remember your

physics.)

Combining P + I + D

Here is a key point to understand. The proportional component is very stable.

The Integral and Derivative components are very unstable. If we build a

proportional only controller, it will be very stable but will stabilize to the wrong

value. (i.e. if we want to go 90km/hr, it might stabilize out to 82km/hr.) If we

build an integral only controller it will quickly hit the target value, but will

overshoot, then overcompensate, and will oscillate wildly around the target

value. It is very unstable. The trick then is to combine these components

together by summing them. The actual output is equal to what the P

component says the output should be plus what the I component says the

output should be plus what the D component says the output should be. You

can assign a weighting value to each component to increase or decrease it's

relative power to influence the final output value.

As you can see, the actual math involved in a PID controller (while rooted in
EXPERIMENTAL PRESSURE CONTROL TRAINER 14
some deep theory) is actually quite simple to implement. The real trick for

creating a well behaved PID controller and a well behaved autopilot is tuning

the relative weights of each of the P, I, and D components.

Control valve :-

Globe valves are named for their spherical body shape. The two halves

of the valve body are separated by an internal baffle which has an opening

forming a seat onto which a movable plug can be screwed in to close (or shut)

the valve. In globe valves, the plug is connected to a stem which is operated

by screw action in manual valves. Typically, automatically controlled valves

are of the sliding stem type. These globe valves have a smooth stem rather

than threaded and are opened or closed by an actuator assembly. When a

globe valve is manually operated, the stem is turned by a handwheel.

Although globe valves in the past had the spherical bodies which gave

them their name, many modern globe valves do not have much of a spherical

shape, but the term globe valve is still often used for valves that have such an

internal mechanism. In plumbing, valves with such a mechanism are also

often called stop valves since they don't have the global appearance, but the

term stop valve may refer to valves which are used to stop flow even when

they have other mechanisms or designs.

EXPERIMENTAL PRESSURE CONTROL TRAINER 15
 Globe valves are used for applications requiring throttling and frequent

operation. For example, globe valves or valves with a similar mechanism may

be used as sampling valves, which are normally shut except when liquid

samples are being taken. Since the baffle restricts flow, they're not

recommended where full, unobstructed flow is required.

Globe valves are typically two-port valves, although three port valves

are also produced. Ports are openings in the body for fluid flowing in or out.

The two ports may be oriented straight' across from each other on the body, or

oriented at an angle such as a 90° angle. Globe valves with ports at such an

angle are called angle globe valves.

Parts of typical globe valve:

A body is the main pressure containing structure of the valve and the

most easily identified as it forms the mass of the valve. It contains all of the

valve's internal parts that will come in contact with the substance being

controlled by the valve. The bonnet is connected to the body and provides the

containment of the fluid, gas or slurry that is being controlled.

A bonnet provides leakproof closure for the valve body. The threaded

section of stem goes through a hole with matching threads in the bonnet.

Globe valves may have a screw-in, union, or bolted bonnet. Screw-in bonnet

is the simplest bonnet, offering a durable, pressure-tight seal. Union bonnet is

suitable for applications requiring frequent inspection or cleaning. It also gives

the body added strength. A bonnet attached with bolts is used for larger or

higher pressure applications. Bonnets also contain the packing, which is a

wearable material that maintains the seal between the bonnet and the stem
EXPERIMENTAL PRESSURE CONTROL TRAINER 16
during valve cycling operations

A plug is the closure member of the valve. Plugs are connected to the

stem which is slid or screwed up or down to throttle the flow. Plugs are

typically of the balance or unbalanced type. Unbalanced plugs are solid and

are used with smaller valves or with low pressure drops across the valve. The

advantages are simpler design, with one possible leak path at the seat and

usually lower cost. The disadvantages are the limited size; with a large

unbalanced plug the forces needed to seat and hold the flow off become

impractical. Balanced plugs have holes through the plug. Advantages include

easier shut off as the plug does not have to overcome static forces. However,

a second leak path is created between the plug and the cage, cost is generally

higher.

A stem serves as a connector from the actuator to the inside of the

valve and transmits this actuation force. Stems are either smooth for actuator

controlled valves or threaded for manual valves. The smooth stems are

surrounded by packing material to prevent leaking material from the valve.

This packing is a wear material and will have to be replaced during

maintenance. With a smooth stem the ends are threaded to allow connection

to the plug and the actuator. The stem must not only withstand a large amount

of compression force during valve closure, but also have high tensile strength

during valve opening. In addition, the stem must be very straight, or have low

runout, in order to insure good valve closure. This minimum runout also

minimizes wear of the packing contained in the bonnet, which provides the

seal against leakage.

EXPERIMENTAL PRESSURE CONTROL TRAINER 17
 A cage is the part of the valve that surrounds the plug and is located

inside the body of the valve. Typically, the cage is one of the greatest

determiners of flow within the valve. As the plug is moved more of the

openings in the cage are exposed and flow is increased and vise versa. The

design and layout of the openings can have a large effect on flow of material

(the flow characteristics of different materials at temperatures, pressures that

are in a range). Cages are also used to guide the plug to the seat of the valve

for a good shutoff, substituting the guiding from the bonnet.

A seat ring provides a stable, uniform and replaceable shut off surface.

Seat rings are usually held in place by pressure from the fastening of the

bonnet to the top of the body. This pushes the cage down on the lip of the

seat ring and holds it firmly to the body of the valve. Seat rings my also be

threaded and screwed into a thread cut in the same area of the body.

However this method makes removal of the seat ring during maintenance

difficult if not impossible. Seat rings are also typically beveled at the seating

surface to allow for some guiding during the final stages of closing the valve.

Economical globe valves or stop valves with a similar mechanism used in

plumbing often have a rubber washer at the bottom of the disc for the seating

surface, so that rubber can be compressed against the seat to form a leak-

tight seal when shut.

Valve positioner :-

A valve Positioner is a device used to increase or decrease the air

pressure operating the actuator until the valve stem reaches the position

called for by the instrument controller.

EXPERIMENTAL PRESSURE CONTROL TRAINER 18

 Positioners are generally mounted on the side or top of the actuator.

They are connected mechanically to the valve stem so that stem position can

be compared with the position dictated by the controller .

A positioner is a type of air relay which is used between the controller

output and the valve diaphragm. The positioner acts to overcome hysteresis,

packing box friction, and valve plug unbalance due to pressure drop. It

assures exact positioning of the valve stem in accordance with the controller

output.

Reasons To Use Positioners

 Increase control system resolution: i.e. fine control

 Allow use of characteristic cams.

 Minimize packing friction effects: i.e. high-temperature packing.

 Negate flow-induced reactions to higher pressure drops.

 Increase speed of response to a change in process.

 Allow split ranging.

 Overcome seating friction in rotary valves.

 Allow distances between controller and control valve.

 Allow wide range of flow variation: i.e. operate at less than 10% travel

under normal conditions.

 Allow increased usage of 4-20 mA electronic signal.

 Increase fast venting (unloading) capability.

Principle of Operation :

The positioner is mechanically connected to the stem of the valve.

This stem position is compared with the position called for by the instrument

EXPERIMENTAL PRESSURE CONTROL TRAINER 19

controller, i.e. by the instrument output air signal. A separate air supply is

brought into the positioner for positioning the valve at exactly the point called

for by the controller.

PRESSURE VESSEL :-
A pressure vessel is a closed, rigid container designed to hold gases or

liquids at a pressure different from the ambient pressure. The end caps fitted to the

cylindrical body are called heads .

In addition to industrial compressed air receivers and domestic hot water

storage tanks, other examples of pressure vessels are: diving cylinder,

recompression chamber, distillation towers and many other vessels in oil refineries

and petrochemical plants, nuclear reactor vessel, habitat of a space ship, habitat of a

submarine, pneumatic reservoir, hydraulic reservoir under pressure, rail vehicle

EXPERIMENTAL PRESSURE CONTROL TRAINER 20

airbrake reservoir, road vehicle airbrake reservoirand storage vessels for liquified

gases such as ammonia, chlorine, propane, butane and LPG.

In the industrial sector, pressure vessels are designed to operate safely at a

specific pressure and temperature, technically referred to as the "Design Pressure"

and "Design Temperature". A vessel that is inadequately designed to handle a high

pressure constitutes a very significant safety hazard.

PRESSURE TRANSMITER :-

When pressure, force or acceleration is applied to a quartz crystal, a charge is

developed across the crystal that is proportional to the force applied.

The fundamental difference between these crystal sensors and static-force devices

such as strain gages is that the electric signal generated by the crystal decays

rapidly. This characteristic makes these sensors unsuitable for the measurement of

static forces or pressures but useful for dynamic measurements.

Piezoelectric devices can further be classified according to whether the

crystal's electrostatic charge, its resistivity, or its resonant frequency electrostatic

charge is measured. Depending on which phenomenon is used, the crystal sensor

can be called electrostatic, piezoresistive, or resonant.

When pressure is applied to a crystal, it is elastically deformed. This deformation

results in a flow of electric charge (which lasts for a period of a few seconds). The

resulting electric signal can be measured as an indication of the pressure which was

applied to the crystal. These sensors cannot detect static pressures, but are used to

measure rapidly changing pressures resulting from blasts, explosions, pressure

pulsations (in rocket motors, engines, compressors) or other sources of shock or

vibration. Some of these rugged sensors can detect pressure events having "rise

times" on the order of a millionth of a second, and are described in more detail later

in this chapter.

EXPERIMENTAL PRESSURE CONTROL TRAINER 21

USER MANUAL OF SOFTWARE :-

 Home Page: This is the Home

Page in Citect /
 As you run the program, Home Page will be open. SCADA for Control

Figure 3.1 - Home Page

 All pages in the Citect/SCADA have a top and a bottom navigation menu that
allow the operator an easy access to all the Citect/SCADA pages.

 Pressure Control Trainer page is segregated into 4 parts.

Parameters Monitoring & Control, Mimic, PV & SP Trend, OP Trend

 Parameters Monitoring & Control window is having display of Process

Parameters such as Set Point (SP), Process Value (PV), Output (OP) and
Alarm Limits.

 User can select Proportional (P), Proportional Integral (PI), Proportional

Derivative (PD), Proportional Integral Derivative (PID) or ON/OFF mode.

 User can also enter values for SP, OP and Alarm Limits using keyboard. For
that, focus on displayed value, enter new value and press Enter. For OP, slider
control is also available.
EXPERIMENTAL PRESSURE CONTROL TRAINER 22
 Top Navigation Menu is having following buttons.
Date &

Page Contact

Alarms &
Login
Figure 3.1.1 – Top Navigation Menu

Back Button – Displays the last viewed Page

Forward Button – Displays next Page – Bar Graph, Mimic

Home Button – Displays the Home Page

Contact Button – Displays Contact Details

EXPERIMENTAL PRESSURE CONTROL TRAINER 23

 Home Page is having P&I diagram, Display of PV,SP,OP,PID settings
adjustments and trends for PV,SP,OP.

 Parameters such as Set Point (SP), Process Value (PV), Output (OP), and
Proportional (P), Integral (I), Derivative (D) are displayed.

 After login, click on tabular of the bottom navigation menu, Tabular page opens
and this Tabular page displays values of all parameters in the tabular format.

EXPERIMENTAL PRESSURE CONTROL TRAINER 24

 Opens the Mimic for Control Trainer
Mimic for Pressure
Control Trainer

PID settings :

EXPERIMENTAL PRESSURE CONTROL TRAINER 25

 Mode

Set Point

Process Value

Output

Alarm Lmits

Figure 3.2.1 – Parameters Monitoring & Control

Manual Button – Selection of Manual / Auto mode

 Currently it is showing Manual mode.
 By clicking on this button, it will change from Manual to Auto.

In Auto mode, PID values can be entered. Also, output entry is

not possible in Auto mode.
 Again clicking on this button will revert to Manual mode.

PID Button – Displays window for PID Parameters entry

 P, I, & D parameters are displayed. User can enter new values using
keyboard. For that, focus on specified parameter in new column,
enter new value and press Enter.
 Click on OK to exit the window.

EXPERIMENTAL PRESSURE CONTROL TRAINER 26

 Now to change the values of P, I and D. set the mouse pointer on the
New column at the particular position of the particular parameter of this
screen, then enter the new value from the key board then press Enter.
Now click the OK button from this screen. During entering the new
value, do not remove the mouse pointer from its particular position.

 Control Trainer Mimic is Pressure displayed with Panel & Zoom buttons.

EXPERIMENTAL PRESSURE CONTROL TRAINER 27

 Figure 3.2.2 – Mimic

Panel Button – Displays Pressure Control Panel window

Zoom button – Displays P&I diagram magnified.

 Panel page : Through down navigation menu open the panel screen.

EXPERIMENTAL PRESSURE CONTROL TRAINER 28

 Displays Pressure Controller Output in mA

 PV & SP Trends are displayed in the right half of the Control Trainer

Zoom
Button

Figure 3.2.3 – PV & SP Trend for Pressure

 PV_Pressure, SP_Pressure, al_h_Pressure & al_l_Pressure are

defined tags for the PV & SP Trend.

 OP Trends are displayed in the right half of the Control Trainer page.

EXPERIMENTAL PRESSURE CONTROL TRAINER 29

 Zoom
Butto
Figure 3.2.4 – OP Trend for Pressure n
 OP_Pressure is defined tag for the OP Trend.

Zoom Button – Displays PV & SP and OP Trends zoomed.

 In the upper graph window there are four different colours of trends, we
can observe, But After making communication between PC and PID
controller. In this graph green line indicates the PV%(Process Value),
yellow line indicates the SP%(Set Point), red line indicates the Alarm
H(high Alarm) and blue line indicates the Alarm L(Low Alarm).

 In the lower graph window the green line indicates the OP%(Output).

EXPERIMENTAL PRESSURE CONTROL TRAINER 30

 PRESSURE
CONTROL
TRAINER
EXPERIMENTAL
MANUAL

EXPERIMENTAL PRESSURE CONTROL TRAINER 31

 EXPERIMENT: 1
OPEN LOOP (MANUAL MODE) CONTROL
AIM : To Study the Open Loop (Manual Mode) Control.

PROCEDURE:

 Start the equipment as mentioned in the startup procedure above.

 Adjust the opening (approx. 50 %) of the disturbance valve provided on the
pressure tank and do not alter it throughout the course of the experiment.
 Select the Manual option by pressing the AUTO/MANUAL button provided on
the main screen. The button should indicate MANUAL when the controller is
in Manual Control mode.
 Open/ Close the Control Valve by increasing / decreasing the output using the
up/ down arrow keys provided besides the indicator of output or directly insert
the value of desired output in the output value box by inserting the cursor.
 Choose the Save As option in the File menu and save the file by giving
appropriate name.
 Apply the step change of 10% every time after the system reaches the steady
state till the controller output reaches the value of 100%. Note down these
steady state process variable values with the corresponding controller output.
 Shut down the equipment as mentioned in the shutdown procedure above.
 While conducting this experiment the process variable value should not
exceed the value of 5-kg/ cm2 (g) as it may damage the pressure tank/
pressure sensor-transmitter.

EXPERIMENTAL PRESSURE CONTROL TRAINER 32

Observations:
Controller Pressure in the
Sr.
Output Tank
No.
(%) (Kg/ cm2)
1 10
2 20
3 30
4 40
5 50
6 60
7 70
8 80
9 90
10 100

CALCULATIONS:

From the above data calculate the output required for maintaining the pressure in the
tank at the desired value with fixed disturbance.

EXPERIMENT: 2
CLOSED LOOP (AUTO MODE) CONTROL
(ON/ OFF CONTROL)

AIM : To Study the Closed Loop (Auto Mode) Control (On/ Off Control).
EXPERIMENTAL PRESSURE CONTROL TRAINER 33
PROCEDURE:
 Start the equipment as mentioned in the startup procedure above.
 Adjust the opening (approx. 20 %) of the disturbance valve provided on the
pressure tank and do not alter it throughout the course of the experiment.
 Select the Auto option by pressing the AUTO/MANUAL button provided on
the main screen. The button should indicate AUTO when the controller is in
Auto Control mode.
 Allow the system to attain the steady state at the initial set point (about 2 kg/
cm2 (g)) value of pressure in the pressure tank.
 Choose the Save As option in the File menu and save the file by giving
appropriate name.
 Choose the On/Off Control action from the Menu Button on the main screen
and also supply the value of difference expressed as % of input span (0.1-
10%, default value 0.5%) in the popped up dialogue box.
 Shut down the equipment as mentioned in the shutdown procedure above.
 While conducting this experiment the process variable value should not
exceed the value of 5-kg/ cm2 (g) as it may damage the pressure tank/
pressure sensor-transmitter.
OBSERVATIONS:
Observe that if the process variable (pressure) value exceeds the set point
beyond the difference value controller totally shutoff the control valve and if
process variable (pressure) value decreases than the control valve is opened
fully i.e. process is operating as an On-Off switch.

EXPERIMENT: 3
CLOSED LOOP (AUTO MODE) CONTROL
(PROPORTIONAL CONTROL)

EXPERIMENTAL PRESSURE CONTROL TRAINER 34

AIM: To Study the Closed Loop (Auto Mode) Control (Proportional
Control).

PROCEDURE:
 Start the equipment as mentioned in the startup procedure above.
 Adjust the opening (approx. 20 %) of the disturbance valve provided on the
pressure tank and do not alter it throughout the course of the experiment.
 Select the Auto option by pressing the AUTO/MANUAL button provided on
the main screen. The button should indicate AUTO when the controller is in
Auto Control mode.
 Allow the system to attain the steady state at the initial set point (about 2 kg/
cm2 (g)) value of pressure in the pressure tank.
 Choose the Save As option in the File menu and save the file by giving
appropriate name.
 Choose the Proportional (P) Control action from the Menu Button on the
main screen.
 Click on to the PID button and enter the desired value of proportional band in
the popped up screen and apply it.
 Allow the system to achieve the steady state and observe the offset between
the process variable and set point. Change the value of proportional band
observes the Load change (regulatory problem) may also be applied by
changing the opening position of the disturbance valve provided on the
pressure tank. / Set point change may also be applied by changing the set
point (servo problem) using the up/ down arrow provided besides the indicator
of set point or directly insert the value of desired set point in the set point
value box by inserting the cursor.
 Shut down the equipment as mentioned in the shutdown procedure above.
 The value of load change / set point change should be approximately 20% of
the range to obtain proper response otherwise the controller may track to its
set point without any overshoot/ undershoot.
 While conducting this experiment the process variable value should not
exceed the value of 5-kg/ cm2 (g) as it may damage the pressure tank/
pressure sensor-transmitter.

EXPERIMENTAL PRESSURE CONTROL TRAINER 35

OBSERVATIONS:

Observe that the offset decreases with decrease in the proportional band value.
Observe the effect of load & set point change on the behavior of the system.

EXPERIMENTAL PRESSURE CONTROL TRAINER 36

 EXPERIMENT: 4
CLOSED LOOP (AUTO MODE) CONTROL
(PROPORTIONAL + INTEGRAL CONTROL)

AIM: To Study the Closed Loop (Auto Mode) Control (Proportional +

Integral Control).

PROCEDURE:
 Start the equipment as mentioned in the startup procedure above.
 Adjust the opening (approx. 20 %) of the disturbance valve provided on the
pressure tank and do not alter it throughout the course of the experiment.
 Select the Auto option by pressing the AUTO/MANUAL button provided on
the main screen. The button should indicate AUTO when the controller is in
Auto Control mode.
 Allow the system to attain the steady state at the initial set point (about 2 kg/
cm2(g) value of pressure in the pressure tank.
 Choose the Save As option in the File menu and save the file by giving
appropriate name.
 Choose the Proportional + Integral (PI) Control action from the Menu Button
on the main screen.
 Click on to the PID button and enter the desired value of proportional band
and reset time in the popped up screen and apply it.
 Allow the system to achieve the steady state and observe the path followed
by the process variable to reach the set point. Change the value of
proportional band as well as reset time and observe the same.
 Load change (regulatory problem) may also be applied by changing the
opening position of the disturbance valve provided on the pressure tank. / Set
point change may also be applied by changing the set point (servo problem)
using the up/ down arrow provided besides the indicator of set point or directly
insert the value of desired set point in the set point value box by inserting the
cursor.
 Shut down the equipment as mentioned in the shutdown procedure above.
 The value of load change / set point change should be approximately 20% of
the range to obtain proper response otherwise the controller may track to its
set point without any overshoot/ undershoot.

EXPERIMENTAL PRESSURE CONTROL TRAINER 37

  While conducting this experiment the process variable value should not
exceed the value of 5-kg/ cm2 (g) as it may damage the pressure tank/
pressure sensor-transmitter.

OBSERVATIONS:

Observe that at any value of proportional band & reset time the value of offset is
zero, however the time required for the same varies as the value changes.
Observe the effect of load & set point change on the behavior of the system.

EXPERIMENTAL PRESSURE CONTROL TRAINER 38

 EXPERIMENT: 5
CLOSED LOOP (AUTO MODE) CONTROL
(Proportional + Derivative Control)

AIM: To Study the Closed Loop (Auto Mode) Control (Proportional +

Derivative Control).

PROCEDURE:
 Start the equipment as mentioned in the startup procedure above.
 Adjust the opening (approx. 20 %) of the disturbance valve provided on the
pressure tank and do not alter it throughout the course of the experiment.
 Select the Auto option by pressing the AUTO/MANUAL button provided on
the main screen. The button should indicate AUTO when the controller is in
Auto Control mode.
 Allow the system to attain the steady state at the initial set point (about 2 kg/
cm2 (g)) value of pressure in the pressure tank.
 Choose the Save As option in the File menu and save the file by giving
appropriate name.
 Choose the Proportional + Derivative (PD) Control action from the Menu/
Radio Button on the main screen.
 Click on to the PID button and enter the desired value of proportional band
and rate time in the popped up screen and apply it.
 Allow the system to achieve the steady state and observe the path followed
by the process variable to reach the set point. Change the value of
proportional band as well as rate time and observe the same.
 Load change (regulatory problem) may also be applied by changing the
opening position of the disturbance valve provided on the pressure tank. / Set
point change may also be applied by changing the set point (servo problem)
using the up/ down arrow provided besides the indicator of set point or directly
insert the value of desired set point in the set point value box by inserting the
cursor.
 Shut down the equipment as mentioned in the shutdown procedure above.
 The value of load change / set point change should be approximately 20% of
the range to obtain proper response otherwise the controller may track to its
set point without any overshoot/ undershoot.
EXPERIMENTAL PRESSURE CONTROL TRAINER 39
  While conducting this experiment the process variable value should not
exceed the value of 5-kg/ cm2 (g) as it may damage the pressure tank/
pressure sensor-transmitter.

OBSERVATIONS:

Observe that at any value of proportional & rate time the process variable is not able
to reach the set point value.

Observe the effect of load & set point change on the behavior of the system.

EXPERIMENTAL PRESSURE CONTROL TRAINER 40

 EXPERIMENT: 6
CLOSED LOOP (AUTO MODE) CONTROL:
(PROPORTIONAL + INTEGRAL + DERIVATIVE CONTROL)

AIM: To Study the Closed Loop (Auto Mode) Control (Proportional +

Integral + Derivative Control).

PROCEDURE:
 Start the equipment as mentioned in the startup procedure above.
 Adjust the opening (approx. 20 %) of the disturbance valve provided on the
pressure tank and do not alter it throughout the course of the experiment.
 Select the Auto option by pressing the AUTO/MANUAL button provided on
the main screen. The button should indicate AUTO when the controller is in
Auto Control mode.
 Allow the system to attain the steady state at the initial set point (about 2 kg/
cm2 (g) value of pressure in the pressure tank.
 Choose the Save As option in the File menu and save the file by giving
appropriate name.
 Choose the Proportional + Integral + Derivative (PID) Control action from
the Menu/ Radio Button on the main screen.
 Click on to the PID button and enter the desired value of proportional band,
reset time and rate time in the popped up screen and apply it.
 Allow the system to achieve the steady state and observe the path followed
by the process variable to reach the set point. Change the value of
proportional band, reset time as well as rate time and observe the same.
 Load change (regulatory problem) may also be applied by changing the
opening position of the disturbance valve provided on the pressure tank. / Set
point change may also be applied by changing the set point (servo problem)
using the up/ down arrow provided besides the indicator of set point or directly
insert the value of desired set point in the set point value box by inserting the
cursor.
 Shut down the equipment as mentioned in the shutdown procedure above.
 The value of load change / set point change should be approximately 20% of
the range to obtain proper response otherwise the controller may track to its
set point without any overshoot/ undershoot.

EXPERIMENTAL PRESSURE CONTROL TRAINER 41

  While conducting this experiment the process variable value should not
exceed the value of 5-kg/ cm2 (g) as it may damage the pressure tank/
pressure sensor-transmitter.

Observations:

Observe that at any value of proportional, reset time & rate time the process variable
reaches the set point value.
Observe the effect of load & set point change on the behavior of the system.

EXPERIMENTAL PRESSURE CONTROL TRAINER 42

TECHNICAL SPECIFICATIONS:

PART NAME DETAILS FUNCTION

MOC: SS304
Capacity: 10 Kg/cm2.
Type: Cylindrical
The tank is equipped with
Pressure tank a  Reservoir for Air
Disturbance valve (gate
valve), Pressure gauge (0
- 100 PSI) and pressure
sensor cum transmitter.
Type: Piezo resistive
silicon type.  Indication of
Range: 0 – 5 bar. Pressure.
Pressure Transmitter
Make: Keller.
Supply: 24V DC, 2 Wire.
Output: 4 – 20 mA
Type: Globe valve, Equal
% Characteristics, Air to
open.
Size: ½ ‘’
Actuator: Spring cylinder
Actuator Size: 25 Sq. in.
Air supply: 1.4 Kg/cm2
Signal: 0.2 – 1 Kg/cm2 or 3  Controlling inlet
Control Valve
–15 PSI Airflow to Pressure
With Valve Positioner
Trim: SS 316 (Contact Vessel.
part), Carbon steel (Body
material)
Accessory: Air filter
regulator with pressure
gauge to control the input
air pressure.

Size ¼ ‘’ BSP
Max. I/P Pressure: 18
Kg/cm2
 Regulation of
Air Filter Regulator Inlet pressure: 10 Kg/cm2
pneumatic Supply
Outlet pressure: 7 Kg/cm2
Pressure gauge: 0 – 7
Kg/cm2.
 Visual indication of
Pressure Gauge Range: 0 – 30 PSI. Pneumatic
Pressure.
 Display of Output
Current of the Level
Range: 4 – 20 mA Transmitter.
Current Indicator
Type: Digital 3 ½ display  Display of the Input
Current of the PID
Controller.
EXPERIMENTAL PRESSURE CONTROL TRAINER 43
  Display output of
Range: 4 – 20 mA controller.
Current Indicator
Type: Digital 3 ½ display  Output 4 – 20 mA to
the E/P Converter.
Make: Toshniwal
Input: 4 – 20 Ma  Actuation of Control
E/P Converter
Output: 0.2 to 1 Kg/ cm2 valve.
Supply pressure 1.4 Kg/
cm2

 Enclosure for
process Indicator,
Control Panel MOC: MS
controller, output
indicator etc.
Size: 48*48 mm
Make: West, U.K.
WithRS485
PID Controller  For process control.
communications.
Input: 4 – 20 Ma
Output: 4 – 20 Ma

EXPERIMENTAL PRESSURE CONTROL TRAINER 44